Lincoln Electric FlexCut 125 Operator's Manual

Download

Page 1

Operator’s Manual

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

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

Page 2

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

Page 3

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

Page 4

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

Page 5

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

Page 6

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

Page 7

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

Page 8

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

Page 9

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.

Page 10

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.

Page 11

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.

Page 12

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

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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

Page 19

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

Page 20

B-6

PERATION

Making a Cut

Setting up a Cut

Use the following procedure to make a cut with the F

LEXCUT™ 125.

. Using the charts, determine the proper torch parts and cutting

conditions for the material being cut.

2. Install the proper consumables into the torch.

3. Turn the power switch to the ON position to apply power to the FLEXCUT™ 125. The LCD will turn on and display the FLEXCUT™ initialization screen.

4. Press the home button and choose the desired operating mode.

5. Turn the control knob to set the desired output current.

6. Press and hold the gas purge button while adjusting the regulator to recommended output pressure (center of green range).

7. The cutting operation is initiated after a start signal is received. The arc should establish approximately 2 seconds after application of the start command. The cutting operation is terminated when the start signal is removed. At the completion of a cut, gas flow through the torch will continue for approximately 20 seconds. The LCD will display the actual output current and gas pressure while the cut is active.

Machine Interface

The FLEXCUT™ 125 comes standard with a machine interface. Interface signals provided include: Arc Start, Arc Initiated, Arc Voltage (raw or divided) and Force Mark. These signals are a

ccessible through the 14 pin connector on the case back. (See

Figure B.7

Arc Start:

The Arc Start circuit allows for triggering of the power source to commence cutting. This circuit can be accessed through pins K and M of the 14 pin connector. The circuit has a 15 VDC nominal open circuit voltage and requires a dry contact closure to activate.

Arc Initiated:

The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece. This circuit can be accessed through pins I and J of the 14 pin connector. The circuit provides a dry contact closure when the arc has transferred. Input to this circuit should be limited to 0.3 A for either 120VAC or 30VDC.

Arc Voltage:

The Arc Voltage circuit can be used for activating a torch height control. This circuit can be accessed through pins D and G of the 14 pin connector. The circuit provides full electrode to work arc voltage (300VDC maximum). A divided arc voltage of 20:1, 30:1, 40:1 or 50:1 is available. See “Accessing Divided Arc Voltage.”

Force Mark:

The Force Mark circuit can be used to change between a cut or grid operating mode and a marking mode quickly and while output is on. This circuit can be accessed though pins A and B of the 14-pin connector. This circuit requires a dry contact closure to operate and both modes should be configured prior to cutting.

Users wishing to utilize the Machine Interface can order a K867 Universal Adapter (please adhere to the pin locations stated above) or manufacture a 14 pin connector cable assembly.

FLEXCUT™ 125

14-PIN BOX RECEPTAC

LE,

FRO

IEW

Arc Star

Force Mark

Arc Voltage

Initia

ted

FIGURE B.7

Page 21

B-7

PERATION

Cutting Charts

The cutting charts shown on the following pages are intended to give t

he 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. Also, remember that the arc voltage must be increased as the electrode wears in order to maintain the correct cutting height.

FLEXCUT™ 125

URRENT

AGE

45 AMPS B-8

65 AMPS B-9

85 AMPS B-10

105 AMPS B-11

125 AMPS B-12

Page 22

!"#$%&#%'()*+,-'.#/),'0.#(1+/2%*30'/

4,0.#56''0

78'//28'

7,'8('#

'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

45-32 67689 67: ;:6 8;: :66 8;< 676<: 878

44-32 676;6 679 ;56 8;: <56 8;< 676<: 878

9-32 676<9 874 ;:6 8;: <86 8;< 676:6 87;

85-32 67656 87: ;4: 8;: <66 8;< 676:6 87;

8<-32 676=: 87> 67;6 4>6 8<6 ;4: 8;> 67656 87:

84-32 6786: 47= 466 8<4 446 8;> 6765: 87=

86-32 678;: ;7< 886 8<< 85= 8<4 6765: 87=

;?85 67899 <79 67:6 96 8<5 886 8<; 6765: 87=

8?< 674:6 57< 6756 6784 ;76 <: 8:4 =; 8:6 67696 476

@-45@86-32-#1%%0-$#-&/0A-,/00%AB-;?85-2'A-8?<-$'-#1%%0-$#-C/1-,/00%A

56*,+0'//#56''0

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

45-32 6768> 67: <66 8:6 :86 8:6 676<6 876

44-32 676;8 679 ;=: 8:6 <=: 8:6 676;6 679

89-32 676:6 87; ;:6 8:6 <66 8:4 676;: 67>

85-32 6765; 875 ;8: 8:4 <66 8:4 676<6 876

8<-32 676=9 476 6746 4<6 8:< 4:6 8:< 676<: 878

84-32 6786> 479 67;6 8=: 8:5 89: 8:< 676:6 87;

86-32 678<8 ;75 67<6 866 8:5 8<6 8:< 676:: 87<

;?85 67899 <79 67:6 =6 8:9 9: 8:5 67656 87:

8?< 674:6 57< 6756 ;6 8:> <6 8:= 67656 87:

$02%,+2%

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

8?;4 676;8 679 6766 ;56 8:4 <:6 8:4 676:: 87<

8?85 6765; 875 6786 ;56 8:< ;>6 8:< 67656 87:

;?;4 676>< 47< 6746 4;: 8:5 ;66 8:4 67656 87:

8?9 6784: ;74 67<6 896 856 46: 8:9 6765: 87=

8?< 674:6 57< 67:6 6785 <78 :: 854 =: 856 6765: 87=

4*8;,+<

78'//28' =288'+6

"#$ +!"# $' !! $' !!

84 6786 47:< 6786 47:<

8==

7,'8('#9'0*:

#%&

6766

./01#

8==

4:6

8==

781.2(6,1+#5'66,+</

=266,+<#>',<)6

7,'8('#>',<)6

781.2(6,1+#5'66,+</

*$0A-D1%%0

D12$'0%##-D1%%0

+0E!$'E!

?8*@'0#5&''.

F+00-GC$&H'%##%#I

()*

4:6

;=J

4*6'8,*0

$8(#A106*<'

7,'8('#>',<)6

=266,+<#>',<)6

B'8C#D,.6)

676<

876

E&6,%2%#5'66,+</

B'8C#D,.6)

6786

47:

67<6

6786

6766

6769

4*6'8,*0#?),(;+'//

=266,+<#>',<)6

6785

<78

56J

6786

47:

4*6'8,*0#?),(;+'//

@-K/,-<:+-&E11$'3-/L-D12$'0%##-D1%%0-M$1C-2-=:-L17-1/,&CB-!$'$!E!-$'"E1-32#-",%##E,%-$#-866-"#$7

E&6,%2%#5'66,+</

7,'8('#>',<)6

B'8C#D,.6)

6786

47:

6746

:78

=6J

6766

6786

476

4*6'8,*0#?),(;+'//

E&6,%2%#5'66,+</

781.2(6,1+#5'66,+</

=266,+<#>',<)6

7,'8('#>',<)6

6746 674:

57<

:78

56J

B-8

PERATION

FLEXCUT™ 125

Shield Retaining Cap Nozzle Swirl Ring Electrode

BK14300-3 BK14300-15 BK14300-7 BK14300-13 BK14300-1

LC125M Torch Body

* Listed Gas Pressures are for 25 ft. torches. Increase Gas Pressure by 5 psi for each additional 25 ft. of torch length.

Explosion Hazard

Do not cut Aluminum over water tables

WARNING

Page 23

B-9

PERATION

FLEXCUT™ 125

!"#$%&#%'()*+,-'.#/),'0.#(1+/2%*30'/

,0.#56''0

78'//28'

,'8('#

9'0*:

!"#$ #%& $'!!$'!!()*

+,&-

/0123%

(

+,&-

/0123%

'!!

