Lincoln Electric FlexCut 200 Operator's Manual
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Lincoln Electric FlexCut 200 Operator's Manual

Lincoln Electric FlexCut 200 Operator's Manual

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Operator's Manual
FlexCut
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10422-A
| Issue D ate Oct-20
© Lincoln Global, Inc. All Rights Reserved.
200
®
For use with machines having Code Numbers:
12731, 12825

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  • Page 1 Operator’s Manual FlexCut ® For use with machines having Code Numbers: 12731, 12825 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10422-A | Issue D ate Oct-20 ©...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELEC TRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 2.d. All welders should use the following procedures in order to St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks etc.
  • Page 6 SAFETY SAFETY ELECTRIC SHOCK PREVENTION General Precautions ULTRAVIOLET RADIATION PROTECTION NOISE PROTECTION TOXIC FUME PREVENTION...
  • Page 7 SAFETY FIRE PREVENTION HEALTH SUPPORT EQUIPMENT EXPLOSION PREVENTION...
  • Page 8 SAFETY Safety Standards Booklet Index...

  • Page 9: Table Of Contents

    INSTALLATION............................. SECTION A TECHNICAL SPECIFICATIONS........................A-1 SAFETY ............................A-2 GENERAL DESCRIPTION ..........................A-2 RECOMMENDED PROCESSES........................A-2 PROCESS LIMITATIONS........................... A-2 EQUIPMENT LIMITATIONS........................A-2 COMMON EQUIPMENT PACKAGES ......................A-2 USER RESPONSIBILITY..........................A-2 DESIGN FEATURES AND ADVANTAGES....................A-2 LOCATION AND VENTILATION FOR COOLING ...................A-3 LIFTING ............................

  • Page 10: Installation

    INSTALLATION 380- 400- 415 / 460 /575 AGENCY APPROVALS CONFORMITY MARKET STANDARD MARK RATED OUTPUT AT 40° C DUTY CYCLE CURRENT VOLTAGE US and Canada 100% 200A OUTPUT OPEN CIRCUIT CURRENT RANGE PILOT CURRENT VOLTAGE 20 - Amps 300 VDC 30 Amps PLASMA GAS SHIELD GAS...

  • Page 11: General Description

    GENERAL DESCRIPTION USER RESPONSIBILITY DESIGN FEATURES AND ADVANTAGES ® RECOMMENDED PROCESSES PROCESS LIMITATIONS...

  • Page 12: Location And Ventilation For Cooling

    INSTALLATION INSTALLATION ENVIROMENTAL LIMITATIONS READ ENTIRE INSTALLATION SECTION BEFORE INSTALLING THE WARNING ELECTRIC SHOCK CAN KILL. • TURN OFF INPUT POWER TO THE POWER SOURCE AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THIS EQUIPMENT. TURN OFF THE INPUT POWER TO ANY OTHER EQUIPMENT CONNECTED TO HIGH FREQUENCY INTERFERENCE PROTECTION THE WELDING SYSTEM AT THE DISCONNECT SWITCH...

  • Page 13: Input Fuse And Supply Wire Considerations

    INSTALLATION INPUT FUSE & SUPPLY WIRE CONSIDERATIONS WARNING ELECTRIC SHOCK CAN KILL. ONLY A QUALIFIED ELECTRICIAN SHOULD CONNECT THE INPUT LEADS TO THE . CONNECTIONS SHOULD BE MADE IN ACCORDANCE WITH ALL LOCAL AND NATIONAL ELECTRICAL CODES AND THE CONNECTION DIAGRAM LOCATED ON THE INSIDE OF THE RECONNECT/INPUT ACCESS DOOR OF THE MACHINE.

  • Page 14: System Overview

    INSTALLATION WARNING CYLINDER could explode if dam- FIGURE A.2 aged. • Keep cylinder upright and chained to a • Keep cylinder away from areas where it could be damaged. • Never lift machine with cylinder attached. • Never allow the cutting torch to touch the cylinder. •...
  • Page 15 INSTALLATION...
  • Page 16 INSTALLATION...
  • Page 17 INSTALLATION...
  • Page 18 INSTALLATION...
  • Page 19 INSTALLATION...

