Lincoln Electric FlexCut 125 Operator's Manual

Operator’s Manual

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IM10300-A | Issue D ate Nov-16

For use with machines having Code Numbers:

12478

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

FlexCut™125

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

se corrective lenses if necessary

U to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

Safety 01 of 04 - 06/15/2016

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring

heir removal is complete. Always use the greatest care when

t working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Safety 02 of 04 - 06/15/2016

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area

f physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding hardfacing

(see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Safety 03 of 04 - 06/15/2016

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks

rom starting a fire. Remember that welding sparks and hot

f materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings,

tc. should be suitable for the application and

e maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Safety 04 of 04 - 06/15/2016

SAFETY

General Precautions

Whereas plasma cutting has been used safely for years, it does r

equire certain precautions to ensure the safety of the operator and other people around the equipment. The following safety information must be provided to each person who will operate, observe, perform maintenance, or work in close proximity to this piece of equipment.

Installation, operation, and repairs made to the system should only be performed by qualified personnel. The system makes use of both A.C. and D.C. circuitry for operation. Fatal shock hazard does exist. Exercise extreme caution while working on the system. Safety decals On the power supply should not be removed.

ULTRAVIOLET RADIATION PROTECTION

Plasma cutting produces ultraviolet radiation similar to a welding arc. This ultraviolet radiation can cause skin and eye burns. For this reason, it is essential that proper protection be worn. The eyes are best protected by using safety glasses or a welding helmet with an AWS No. 12 shade or ISO 4850 No. 13 shade, which provides protection up to 400 amperes. All exposed skin areas should be covered with flame-retardant clothing. The cutting area should also be prepared in such a way that ultraviolet light does not reflect. Walls and other surfaces should be painted with dark colors to reduce reflected light. Protective screens or curtains should be installed to protect additional workers in the area from ultraviolet radiation.

NOISE PROTECTION

The system generates high noise levels while cutting. Depending on the size of the cutting area, distance from the cutting torch, and arc current cutting level, acceptable noise levels may be exceeded. Proper ear protection should be used as defined by local or national codes.

TOXIC FUME PREVENTION

Care should be taken to ensure adequate ventilation in the cutting area. Some materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting area. Also, some solvents decompose and form harmful gases when exposed to ultraviolet radiation. These solvents should be removed from the area prior to cutting. Galvanized metal can produce harmful gases during the cutting process. Ensure proper ventilation and use breathing equipment when cutting these materials.

Certain metals coated with or containing lead, cadmium, zinc, beryllium, and mercury produce harmful toxins. Do not cut these metals unless all people subjected to the fumes wear proper air breathing equipment.

ELECTRIC SHOCK PREVENTION

The system uses high open circuit voltages that can be

fatal. Extreme care should be used when operating or performing maintenance on the system. Only qualified personnel s

hould service the system. Observe the following guidelines to protect

against electric shock:

• A wall-mounted disconnect switch should be installed and fused according to local and national electrical codes. The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency.

• The primary power cord should have a 600 volt minimum rating in order to protect the operator. In addition, it should be sized according to local and national electrical codes. Inspect the primary power cord frequently. Never operate the system if the power cord is damaged in any way.

• Make sure the primary power ground wire is connected at the input power ground location on the power supply. Make sure the connection is securely tightened.

• Make sure the positive output (work ground) of the power supply is connected to a bare metal area on the cutting table. A driven ground rod should be placed no further than five feet from this connection. Make sure this ground point on the cutting table is used as the star ground point for all other ground connections.

• Inspect the torch leads frequently. Never use the system if the leads are damaged in any way.

• Do not stand in wet, damp areas when operating or performing maintenance on the system.

• Wear insulated gloves and shoes while operating or performing maintenance on the system.

• Make sure the system is switched off at the wall disconnect before servicing the power supply or torch.

• Never change torch consumable parts unless main power to the system is switched off at the power supply or wall disconnect.

• Do not attempt to remove any parts from beneath the torch when cutting. Remember that the workpiece forms the current path back to the power supply.

• Never bypass the safety interlock devices.

