Lincoln Electric FlexCut 125 CCC Operator's Manual
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Lincoln Electric FlexCut 125 CCC Operator's Manual

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Operator's Manual
FlexCut
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10450-A
| Issue D ate Mar - 22
© Lincoln Global, Inc. All Rights Reserved.
125 CCC
®
For use with machines having Code Numbers:
12771, 12918

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Summary of Contents for Lincoln Electric FlexCut 125 CCC

  • Page 1 Operator’s Manual FlexCut 125 CCC ® For use with machines having Code Numbers: 12771, 12918 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) IM10450-A | Issue D ate Mar - 22 ©...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. 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 P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). 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. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • 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. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 ® FLEXCUT 125 CCC SAFETY SAFETY ELECTRIC SHOCK PREVENTION The system uses high open circuit voltages that can be fatal. Extreme care should be used when operating or General Precautions performing maintenance on the system. Only qualified personnel Whereas plasma cutting has been used safely for years, it does should service the system.
  • Page 7 ® FLEXCUT 125 CCC SAFETY FIRE PREVENTION HEALTH SUPPORT EQUIPMENT When using the system , it is necessary to exercise good The system creates electric and magnetic fields that judgment. While cutting, the arc produces sparks that could cause a may interfere with certain types of health support fire if they fall on flammable materials.
  • Page 8 ® FLEXCUT 125 CCC SAFETY 17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from Safety Standards Booklet Index the Compressed Gas Association, 1725 Jefferson Davis Highway, For further information concerning safety practices to be exercised Suite 1004, Arlington, VA 22202. with plasma arc cutting equipment, please refer to the following 18.

  • Page 9: Table Of Contents

    ® FLEXCUT 125 CCC TABLE OF CONTENTS Safety General Description...........................10 Preheat Temperature For Plasma Cutting ..................10 Duty Cycle............................10 User Responsibility..........................10 Design Features And Advantages ......................10 Installation ..........................Section A Select Suitable Location........................A-2 Lifting ............................A-2 Stacking ............................A-2 Tilting ............................A-2 High Frequency Interference Protection ...................A-2 Input Connection..........................A-2 Machine Grounding..........................A-2 Input Plug Installation ........................A-3...

  • Page 10: General Description

    ® FLEXCUT 125 CCC GENERAL DESCRIPTION USER RESPONSIBILITY Because design, fabrication, erection and cutting variables affect the results obtained in applying this type of information, the serviceability The FLEXCUT® 125 CCC is a constant current, continuous control of a product or structure is the responsibility of the user. Variation plasma cutting power source.
  • Page 11 ® FLEXCUT 125 CCC INSTALLATION TECHNICAL SPECIFICATIONS - K4811-3 FLEXCUT 125 CCC ® RATED OUTPUT AT 40° C RECOMMENDED INPUT WIRE Duty Cycle CURRENT VOLTAGE For all plasma cutting applications 100% 125A 175 VDC Based on U.S. National Electrical Code Ambient Temperature 30 C or Less OUTPUT...

  • Page 12: Installation

    Only a qualified electrician should connect the input leads to and side louvers. Maintain at least 10 inches of space on all sides of the FLEXCUT 125 CCC. Connections should the unit. Dirt, dust, or any foreign material that can be drawn into the be made in accordance with all local and machine should be kept to a minimum.

  • Page 13: Input Connection

    ® FLEXCUT 125 CCC INSTALLATION INPUT CONNECTION Use a three-phase supply line. A 1.40 inch diameter access hole with WARNING strain relief is located on the case back. Route input power cable through this hole and connect L1, L2, L3, and ground per connection The FLEXCUT®...

  • Page 14: Input Voltage Selection

    ® FLEXCUT 125 CCC INSTALLATION INPUT VOLTAGE SELECTION ® The FLEXCUT 125 CCC is shipped connected for 460 VAC input. To reconfigure the machine for a different input voltage see the panel on the rear of the unit (Figure A.2). With input power removed from the machine, move the Auxiliary (“A”) lead from the 460V tap to the desired input voltage.

  • Page 15: Operation

    ® FLEXCUT 125 CCC OPERATION OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SAFETY PRECAUTIONS WARNING OR CAUTION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts GAS PURGE or electrode with skin or wet clothing.

