Lincoln Electric FlexCut 125 User manual

Operat r’s Manual

www.lincolnelectric.com/register

Auth rized Service and Distribut r L cat r:

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IM10300-A | Issue D ate Nov-16

For use with machines having Code Num ers:

12478

Save f r future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

FlexCut™125

THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR

DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser

upon receipt by the carrier. Consequently, claims for material

damaged in shipment must be made by the purchaser against the

transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

incoln 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.

This statement appears where the information must be followed

exactly to avoid serious personal injury or loss of life.

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.

Use corrective lenses if necessary

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.

EAR 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.

WARNING

CAUTION

Safety 01 of 04 - 06/15/2016

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel En ines

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 En ines

The engine exhaust from this product contains chemicals known

to the State of California to cause cancer, birth defects, or other

reproductive harm.

ARC ELDING CAN BE HAZARDOUS. PROTECT

YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

INJURY OR DEATH. KEEP CHILDREN A AY.

PACEMAKER EARERS SHOULD CONSULT ITH

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 incoln 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.

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.

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

their removal is complete. Always use the greatest care when

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

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 pos-

sible to the area being welded.

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

SAFETY

Safety 02 of 04 - 06/15/2016

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

of 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

between the

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.

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

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. hen 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 PE and

ACGIH T V 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.

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

Safety 03 of 04 - 06/15/2016

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

from starting a fire. Remember that welding sparks and hot

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.

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.

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,

etc. should be suitable for the application and

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.

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

Safety 04 of 04 - 06/15/2016

SAFETY

General Precautions

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

require 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.

ULTRA IOLET 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 PRE ENTION

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 PRE ENTION

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

should service the system. Observe the following guidelines to protect

against electric shock:

• A wall-mounted disconnect switch should be installed and fused

according to local and national electrical codes. The disconnect

switch should be located as close as possible to the power supply

so it can be turned off in case of an emergency.

• The primary power cord should have a 600 volt minimum rating in

order to protect the operator. In addition, it should be sized

according to local and national electrical codes. Inspect the primary

power cord frequently. Never operate the system if the power cord

is damaged in any way.

• Make sure the primary power ground wire is connected at the input

power ground location on the power supply. Make sure the

connection is securely tightened.

• Make sure the positive output (work ground) of the power supply is

connected to a bare metal area on the cutting table. A driven

ground rod should be placed no further than five feet from this

connection. Make sure this ground point on the cutting table is

used as the star ground point for all other ground connections.

• Inspect the torch leads frequently. Never use the system if the leads

are damaged in any way.

• Do not stand in wet, damp areas when operating or performing

maintenance on the system.

• Wear insulated gloves and shoes while operating or performing

maintenance on the system.

• Make sure the system is switched off at the wall disconnect before

servicing the power supply or torch.

• Never change torch consumable parts unless main power to the

system is switched off at the power supply or wall disconnect.

• Do not attempt to remove any parts from beneath the torch when

cutting. Remember that the workpiece forms the current path back

to the power supply.

• Never bypass the safety interlock devices.

• Before removing any of the covers, switch the system off at the wall

disconnect. Wait at least five (5) minutes before removing any

cover. This will give the capacitors inside the unit time to discharge.

See Section 5 for additional safety precautions.

• Never operate the system without all of the covers in place. See

Section 5 for additional safety precautions.

• Preventive maintenance should be performed daily to avoid

possible safety hazards.

FLEXCUT™ 125 SAFETY

FLEXCUT™ 125

FIRE PRE ENTION

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

materials 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 PRE ENTION

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

or similar item should consult a doctor before operating, observing,

maintaining, or servicing the system. Observe the following guidelines

to minimize exposure to these electric and magnetic fields:

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

as possible.

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

cable.

• Never place your body between the torch leads and work ground

cable. Keep the work ground cable and the torch leads on the

same side of your body.

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

ground cable.

SAFETY

FLEXCUT™ 125

Safety Standards Booklet Index

For further information concerning safety practices to be exercised

with plasma arc cutting equipment, please refer to the following

publications:

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

from the American Welding Society, 550 NW Le eune Road, Miami,

FL 33126.

2. AWS Standard C5.2, Recommended Practices for Plasma Arc

Cutting, obtainable from the American Welding Society, 550 NW

Le eune Road, Miami, FL 33126.

3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable

from the American Welding Society, 550 NW Le eune 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 Le eune Road, Miami, FL

33126.

5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable

from the American Welding Society, 550 NW Le eune 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

Le eune 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 efferson 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 efferson Davis Highway, Suite 1004,

Arlington, VA 22202.

17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from

the Compressed Gas Association, 1725 efferson Davis Highway,

Suite 1004, Arlington, VA 22202.

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

Processes, 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

FLEXCUT™ 125

TABLE OF CONTENTS

Safety

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

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

Duty Cycle.........................................................................................................................................10

User Responsibility............................................................................................................................10

Design Features And Advantages ......................................................................................................10

Installation ..................................................................................................................................Section A

Select Suitable Location...................................................................................................................A-2

Lifting ............................................................................................................................................A-2

Stacking ..........................................................................................................................................A-2

Tilting ............................................................................................................................................A-2

High Frequency Interference Protection ...........................................................................................A-2

Input Connection..............................................................................................................................A-2

Machine Grounding..........................................................................................................................A-2

Input Plug Installation ......................................................................................................................A-3

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

arts List .........................................................................................................parts.lincolnelectric.com

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

parts.lincolnelectric.com.

FLEXCUT™ 125

GENERAL DE CRIPTION

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

has 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 PLA MA 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. ob 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.

U ER RE PON IBILITY

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

such 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.

DE IGN FEATURE AND ADVANTAGE

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 re-

initiated in Postflow.

- Thermostatic Protection.

- Solid state over-current protection.

- Patented electrode, nozzle and shield cap for optimum cooling,

cut quality and long life.

Table of contents

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