• Before removing any of the covers, switch the system off at the wall disconnect. Wait at least five (5) minutes before removing any cover. This will give the capacitors inside the unit time to discharge. See Section 5 for additional safety precautions.

• Never operate the system without all of the covers in place. See Section 5 for additional safety precautions.

• Preventive maintenance should be performed daily to avoid

possible safety hazards.

FLEXCUT™ 125

SAFETY

FLEXCUT™ 125

FIRE PREVENTION

When using the system , it is necessary to exercise good judgment. While cutting, the arc produces sparks that could cause a fire if they fall on flammable materials. Make sure that all flammable m

aterials are a suitable distance away from the cutting area. All flammable liquids should be at least 40 feet away from the cutting area, preferably stored in a metal cabinet. Plasma cutting should never be attempted on containers that contain flammable materials. Make sure that fire extinguishers are readily accessible in the cutting area.

EXPLOSION PREVENTION

The system uses compressed gases. Use proper techniques when handling compressed gas cylinders and other compressed gas equipment. Observe the following guidelines to protect against explosion:

• Never operate the system in the presence of explosive gases or other explosive materials.

• Never cut pressurized cylinders or any closed container.

• When using a water table and cutting aluminum under water or with water touching the underside at the aluminum plate, hydrogen gas is produced. This hydrogen gas may collect under the plate and explode during the cutting process. Make sure the water table is properly aerated to help prevent the accumulation of hydrogen gas.

• Handle all gas cylinders in accordance with safety standards published by the U.S. Compressed Gas Association (CGA), American Welding Society (AWS), Canadian Standards Association (CSA), or other local or national codes.

• Compressed gas cylinders should be maintained properly. Never attempt to use a cylinder that is leaking, cracked, or has other signs of physical damage.

• All gas cylinders should be secured to a wall or rack to prevent accidental knock over.

• If a compressed gas cylinder is not being used, replace the protective valve cover.

• Never attempt to repair compressed gas cylinders.

• Keep compressed gas cylinders away from intense heat, sparks, or flames.

• Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator.

• Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease.

• Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended.

• Never use a pressure regulator for any gas other than which it is intended.

• Never use a pressure regulator that is leaking or has other signs of physical damage.

• Never use any gas hose that is leaking or has other signs of physical damage.

HEALTH SUPPORT EQUIPMENT

The system creates electric and magnetic fields that

may interfere with certain types of health support equipment, such as pacemakers. Any person who uses a pacemaker o

r similar item should consult a doctor before operating, observing, maintaining, or servicing the system. Observe the following guidelines to minimize exposure to these electric and magnetic fields:

• Stay as far away from the~power supply, torch, and torch leads as possible.

• Route the torch leads as close as possible to the work ground cable.

• Never place your body between the torch leads and work ground cable. Keep the work ground cable and the torch leads on the same side of your body.

• Never stand in the center of a coiled up set of torch leads or work ground cable.

SAFETY

FLEXCUT™ 125

Safety Standards Booklet Index

For further information concerning safety practices to be exercised with plasma arc cutting equipment, please refer to the following p

ublications:

. AWS Standard AWN, Arc Welding and Cutting Noise, obtainable

from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

2. AWS Standard C5.2, Recommended Practices for Plasma Arc Cutting, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

4. AWS Standard F4.1, Recommended Safe Practices for Preparation for Welding and Cutting of Containers and Piping, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL

33126.

5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

6. AWS I ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

7. ANSI Standard Z41.1 , Standard For Men's Safety-Toe Footwear, obtainable from the American National Standards Institute, 11 West 42nd Street, New York, NY 10036.

8. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, obtainable from the American National Standards Institute, 11 West 42nd Street, New York, NY 10036.

9. ANSI Standard Z87.1, Safe Practices For Occupation and Educational Eye and Face Protection, obtainable from the American National Standards Institute, 11 West 42nd Street, New York, NY

10036.

10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the

American National Standards Institute, 11 West 42nd Street, New York, NY 10036.

11. OSHA Standard 29CFR 1910.252, Safety and Health Standards,

obtainable. from the U.S. Government Printing Office, Washington, D.C. 20402.