45-32 67656 478 6746 986 4:; 9<8 4:4 67656 478 4

6-32 674;8 ;7: 67;6 4<8 4:8 995 4:; 676=6 47>

;?45 674>> :7> 6786 4:6 4:8 4=6 4:; 676=6 47>

4?: 67986 57: 67>6 <8 4:8 448 4:; 676=6 47> ;

?> 67;=8 <78 4796 86 489 5; 4:> 676=8 47<

?9 67866 497= 679 874 ;8 48; :6 486 676>8 979 8?> 67598 487< 67; =75 96 485 9: 488 676>8 979 ;?: 67=86 4<74 48 459 4< 456 676<6 97; @%# =?> 67>=8 9979 46 458 4: 45: 676<6 97; @%#

447666987: = 4=6 46 455676<997; @%#

A-45-2'B-46-32-#1%%0-$#-&/0B-,/00%BC-;?45-A-4-$'-#1%%0-$#-D/1-,/00%B

56*,+0'//#56''0

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

45-32 6765; 475 ;98 4:< :98 4:< 67686 47;

46-32 674:4 ;75 946 484 95: 4:< 67656 478

;?45 674>> :7> 6796 4:= 48; 45> 484 676=6 47>

4?: 67986 57: 67:6 =6 488 <6 48; 676>6 976

;?> 67;=8 <78 67>6 :; 48> 86 48= 676<6 97;

4?9 67866 497= 4796 96 45= ;9 48< 67466 978

8?> 67598 487< 4< 458 99 45; 67468 97= @%#

;?: 67=86 4<74 4: 45> 4> 455 67446 97> @%#

$02%,+2%

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

4?45 6765; 475 6746 ;:8 456 :9> 456 676=6 47>

4?> 67498 ;79 6796 988 486 ;98 486 67656 478

4?: 67986 57: 67:6 466 456 4:= 48< 676=8 47<

;?> 67;=8 <78 6756 88 458 =6 45; 676>8 979

4?9 67866 497= 4766 ;8 45> :8 45> 676<6 97;

8?> 67598 487< 99 4=6 ;6 45> 67466 978 @%#

;?: 67=86 4<74 4: 4=: 99 4=9 67468 97= @%#

4*8;,+<

78'//28' =288'+6

"#$ +!"# $' !! $' !!

4: 6746 978: 6746 978:

>'8?#@,.6)

A.<'#

6*86

./01#

$8(#B106*<'

>'8?#@,.6)

4=>

*$0B-E1%%0

7,'8('#C',<)6

>'8?#@,.6)

4*6'8,*0#D),(;+'//

781.2(6,1+#5'66,+</

=266,+<#C',<)6

6749

;76

E&6,%2%#5'66,+</

9766

56F

E12$'0%##-E1%%0

4=>

A.<'#

56*86

A.<'#

56*86

4=>

+0G!$'G!

D8*F'0#5&''.

H+00-ID$&J'%##%#K

()*

986

4*6'8,*0

986

;=F

7,'8('#C',<)6

=266,+<#C',<)6

6766

986

7,'8('#9'0*:

#%&

6766

6746

4*6'8,*0#D),(;+'//

E&6,%2%#5'66,+</

781.2(6,1+#5'66,+</

=266,+<#C',<)6

7,'8('#C',<)6

67;;

>7;

6796

874

6756

56F

6796

874

4*6'8,*0#D),(;+'//

E&6,%2%#5'66,+</

=75

6798

57:

56F

781.2(6,1+#5'66,+</

=266,+<#C',<)6

7,'8('#C',<)6

6786

6745

:74 679

874

67;6

Shield Retaining Cap Nozzle Swirl Ring Electrode

BK14300-3 BK14300-15 BK14300-8 BK14300-13 BK14300-1

C125M Torch Body

* Listed Gas Pressures are for 25 ft. torches. Increase Gas Pressure by 5 psi for each additional 25 ft. of torch length.

Explosion Hazard

Do not cut Aluminum over water tables

WARNING

Page 24

!"#$%&#%'()*+,-'.#/),'0.#(1+/2%*30'/

4,0.#56''0

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

45 56478 769 5655 :;5 47< 748 47= 56585 46:=

7>4; 564<< 96< 56:5 4?5 495 ::5 47? 5658< 469=

4>9 56:85 ;69 4:5 494 488 495 565;5 468: 7>< 567=8 ?68 =8 499 << 497 565;< 46=7 4>: 56855 4:6= 95 498 89 498 565=< 46?< 8>< 56;:8 486? 4655 75 485 95 49= 565<8 :64; 7>9 56=85 4?64 4685 5675 =6; :9 487 75 485 565<8 :64; =>< 56<=8 ::6: 46:8 4; 48< :: 487 565?5 :6:? @%#

446555:869 47 4;5 4; 48;56455:689 @%#

4-4>9 46:85 746< = 4;< 45 4;4 56445 :6=? @%#

A-45-32-#1%%0-$#-&/0B-,/00%BC-7>4;-A-4-4>9-$'-#1%%0-$#-D/1-,/00%B

56*,+0'//#56''0

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

45 56494 76; 56:5 :<8 47? 798 47< 565=8 46?4

7>4; 564<< 96< 5675 :45 47? :85 47< 565=8 46?4

4>9 56:85 ;69 5695 478 47? 4=5 47< 565<5 :657

7>< 567=8 ?68 5685 ;5 497 <5 49: 565<5 :657

4>: 56855 4:6= 56=5 7; 49< 9; 49; 565<9 :647

8>< 56;:8 486? :; 485 77 49? 565?7 :67;

7>9 56=85 4?64 4< 489 :9 487 56458 :6;= @%#

=>< 56<=8 ::6: 4; 488 4? 489 56458 :6;= @%#

446555:869 44 48? 49 48<56458:6;= @%#

$02%,+2%

78'//28'

7,'8('#

9'0*:

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

4>< 564:8 76: 56:5 745 489 7;5 489 565<8 :64;

4>9 56:85 ;69 5695 495 48< 4;= 48< 565?5 :6:?

7>< 567=8 ?68 56;5 =8 4;5 459 48< 565?8 :694

4>: 56855 4:6= 56<5 88 4;: =7 4;: 56455 :689

8>< 56;:8 486? 4655 7< 4;= 9< 4;= 56458 :6;=

7>9 56=85 4?64 :< 4;? 95 4;= 56458 :6;= @%#

=>< 56<=8 ::6: :: 4=: 75 4=4 56458 :6;= @%#

446555:869 48 4=8 :5 4=856458:6;= @%#

4*8;,+<

78'//28' =288'+6

"#$ +!"# $' !! $' !!

47 5645 :689 5645 :689

49 5645 :689 5645 :689

4<<

>.<'#

56*86

>.<'#

56*86

>.<'#

56*86

56<5

;64

56:9

7,'8('#9'0*:

#%&

5655

./01#

$8(#?106*<'

7,'8('#@',<)6

=266,+<#@',<)6

4<<

:85

4<<

*$0B-E1%%0

E12$'0%##-E1%%0

A8*B'0#5&''.

F+00-GD$&H'%##%#I

()*

:85

4*6'8,*0

:85

7,'8('#@',<)6

+0J!$'J!

5677

<67

7,'8('#@',<)6

7=K

;5K

C'8D#E,.6)

4*6'8,*0#A),(;+'//

F&6,%2%#5'66,+</

781.2(6,1+#5'66,+</

=266,+<#@',<)6

5685 4685

6:8;69

56:8

;69

=266,+<#@',<)6

7,'8('#@',<)6

F&6,%2%#5'66,+</

564:

765

56:4

867

=266,+<#@',<)6

C'8D#E,.6)

4*6'8,*0#A),(;+'//

F&6,%2%#5'66,+</

781.2(6,1+#5'66,+</

;5K

56:8

;69

5685

;5K

564:

765

C'8D#E,.6)

781.2(6,1+#5'66,+</

B-10

FLEXCUT™ 125

PERATION

Retaining Cap Nozzle Swirl Ring Electrode

BK14300-15 BK14300-9 BK14300-13 BK14300-1

hield

K14300-4

LC125M Torch Body

* Listed Gas Pressures are for 25 ft. torches. Increase Gas Pressure by 5 psi for each additional 25 ft. of torch length.