  • Page 16: Controls And Settings

    ® FLEXCUT 125 CCC OPERATION CONTROLS AND SETTINGS FIGURE B.2 - Front Panel FIGURE B.3 - Back Panel 1. LCD Display: Shows available modes and real time parame- 9. Input Cord Strain Relief: Used to connect the unit to input ters.

  • Page 17: User Interface

    ® FLEXCUT 125 CCC OPERATION USER INTERFACE Active Mode Screen - See Figure B.4 Mode Select Screen FIGURE B.4 Cutting Output Current Active Mode Icon Output Gas Pressure 25ft Torch Length Press to Select Active Mode Icon – The currently selected mode icon will be displayed here.
  • Page 18 ® FLEXCUT 125 CCC OPERATION Settings Press both the home and purge buttons at the same time to enter or exit the settings menu. Options (turn the knob to scroll and press the knob to select): Reset Factory Settings Torch Size Reset Factory Settings –...

  • Page 19: Mechanized Cutting

    ® FLEXCUT 125 CCC OPERATION MECHANIZED CUTTING Removing the Torch Consumables Mechanized Torch Installation WARNING ® It is recommended that the FLEXCUT 125 CCC mechanized torch be installed on a positioner with an arc voltage control capable of Turn off the machine prior to removing maintaining the cutting arc voltage within 1 volt.
  • Page 20 ® FLEXCUT 125 CCC OPERATION Making a Cut Machine Interface ® The FLEXCUT 125 CCC comes standard with a machine interface. Setting up a Cut Interface signals provided include: Arc Start, Arc Initiated, Use the following procedure to make a cut with the Arc Voltage (raw or divided) and Force Mark.
  • Page 21 FLEXCUT™ 125 CCC OPERATION CUTTING CHARTS The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness. Small adjustments may have to be made to achieve the best cut.
  • Page 22 FLEXCUT™ 125 CCC OPERATION 45 Amps - Mild Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.0179...
  • Page 23 FLEXCUT™ 125 CCC OPERATION 65 Amps - Mild Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.0598...
  • Page 24 FLEXCUT™ 125 CCC OPERATION 85 Amps - Mild Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.1345...
  • Page 25 FLEXCUT™ 125 CCC OPERATION 105 Amps - Mild Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.160...
  • Page 26 FLEXCUT™ 125 CCC OPERATION 125 Amps - Mild Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.160...
  • Page 27 FLEXCUT™ 125 CCC OPERATION 45 Amps - Stainless Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.0179...
  • Page 28 FLEXCUT™ 125 CCC OPERATION 65 Amps - Stainless Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.060...
  • Page 29 FLEXCUT™ 125 CCC OPERATION 85 Amps - Stainless Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.1345...
  • Page 30 FLEXCUT™ 125 CCC OPERATION 105 Amps - Stainless Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.180...
  • Page 31 FLEXCUT™ 125 CCC OPERATION 125 Amps - Stainless Steel Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.200...
  • Page 32 FLEXCUT™ 125 CCC OPERATION 45 Amps - Aluminum Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 1/32 0.100...
  • Page 33 FLEXCUT™ 125 CCC OPERATION 65 Amps - Aluminum Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 1/16 0.200...
  • Page 34 FLEXCUT™ 125 CCC OPERATION 85 Amps - Aluminum Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.210 0.325...
  • Page 35 FLEXCUT™ 125 CCC OPERATION 105 Amps - Aluminum Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.180 0.325...
  • Page 36 FLEXCUT™ 125 CCC OPERATION 125 Amps - Aluminum Imperial Optimum Production Travel Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Voltage Speed Voltage Speed Height Height Time Width Start (ga) (in) (psi) (volts) (ipm) (volts) (ipm) (in) (in) (msec) (in) 0.200 0.300...

  • Page 37: Consumable Life

    ® FLEXCUT 125 CCC OPERATION CONSUMABLE LIFE CUT QUALITY Use the following guidelines to maximize consumable parts life: Before the optimum cutting condition can be achieved on a particular material type and thickness, the machine operator must have a ® 1.

  • Page 38: Inspection Of Consumable Parts

    ® FLEXCUT 125 CCC OPERATION INSPECTION OF CONSUMABLE PARTS When the cut quality is not satisfactory, use the following guidelines for determining which consumable parts need to be changed. Inspect all parts for dirt or debris and clean as necessary. !"#$ %&'!()$*+,# ),##()$%-(*")$%,&...