12. NFPA Standard 51 , Oxygen - Fuel Gas Systems for Welding,

Cutting, and Allied Processes, obtainable from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

13. NFPA Standard 51 B, Cutting and Welding Processes, obtainable

from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

14. NFPA Standard 70, National Electrical Code, obtainable from the

National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

15. CGA booklet P-1 , Safe Handling of Compressed Gases in

Containers, obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202.

16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and

Oxygen-Deficient Atmospheres, obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202.

17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202.

18. CSA Standard W117 .2, Safety in Welding, Cutting, and Allied P

rocesses, obtainable from Canadian Standards Association, 178

Rexdale Boulevard, Toronto, Ontario M9W IR3, Canada.

19. Canadian Electrical Code Part 1, Safety Standard for Electrical Installations, obtainable from the Canadian Standards Association, 178 Rexdale Boulevard, Toronto, Ontario M9W 1 R3, Canada.

SAFETY

LEXCUT™ 125

TABLE OF CONTENTS

Safety

General Description...........................................................................................................................10

Preheat Temperature For Plasma Cutting ..........................................................................................10

uty 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

Input Connection..............................................................................................................................A-3

Input Fuse And Supply Wire Considerations .....................................................................................A-3

Input Voltage Selection ....................................................................................................................A-4

Gas Supply Requirements................................................................................................................A-4

Connecting The Gas Supply .............................................................................................................A-4

Output Connections .........................................................................................................................A-4

Operation ..................................................................................................................................Section B

Controls And Settings ......................................................................................................................B-2

User Interface..................................................................................................................................B-3

Mechanized Cutting.........................................................................................................................B-5

Cut Charts .......................................................................................................................................B-7

Consumable Life............................................................................................................................B-13

Cut Quality.....................................................................................................................................B-13

Inspection Of Consumable Parts ....................................................................................................B-14

Suggestions For Extra Utility From The Flexcut™ 125 System: ....................................................B-15

Accessing Divided Arc Voltage.......................................................................................................B-16

Options/Accessories...................................................................................................................Section C

Maintenance ...............................................................................................................................Section D

Daily Procedures .............................................................................................................................D-1

Monthly Procedures.........................................................................................................................D-1

Troubleshooting ..........................................................................................................................Section E

Diagrams ..................................................................................................................................Section F

Wiring Diagram................................................................................................................................F-1

Dimension Print ...............................................................................................................................F-2

Parts List .........................................................................................................parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

LEXCUT™ 125

GENERAL DESCRIPTION

The FLEXCUT™ 125 is a constant current, continuous control plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and arc stability. The control system h

as a safety mechanism to ensure that the nozzle and electrode are in place before cutting or gouging. This is extremely important due to the high voltages involved.

The FLEXCUT™ 125 comes standard with an air regulator and digital pressure display.

The FLEXCUT™ 125 initiates the plasma arc with a simple, yet reliable, contact start mechanism. This system eliminates many of the failure problems associated with hi-frequency start systems.

PREHEAT TEMPERATURE FOR PLASMA CUTTING

Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging. Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control. The following minimum preheat temperature is recommended as a starting point. Higher temperatures may be used as required by the job conditions and/or prevailing codes. If cracking or excessive hardness occurs on the cut face, higher preheat temperature may be required. The recommended minimum preheat temperature for plate thickness up to 1/2" (12.7mm) is 70°F (21.1°C).

DUTY CYCLE

The duty cycle of a plasma machine is the percentage of time in a 10 minute cycle at which the operator can operate the machine at rated cutting current.

Example: 60% duty cycle means that it is possible to cut for 6 minutes, then the machine stops for 4 minutes.

Refer to the Technical Specification section for more information about the machine rated duty cycles.

USER RESPONSIBILITY

Because design, fabrication, erection and cutting variables affect the results obtained in applying this type of information, the serviceability of a product or structure is the responsibility of the user. Variation s

uch as plate chemistry, plate surface condition (oil, scale), plate thickness, preheat, quench, gas type, gas flow rate and equipment may produce results different than those expected. Some adjustments to procedures may be necessary to compensate for unique individual conditions. Test all procedures duplicating actual field conditions.

