F-2
DIAGRAMS
FLEXCUT™ 80
L1
66
73
11
.8
1
10
.7
3
24
.0
25
.4
0
17
6
15
.3
2
D
IM
E
N
S
IO
P
R
IN
T
F
L
X
C
U
8
7
Page 1: ...rized Service and Distributor Locator www lincolnelectric com locator IM10197 B Issue Date Oct 16 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12249 12589 Save for...
Page 2: ...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 develop unusual s...
Page 3: ...rs 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 case...
Page 4: ...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 su...
Page 5: ...nt 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 N...
Page 6: ...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 c...
Page 7: ...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 ga...
Page 8: ...le 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...
Page 9: ...r A 3 Gas Supply Requirements A 3 Connecting The Gas Supply A 4 Output Connections A 4 Operation Section B Controls And Settings B 2 Hand Cutting B 4 Hand Cutting Charts B 5 Mechanized Cutting B 10 Me...
Page 10: ...UTY 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 80 duty cycle means that it i...
Page 11: ...UTPUT AT 40 C Duty Cycle CURRENT VOLTAGE 100 60A 140 VDC 80 80A 140 VDC RECOMMENDED INPUT WIRE For all plasma cutting applications Based on U S National Electrical Code Ambient Temperature 30o C or Le...
Page 12: ...in an environment where other high frequency generating machines are operating By taking the following steps high frequency interference into the FLEXCUT 80 can be minimized 1 Make sure the power supp...
Page 13: ...EARTH GROUND ENGINE DRIVEN GENERATOR For use on engine drives keep in mind the above input draw restrictions and the following precaution The FLEXCUT 80 can be operated on engine driven generators as...
Page 14: ...ds are based on results obtained from Lincoln Electric s laboratory testing Different cutting applications may alter the actual cutting speed A 4 INSTALLATION FLEXCUT 80 MAXIMUM OUTPUT CURRENT Mechani...
Page 15: ...ainers 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...
Page 16: ...LED illuminates the machine will automatically enter into Purge mode for 10 seconds During Purge time verify and adjust the gas pressure using the gas pressure regulator knob If necessary also verify...
Page 17: ...contact and raw Arc Voltage Items 12 thru 15 on the back of the FLEXCUT 80 See Figure B 3 12 Fan Provides machine cooling When the machine is switched ON the fan runs continuously 13 Power Switch Turn...
Page 18: ...s required for each of these setups ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES NOZZLES AND EXPENDABLE PARTS FOR THE BEST CUTTING PERFORMANCE Handle S28175 1 Head S28176 1 Insulation Kit S28176 4 E...
Page 19: ...ive pilot arc time by transferring the arc to the workpiece quickly This will extend consumable life When the arc is brought within 1 8 1 4 from the work piece the arc will transfer the current will r...
Page 20: ...teel Cut CHarts FlexCut 80 lC105 Hand torCH TOMAHAWKTM 1500 5 0 4 0 E 5 D C B A 9 9 8 0 0 9 4 5 8 7 5 0 4 0 73 6 2 1 3 2 1 0 Above listed speeds provide best cut quality best cut angle least dross bes...
Page 21: ...ON stainless steel Cut CHarts FlexCut 80 lC105 Hand torCH TOMAHAWKTM 1500 7 A 3 5 95 8 2 7 3 5 2 6 5 4 2 4 3 2 1 0 Above listed speeds provide best cut quality best cut angle least dross best cut surf...
Page 22: ...er 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 ta...
Page 23: ...gle of about 30 to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper This process will blow a lot of molten metal and dross Be careful...
Page 24: ...from retaining cap 4 Remove the electrode from the torch body using the 3 8 socket 5 Remove the swirl ring from the nozzle Contaminants such as dirt metallic dust oil and moisture present on the surf...
Page 25: ...s depending on the cutting current Machine Interface The FLEXCUT 80 comes standard with a machine interface Interface signals provided include arc start arc initiated and arc voltage These signals are...
Page 26: ...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 a...