  • Page 39: Suggestions For Extra Utility From The Flexcut® 125 Ccc System

    ® FLEXCUT 125 CCC OPERATION SUGGESTIONS FOR EXTRA UTILITY FROM THE ® FLEXCUT 125 CCC SYSTEM: WARNING ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect switch on the rear of th machine before tightening, cleaning or replacing consumables.

  • Page 40: Accessing Divided Arc Voltage

    ® FLEXCUT 125 CCC OPERATION ACCESSING DIVIDED ARC VOLTAGE ® The FLEXCUT 125 CCC is factory set to provide raw arc voltage through the 14 pin CNC Connector (see arc voltage on page B-6). 5. Set the switch as follows to get the desired divided voltage: The machine is configurable to provide a divided voltage of 20:1, 30:1, 40:1, or 50:1 instead of raw arc voltage by following these steps:...

  • Page 41: Options/Accessories

    ® FLEXCUT 125 CCC ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your FlexCut™ Plasma cutter from your local Lincoln Distributor. TORCHES The following replacement or optional torches are available: K4300-4 LC125 Mechanized Torch 25' (7.5m) K4300-5 LC125 Mechanized Torch 50' (15m) K4300-6 LC125 Mechanized Torch 75' (22.5m) K4302-2...

  • Page 42: Maintenance

    ® FLEXCUT 125 CCC MAINTENANCE MAINTENANCE MONTHLY PROCEDURES POWER SUPPLY WARNING 1. Using clean, dry, compressed air, blow out all accumulated dust ELECTRIC SHOCK CAN KILL. inside the machine. Be sure to clean all printed circuit boards, • Have an electrician install and service heatsinks, power switch, and fan.

  • Page 43: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 44 ® FLEXCUT 125 CCC TROUBLESHOOTING Possible Cause 0298 Gas input line is disconnected or input pressure is too low. Recommended Course of Action Check that the gas line feeding the machine is properly connected and that the pressure is above 90 psi for cutting or above 50 psi for marking or gouging. DESCRIPTION: Low Gas Pressure Possible Cause...
  • Page 45 ® FLEXCUT 125 CCC TROUBLESHOOTING Possible Cause 0021 Pilot Stuck Open Recommended Course of Action Nozzle could be missing or debris could be stuck between the torch consumables. Remove and replace the consumables, checking for proper DESCRIPTION: installation. Open Pilot - Check Consumables Possible Cause Pilot Stuck Closed...
  • Page 46 ® FLEXCUT 125 CCC TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION Input circuit breaker trips repeatedly. 1. Verify that the input circuit protection is properly sized per the voltage being sup- plied.
  • Page 47 ® FLEXCUT 125 CCC TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION ® The FLEXCUT 125 CCC powers up proper- 1. Press the purge button on the front of the ® ly but there is no response when output is FLEXCUT 125 CCC .
  • Page 48 ® FLEXCUT 125 CCC TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION When the trigger is pulled air begins to flow, 1. Check the torch consumables to be sure but there is no pilot arc after at least 3 they are not dirty or greasy, and are in seconds.
  • Page 49 ® FLEXCUT 125 CCC TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION Pilot arc starts but will not transfer when 1. Check work lead connection for clean, brought near work. secure connection. 2.

  • Page 50: Diagrams

    ® FLEXCUT 125 CCC DIAGRAMS FRONT OF MACHINE J23-1 J23-2 J4-1 J23-3 J4-2 J23-4 J4-3 J4-4 J24-1 J4-5 J24-2 J4-6 J24-3 J4-7 J24-4 J4-8 J22-1 J22-1 J22-2 J22-2 J22-3 J22-3 J22-4 J22-4 J22-5 J22-5 J1-1 J22-6 J22-6 J1-2 J1-3 J1-4 J1-5 J28-1 J1-6...
  • Page 51 ® FLEXCUT 125 CCC DIAGRAMS...
  • Page 52 ® FLEXCUT 125 CCC DIAGRAMS 1.750 15.12 13.760 4.710 2.650 2.529 1.480 ALL DIMENSIONS ARE IN INCHES...
  • Page 54 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 55 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 56 Lincoln Electric is a responsive manufacturer, but the de nition of speci cations, and the selection and use of speci c products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

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