DESIGN FEATURES AND ADVANTAGES

The FLEXCUT™ 125 design makes plasma cutting uncomplicated. This list of design features and advantages will help you understand the machine's total capabilities so that you can get maximum use from your machine.

- Light weight and portable design for industrial use.

- Continuous control, 20 - 125 amps.

- Reliable touch start mechanism for plasma arc initiation.

- Rapid arc restrike for fast cutting of expanded metal.

- Input over voltage protection.

- Bright 5.0 second timed pilot arc.

- Gas purge selection.

- Air regulator and pressure gage included.

- Internal water separator included.

- Parts-in-Place mechanism to detect proper installation of consumables and torch.

- Preflow/Postflow timing. Preflow is eliminated if arc is reinitiated in Postflow.

- Thermostatic Protection.

- Solid state over-current protection.

- Patented electrode, nozzle and shield cap for optimum cooling, cut quality and long life.

TECHNICAL SPECIFICATIONS K4160-1 FLEXCUT™ 125

A-1

NSTALLATION

LEXCUT™ 125

ASE/

nput

Amp

Rated

)

Amp

RATED OUTPUT AT 40° C

Duty Cycle CURRENT VOLTAGE

100% 125A 175 VDC

RECOMMENDED INPUT WIRE

For all plasma cutting applications

Based on U.S. National Electrical Code

Ambient Temperature 30

C or Less

Input Cord Supplied

with Machine

STO, 600V

Type S, SO, ST, STO

or Extra Hard Usage Cord

AWG (IEC) Sizes

Input Supply Wires

#8 (8.4 mm2)

1 Ground Wire

#8 (8.4 mm

)

OUTPUT

Current Range Open Circuit Voltage Pilot Current

20 - 125 Amps 300 VDC 30 Amps

PHYSICAL DIMENSIONS

Height Width Depth Weight

20.72 in.

(526 mm)

12.25 in.

(311 mm)

25.53 in.

(648 mm)

118 lbs.

(53.5 kgs)

TEMPERATURE RANGES

OPERATING TEMPERATURE

RANGE

STORAGE TEMPERATURE

RANGE

-10°C to +40°C -25°C to +55°C

GAS

REQUIRED GAS FLOW RATE

REQUIRED GAS INLET

PRESSURE

550 SCFH min @ 90 PSI

(260 SLPM min @ 6.21 bar)

90 to 120 PSI

(6.21 to 8.27 Bar.)

*In some countries Uois also known as OCV (see CAN/CSA - W117.2)

*Ground wire should be longer than the three current carrying conductors inside the machine.

A-2

NSTALLATION

LEXCUT™ 125

ead entire Installation Section before installing the

FLEXCUT™ 125 .

INSTALLATION

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel should install this machine.

• Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment.

• Do not touch electrically hot parts.

• Turn the FLEXCUT™ 125 Power Switch OFF when connecting power cord to input power.

SELECT SUITABLE LOCATION

Place the FLEXCUT™ 125 where clean cool air can freely circulate in through the rear of the machine and out through the front and side louvers. Maintain at least 10 inches of space on all sides of the unit. Dirt, dust, or any foreign material that can be drawn into the machine should be kept to a minimum. A properly installed machine will allow for dependable service and reduce periodic maintenance time. Failure to observe these precautions may result in excessive operating temperatures and nuisance shutdowns of the machine.

Keep machine dry.

Shelter from rain and snow. Do not place on wet ground or in puddles.

LIFTING

The FLEXCUT™ 125 power supply should be lifted by two people or a hoist. In order to prevent damage, the power supply should be lifted by both handles while keeping the unit as horizontal as possible. Only hoisting straps approved for the weight of the machine should be used.

STACKING

The FLEXCUT™ 125 cannot be stacked.

TILTING

The FLEXCUT™ 125 must be placed on a stable, level surface so it will not topple over.