Page 27: ...9 6 67 8 87 886 496 886 6 67 8 87 884 466 886 6 67 8 87 88 8 88 6 6 67 87 885 6 88 6 67 87 88 88 656 67 87 3 2 1 0 3 2 1 0 84 4 869 656 67 87 84 6 886 656 67 87 8 99 88 65 67 87 8 5 4 88 65 67 87 3 2...
Page 28: ...4 6 6 67 6 7 486 49 4 6 6 67 7 A 48 4 48 6 8 67 7 A 489 488 466 67 8 7 A 3 2 1 0 3 2 1 0 4 8 6 4 686 67 47 4 5 4 9 688 67 47 4 8 48 4 8 658 67 9 47 4 5 4 4 696 67 47 4 6 4 658 67 9 47 486 9 4 5 6 67 4...
Page 29: ...9 78 798 B 7 9 78 78 7 9 0 56 56 0 0 8 6 4 6 8 7 6 6 6 2 B A 9 2 3 D 2 2 1 3 1 H 2 2 4 B 9 8 6 6 5 1 6 2 781 2 2 0 7 0 8 6 4 6 8 7 6 6 6 2 6 6 5 2 6 6 6 5 2 6 A 6 6 5 1 6 2 781 A A 7 A 7 A 8 7 8 7 7 9...
Page 30: ...rements 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 to...
Page 31: ...R HOLE OUT OF ROUND DENTS SCRATCHES REPLACE SHIELD CAP REPLACE SHIELD CAP RETAINING CAP CENTER HOLE OUT OF ROUND DENTS CRACKS REPLACE RETAINING CAP REPLACE RETAINING CAP NOZZLE CENTER HOLE OUT OF ROUN...
Page 32: ...e 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...
Page 33: ...C105 Handheld Plasma Torch 50 15m K2849 3 LC105M Mechanized Plasma Torch 25 7 5m K2849 4 LC105M Mechanized Plasma Torch 50 15m EXPENDABLE PARTS FLEXCUT 80 ACCESSORIES TORCH COMPONENTS TORCH ELECTRODE...
Page 34: ...inks power switch and fan In excessively dirty environments blow out the machine on a weekly basis Keeping the machine clean will result in cooler operation and higher reliability 2 Verify that all to...
Page 35: ...ENDED 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...
Page 36: ...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...
Page 37: ...Control board 2 Remove the handles or barrel of the torch and examine all the connections 3 Check for proper trigger switch operation Replace the trigger switch or torch cable if defective 4 Possible...
Page 38: ...ossible 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 3 Possi...
Page 39: ...ve material 3 Make sure work piece is clean and dry Remove any scale rust or dross 4 Check all connections to Control board 5 Possible faulty Control board If all recommended possible areas of mis adj...
Page 40: ...OFF 3 Possible faulty Pressure Switch 4 Possible faulty Control board 1 Verify Torch consumables are in good condition and properly installed If torch and consumables are properly installed the Yellow...
Page 41: ...e the machine Turn OFF the Power switch Check the correct placement of the Torch consumables and parts Check the Torch electrical connections Turn ON the machine No pilot arc established On Green LED...
Page 42: ...IST MATE CONNECTOR PARTS IN PLACE J30 AC1 AC2 AC3 DC DC DC J2 1 2 J8 2 3 4 1 5 6 8 9 10 7 11 12 J9 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 RECTIFIER BOARD 1 3 4 2 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13...
Page 43: ...F 2 DIAGRAMS FLEXCUT 80 L16673 11 81 10 73 24 03 25 40 17 86 15 32 DIMENSION PRINT FLEXCUT 80 L16673...
Page 44: ...FlexCut 80 12589...
Page 45: ...ii THIS PAGE INTENTIONALLY LEFT BLANK...
Page 46: ...EOUS ITEMS AR 1 P 1022 C CASE FRONT ASSEMBLY AR 2 P 1022 D UPPER SHELF ASSEMBLY AR 3 P 1022 E BASE ASSMEBLY AR 4 P 1022 F HEATSINK ASSEMBLIES AR 5 P 1022 G CASE BACK WRAPAROUND ASSEMBLY AR Index of Su...