  • Page 20: Power Supply Output Connections

    INSTALLATION POWER SUPPLY OUTPUT CONNECTIONS CONTROL CABLE CONNECTIONS General Guidelines ® Electrode Lead ® Lead ® Common Equipment Connections Connection Between the Flex ut , Flex ool 35 an ex tart Work Lead ® ® Connection Between the Flex tart and the 2-Gang Valve ®...

  • Page 21: Operation

    OPERATION OPERATION POWER-UP SEQUENCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. ® ® If the status lights do not become steady green consult the troubleshooting section of this manual for further instruction. FUMES AND GASES can be dangerous. GRAPHIC SYMBOLS THAT APPEAR ON THIS •...

  • Page 22: Case Front Controls

    OPERATION CASE FRONT CONTROLS CASE BACK CONTROLS FIGURE B.2 FIGURE B.1 LCD Display: Shielding Gas Inlet (optional): Plasma Gas Inlet: Home Button: Menu Control Knob/Button: 115V/1 A Auxiliary Power Receptacle. 1 Amp Circuit Breaker (CB- ): On/Off Switch: Ethernet Connector (RJ-45): 10 Amp Circuit Breaker (CB-2): Lead Connection: ®...

  • Page 23: User Interface

    OPERATION USER INTERFACE FIGURE B.4 - ACTIVE MODE SCREEN Mode Select Screen Choose between four available modes: Cut – Mark – Grid – Gouge –...
  • Page 24 OPERATION Settings Options (turn the knob to scroll and press the knob to select): Language – Reset Factory Settings – Units – Brightness – UI Control Advanced –...
  • Page 25 FlexCut OPERATION ® Arc Start: Arc Initiated: Arc Voltage: Force Mark: FIGURE B.5 20:1 30:1 40:1 50:1...
  • Page 26 FlexCut OPERATION ® MATERIAL CURRENT PAGE...
  • Page 27 ® OPERATION FlexCut SELECTING CONSUMABLES - AIR PLASMA / AIR SHIELD Outer Retaining Shield Inner Nozzle Swirl Ring Electrode Torch Head Retaining Cap MS/AL 100A MS/SS/AL 150A MS/SS/AL 200A 200A SS/AL...
  • Page 28 FlexCut OPERATION ® 50 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 29 FlexCut OPERATION ® 100 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 30 FlexCut OPERATION ® 150 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 31 FlexCut OPERATION ® 200 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 32 FlexCut OPERATION ® 50 Amps - Stainless Steel Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 33 FlexCut OPERATION ® 100 Amps - Stainless Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 34 FlexCut OPERATION ® 150 Amps - Stainless Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 35 FlexCut OPERATION ® 200 Amps - Stainless Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed...
  • Page 36 FlexCut OPERATION ® 50 Amps - Aluminum Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height...
  • Page 37 FlexCut OPERATION ® 100 Amps - Aluminum Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height...
  • Page 38 FlexCut OPERATION ® 150 Amps - Aluminum Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height...
  • Page 39 FlexCut OPERATION ® 200 Amps - Aluminum Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height...
  • Page 40 ® OPERATION FlexCut SELECTING CONSUMABLES - OXYGEN PLASMA / OXYGEN OR AIR SHIELD (50A) OXYGEN PLASMA / AIR SHIELD (100A, 150A, 200A) Outer Retaining Shield Inner Nozzle Swirl Ring Electrode Torch Head Retaining Cap 100A 150A 200A...
  • Page 41 FlexCut OPERATION ® 50 Amps - Mild Steel - Oxygen Plasma / Oxygen or Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Cold-Rolled Steel – Oxygen Shield – Swirl Ring Hot-Rolled Steel –...
  • Page 42 FlexCut OPERATION ® 100 Amps - Mild Steel - Oxygen Plasma / Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge...
  • Page 43 FlexCut OPERATION ® 150 Amps - Mild Steel - Oxygen Plasma / Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Retaining Cap Retaining Cap Metric Plasma Shield Travel Cutting...
  • Page 44 FlexCut OPERATION ® 200 Amps - Mild Steel - Oxygen Plasma / Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge...
  • Page 45 ® OPERATION FlexCut SELECTING CONSUMABLES - AIR PLASMA / NITROGEN SHIELD Outer Retaining Shield Inner Nozzle Swirl Ring Electrode Torch Head Retaining Cap BK277122 100A SS/AL 150A SS/AL 200A SS/AL...
  • Page 46 FlexCut OPERATION ® 50 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge...
  • Page 47 FlexCut OPERATION ® 100 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge...
  • Page 48 FlexCut OPERATION ® 150 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge...
  • Page 49 FlexCut OPERATION ® 200 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge...
  • Page 50 FlexCut OPERATION ® 50 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness...
  • Page 51 FlexCut OPERATION ® 100 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness...
  • Page 52 FlexCut OPERATION ® 150 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness...
  • Page 53 FlexCut OPERATION ® 200 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start Metric Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness...