HIGH FREQUENCY INTERFERENCE PROTECTION

The FLEXCUT™ 125 employs a touch start mechanism for arc i

nitiation which eliminates high frequency emissions from the machine as compared with spark gap and solid state type high frequency generators. Keep in mind though, that these machines may be used in an environment where other high frequency generating machines are operating. By taking the following steps, high frequency i

nterference into the FLEXCUT™ 125 can be minimized:

(

1) Make sure the power supply chassis is connected to a good earth ground. The work terminal ground does NOT ground the machine frame.

(2) Keep the work clamp isolated from other work clamps that have

high frequency.

(3) If the work clamp cannot be isolated, then keep the clamp as far

as possible from other work clamp connections.

(4) When the machine is enclosed in a metal building, several good

earth driven grounds around the periphery of the building are recommended.

INPUT CONNECTION

Only a qualified electrician should connect the input leads to the FLEXCUT 125. Connections should be made in accordance with all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injure or death.

The FLEXCUT™ 125 is rated for 380 VAC through 575 VAC input voltages, three phase and 50 or 60 Hertz. Before connecting the machine to power, be sure the input supply voltage, phase and frequency all match those listed on the machine’s rating plate.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with a ground symbol is located next to the input power connection block.

See your local and national electrical codes for proper grounding methods.

The FLEXCUT 125 ON/OFF switch is not intended as a service disconnect for this equipment. Only a qualified electrician should connect the input leads to the FLEXCUT 125. Connections should be made in accordance with all local and national electrical codes. Failure to do so may result in bodily injury or death.

WARNING

CAUTION

A-3

NSTALLATION

LEXCUT™ 125

INPUT PLUG INSTALLATION

10 ft.(3m) power cord is provided with the FLEXCUT 125.

Three Phase Input Only

Connect green lead to ground per National Electric Code.

Connect black, red and white leads to power.

In all cases, the green or green/yellow grounding wire must be connected to the grounding pin of the plug, usually identified by a green screw.

Attachment plugs must comply with the Standard for Attachment Plugs and Receptacles, UL498.

The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord.

ocated on the inside of the reconnect access door of the machine. Failure to do so may result in bodily injury or death.

POWER CORD REPLACEMENT

If the input cord is damaged or needs to be replaced, the new cord should be routed through the strain relief and into the connection block.

(See Figure A.1)

Use a three-phase supply line. A 1.40 inch diameter access hole with strain relief is located on the case back. Route input power cable through this hole and connect L1, L2, L3, and ground per connection diagrams and National Electric Code. To access the input power connection block, remove the seven screws and the left case side of the machine as shown.

ALWAYS CONNECT THE GROUNDING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY (EARTH) GROUND.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to the Specification Section for recommended fuse, wire sizes, and type of copper wires. Fuse the input circuit with the recommended super lag fuses or delay type breakers (also called “inverse time” or “thermal/magnetic” circuit breakers). Choose input and grounding wire size according to local or national electric codes. Using input wire sizes, fuses, or circuit breakers smaller than recommended may result in “nuisance” shut-offs from high inrush currents, even if the machine is not being used at high currents.

WARNING

GROUND CONNECTION CONNECT GROUND LEAD PER LOCAL AND NATIONAL ELE CTRIC CODE

INPUT CORD STRAIN RELIEF ROUTE INPUT CORD THROUGH RELIEF AND TWIST NUT TO TIGHT EN

POWER CONNECTION BLOCK CONNECT EACH PHASE OF A THREE PHASE CONDUCTOR HERE

FIGURE A.1

INPUT VOLTAGE SELECTION

The Flexcut™ 125 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 m

achine, move the Auxiliary (“A”) lead from the 460V tap to the

desired input voltage. Always replace the cover when finished.

If the “A” lead is not connected to the proper voltage tap, the machine may not power on, it may throw an error, or the fuse may open. Should the fuse open, replace the fuse, reconnect the “A” lead to the correct voltage and re-apply power.

GAS SUPPLY REQUIREMENTS

Supply the FLEXCUT™ 125 with clean, dry, oil-free compressed air or nitrogen. A high pressure regulator MUST be used with a compressor or a high pressure cylinder.

Supply pressure must be between 90-120 psi (6.21 - 8.27 bar) with flow rates of at least 550 SCFH or 260 SLPM.