Page 47: ...P 1022 A jpg Index of Sub Assemblies 12589 2 FlexCut 80 12589 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 48: ...PLUG AND LEAD ASSEMBLY P2 TO P22 1 9SM25209 PLUG LEAD ASBLY P6 TO P1 P66 1 K2849 1 LC105 HANDHELD PLASMA TORCH 25 7 5m 1 K2849 2 LC105 HANDHELD PLASMA TORCH 50 15m 1 K2849 3 LC105M MACHINE PLASMA TOR...
Page 49: ...No Image Miscellaneous Items 4 FlexCut 80 12589 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 50: ...A 9SS29489 4 PUSHBUTTON CAP NYLON ORANGE 1 7B 9SS29489 3 PUSHBUTTON CAP EXTENSION 1 8 9SS29508 1 TWIST MATE SOCKET 1 9SM25210 TORCH CONNECTOR ASSEMBLY 1 9A 9SS22990 2A BULKHEAD NUT 1 9SS30904 KEYING P...
Page 51: ...P 1022 C jpg Case Front Assembly 6 FlexCut 80 12589 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 52: ...CB ONLY 0 25 3 9SS8025 115 SELF TAPPING SCREW 3 9SS9225 99 SELF TAPPING SCREW 2 6 9SS10255 15 GROMMET 3 7 9ST12380 4 BUSHING 3 9SS30897 FILTER ASSEMBLY 1 8A 9SS22183 1 COALESCING FILTER 1 8B 9SM25010...
Page 53: ...SE106A 13 LOCKWASHER 4 18 9SS9262 181 PLAIN WASHER 4 19 9ST10642 360 FLEX TUBE 1 20 9ST10642 361 FLEX TUBE 1 21 9ST10642 385 FLEX TUBE 1 22 9ST10642 362 FLEX TUBE 1 23 9ST10642 363 FLEX TUBE 1 Upper S...
Page 54: ...P 1022 D jpg Upper Shelf Assembly FlexCut 80 12589 9 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 55: ...2 9SM25328 FAN ASSEMBLY 1 8A 9SL16513 FAN BRACKET 1 8B 9SM25370 FAN ASBLY 1 8C 9SS9262 3 PLAIN WASHER 3 8D 9ST4291 A LOCKWASHER 3 8E 9SCF000415 8 32X2 25HHMS 3 8F 9SM25008 1 FAN BAFFLE 2 8G 9SS9225 99...
Page 56: ...P 1022 E jpg Base Assembly FlexCut 80 12589 11 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 57: ...9SE106A 1 LOCKWASHER 4 16 9SM24769 1 IGBT W ULTRA FAST DIODE SOT 227 4 17 9ST9447 87 SOCKET HEAD CAP SCREW 6 32X 50 8 18 9SS9262 181 PLAIN WASHER 8 19 9SE106A 13 LOCKWASHER 8 20 9SM17192 47 THERMOSTA...
Page 58: ...13 LOCKWASHER 2 36 9SG7890 1 OUTPUT PC BD ASBLY 1 37 9SS29965 1 METRIC SEMS SCREW 12 38 9SM24912 5 SOT 227B HEAT SINK MOUNT POWER RESISTOR 1 39 9ST9447 87 SOCKET HEAD CAP SCREW 6 32X 50 2 40 9SS9262 1...
Page 59: ...P 1022 F jpg Heatsink Assemblies 14 FlexCut 80 12589 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 60: ...5 9SS9225 99 SELF TAPPING SCREW 4 9SS9225 100 SELF TAPPING SCREW 4 9SS9262 184 WASHER 4 6 9SS30277 2 WARRANTY DECAL 1 7 9SS27368 4 DECAL LE LOGO 2 8 9SM25585 1 DECAL 2 9SM26006 RATING PLATE 1 11 9SS28...
Page 61: ...P 1022 G jpg Case Back Wraparound Assembly 16 FlexCut 80 12589 Printed 11 01 2016 at 15 17 10 Produced by Enigma...
Page 62: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...
Page 63: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...
Page 64: ...tion 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 o...