Explosion Hazard

Do not cut Aluminum over water tables

WARNING

Page 25

B-11

PERATION

FLEXCUT™ 125

$ $ $ $

5-1/$67((1

89(0039(

8-(9)($

:(1+;

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

456 789:7 ;86 7867 4:7 46: 4<7 46: 78477 98:

=5< 78=>: ?8: 78:7 47: 46> 446 46; 78477 98: 459 78:77 498> 78;7 ;7 4:7 >= 4:7 7847: 98>

:5< 78;9: 4:8? 69 4:= :7 4:7 7847: 98>

=56 78>:7 4?84 == 4:6 => 4:9 7847: 98> >5< 78<>: 9989 9877 9: 4:; =4 4:: 78447 98<

4487779:86 48<7 4? 4;7 9= 4:?78497=87 @%#

4-456 489:7 =48< 9877 46 4;: 4; 4;6 7849: =89 @%#

A-+00-B/1-,/00%C-#1%%0

67+-,1(00$67((1

89(0039(

8-(9)($

:(1+;

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

456 789:7 ;86 78=7 >8; 4?< 4:< 94: 46: 78477 98:

=5< 78=>: ?8: ?7 4:7 479 46< 7847: 98 >

459 78:77 498> :: 4:= ;? 46? 7847: 98>

:5< 78;9: 4:8? 4897 7867 4789 =< 4;; 69 4:; 7844: 98?

=56 78>:7 4?84 786= 478< 9; 4;7 =7 4:< 78497 =87

>5< 78<>: 9989 94 4;: 9: 4:? 78499 =84 @%#

4487779:86 4> 4>6 97 4;=784=7=8= @%#

4-456 489:7 =48< 98:7 44 4;< 46 4;; 784=7 =8= @%#

%13&-,3&

89(0039(

8-(9)($

:(1+;

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

456 789:7 ;86 78:7 947 4:7 99: 46? 78477 98:

=5< 78=>: ?8: 78;7 47: 4:: 4=7 4:6 7847: 98>

459 78:77 498> 78<7 >> 4:< ?= 4:; 78447 98<

:5< 78;9: 4:8? 4877 78=< ?8: :6 4;= ;9 4;9 78447 98<

=56 78>:7 4?84 4897 =< 4;> 64 4;; 7844: 98?

>5< 78<>: 9989 48=: 9? 4;? =6 4;< 7844: 98?

4487779:86 9= 4>9 9? 4>778497=87 @%#

4-456 489:7 =48< 4: 4>? 4< 4>> 78497 =87 @%#

5+9<-,=

89(0039( >399(,7

"#$ +!"# $' !! $' !!

46 7847 98:6 7847 98:6

4: 7847 98:6 7847 98:6

4<6

?/=($

67+97

?/=($

67+97

?/=($

67+97

./01#

%9)$@217+=(

4<6

9:7

4<7

784<

68;

>377-,=$A(-=*7

+0D!$'D!

B9+C(1$6'((/

E+00-FB$&G'%##%#H

()*

9:7

5+7(9-+1

9:7

=>I

*$0C-J1%%0

J12$'0%##-J1%%0

7877

8-(9)($:(1+;

#%&

7877

8-(9)($A(-=*7

4877

78=:

<8?

78==

<8=

78=:

<8?

784<

68;

>377-,=$A(-=*7

789<

>84

78=<

?8:

78=7

>8;

D'7-&3&$6(77-,=0

E(9F$G-/7*

892/3)7-2,$6(77-,=0

48<7

78=:

<8?

E(9F$G-/7*

D'7-&3&$6(77-,=0

892/3)7-2,$6(77-,=0

>377-,=$A(-=*7

E(9F$G-/7*

D'7-&3&$6(77-,=0

892/3)7-2,$6(77-,=0

>377-,=$A(-=*7

784;

684

5+7(9-+1$B*-)<,(00

7867

4789

8-(9)($A(-=*7

9877

78;7

$'$'5+7(9-+1$B*-)<,(00

8-(9)($A(-=*7

5+7(9-+1$B*-)<,(00

;7I ;7I

;7I

8-(9)($A(-=*7

$$ $ $

(14+&30,2)/1(-*0/(.-,+*)(&'%&#"!

$$ $ $

Retaining Cap Nozzle Swirl Ring Electrode

BK14300-15 BK14300-10 BK14300-13 BK14300-1

hield

BK14300-4

LC125M Torch Body

* Listed Gas Pressures are for 25 ft. torches. Increase Gas Pressure by 5 psi for each additional 25 ft. of torch length.

Explosion Hazard

Do not cut Aluminum over water tables

WARNING

Page 26

!"#$%&'$&()*+,-.(/$0*-(1/$)2,03&+41(0

5-1/$67((1

89(0039(

8-(9)($

:(1+;

!! "#$ #%& $' !! $' !! ()*

+,&-

/0123%

()*

+,&-

/0123%

$' !!

456 789:7 ;86 78<7 4=7 46: 947 466 78477 98: <5= 78<>: ?8: 78:7 447 46> 49= 46; 7847: 98> 459 78:77 498> 78>7 >9 46? == 46> 7847: 98> :5= 78;9: 4:8? 4877 :7 4:4 ;< 4:7 78447 98= <56 78>:7 4?84 4897 78<< =8< 67 4:< :9 4:9 78447 98= >5= 78=>: 9989 48=7 78<: =8? <4 4:; 67 4:: 7844: 98?

4487779:86 98:778<=?8: 9< 4;7 <9 4:>78497<87

4-456 489:7 <48= 4; 4;< 94 4;9 7849: <89 @%# 4

-459 48:77 <=84 44 4;= 46 4;= 7849: <89 @%#

A-+00-B/1-,/00%C-#1%%0

67+-,1(00$67((1

89(0039(

8-(9)($

:(1+;

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

456 789:7 ;86 99: 46; 9;7 46= 78477 98:

<5= 78<>: ?8: 47> 46= 4:9 46= 78447 98=

459 78:77 498> 78;7 >= 4:< ?6 4:7 78447 98=

:5= 78;9: 4:8? 78>7 6> 4:: ;7 4:< 7844: 98?

<56 78>:7 4?84 4897 67 4:> 6: 4:; 7844: 98?

>5= 78=>: 9989 48:7 9; 4;4 <9 4:? 7844> <87 @%#

4487779:86 48=7 4? 4;; 9: 4;<78497<87 @%#

4-456 489:7 <48= 9877 46 4;= 4= 4;: 7849: <89 @%#

4-459 48:77 <=84 9897 ? 4>: 44 4>9 7849: <89 @%#

%13&-,3&

89(0039(

8-(9)($

:(1+;

!! "#$ #%& $' !! $' !! ()*

+,&-

./0123%

()*

+,&-

./0123%

$' !!

456 789:7 ;86 7897 9:7 4:7 9>: 46? 7844: 98?

<5= 78<>: ?8: 7867 49= 4:6 4:= 4:9 78497 <87

459 78:77 498> 78:7 =< 4:> 449 4:6 78497 <87

:5= 78;9: 4:8? 78>7 78<< =8< ;< 4;4 =< 4:? 78497 <87

<56 78>:7 4?84 4877 78<: =8? :9 4;6 ;9 4;9 7849: <89

>5= 78=>: 9989 48;7 7867 4789 <6 4;> 6; 4;6 7849> <89

4487779:86 9897786<478= <9 4>7 67 4;>784<7<8<

4-456 489:7 <48= 4> 4>= <7 4>< 784<7 <8< @%#

4-459 48:77 <=84 49 4=< 4; 4=7 78467 <8; @%#

5+9<-,=

89(0039(

>399(,7

"#$ +!"# $' !! $' !!