Air supply pressure should never exceed 130 psi or damage to the machine may occur!

The FLEXCUT™ 125 contains a built-in filter but depending on the quality of the supply, additional filtration may be required. Be aware that shop air systems are prone to oil and moisture contamination. If shop air is used, it must be cleaned to ISO 8573-1:2010, Class 1.4.1. See the Maintenance Gas Supply Section for information on changing the internal filter element.

Specify dry air when using compressed cylinders. Breathing quality air contains moisture and should not be used.

A standard nominal 5 micron inline filter is recommended, but for optimal performance, select a pre-filter with a 3 micron absolute rating.

CYLINDER could explode if damaged.

• Keep cylinder upright and chained to a fixed support.

• 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.

• Keep cylinder away from live electrical parts.

• Maximum inlet pressure 130 psi.

CONNECTING THE GAS SUPPLY

Air or gas must be supplied to the FLEXCUT™ 125 with 3/8” inside diameter tubing and a ¼” NPT quick disconnect coupler.

OUTPUT CONNECTIONS

The FLEXCUT™ 125 is sent from the factory with a work clamp included. The work clamp must be securely connected to the work piece. If the work piece is painted or extremely dirty it may be necessary to expose the bare metal in order to make a good electrical connection.

WARNING

A-4

NSTALLATION

LEXCUT™ 125

AUXILIARY ("A") LEAD

FIGURE A.2

B-1

PERATION

OPERATION

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear and body protection.

PLASMA ARC can injure

• Keep your body away from nozzle and plasma arc.

• Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.

Observe additional Safety Guidelines detailed in the beginning of this manual.

GRAPHIC SYMBOLS THAT APPEAR ON THIS M

ACHINE OR IN THIS MANUAL

WARNING

FLEXCUT™ 125

WARNING OR CAUTION

READ INSTRUCTION MANUAL

CUT

GAS INPUT

GRID or EXPANDED METAL

GOUGE

POWER ON

POWER OFF

PROTECTIVE GROUND

GAS PURGE

MARKING

B-2

CONTROLS AND SETTINGS

FIGURE B.2 - Front Panel

1. LCD Display: Shows available modes and real time parame-

ters.

2. Home Button: Allows the user to return to the Home Screen.

3. Menu Control Knob/Button: Used to navigate and select

items on the display.

4. Pressure Regulator: Allows the regulation of the primary air/gas pressure.

5. Purge: Allows the user to enable air flow from the machine.

6. On/Off Switch: Turns the input power to the machine

ON/OFF.

7. Torch Connection: Connect the torch.

8. Work Lead Connection: Connect cable with work clamp.

FIGURE B.3 - Back Panel

9. Input Cord Strain Relief: Used to connect the unit to input

power.

10. Reconnect Panel Access: Allows the unit to be configured for 380, 460, or 575 VAC input.

11. 14-pin CNC Interface: Allows access to Arc Start Trigger, Arc Initiated contact, raw or divided Arc Voltage, and Forced Mark.

12. Air or Gas Inlet (1/4” NPT Quick Connect): Compressed air or gas connection.

FLEXCUT™ 125

PERATION

B-3

PERATION

USER INTERFACE

Mode Select Screen

Choose between four available modes:

Cut – For cutting operations on a solid workpiece.

Mark – For discoloring or slight removal of material. Can

be used to add part numbers, bend lines, drill marks, or many other surface modifications.

Grid – For cutting operations on a non-continuous workpiece.

Gouge – For removing material from a workpiece (removing a weld).

Active Mode Screen - See Figure B.4

Active Mode Icon – The currently selected mode icon will be displayed here. Return to the mode select screen to choose a new mode.

Output Current – Turn the control knob to adjust the desired output current. While cutting, the screen will display the actual cutting current in Amps. Output current range is dependent on Mode selected.

Output Gas Pressure – The output gas pressure is displayed on a linear scale, with the center of the green range as the recommended output gas pressure based on selected mode and torch length. Use the regulator knob on the front of the machine to adjust the output gas pressure, but do so only while gas is flowing. Hold the purge button while pulling and turning the regulator knob to adjust the pressure as desired.