  • Page 54: Options/Accessories

    ACCESSORIES OPTIONS/ACCESSORIES ® BK279000 BK279100...

  • Page 55: Maintenance

    MAINTENANCE MAINTENANCE GAS SUPPLY WARNING ELECTRIC SHOCK CAN KILL. • perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE PERIODIC MAINTENANCE POWER SUPPLY CALIBRATION SPECIFICATION...

  • Page 56: Troubleshooting

    TROUBLE SHOOTING TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 57 TROUBLESHOOTING Possible Cause 0021 Recommended Course of Action DESCRIPTION: Transfer Failed Possible Cause 0021 Recommended Course of Action DESCRIPTION: Open Pilot - Check Consumables Possible Cause 0729 Recommended Course of Action DESCRIPTION: Release Trigger Possible Cause 0036 Recommended Course of Action DESCRIPTION: Thermal Trip...
  • Page 58 TROUBLESHOOTING Possible Cause 0006 Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION:...
  • Page 59 TROUBLESHOOTING Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION:...
  • Page 60 TROUBLESHOOTING Possible Cause Recommended Course of Action DESCRIPTION:...
  • Page 61 DIAGRAMS...
  • Page 62 FlexCut ® DIAGRAMS FRONT OF MACHINE J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-8 J23-3 J1-9 J23-4 J1-10 J23-9 J23-10 J1-11 J23-1 J1-12 J23-2 J1-13 J1-14 J23-7 J23-8 J1-16 J23-11 J23-6 J23-5 J28-1 J28-2 J28-3 J28-4 J28-5 J28-6 J28-8 J28-9 J28-10 J28-11 J28-12 J28-13...
  • Page 63 DIAGRAMS...
  • Page 64 DIAGRAMS 200 DUAL GAS INSTRUCTIONS INSTALLATION INSTRUCTIONS: OVERVIEW: WARNING ELECTRIC SHOCK CAN KILL PARTS LIST: Oxygen Plasma Gas – Air Shield Gas RECOMMENDED TOOLS: INSTALLATION:...
  • Page 65 DIAGRAMS FIGURE 1 FIGURE 2 FIGURE 3...
  • Page 66 DIAGRAMS FIGURE 4 Air Plasma Gas – Nitrogen Shield Gas RECOMMENDED TOOLS: INSTALLATION:...
  • Page 67 DIAGRAMS FIGURE 5 FIGURE 6 FIGURE 7 A.01 L17477PRINT...
  • Page 70 Do not touch electrically live parts or Keep mmable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 71 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Los humos fuera de la zona de res- Spanish Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 72 CUSTOMER ASSISTANCE POLICY...

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