4: 7847 98:6 7847 98:6

4; 7847 98:6 7847 98:6

?/=($

67+97

?/=($

67+97

?/=($

67+97

7877

78:7

8-(9)($:(1+;

@9+A(1$6'((/

%9)$B217+=(

8-(9)($C(-=*7

>377-,=$C(-=*7

()*

./01#

4>>

4=6

4>?

9:7

5+7(9-+1

*$0C-D1%%0

D12$'0%##-D1%%0

+0E!$'E!

F+00-GB$&H'%##%#I

D(9E$F-/7*

784;

684

78<7

>8;

78<7

>8;

892/3)7-2,$6(77-,=0

G'7-&3&$6(77-,=0

5+7(9-+1$@*-)<,(00

G'7-&3&$6(77-,=0

892/3)7-2,$6(77-,=0

>377-,=$C(-=*7

8-(9)($C(-=*7

9897

5+7(9-+1$@*-)<,(00

>377-,=$C(-=*7

8-(9)($C(-=*7

;7J

$'$'D(9E$F-/7*

98:7

5+7(9-+1$@*-)<,(00

G'7-&3&$6(77-,=0

892/3)7-2,$6(77-,=0

>377-,=$C(-=*7

8-(9)($C(-=*7

7897

:84

7897

:84

78<7

>8;

7867

;7J

<>J

D(9E$F-/7*

4789

>8;

78<:

=8?

78<7

>8;

9:7

#%&

7877

9:7

B-12

PERATION

FLEXCUT™ 125

Retaining Cap Nozzle Swirl Ring Electrode

K14300-15 BK14300-11 BK14300-13 BK14300-1

BK14300-4

Shield

LC125M Torch Body

%% % %

(#D-320/>+$#(":0$(C"/-:+(3=13BA@

%% % %

* Listed Gas Pressures are for 25 ft. torches. Increase Gas Pressure by 5 psi for each additional 25 ft. of torch length.

Explosion Hazard

Do not cut Aluminum over water tables

WARNING

Page 27

B-13

PERATION

CONSUMABLE LIFE

Use the following guidelines to maximize consumable parts life:

1. The FLEXCUT™ 125 utilizes the latest advancement in technology for extending the life of the torch consumable parts. To maximize the life of the consumable parts, it is imperative t

hat the shutdown procedure of the arc is carried out properly. The arc must be extinguished while it is still attached to the workpiece. A popping noise may be heard if the arc extinguishes abnormally. Note that holes are usually programmed without lead-outs to prevent loss of the arc during shutdown.

2. Use the recommended pierce height given in the cutting charts. A pierce height that is too low will allow molten metal that is ejected during the piercing process to damage the shield cap and nozzle. A pierce height that is too high will cause the pilot arc time to be excessively long and will cause nozzle damage.

3. Minimize firing the torch in the air. Nozzle damage will occur.

4. Make sure the torch does not touch the plate while cutting. Shield cap and nozzle damage will result.

5. Use a chain cut when possible. Starting and stopping the torch is more detrimental to the consumables than making a continuous cut.

CUT QUALITY

Before the optimum cutting condition can be achieved on a particular material type and thickness, the machine operator must have a thorough understanding of the cutting characteristics of the F

LEXCUT™ 125. When the cut quality is not satisfactory, the cutting speed, torch height, or gas pressures may need to be adjusted in small increments until the proper cutting condition is obtained. The following guidelines should be useful in determining which cutting parameter to adjust.

Before making any parameter changes, verify that the torch is square to the work piece. Also, it is essential to have the correct torch parts in place and to ensure that they are in good condition. Check the electrode for excessive wear and the nozzle and shield cap orifices for roundness. Also, check the parts for any dents or distortions. Irregularities in the torch parts can cause cut quality problems.

1. A positive cut angle (top dimension of piece smaller than the bottom dimension) usually occurs when the torch standoff distance is too high, when cutting too fast, or when excessive power is used to cut a given plate thickness.

2. A negative cut angle (top dimension of piece larger than the bottom dimension) usually occurs when the torch standoff distance is too low or when the cutting speed is too slow.

3. Top dross usually occurs when the torch standoff distance is too high.

4. Bottom dross usually occurs when the cutting speed is either too slow (slowspeed dross) or too fast (high-speed dross). Lowspeed dross is easily removed, while high-speed dross usually requires grinding or chipping off. Bottom dross also occurs more frequently as the metal heats up. As more pieces are cut out of a particular plate, the more likely they are to form dross.

5. Note that different material compositions have an effect on dross formation.

6. If the material is not being completely severed, the likely causes are that the cutting current is too low, the travel speed is too high, the gas pressure is incorrect, the incorrect consumables are installed in the torch, or the consumables are worn.

FLEXCUT™ 125

Page 28

B-14

PERATION

FLEXCUT™ 125

INSPECTION OF CONSUMABLE PARTS

When the cut quality is not satisfactory, use the following guidelines for determining which consumable parts need to be changed. I

nspect all parts for dirt or debris and clean as necessary.

!"#$ %&'!()$*+,# ),##()$%-(*")$%,&

!"#$%&'()*

+$,)#-#-.'()*

-/00%$

!1#+%'+#-.

$%$(,+/&$

,/+("

&)2).$&3'1/+-3'/+'&+4'/5+#-.

*)+,!'#-'*%)($'*#-!')+$'(%$)-'

)-&'2/6$'#-')-&'/7,'$)!#%4

8$$*'*#-!')!'(%$)-')!'*/!!#9%$:'#;',"$4'-/'

%/-.$+'2)8$'.//&'(/-,)(,'1#,"'

+$,)#-#-.'()*',"$4'27!,'9$'+$*%)($&:

#;',"$'/5+#-.'#!'&)2).$&'/+'(+)(8$&3'

+$*%)($'#,:')**%4')'!#%#(/-$'9)!$&'

%79+#()-,',/',"$'/5+#-.')!'-$$&$&',/'

*+/%/-.'%#;$:

($-,$+'"/%$'/7,'/;'+/7-&

+$*%)($'-/00%$

9%/1'/7,'1#,"'(/2*+$!!$&')#+:'+$*%)($'

*)+,'#;'"/%$!'()--/,'9$'(%$)+$&:

(%/..$&'"/%$!

&)2).$

+$*%)($'!1#+%'+#-.

*#,'&$*,"

!7+;)($')+(#-.'/+'$+/!#/-

+$*%)($'$%$(,+/&$'#;'!7+;)($'#!'$<($!!#6$%4'

(/++/&$&:

+$*%)($'$%$(,+/&$'#;'($-,$+'*#,'&$*,"'#!'

.+$),$+',")-':=>=?'@A:B'CCD:

$+/!#/-'/+')+(#-.

+$*%)($'!"#$%&'()* +$*%)($'!"#$%&'()*

+$*%)($'+$,)#-#-.'()*

.)!'*)!!'"/%$!'(%/..$&

&$-,!3'(+)(8!3'/+'/,"$+'&)2).$

%//!$'/"2#('!$-!$'(/--$(,/+

&$-,!3'!(+),("$!3'/+'/,"$+'

&)2).$

($-,$+'"/%$'/7,'/;'+/7-&

IF THE O-RING IS DAMAGED OR CRACKED,

REPLACE IT. APPLY A LUBRICANT WHICH IS

COMPATIBLE IN OXYGEN OR REACTIVE ENVI-

RONMENT.

Page 29

B-15

PERATION

SUGGESTIONS FOR EXTRA UTILITY FROM THE FLEXCUT™ 125 SYSTEM:

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the rear of th machine before tightening, cleaning or replacing consumables.

1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle. This will result in false starts. When this happens turn the power off, remove the shield cup and nozzle. Rub the inside surface of the nozzle, this will help remove any oxide buildup. Also, clean any oxide build up from the electrode. Replace the shield cup and nozzle, turn on the power and continue cutting. If false starts continue to occur after cleaning the consumables, then replace them with a new set. Do not continue to try and cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality. Do not allow torch cable or body to contact hot surfaces.

2. To improve consumable life, here are some suggestions that may be useful:

• Use only Lincoln consumable parts. These parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality.

• Make sure the air supply to the FLEXCUT™ 125 is clean and free of oil. Use several extra in line filters if necessary.

• Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible.

• Pierce cutting should be done only when necessary. If piercing, angle torch about 30° from the plane perpendicular to the work piece, transfer the arc, then bring the torch perpendicular to the work and begin parallel movement.

• Reduce the number of pilot arc starts without transferring to the work.

• Reduce the pilot arc time before transferring to the work.

• Set air pressure to recommended setting. A higher or lower pressure will cause turbulence in the plasma arc, eroding the orifice of the nozzle tip.

WARNING

FLEXCUT™ 125

Page 30

B-16

PERATION

FLEXCUT™ 125

ACCESSING DIVIDED ARC VOLTAGE

The Flexcut™ 125 is factory set to provide raw arc voltage through the 14 pin CNC Connector (see arc voltage on page B-6).

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 s

teps:

. Turn off and disconnect the Flexcut™ 125 from incoming power.

. Remove the left case side (left side while viewing the front of the

machine).

3. Located in the lower left rear corner is the voltage divider board.

4. Remove the 2-pin connector from J2 and plug it into J3:

5. Set the switch as follows to get the desired divided voltage:

6. Reinstall the left case side.

7. Apply power to the machine and confirm output voltage during operation.

ONOFF

0:1

ONOFF

0:1

OFF

0:1

ONOFF

Page 31

C-1

OPTIONS/ACCESSORIES

he following options/accessories are available for your FlexCut™

Plasma cutter from your local Lincoln Distributor.

ORCHES

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 LC125 Mechanized Consumable Starter Kit*

EXPENDABLE PARTS BK14300-1 Electrode BK14300-3 Shield Cap (45A - 65A) BK14300-4 Shield Cap (85A - 125A) BK14300-7 Nozzle 45A BK14300-8 Nozzle 65A BK14300-9 Nozzle 85A BK14300-10 Nozzle 105A BK14300-11 Nozzle 125A BK14300-13 Swirl Ring BK14300-14 Retaining Cap BK14300-15 Retaining Cap, CTP BK14300-18 Front Isolator Assembly

FLEXCUT™ 125

CCESSORIES

Page 32

D-1

MAINTENANCE

ELECTRIC SHOCK CAN KILL.

• Have an electrician install and service t

his equipment.

•

Turn the input power off at the fuse box

before working on equipment.

• Do not touch electrically hot parts.

DAILY PROCEDURES

POWER SUPPLY

1. Verify that the display light is illuminated when primary power is applied to the system.

2. Press the purge button and verify that air is flowing through the torch. While air is flowing, adjust the regulator to 60 psi for 25’ torches and 65 psi for 50’ torches and 70 psi for 75’ torches.

3. Raise the torch a minimum of 2 inches above the workpiece. Apply a trigger signal through the 14-pin connector. The pilot arc should be established in approximately 2 seconds. The arc should extend approximately 1 inch from the nozzle.

TORCH ASSEMBLY

1. Check the output cover of the torch lead for nicks or cuts. If the outer cover is damaged and the underlying wires are visible, the torch lead must be replaced. Check to make sure nothing is crushing the cable and blocking the flow of air through the torch. Also, check for and remove any kinks in the cable to maximize air flow to the torch.

2. Remove all consumables from the torch and verify that the anode-cathode insulator (brown plastic) is in good condition and has no signs or arcing.

3. Check all consumables and discard any damaged items.

4. Verify that the electrode seat is clean to ensure proper electrical contact.

5. Inspect the threads on the torch body for nicks or defects. Remove any debris and keep area clean.

6. Reassemble the torch consumables making sure that all parts are seated properly and that the retaining cap is hand tight.

7. Always make sure the electrode freely moves in the torch. if not check the electrode for structural damage. If electrode is fine, change the Front Isolator Assembly (BK14300-18).

ONTHLY PROCEDURES

POWER SUPPLY

1. Using clean, dry, compressed air, blow out all accumulated dust inside the machine. Be sure to clean all printed circuit boards, heatsinks, power switch, and fan. In excessively dirty e

nvironments, blow out the machine on a weekly basis. Keeping the machine clean will result in cooler operation and higher reliability.

2. Verify that all torch lead and ground connections are secure and free of corrosion.

3. Verify that the primary three phase AC connections are tight.

4. Verify that all printed circuit board connectors are installed properly.

5. Examine the sheet meetal case for dents or other damage and repair as required. Keep case in good condition to ensure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to ensure case strength and electrical ground continuity,

TORCH ASSEMBLY

1. Verify that the torch lead connection at the power supply is tight and that there are no leaks. Only tighten enough to provide an air tight seal. The connections are subject to damage if overtightened.

2. Inspect the torch leads for nicks or cuts and replace if necessary.

Work Ground

1. Verify that work ground lead is securely fastened to the cutting table and that the connection point is free from corrosion. Use a wire brush to clean the connection point if necessary.

Gas Supply

1. Check for signs of contamination in the gas supply lines.

2. Drain filter bowl as needed.

3. Listen for gas leaks in the supply lines and the internal plumbing system. Tighten any leaking connections. Leaks can cause poor cut quality as well as torch overheating.

4. Replace the filter element as necessary. If the pressure drop across the filter is more than 10 psi, the element needs to be replaced. To replace the element:

- Remove the bowl from the filter body

- Remove the element and holder from body

- Separate the element from its holder

- Discard the used element

- Place the new element on its holder

- Thread the element and holder onto the body

- Tighten the bowl onto the body

WARNING

FLEXCUT™ 125

AINTENANCE

Page 33

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

E-1

ROUBLESHOOTING

FLEXCUT™ 125

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS).” This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact you local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact you local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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.

__________________________________________________________________________

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the rear of the machine and remove main power supply connections before doing any troubleshooting.

------------------------------------------------------------------------

WARNING

CAUTION

TROUBLESHOOTING

Page 34

E-2

ROUBLESHOOTING

FLEXCUT™ 125

0298

DESCRIPTION: Low Gas Pressure

0728

DESCRIPTION: Check Retaining Cap

0021

DESCRIPTION: Work Transfer Failed

0729

DESCRIPTION: Release Trigger

Possible Cause

Gas input line is disconnected or input pressure is too low.

ecommended Course of Action

Check that the gas line feeding the machine is properly connected and that the p

ressure is above 90 psi for cutting or above 50 psi for marking or gouging.

Possible Cause

Torch is disconnected or the torch retaining cap is missing or loose.

Recommended Course of Action

Check that the consumables are properly installed. Tighten retaining cap (hand-tight only) and check that it touches the two pins extending down from the torch body. The pins on the torch should extend and retract freely.

Possible Cause

Pilot timeout error

Recommended Course of Action

In cut, mark, and grid modes, the pilot arc will only run for 5 seconds to prevent unnecessary consumable wear. Verify the correct torch to workpiece height and that the work lead is connected and making a good electrical connection.

If error occurs immediately after triggering, verify correct three phase input.

Possible Cause

Trigger locked

Recommended Course of Action

Release the trigger before continuing. The trigger must be disabled at machine startup or when changing modes.

Page 35

E-3

ROUBLESHOOTING

FLEXCUT™ 125

0021

DESCRIPTION: Open Pilot Check Consumables

0021

DESCRIPTION: Shorted Pilot Check Consumables

0036

DESCRIPTION: Thermal Trip

0006

DESCRIPTION: Control Board Ofine

Possible Cause

ilot 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 installation.

Possible Cause

Pilot Stuck Closed

Recommended Course of Action

Electrode is not retracting from the nozzle after trigger initiation. The parts could be stuck together or air is not properly flowing through the torch. Remove and replace the consumables, checking for proper installation.

Check the electrode for structural damage. If electrode is fine, replace Front Isolator Assembly (BK14300-18).

Possible Cause

Machine has overheated and must be allowed to cool before continuing.

Recommended Course of Action

Check that the fan is spinning freely and that the rear brickwork and side/front louvers are not obstructed. If thermal faults continue, blow dust out from the rear of the machine.

Possible Cause

Communication error between power board and control board.

Recommended Course of Action

Cycle power to the machine to see if the error clears. Otherwise a qualified technician must check communication between the power and control boards.

Page 36

bserve all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE CAUSE RECOMMENDED

COURSE OF ACTION

Input circuit breaker trips repeatedly.

No display after the power switch is turned on.

CAN Error

The Thermal Error does not clear.

Pilot Power Supply Fault

1. Verify that the input circuit protection is p

roperly sized per the voltage being sup-

plied. See Technical Specification page.

2. Install a larger input circuit or turn the o

utput control to a lower amperage.

3. Check the input power to be sure it is on.

1. Check the power line fuses or breakers and machine connection.

2. Disconnect input power at fuse/breaker panel and check line switch continuity. Replace line switch if bad.

3. Possible faulty Display Board.

4. Possible faulty Auxiliary Transformer. Check for status LED’s on Display Board

1. Possible faulty Switch board. Check for status LED’s

1. Check that rear brickwork is not blocked.

2. Check that fan rotates freely

3. Check that heatsink fins are not clogged with dirt

1. Check connections between switchboard and output board.

2. Possible faulty output board.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lincoln Authorized Field Service Facility.

E-4

ROUBLESHOOTING

FLEXCUT™ 125

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 37

bserve all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE CAUSE RECOMMENDED

COURSE OF ACTION

The FLEXCUT™ 125 powers up properly b

ut there is no response when output is

triggered.

1. Press the purge button on the front of the F

LEXCUT™ 125 . If air does not flow,

then:

• The main gas solenoid assembly/ may b

e faulty. Check or replace.

• Possible faulty Control board.

2. Remove the body of the torch and examine all the connections.

3. Check for proper CNC trigger operation. Replace the trigger or cable if defective.

4. Possible faulty Output board.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lincoln Authorized Field Service Facility.

E-5

ROUBLESHOOTING

FLEXCUT™ 125

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 38

bserve all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE CAUSE RECOMMENDED

COURSE OF ACTION

When the trigger is pulled air begins to flow, b

ut there is no pilot arc after at least 3

seconds.

The air begins to flow and there is a very brief arc that snaps out consistently with repeated trigger pulls.

The arc starts but sputters badly.

Check the torch consumables to be sure they are not dirty or greasy, and are in good shape. Replace the consumables if necessary.

. Make sure the air pressure is set

correctly.

3. Make sure there are no kinks or restrictions for air flow in the torch cable. Replace cable as needed.

4. If a slight thump cannot be felt in the torch when the trigger is pulled, check for loose connection in the torch head.

5. Possible faulty Control board.

1. Check the torch consumables to be sure they are in tight, not dirty or greasy and in good shape. Replace if necessary.

2. Make sure the air pressure is set correctly.

Possible faulty Control board.

1. Check the torch consumables to be sure they are in tight, not dirty or greasy and in good shape. Replace if necessary.

2. Check air supply for oil or a great deal of water. If there is oil or a great deal of water, the air must be filtered or the machine switched to nitrogen or bottled air.

3. Make sure the air pressure is set correctly.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lincoln Authorized Field Service Facility.

E-6

ROUBLESHOOTING

FLEXCUT™ 125

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 39

bserve all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE CAUSE RECOMMENDED

COURSE OF ACTION

Pilot arc starts but will not transfer when b

rought near work.

1. Check work lead connection for clean, s

ecure connection.

Plasma will only cut conductive material. Do not attempt to cut fiberglass, plastic, r

ubber, PVC or any other non-conduc-

tive material.

3. Make sure work piece is clean and dry. Remove any scale, rust or dross.

4. Check all connections to Output board.

5. Possible faulty Output board.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lincoln Authorized Field Service Facility.

E-7

ROUBLESHOOTING

FLEXCUT™ 125

WWW.LINCOLNELECTRIC.COM/LOCATOR

Page 40

F-1

IAGRAMS

FLEXCUT™ 125

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

RIGHT SIDE OF MACHINE

VOLTAGE. CONNECTION SHOWN IS FOR 460 V OERATION.

N.A. PLACE "A" LEAD ON APPROPRIATE CONNECT ION FO

R INPUT

NOTES:

LEFT SIDE OF MACHINE

FRONT OF MACHINE

REAR OF MACHINE

J4, J29

J1, J3, J22,

)

(

J20

J1 ,J3,

J2, J3

4 3

(VIEWED FR OM COMPONENT SIDE OF P.C. BOARD)

CAVITY NUMBERI NG SEQUENCE

FLEXCUT 125 WIRING DIAGRAM (CODE 12478)

A.03

G8559PRINT

TOP SHELF

SWITCH

SWITCH BOA RD

INPUT

RECTIFIER

~52V

~42V

~460V

~380V

~575V

RECONNECT PA NEL

L1A

L3A

AUXILIARY

TRANSFORMER

INPUT TERMINAL BLOCK

CASE FRONT

BASE

CASE BACK

GROUND BOND CIR CUIT

EARTH GROUND

FAN

L2A

~460V

~575V

~380V

RECONNECT

PANEL

4A FUSE

209

~115V

L3B

L1B

L3B

N.A.

J22-1

221

J22-2

222

J20-5

J20-13

J26-1

J26-2

J22-3

223

J22-4

224

207

204

J23-2

53J23-1

TO EARTH GROUN D PER THE NATIO NAL ELECTRIC CO DE

BASE

J20-3

J20-11

J23, J26

J23-3

U.I. BOARD

22-5

225

J22-6

226

J20-2

J20-1

J20-4

J20-12

J20-14

J20-15

J20-16

J20-9

J20-10

J20-8

J20-7

J20-6

AUXILIARY

RECTIFIER

J23-4

J29-2

J29-1

J29-3

J29-4

J29-5

J29-7

J29-6

J29-8

211

216

B10

B12

OUTPUT

BOARD

OUTPUT

CHOKE

POWER

TRANSFORMER

TWIST MATE

CONNECTOR

9 1

WORK W ORK

B4A

B3A

ELECTRODE

CNC

CONNECTOR

J3-3

J3-4

J3-5

J3-6

J2-2

J2-3

J2-1

139

201

204

J1-2

J1-1

83A

J1-3

82A

J1-4

J21-2

J21-3

802

J21-4

J21-5

J21-6 806

J21-1

L2A

L1A

L1B

J26-3

J26-4

J28-2

J28-1

J28-3

J28-4

J28-5

J28-7

J28-6

J28-8

J28-9

J28-10

291

212

213

215

82A

83A

J24-2

J24-1

J24-3

J24-4

J28-11

28-12

J1-2

J1-1

J1-3

J1-4

J1-5

J1-7

J1-6

J1-8

J1-9

J1-10

291

296

J1-11

J1-12

4-2

J4-1

J4-3

J4-4

J4-5

J4-7

J4-6

J4-8

211

216

212

213

215

292

293

297

298

299

290

297

298

299

290

296

293

292

806

802

SOLENOID 1 -

CUTTING

SOLENOID 2 -

MARKING

TRANSDUCER

BOARD

J22-1

221

J22-2

222

J22-3

223

J22-4

224

22-5

225

J22-6

226

201

DIVIDER

BOARD

J1-2

J1-3

J1-1

B3A

J2-2

J2-1

J3-1

J3-2

J1-4 B4 A

J1-5

J1-6

ARCIN2

ARCIN1

TRIG2

TRIG1

PROCB

PROCA

J3-1

J3-2

TRIG2

PROCB

ARCIN2

TRIG1

PROCA

ARCIN1

X11

X13

809

802A

802B

809

1:1

ARC

VOLTAGE

DIVIDED

ARC

VOLTAGE

J2-4

J22, J22

J1, J28

THERMOSTAT

(UNDER

OUTPUT

BOARD)

409

410

409

410

802A

B13

B11

802B

TRIGGER

PARTS

PLACE

Page 41

F-2

IAGRAMS

FLEXCUT™ 125

EN-168

L16973

A.01

12.25

11.31

26.44

24.17

18.04

20.71

Page 42

F-3

IAGRAMS

FLEXCUT™ 125

1.750

15.12

1.480

2.650

2.529

4.710

13.760

ALL DIMENSIONS ARE IN INCHES

Page 43

Flexcut 125 - 12478

Page 44

Index of Sub Assemblies - 12478

KEY PART NUMBER DESCRIPTION QTY

P-898-A INDEX OF SUB ASSEMBLIES AR

P-898-B.2 MISCELLANEOUS ITEMS AR

1 P-898-C CASE FRONT ASSEMBLY AR

2 P-898-D UPPER SHELF ASSEMBLY AR

3 P-898-E BASE ASSEMBLY AR

4 P-898-F HEATSINK ASSEMBLIES AR

5 P-898-G CASE BACK ASSEMBLY AR

6 P-898-H ROOF & SIDES AR

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 1

Page 45

Index of Sub Assemblies - 12478

2 Flexcut 125 - 12478

P-898-A.jpg

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 46

Miscellaneous Items

KEY PART NUMBER DESCRIPTION QTY

9SM25672 PLUG AND LEAD ASBLY 1

9SS18250-1091 PLUG AND LEAD ASBLY 1

9SS18250-1092 PLUG AND LEAD ASBLY 1

9SS18250-1095 PLUG AND LEAD ASBLY 1

9SM25351-1 GROUND CLAMP ASSEMBLY 1

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 3

Page 47

Miscellaneous Items

4 Flexcut 125 - 12478

No Image

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 48

Case Front Assembly

KEY PART NUMBER DESCRIPTION QTY

9SG8484 CASE FRONT ASSEMBLY 1

1 9SG8483 CASE FRONT 1

2 9SL16976 NAMEPLATE 1

3A 9SG6525-3 HANDLE 1

3B 9SM24996-1 FRONT HANDLE SUPPORT BRACKET 1

3C 9SS9225-66 SELF TAPPING SCREW 4

4A 9SS30203 FRAME R-0010-423-1 1

4B 9SS30204 COVER R-0010-450-1 1

5 9SS31655 USER INTERFACE PC BD. ASSEMBLY 1

9SS31635 UI ENCODER STANDOFF 1

9ST10082-27 SEMS SCREW 4

6A 9ST10940-10 3/8-32HJN 1

6B 9SM22778-1 KNOB 1.0" 1

9SM25318-1 PRESSURE REGULATOR ASBLY 1

7A 9SM25689-1 PRESSURE REGULATOR 1

7B 9SS30229-2 PUSH IN FITTING 1

7C 9SS30229-13 PUSH-IN FITTING 1

7D 9SS31648-1 HEX SOCKET PLUG - 1/8 NPT 1

8 9ST10642-398 FLEX TUBE 1

9 9ST10642-401 FLEX TUBE 1

9SM25685 POWER SWITCH ASSEMBLY 1

10 9SS29541 MAIN POWER SWITCH 1

11 9SM25210-1 TORCH CONNECTOR ASBLY 1

11B 9SS22990-2A BULKHEAD NUT 1

9SS30904 KEYING PIN 1

12 9SS29508 TWIST MATE RECEPTACLE 1

9SS9262-2 PLAIN WASHER 1

13 9ST13086-233 WARNING DECAL 1

18A 9SS30683 ADAPTER M12 TO 1/4 NPT 1

18B 9SS30229-2 PUSH IN FITTING 1

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 5

Page 49

Case Front Assembly

6 Flexcut 125 - 12478

P-898-C.jpg

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 50

Upper Shelf Assembly

KEY PART NUMBER DESCRIPTION QTY

1 9SG8487 TOP SHELF 1

9SL16919 RECONNECT ASSEMBLY 1

2A 9SG8488 RECONNECT PANEL 1

2B 9SM19656 RECONNECT PANEL 1

9SS28845-2 RECONNECT NAMEPLATE 1

2D 9ST14530-1 RECEPTACLE 3

9ST12584-11 BLIND RIVET 2

2F 9SS9262-136 PLAIN WASHER 4

2G 9ST12386 FUSE HOLDER 1

9ST9447-91 SOCKET HEAD CAP SCREW #8-32X.50 SS 2

9ST10728-77 FUSE 1

9SS28929 INPUT CONNECTION DECAL 1

2L 9SS20763-3 TERMINAL BLOCK 1

2M 9ST9447-129 SHCS 2

9SS31135 FUSE DECAL 1

9SCF000010 #10-24HN 2

9SE106A-1 LOCKWASHER 1

4 9SS9225-68 THREAD FORMING SCREW (CUTTING) 4

5A 9SS28841 GROUND LUG 1

9SS9225-45 THREAD FORMING SCREW 1

9ST9695-17 LOCKWASHER 1

9ST10728-77 FUSE 1

9ST13260-4 DECAL-EARTH GROUND CONN 1

9SM22062-4 INPUT RECTIFIER ASSEMBLY 1

8A 9SM15454-18 INPUT RECTIFIER MODULE 1

9SS9262-3 PLAIN WASHER 2

9SE106A-1 LOCKWASHER 2

9SS25930-5 TORX BUTTON HEAD SCREW #10-24X.62 2

8E 9SS24574-3 HEATSINK 1

9A 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 1

9SS9262-3 PLAIN WASHER 1

9SE106A-1 LOCKWASHER 1

9SCF000010 #10-24HN 1

10 9ST14605 INSULATOR 2

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 7

Page 51

Upper Shelf Assembly

KEY PART NUMBER DESCRIPTION QTY

11 9SS31808 INSULATION 2

12 9ST11267-B INSULATOR 4

9SM25688-2 SOLENOID ASSEMBLY 1

13A 9SS31191-1 SOLENOID ASBLY 1

13B 9SS31649-1 FLOW CONTROL ORIFICE 1

13C 9SS31132 SILENCER/FILTER 1

13D 9SS30229-1 PUSH IN FITTING 1

13E 9SS30229-7 PUSH-IN FITTING 1/8 NPT TO 3/8 TUBE 1

13F 9SS31659 SOLENOID SPACER 1

9SM25688-1 SOLENOID ASSEMBLY 1

14A 9SS31191-1 SOLENOID ASBLY 1

14B 9SS31648-1 HEX SOCKET PLUG - 1/8 NPT 1

14C 9SS30229-1 PUSH IN FITTING 1

14D 9SS30229-7 PUSH-IN FITTING 1/8 NPT TO 3/8 TUBE 1

14E 9SS31659 SOLENOID SPACER 1

14F 9SCF000417 #4-40X2.00PPNHS 2

14G 9SS9262-39 PLAIN WASHER 4

9ST4291-B LOCKWASHER 2

9SCF000002 #4-40HN 2

15 9SM25683-1 PRESSURE SENSE PC BD ASBLY 1

16A 9SCF000069 1/4-20X1.25HHCS 2

16B 9SS9262-98 PLAIN WASHER 2

16C 9SE106A-2 LOCKWASHER 2

17 9SS18491-1 MOV ASBLY 1

18 9ST10642-397 FLEX TUBE 1

19 9ST10642-400 FLEX TUBE 2

20 9ST10642-399 FLEX TUBE 2

21 9SS30229-9 PUSH-IN FITTING WYE 3/8 TUBE 1

22 9SS13000-129 AUXILIARY TRANSFORMER 1

22A 9SS9262-98 PLAIN WASHER 4

22B 9SS9225-32 THREAD FORMING SCREWS 4

23 9SS30229-12 PUSH-IN FITTING BRANCH TEE 1

8 Flexcut 125 - 12478

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 52

Upper Shelf Assembly

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 9

P-898-D.jpg

Page 53

Base Assembly

KEY PART NUMBER DESCRIPTION QTY

9SG8491 BASE ASSEMBLY 1

1 9SG8489 BASE 1

2A 9SS29507 CORNER CAP 4

2B 9SS9225-66 SELF TAPPING SCREW 8

3A 9SG8552 TRANSFORMER ASBLY 1

3B 9SS9225-68 THREAD FORMING SCREW (CUTTING) 4

4A 9SG8580 SWITCHBOARD ASSEMBLY 1

4B 9SS9225-68 THREAD FORMING SCREW (CUTTING) 2

5A 9SL16608-1 OUTPUT BD & HEATSINK ASSEMBLY 1

9SS9225-68 THREAD FORMING SCREW (CUTTING) 2

6A 9SL16922 OUTPUT CHOKE ASBLY 1

6B 9SS9225-68 THREAD FORMING SCREW (CUTTING) 4

10 Flexcut 125 - 12478

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 54

Base Assembly

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 11

P-898-E.jpg

Page 55

Heatsink Assemblies

KEY PART NUMBER DESCRIPTION QTY

9SL16608-1 OUTPUT BD & HEATSINK ASSEMBLY 1

1 9SL16607-3 HEATSINK 1

2 9SM24769-4 ISOTOP PARALLEL DIODES 4

2A 9ST9447-87 SOCKET HEAD CAP SCREW #6-32X.50 8

2B 9SS9262-181 PLAIN WASHER 8

2C 9SE106A-13 LOCKWASHER 8

3 9SM24769-5 ISOTOP IGBT W/ULTRAFAST DIODE 1

3A 9ST9447-87 SOCKET HEAD CAP SCREW #6-32X.50 2

3B 9SS9262-181 PLAIN WASHER 2

3C 9SE106A-13 LOCKWASHER 2

4A 9SM25576 HEATSINK BRACKET 1

4B 9SS25930-6 TORX BUTTON HEAD SCREW 1/4-20X.62 2

4C 9SE106A-2 LOCKWASHER 2

5A 9SM25592 AIR DEFLECTOR 1

9SS25930-6 TORX BUTTON HEAD SCREW 1/4-20X.62 2

9SE106A-2 LOCKWASHER 2

6 9SG8447-1 OUTPUT PC BD ASBLY 1

6A 9SS29965-1 METRIC SEMS SCREW 20

9SS18250-1093 PLUG AND LEAD ASBLY 1

9ST13359-13 THERMOSTAT 1

9SS8025-80 SELF TAPPING SCREW 2

9SG8580 SWITCHBOARD ASSEMBLY 1

10 9SM24992 HEATSINK 1

11 9SM24993 HEATSINK BRACKET 1

11A 9SCF000069 1/4-20X1.25HHCS 2

11B 9SS9262-98 PLAIN WASHER 2

11C 9SE106A-2 LOCKWASHER 2

11D 9ST14605 INSULATOR 2

11E 9ST11267-B INSULATOR 4

11F 9SS31808 INSULATION 2

12 9SS31654-1 SWITCH BOARD ASBLY 1

12A 9SS25930-6 TORX BUTTON HEAD SCREW 1/4-20X.62 6

12B 9SE106A-2 LOCKWASHER 6

12 Flexcut 125 - 12478

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 56

Heatsink Assemblies

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 13

P-898-F.jpg

Page 57

Case Back Assembly

KEY PART NUMBER DESCRIPTION QTY

9SG8486 CASE BACK ASSEMBLY 1

1 9SG8485 CASE BACK 1

2A 9SM25206-1 PLUG AND LEAD ASBLY 1

9SS17062-11 CABLE CONNECTOR CAP 1

9SS8025-96 SELF TAPPING SCREW 2

3 9SM25055 FAN 1

9SS18250-1062 PLUG & LEAD ASBLY 1

9SS25930-14 M6 X 1.00 TBHS-FULL-4554 4

4A 9SG6525-3 HANDLE 1

4B 9SM24995-2 REAR HANDLE SUPPORT BRACKET 1

4C 9SS9225-66 SELF TAPPING SCREW 4

5A 9SS31804-2 ETHERNET COVER PLATE 1

5B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

9SM25318-2 PIGGYBACK ASSEMBLY 1

6A 9SM25689-2 PRESSURE REGULATOR 1

6B 9SS30229-3 PUSH IN FITTING 1

6C 9SS30229-11 PUSH-IN FITTING ELBOW 1

6D 9SM25531 FILTER MOUNTING BRACKET 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 3

7A 9SS19999 CORD GRIP CONNECTOR 1

7B 9ST14370-3 CONDUIT LOCKNUT 1

9SL16976 NAMEPLATE 1

9SCF000010 #10-24HN 2

9SE106A-1 LOCKWASHER 1

9SCF000010 #10-24HN 1

9SS31656 RATING PLATE 1

12 9SM25739 VOLTAGE DIVIDER BRACKET 1

13A 9SS31412-1 VOLTAGE DIVIDER PC BD ASBLY 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

13C 9ST11248 BRASS TUBE FITTING 1

14A 9SS23044 PNEUMATIC NIPPLE-1/4NPT 1

14B 9SS9262-36 PLAIN WASHER 1

9SS9225-68 THREAD FORMING SCREW (CUTTING) 3

14 Flexcut 125 - 12478

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 58

Case Back Assembly

KEY PART NUMBER DESCRIPTION QTY

9SS9225-66 SELF TAPPING SCREW 2

15 9SM25530 RECONNECT COVER 1

16 9ST13259-2 GROUNDING DECAL 1

17 9SS9225-68 THREAD FORMING SCREW (CUTTING) 3

18 9SS31805 REGULATOR LOCK 1

19 9SS31806 FACTORY CALIBRATED DECAL 1

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 15

Page 59

Case Back Assembly

16 Flexcut 125 - 12478

P-898-G.jpg

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 60

Roof & Sides

KEY PART NUMBER DESCRIPTION QTY

1 9SG8490 ROOF 1

1A 9SS9225-68 THREAD FORMING SCREW (CUTTING) 2

9SG8559 WIRING DIAGRAM 1

3 9SS19720-1 PLASMA WARNING DECAL (ENGLISH) 1

4 9SS19720-1S PLASMA WARNING DECAL SPANISH 1

5 9SS19720-1F PLASMA WARNING DECAL FRENCH 1

6 9SS30277-2 WARRANTY DECAL 1

9SM25673 RIGHT CASE SIDE ASSEMBLY 1

7A 9SL16920 RIGHT CASE SIDE 1

7B 9SM25585-1 DECAL 1

7C 9SS27368-4 DECAL LE LOGO 1

7D 9SS28039-2 DECAL GREEN INITIATIVE 1

7E 9ST10097-5 SPEED GRIP NUT RETAINER 1

7F 9SS9225-68 THREAD FORMING SCREW (CUTTING) 7

9SM25674 LEFT CASE SIDE ASSEMBLY 1

8A 9SL16921 LEFT CASE SIDE 1

9SM25585-1 DECAL 1

9SS27368-4 DECAL LE LOGO 1

9SS28039-2 DECAL GREEN INITIATIVE 1

9ST10097-5 SPEED GRIP NUT RETAINER 1

9SS9225-68 THREAD FORMING SCREW (CUTTING) 7

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Flexcut 125 - 12478 17

Page 61

Roof & Sides

18 Flexcut 125 - 12478

P-898-H.jpg

Printed 04/07/2016 at 08:32:05. Produced by Enigma.

Page 62

CustOMEr assistanCE POLiCY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and t

o exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific 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.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

TABLE OF CONTENTS GENERAL DESCRIPTION I

NSTALLATION OPERATION ACCESSORIES MAINTENANCE TROUBLESHOOTING DIAGRAMS