Lincoln Electric FLEXCUT 200 CE Manual
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Lincoln Electric FLEXCUT 200 CE Manual

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FLEXCUT
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
EDITION
: EN
REVISION : B
DATE
: 07-2019
INSTALLATION
200 CE
INSTALLATION N° P07085760NG
Instructions for use
8695 4497
REF :
Original instructions

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Summary of Contents for Lincoln Electric FLEXCUT 200 CE

  • Page 1 INSTALLATION FLEXCUT 200 CE SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE INSTALLATION N° P07085760NG 8695 4497 EDITION : EN Instructions for use REF : REVISION : B DATE : 07-2019 Original instructions...
  • Page 2 Thank for the trust you have expressed by purchasing this equipment, which will give you full satisfaction if you follow its instructions for use and maintenance. Its design, component specifications and workmanship comply with applicable European directives. Please refer to the enclosed CE declaration to identify the directives applicable to it.

  • Page 3: Table Of Contents

    1 - FLEXCUT 200 CE INSTALLATION ..................1 2 - TOOL HOLDER THD ......................2 3 - FLEXCUT 200 CE POWER SOURCE + FLEXCOOL 35 + FLEXSTART ......2 4 - TORCH T5........................... 2 5 - IHM FOR INTEGRATED INSTALLATION ON MACHINE ..........2 B - SAFETY INSTRUCTIONS ......................
  • Page 4 8695 4497 / B INFORMATIONS For operating instructions, adjustments, troubleshooting and spare parts see safety instructions for use and maintenance. ISEE N° ISUM FLEXCUT 200 CE power Source IM10485 T5 torch IM10485 Cooler FLEXCOOL 35 IM10423 FLEXSTART IM10457 Tool holder THD...

  • Page 5: A - Identification

    8695 4497 / A A - IDENTIFICATION 1 - FLEXCUT 200 CE INSTALLATION Please note the serial number of your installation in the box below. This information will be required if you need to contact our after-sales service staff. Other locations have been provided for stating the references of each component of the installation.

  • Page 6: Tool Holder Thd

    8695 4497 / A 2 - TOOL HOLDER THD Please refer to the document : 8695 4568. 3 - FLEXCUT 200 CE POWER SOURCE + FLEXCOOL 35 + FLEXSTART Please refer to the document : IM10485, IM10423, IM10457. 4 - TORCH T5 Please refer to the document : IM10485.

  • Page 7: B - Safety Instructions

    Standard EN 169 requires the use of shade 12 dark glass for the intensities from this process. 2 - GROUNDING PRINCIPLE In the event of electrical faults, in order to prevent all troubles on the Flexcut 200 CE installation, all metallic parts within the operator’s reach must imperatively be linked to the ground. MARKS...

  • Page 8: Electrical User Safety

    Check regularly the condition of power and ground connections We remind you that the power supplies of FLEXCUT 200 CE and machine must be equipped with primary protection devices, i.e. manual locking and unlocking breakers or breakers activated when an electrical fault is detected.

  • Page 9: Electromagnetic Pollution

    Plasma cutting generates a large quantity of heat. The installation needs to be cooled. To that end, coolant fluid is required for the proper working of the installation. Refer to the maintenance instructions of the cooling unit. The coolant fluid used must be that stated in the instructions. FLEXCUT 200 CE INSTALLATION...

  • Page 10: Fire Risk

    275 A and a 145 V arc The use of a helmet is required with a noise level above 80 dB, for the operator and for persons located nearby. The noise generated by the process can cover external sound warnings. FLEXCUT 200 CE INSTALLATION...

  • Page 11: C - Description

    8695 4497 / A C - DESCRIPTION 1 - CAPACITIES OF THE FLEXCUT 200 CE INSTALLATION This complete installation consists of a group of industrial equipment (power source, torch, control unit, tool holder, bundles...) especially designed to allow automatic thermal cutting by plasma jet.

  • Page 12: Integrated Installation On Lincoln Machine

    This installation may be used in an integrated manner on a machine supplied by us. The main functions are accessible by the NC that will steer the cutting processes via Ethernet. This installation can manage the plasma cutting function for a maximum of 2 torches. FLEXCUT 200 CE INSTALLATION...
  • Page 13 Cycle function assembly THD tool holder P07054360 Programming interface Torch T5 + torch bundle Magnetic torch impact safety system FLEXCUT 200 CE power source Integrated in : K4328-2 Cutting/annular gas (air) Annular / gas (nitrogen) (option) Cutting/annular gas (oxygen) (option) Transverse chain...

  • Page 14: Flexstart

    Please refer to the document: IM10485 6 - FLEXCUT 200 CE POWER SOURCE + COOLING UNIT FLEXCOOL 35 The function of FLEXCUT 200 CE power source is to regulate the cutting current according to the required setpoints. The FLEXCUT 200 CE can deliver a maximum of 200A.

  • Page 15: Optional Quick Gas Change

    The optional remote starting of the power source allows you to switch off the power to the power source (and cooler) from the control console. That option makes it necessary to use a disconnecting box LINCOLN ELECTRIC (see power supply section). FLEXCUT 200 CE INSTALLATION...
  • Page 16 C - DESCRIPTION 8695 4497 / A FLEXCUT 200 CE INSTALLATION C-12...

  • Page 17: D - Assembly And Installation

    142 l/mn Class 1.4.1 Oxygen > 99,5% 7,2 bar +/-1 41 l/mn STAINLESS STEEL, ALUMINIUM AND ALLOYS ISO 8573-1:2010, 7.2 bar +/-1 142 l/mn Compressed air Class 1.4.1 Nitrogen > 99,5% 7,2 bar +/-1 106 l/mn FLEXCUT 200 CE INSTALLATION D-13...
  • Page 18 The operative power depends on the serviceable voltage used. A cable of adequate section is to be provided to linkthe isolating switch to the power source. Consumption of installation except power source For installations integrated into LINCOLN ELECTRIC, refer to the machine instructions. FLEXCUT 200 CE INSTALLATION D-14...

  • Page 19: Installation

    THD the torch connection box (FLEXSTART) torch T5 the power source FLEXCUT 200 CE and cooler FLEXCOOL 35 the supply of gas and electricity. FLEXCUT 200 CE INSTALLATION D-15...
  • Page 20 D - ASSEMBLY AND INSTALLATION 8695 4497 / A FLUID CONNECTIONS Mark Designation FLEXCUT 200 CE power source Cooler FLEXCOOL 35 Torch T5 Torch bundle Set of two solenoid valves Cutting/annular gas (air) Annular / gas (nitrogen) (option) Cutting/annular gas (oxygen) (option)
  • Page 21 D - ASSEMBLY AND INSTALLATION 8695 4497 / A ELECTRICAL CONNECTIONS Mark Designation FLEXSTART Cycle function assembly FLEXCUT 200 CE power source Tool holder THD Torch T5+ torch bundle FLEXCUT 200 CE INSTALLATION D-17...

  • Page 22: Cycle Function Installation

    6 - INSTALLATION OF TORCH T5 + BUNDLE Please refer to the document: IM10485 7 - FLEXCUT 200 CE POWER SOURCE INSTALLATION Place the power source near the chain exit (see layout). Connect an electricity supply to the power source and a gas supply (see power source instructions IM10485).
  • Page 23 D - ASSEMBLY AND INSTALLATION 8695 4497 / A FLEXCUT 200 CE INSTALLATION D-19...

  • Page 24: E - Operator Manual

    The part program particularities (size and location of striking, cutting quality etc.) also influence cutting quality. The post-processor must comply with the recommendations of LINCOLN ELECTRIC. The gas pressure values are to be adjusted on the power source (See the documentation IM10485)

  • Page 25: Cycles

    E - OPERATOR MANUAL 8695 4497 / A 5 - CYCLES FLEXCUT 200 CE INSTALLATION E-21...
  • Page 26 E - OPERATOR MANUAL 8695 4497 / A FLEXCUT 200 CE INSTALLATION E-22...

  • Page 27: F - Maintenance

    Maintenance should be more frequent if production is greater  For the maintenance of the FLEXCUT 200 CE, power source, please refer to instructions IM10485. Your maintenance department may photocopy these pages so that it can follow up maintenance dates and...

  • Page 28: Troubleshooting

    While troubleshooting, the technician may ask you to check the status of the indicators on the PLC « E2 », and also those on each of the solenoid valves, which have an indicator that goes on when the valve supply is on. On the PLC, faulty inputs/outputs are red. FLEXCUT 200 CE INSTALLATION F-24...
  • Page 29 1011 = Cycle stop for Head Probe impact (oxycutting) or torch Correct the fault, raise the tool Collision. Jog in limited speed impact (plasma) holder and clear the alarm FLEXCUT 200 CE INSTALLATION F-25...
  • Page 30 F - MAINTENANCE 8695 4497 / B Explanation of alarms : plasma FLEXCUT 200 CE The alarms indicating FLEXCUT 200 CE plasma process faults are indicated on the UI. Alarm Probable causes Possible remedies The filter has been activated, but...
  • Page 31 Set the speed offset of the The tool holder speed offset has variable speed drive not been set. Incorrect cutting height Reposition the plate or change The plate is not on fixed supports the detection method (using pilot arc) FLEXCUT 200 CE INSTALLATION F-27...

  • Page 32: Thd Tool Holder Maintenance

    8695 4497 / B 3 - THD TOOL HOLDER MAINTENANCE Please refer to the document: 8695 4568. 4 - FLEXCUT 200 CE POWER SOURCE MAINTENANCE Please refer to the document: IM10485. 5 - TORCH T5 MAINTENANCE Please refer to the document: IM10485.

  • Page 33: Spare Parts

    W000XXXXXX Machine interface board  W000XXXXXX Flowmeter P9357XXXX Silk-screen printed front panel  For parts order, give the quantity required and put the number of your machine in the box below. TYPE : Number : FLEXCUT 200 CE INSTALLATION F-29...
  • Page 34 F - MAINTENANCE 8695 4497 / B MAIN PARTS FLEXCUT 200 CE INSTALLATION F-30...
  • Page 35   (Please refer to the document: IM10457) Torch T5 + torch bundle   (Please refer to the document: IM10485) FLEXCUT 200 CE power source   (Please refer to the document: IM10485) Cooler FLEXCOOL 35   (Please refer to the document: IM10423) THD tool holder ...
  • Page 36 ELECTRICAL BUNDLE MAINTENANCE Rep/ISUM Rep / installation Designation Composition P1-W60 Power source control bundle P1-W2 Tool-holder power P1-W3 Tool-holder encoder P1-W65 Tool-holder limit switch P1-W66 Tool-holder torch impact safety system P1-W67 Detection P1-W69 F200 remote starting option FLEXCUT 200 CE INSTALLATION F-32...
  • Page 37 F200 remote starting option, 10 metres   AS-CS-07085831 F200 remote starting option, 20 metres  For parts order, give the quantity required and put the number of your machine in the box below. TYPE : Number : FLEXCUT 200 CE INSTALLATION F-33...
  • Page 38 F - MAINTENANCE 8695 4497 / B GAS AND ELECTRICAL BUNDLE MAINTENANCE Rep/ISUM Rep / installation Designation Composition P1-W12 Electrode bundle Nozzle bundle P1-W9 P1-W80 Valves bundle P1-W79 Torch bundle FLEXCUT 200 CE INSTALLATION F-34...
  • Page 39 Please refer to the document IM10485 Solenoid valve bundle Please refer to the document IM10485  For parts order, give the quantity required and put the number of your machine in the box below. TYPE : Number : FLEXCUT 200 CE INSTALLATION F-35...
  • Page 40 X20BM11 back panel   W000383703 X20TB12 terminal block   W000276961 Detection board  For parts order, give the quantity required and put the number of your machine in the box below. TYPE : Number : FLEXCUT 200 CE INSTALLATION F-36...
  • Page 41 F - MAINTENANCE 8695 4497 / B FLEXCUT 200 CE INSTALLATION F-37...

  • Page 42: Personal Notes

    F - MAINTENANCE 8695 4497 / B PERSONAL NOTES Lincoln Electric France S.A.S. Avenue Franklin Roosevelt 76120 Le Grand Quevilly 76121 Le Grand Quevilly cedex www.lincolnelectriceurope.com FLEXCUT 200 CE INSTALLATION F-38...

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