Torch Length – The selected torch length will be displayed here. Be sure the torch length matches the torch that is being used with the machine. The torch length can be modified in the settings menu.

FLEXCUT™ 125

Cutting

Press to Select

125

PSI

5ft

Active Mode Icon

Output Current

utput Gas Pressure

orch Length

IGURE B.4

B-4

PERATION

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):

Torch Size – Choose between 25 ft. (7.6m), 50 ft. (15.2m), or 75 ft. (22.9m) torch lengths. This will change the recommended output gas pressure.

Language – Choose between English, Spanish, French, or German

Units – Choose between English or Metric units

Reset Factory Settings – Use to restore the machine back to the factory settings

Brightness – Used to dim or brighten the LCD display

Advanced – Used for diagnostic purposes

FLEXCUT™ 125

25’

50’ 75’

ress to Select

Torch Size

EN SP FR GR

ress to Select

Language

English Metric

Press to Select

Units

No Yes

ress to Select

Reset Factory Settings

Press to Select

110

Brightness

No Yes

Press to Select

Information

B-5

PERATION

FLEXCUT™ 125

MECHANIZED CUTTING

Mechanized Torch Installation

It is recommended that the FLEXCUT™ 125 mechanized torch be i

nstalled on a positioner with an arc voltage control capable of maintaining the cutting arc voltage within 1 volt. The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended.

Installing the Mechanized Torch Consumables

To install the torch parts, perform the following steps (See Figure B.5):

Note: Do not over tighten the consumables! Only tighten until the parts are seated properly.

1. Inspect the threads on the torch body and retaining cap and clean as necessary. Apply lubricant to the torch o-ring as necessary. Lubricant should be oxygen safe and inert in a flammable environment.

2. Install the electrode (1) into the torch body and press into place.

3. Thread the shield cap (5) onto the retaining cap assembly. (4)

4. Insert the nozzle (3) into the swirl ring. (2)

5. Place the swirl ring / nozzle assembly into the retaining cap.

6. Thread and tighten the retaining cap assembly onto the torch body. (6)

Removing the Torch Consumables

Turn off the machine prior to removing consumables.

To remove the torch consumables, perform the following steps:

1. Remove the retaining cap from the torch.

2. Remove the swirl ring and nozzle from the retaining cap.

3. Separate the shield cap from retaining cap.

4. Remove the electrode from the torch body.

5. Remove the swirl ring from the nozzle.

Contaminants such as dirt, metallic dust, oil and moisture present on the surface of the electrode and/or torch body can cause electrical arcing between these components and ultimately result in failure of the torch and consumables.

Do not continue to try and cut excessively worn consumables as this can cause damage to the Torch Head.

In order to avoid damaging the torch and/or consumables, adhere to the following guidelines:

1. Ensure that the air supplied to the torch does not contain contaminants such as debris, moisture and oil.

2. Ensure that the torch cathode body and electrode body are clean prior to assembling the consumables into the torch. Wipe away any contaminants with a dry, lint free cloth.

3. Be sure that the consumables are properly tightened and fully inserted when installing them into the torch. Check the installation of the consumables before the start of each work shift and frequently to ensure that the parts have not become loose as a result of normal operation.

4. Inspect the surfaces of the cathode body and electrode body to ensure no contaminants have collected during operation. (Reference Figure B.6)

FIGURE B.6

WARNING

ELECTRODE BODY

CATHODE BODY

(1) ELECTRODE BK14300-1

BK500024

(2) SWIRL RING BK14300-13

(3) NOZZLE 45A - BK14300-7 65A - BK14300-8 85A - BK14300-9 105A - BK14300-10 125A - BK14300-11

(4) RETAINING CAP BK14300-15

(5) SHIELD CAP 45A - 65A - BK14300-3 85A - 125A - BK14300-4

O-RING

BK14300-18

(7) FRONT ISOLATOR ASSEMBLY

(6) LC125M TORCH BODY

FIGURE B.5

+ 43 hidden pages

Lincoln Electric FlexCut 125 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual