Lincoln Electric FLEXCUT 200 CE User manual

INSTALLATION
FLEXCUT
200 CE
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
INSTALLATION N° P07085760NG
EDITION : EN Instructions for use REF : 8695 4497
REVISION : B
DATE : 07-2019 Original instructions

Thank for the trust you have expressed by purchasing this equipment, which
will give you full satisfaction if you follow its instructions for use and
maintenance.
Its design, component specifications and workmanship comply with
applicable European directives.
Please refer to the enclosed CE declaration to identify the directives
applicable to it.
The manufacturer will not be held responsible where items not recommended
by themselves are associated with this product.
For your safety,there follows a non-restrictive list of recommendations or
requirements, many of which appear in the employment code.
Finally we would ask you kindly to inform your supplier of any error which
you may find in this instruction manual.

8695 4497 / B
FLEXCUT 200 CE INSTALLATION I
CONTENTS
A - IDENTIFICATION .........................................................................................................................1
1 - FLEXCUT 200 CE INSTALLATION.....................................................................................1
2 - TOOL HOLDER THD ..........................................................................................................2
3 - FLEXCUT 200 CE POWER SOURCE + FLEXCOOL 35 + FLEXSTART.............................2
4 - TORCH T5...........................................................................................................................2
5 - IHM FOR INTEGRATED INSTALLATION ON MACHINE..................................................2
B - SAFETY INSTRUCTIONS............................................................................................................3
1 - GENERAL SAFETY INSTRUCTION ..................................................................................3
2 - GROUNDING PRINCIPLE..................................................................................................3
3 - ELECTRICAL USER SAFETY............................................................................................4
4 - THERMAL HAZARDS.........................................................................................................4
5 - ELECTROMAGNETIC POLLUTION...................................................................................5
6 - GASEOUS POLLUTION.....................................................................................................5
7 - LIQUID POLLUTION...........................................................................................................5
8 - FIRE RISK...........................................................................................................................6
9 - SOUND POLLUTION..........................................................................................................6
10 - AIRBORNE NOISE ...........................................................................................................6
C-DESCRIPTION..............................................................................................................................7
1 - CAPACITIES OF THE FLEXCUT 200 CE INSTALLATION................................................7
2 - INTEGRATED INSTALLATION ON LINCOLN MACHINE .................................................8
3 - FLEXSTART.........................................................................................................................10
4 - TOOL HOLDER THD AND MAGNETIC TORCH IMPACT SAFETY SYSTEM..................10
5 - TORCH T5 + BUNDLE........................................................................................................10
6 - FLEXCUT 200 CE POWER SOURCE + COOLING UNIT FLEXCOOL 35 ..........................10
7 - OPTIONAL QUICK GAS CHANGE.....................................................................................11
8 - OPTIONAL REMOTE STARTING OF POWER SOURCE.................................................11
D-ASSEMBLY AND INSTALLATION ..............................................................................................13
1 - CONDITIONS OF INSTALLATION.....................................................................................13
2 - INSTALLATION...................................................................................................................15
3 - CYCLE FUNCTION INSTALLATION..................................................................................18
4 - TOOL-HOLDER THD INSTALLATION ...............................................................................18
5 - INSTALLATION OF FLEXSTART ........................................................................................18
6 - INSTALLATION OF TORCH T5 + BUNDLE.......................................................................18
7 - FLEXCUT 200 CE POWER SOURCE INSTALLATION......................................................18
E-OPERATOR MANUAL..................................................................................................................20
1 - OPERATOR CONTROLS...................................................................................................20
2 - ADJUSTMENTS..................................................................................................................20
3 - GAS SUPPLY CHANGE.....................................................................................................20
4 - CHANGE IN CONSUMABLE..............................................................................................20
5 - CYCLES..............................................................................................................................21
F-MAINTENANCE ............................................................................................................................23
1 - SERVICING.........................................................................................................................23
2 - TROUBLESHOOTING........................................................................................................24
3 - THD TOOL HOLDER MAINTENANCE...............................................................................28
4 - FLEXCUT 200 CE POWER SOURCE MAINTENANCE .....................................................28
5 - TORCH T5 MAINTENANCE...............................................................................................28
6 - SPARE PARTS...................................................................................................................29
PERSONAL NOTES ..........................................................................................................................38

8695 4497 / B
II FLEXCUT 200 CE INSTALLATION
INFORMATIONS
For operating instructions, adjustments, troubleshooting and spare parts see safety instructions for use and
maintenance.
ISEE N°
ISUM
IM10485
FLEXCUT 200 CE power Source
IM10485
T5 torch
IM10423
Cooler FLEXCOOL 35
IM10457
FLEXSTART
86954568
Tool holder THD
86954606
Magnetic torch impact safety system
86954944
HPC DIGITAL PROCESS II
DISPLAYS AND PRESSURE GAUGES
The measuring devices or displays for voltage, current, speed, pressure, etc., whether analog or digital, should be
considered as indicators.
REVISIONS
REVISION B 07/19
DESIGNATION
PAGE
Update ʺSpare partsʺ
33 - 35 - 36

8695 4497 / A
FLEXCUT 200 CE INSTALLATION A-1
A - IDENTIFICATION
1 - FLEXCUT 200 CE INSTALLATION
Please note the serial number of your installation in the box below. This information will be
required if you need to contact our after-sales service staff.
Other locations have been provided for stating the references of each component of the
installation.
Object
Type
Serial no
Year
manufactured
FLEXCUT 200 CE power source
Cooler FLEXCOOL 35
FLEXSTART
THD tool holder
Torch T5
FLEXCUT 200 CE INSTALLATION
REFERENCE
DESCRIPTION
T
Torch T5
ET
Torch connector + torch bundle (1.5 m long)
G
FLEXCUT 200 CE power source
R
Cooler FLEXCOOL 35
F
FLEXSTART torch connection box
P
Numerical tool holder THD
CT
Magnetic torch impact safety system

A - IDENTIFICATION 8695 4497 / A
A-2 FLEXCUT 200 CE INSTALLATION
2 - TOOL HOLDER THD
Please refer to the document : 8695 4568.
3 - FLEXCUT 200 CE POWER SOURCE + FLEXCOOL 35 + FLEXSTART
Please refer to the document : IM10485, IM10423, IM10457.
4 - TORCH T5
Please refer to the document : IM10485.
5 - IHM FOR INTEGRATED INSTALLATION ON MACHINE
Please refer to the document : 8695 4944.

8695 4497 / A
FLEXCUT 200 CE INSTALLATION B-3
B - SAFETY INSTRUCTIONS
1 - GENERAL SAFETY INSTRUCTION
For general safety instructions, please refer to the specific manual
supplied with the equipment : reference IM10485
In the operating phase, and also in the adjustment phase, appropriate personal protection is required (see
document IM10485 for more details).
Standard EN 169 requires the use of shade 12 dark glass for the intensities from this process.
2 - GROUNDING PRINCIPLE
In the event of electrical faults, in order to prevent all troubles on
the Flexcut 200 CE installation, all metallic parts within the
operator’s reach must imperatively be linked to the ground.
MARKS
B
Shield
T
Torch T5
C
Cycle function
RA
Rail
D
Cutting table
F
FLEXSTART

B - SAFETY INSTRUCTIONS 8695 4497 / A
B-4 FLEXCUT 200 CE INSTALLATION
3 - ELECTRICAL USER SAFETY
Before starting any work on the installation, make sure that the
power source is switched off. Emergency stop does not turn off
the power supply of the power source.
Plasma arc cutting imposes relatively high output voltages, in open circuit, to the equipment. It is thus necessary to
take special precautions as regards the electrical supply of that equipment.
Check regularly the condition of power and ground connections
We remind you that the power supplies of FLEXCUT 200 CE and machine must be equipped with primary
protection devices, i.e. manual locking and unlocking breakers or breakers activated when an electrical fault is
detected. Emergency stop buttons are to be installed on the general locking circuit of all installations and placed on
the machine receiving the cutting installation to allow its grounding from the operator’s stand and from one or
several points on the machine.
Turn off the power supply of the electrical cabinet doesn’t turn off power supply of the power source.
A voltage over 100 V is present in the power source when in
operation
4 - THERMAL HAZARDS
It is absolutely necessary to be protected from the risk of burns
(direct contact)
Plasma cutting generates a large quantity of heat.
There is risk of burns at the torch and at the cut material.
It is absolutely necessary to be protected from the splatter of
molten metals during cutting (indirect contact)
High-temperature metal splatter can be emitted during cutting.

8695 4497 / AB - SAFETY INSTRUCTIONS
FLEXCUT 200 CE INSTALLATION B-5
5 - ELECTROMAGNETIC POLLUTION
It is indispensable to protect the eyes from arc radiation
The plasma process creates electrical and magnetic fields that can
interfere with some pacemakers. People wearing pacemakers in
the vicinity of the machine need to seek medical attention.
The plasma arc, like all electric arcs, is a source of high intensity radiation ; the radiation emitted in the ultraviolet
spectrum can damage eyes and skin. The operator must thus wear filtering glasses to prevent eye fatigue.
6 - GASEOUS POLLUTION
It is indispensable to be protected from the fumes produced during
cutting
Plasma cutting provokes an emission of fumes (metallic vapours and oxides). In order to reduce their concentration
near the operator, the cutting area must be ventilated. The installation is designed to operate with an appropriate
extraction table (please call us for rating). Regularly check the effectiveness of the extraction.
Standard EN ISO 17916 imposes a speed of 1,15 m/s per torch at the table:
It is indispensable to regularly carry out preventive maintenance of
the installation
The installation can sometimes be damaged (pierced hoses, leaking solenoid valves). That can lead to the
uncontrolled discharge of gas. Fittings and pipes must be verified every month.
7 - LIQUID POLLUTION
Plasma cutting generates a large quantity of heat. The installation needs to be cooled. To that end, coolant fluid is
required for the proper working of the installation.
Refer to the maintenance instructions of the cooling unit. The coolant fluid used must be that stated in the
instructions.

B - SAFETY INSTRUCTIONS 8695 4497 / A
B-6 FLEXCUT 200 CE INSTALLATION
8 - FIRE RISK
Oxygen cutting creates a fire risk. An extraction system should be used during oxygen cutting. Flashback arresters
must be supplied (unless they do not exist for the selected gas and pressure values) in order to avoid the risk of the
flame returning towards the gas supply systems.
Make sure that the oxygen lines are not contaminated with oil or grease, for example. Mixing such contaminants
with oxygen leads to an additional fire risk.
9 - SOUND POLLUTION
It is indispensable to protect the ears from the noise produced
during cutting
Plasma arc cutting generates variable quantities of noise depending on the cutting conditions.
It is to be noted that legislation allows noise emission of 80 dB (A) for 8 hours of exposure.
In fact, the period of use of plasma cutting is often less (ISO R1996 and R1999).
10 - AIRBORNE NOISE
T5
MEASUREMENT CONDITIONS
M1
M2
Current
150 A
275 A
Weighted acoustic
pressure level A
97 dB
110 dB
Weighted acoustic
pressure level C
94 dB
107 dB
Torch distance: 1 m horizontal/1.6 m above the part
Measurement 1 (M1): The maximum sound level is 121 dB at a distance of 76.2 mm from the torch with
cutting at 150 A and a 130 V arc
Measurement 2 (M2): The maximum sound level is 127 dB at a distance of 76.2 mm from the torch with
cutting at 275 A and a 145 V arc
The use of a helmet is required with a noise level above 80 dB,
for the operator and for persons located nearby.
The noise generated by the process can cover external sound
warnings.

8695 4497 / A
FLEXCUT 200 CE INSTALLATION C-7
C-DESCRIPTION
1 - CAPACITIES OF THE FLEXCUT 200 CE INSTALLATION
This complete installation consists of a group of industrial equipment (power source, torch, control unit, tool
holder, bundles...) especially designed to allow automatic thermal cutting by plasma jet.
Thermal cutting using plasma jet is a cutting process by fusion and ejection of the molten metal by the
plasmagene gas.
The installation is designed for cutting from 50 A to 200 A up to 30 mm with mid-plate strike (50 mm with
plate edge strike), mainly with steel, stainless steel or aluminium, using the following gases: air, nitrogen and
oxygen. The machine can also carry out plasma marking from 12 A to 16 A.
NOTE : The speed/quality ratio can be chosen according to the final use of the parts cut out.

C - DESCRIPTION 8695 4497 / A
C-8 FLEXCUT 200 CE INSTALLATION
2 - INTEGRATED INSTALLATION ON LINCOLN MACHINE
This installation may be used in an integrated manner on a machine supplied by us. The main functions are
accessible by the NC that will steer the cutting processes via Ethernet. This installation can manage the plasma
cutting function for a maximum of 2 torches.

8695 4497 / AC - DESCRIPTION
FLEXCUT 200 CE INSTALLATION C-9
FLEXCUT 200 CE INSTALLATION
Mark
Designation
Reference
B
FLEXSTART
Integrated in : K4328-2
C
Cycle function assembly
P
THD tool holder
P07054360
I
Programming interface
T
Torch T5 + torch bundle
CT
Magnetic torch impact safety system
G
FLEXCUT 200 CE power source
Integrated in : K4328-2
G1
Cutting/annular gas (air)
G2
Annular / gas (nitrogen) (option)
G3
Cutting/annular gas (oxygen) (option)
FT
Transverse chain
FL
Longitudinal chain
1
Torch harness
BK284304-5
O1
Optional quick gas change
O2
Optional remote stopping of power source
S
Disconnecting box
R
Cooler FLEXCOOL 35
Integrated in : K4328-2

C - DESCRIPTION 8695 4497 / A
C-10 FLEXCUT 200 CE INSTALLATION
3 - FLEXSTART
Please refer to the document: IM10457
4 - TOOL HOLDER THD AND MAGNETIC TORCH IMPACT SAFETY SYSTEM
The functions of the tool holder are as follows :
- Management of the Z axis (vertical axis)
- Torch holding to prevent vibrations
The functions of the torch impact safety system are as follows :
- Indication of mechanical impacts on the torch
- Protection of the torch during mechanical impacts
The tool holder is usually mounted on the tool holder carriage (mobile part).
Space taken up by the equipment:
Please refer to the document : 8695 4568
5 - TORCH T5 + BUNDLE
The FLEXCUT 200 CE installation is designed to operate with the T5 torch.
The function of the torch is to diffuse gas and current so as to achieve high quality cutting.
The torch is connected to the power source and the FLEXSTART via different bundles. It is fixed to the machine via
the torch impact safety system of the tool holder.
The torch is cooled by the coolant.
Space taken up by the equipment:
Please refer to the document: IM10485
6 - FLEXCUT 200 CE POWER SOURCE + COOLING UNIT FLEXCOOL 35
The function of FLEXCUT 200 CE power source is to regulate the cutting current according to the required
setpoints.
The FLEXCUT 200 CE can deliver a maximum of 200A.
The power source is generally located close to the installation.
The FLEXCOOL 35 cooling unit is powered by the power source.
Space taken up by the equipment :
Please refer to the document : IM10485, IM10423.

8695 4497 / AC - DESCRIPTION
FLEXCUT 200 CE INSTALLATION C-11
7 - OPTIONAL QUICK GAS CHANGE
As standard, the FLEXCUT 200 CE machine allows cutting with compressed air only.
The optional quick gas change facility makes it possible to easily use different gases for cutting and shielding.
That gas option is compatible with the use of oxygen.
8 - OPTIONAL REMOTE STARTING OF POWER SOURCE
The optional remote starting of the power source allows you to switch off the power to the power source (and
cooler) from the control console.
That option makes it necessary to use a disconnecting box LINCOLN ELECTRIC (see power supply section).

C - DESCRIPTION 8695 4497 / A
C-12 FLEXCUT 200 CE INSTALLATION

8695 4497 / A
FLEXCUT 200 CE INSTALLATION D-13
D-ASSEMBLY AND INSTALLATION
1 - CONDITIONS OF INSTALLATION
THE FOLLOWING CONDITIONS MUST BE COMPLIED
WITH BEFORE INSTALLING THE EQUIPMENT
THE LAYOUT OF THE INSTALLATION MUST COMPLY WITH
SAFETY STANDARD NF EN 547 -1 -3 TO ASSURE PERSONAL
PROTECTION.
1.1 GAS SUPPLY
Provide the gas sources (cylinders, cylinder frames, evaporators etc.) below, each with a regulator that is capable
of supplying the recommended flow rates and pressure values and a shut-off valve if the supply is through a pipe.
The pressure supplied to the machine must never exceed 9 bar
Starting up the gas sources
Please refer to section:
« 6-2 CYLINDER CHANGE PROCEDURE » in the safety booklet
8695 7050
Conditions for gas types
CUTTING AND SHIELDING GAS
Fluids used
Purity type
Supply pressures of the
installation
(pressure reducing valve
exit)
Fully flow rates used
CARBON STEEL
Compressed air
ISO 8573-1:2010,
Class 1.4.1
7,2 bar +/-1
142 l/mn
Oxygen
> 99,5%
7,2 bar +/-1
41 l/mn
STAINLESS STEEL, ALUMINIUM AND ALLOYS
Compressed air
ISO 8573-1:2010,
Class 1.4.1
7.2 bar +/-1
142 l/mn
Nitrogen
> 99,5%
7,2 bar +/-1
106 l/mn

D - ASSEMBLY AND INSTALLATION 8695 4497 / A
D-14 FLEXCUT 200 CE INSTALLATION
* The quality of the compressed air has a significant effect on the
cutting results.
It must be filtered (5µm)
IT MUST BE DRY AND FREE OF OIL
Layout of cables and flexible pipes
The customer should provide the means for supporting and keeping away from mechanical, chemical, or thermal
damage, the cables and flexible pipes from their source to the entry of the power source.
1.2 ELECTRICAL SUPPLY
In order to comply with European safety regulations, connection to
the mains must be made using a wall box fitted with an individual
disconnecting switch of suitable size according to the mains'
voltage and to the consumption of the apparatuses.
This protective disconnecting switch will have to have a cutting
capacity > 50kA.
We markets units meeting such requirements. Do not hesitate to
contact us.
The operative power depends on the serviceable voltage used.
A cable of adequate section is to be provided to linkthe isolating
switch to the power source.
Consumption of installation except power source
For installations integrated into LINCOLN ELECTRIC, refer to the machine instructions.

8695 4497 / AD - ASSEMBLY AND INSTALLATION
FLEXCUT 200 CE INSTALLATION D-15
Consumption of FLEXCUT 200 CE power source
Power supply
3 phases + earth
400 V
I eff (125A-175VDC)
71 A
Fuse rating
80 A aM
Fuse size
22*58
Power supply cable
section
4*16 mm²
Cable part number
P00641054NG
The consumption values are stated for working
with 200 A - 190 VDC for cutting
Sectioning box
3-phase power supply +
ground
400 V
Flexcut 200 CE
Single torch
P06942335NG
Dual torch
P06942336NG
Control console harness (with console on the floor)
The customer should ensure that all cables and flexible pipes between the machine and the control console inlet
are protected from mechanical, chemical, and thermal damage.
1.3 OPERATING TEMPERATURE
The optimum operating conditions range from 0°C to 40°C.
2 - INSTALLATION
Installation is carried out in the following order:
- placing and securing of each component of the installation
- connection of each component of the installation, starting with:
- cycle function
- the tool-holder THD
- the torch connection box (FLEXSTART)
- torch T5
- the power source FLEXCUT 200 CE and cooler FLEXCOOL 35
- the supply of gas and electricity.

D - ASSEMBLY AND INSTALLATION 8695 4497 / A
D-16 FLEXCUT 200 CE INSTALLATION
2.1 FLUID CONNECTIONS
Mark
Designation
G
FLEXCUT 200 CE power source
R
Cooler FLEXCOOL 35
T
Torch T5
FT
Torch bundle
V
Set of two solenoid valves
G1
Cutting/annular gas (air)
G2
Annular / gas (nitrogen) (option)
G3
Cutting/annular gas (oxygen) (option)