Lincoln Electric FLEXCUT 125 CE Mounting instructions

INSTALLATION
FLEXCUT
125 CE
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
INSTALLATION N° 07085710NG
EDITION : EN Instructions for use REF : 8695 4496
REVISION : B
DATE : 02-2019 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 4496 / B
FLEXCUT 125 CE INSTALLATION I
CONTENTS
A - IDENTIFICATION .........................................................................................................................1
1 - FLEXCUT 125 CE INSTALLATION....................................................................................1
2 - TOOL HOLDER PO150D ....................................................................................................2
3 - FLEXCUT 125 CE POWER SOURCE.................................................................................2
4 - TORCH LC125M .................................................................................................................2
5 - HMI FOR HPC INSTALLATION..........................................................................................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 - SOUND POLLUTION..........................................................................................................5
8 - AIRBORNE NOISE .............................................................................................................6
C-DESCRIPTION..............................................................................................................................7
1 - CAPACITIES OF THE FLEXCUT 125 CE INSTALLATION ...............................................7
2 - INTEGRATED INSTALLATION ON LINCOLN MACHINE .................................................8
3 - DETECTION BOX...............................................................................................................10
4 - TOOL HOLDER AND TORCH IMPACT SAFETY..............................................................11
5 - TORCH LC125M+ BUNDLE...............................................................................................11
6 - POWER SOURCE ..............................................................................................................11
D-ASSEMBLY AND INSTALLATION ..............................................................................................13
1 - CONDITIONS OF INSTALLATION.....................................................................................13
2 - INSTALLATION...................................................................................................................17
3 - CYCLE FUNCTION INSTALLATION FOR INTEGRATED INSTALLATION......................20
4 - TOOL-HOLDER INSTALLATION........................................................................................20
5 - INSTALLING THE DETECTION BOX.................................................................................21
6 - TORCH LEAD-BUNDLES INSTALLATION........................................................................22
7 - POWER SOURCE INSTALLATION....................................................................................22
E-OPERATOR MANUAL..................................................................................................................24
1 - OPERATOR CONTROLS...................................................................................................24
2 - ADJUSTMENTS..................................................................................................................24
3 - GAS SUPPLY CHANGE.....................................................................................................24
4 - CYCLES..............................................................................................................................25
F-MAINTENANCE ............................................................................................................................27
1 - SERVICING.........................................................................................................................27
2 - TROUBLESHOOTING........................................................................................................28
3 - PO150D TOOL HOLDER MAINTENANCE ........................................................................32
4 - FLEXCUT 125 CE POWER SOURCE MAINTENANCE .....................................................32
5 - TORCH LC125M MAINTENANCE .....................................................................................32
6 - SPARE PARTS...................................................................................................................33
PERSONAL NOTES ..........................................................................................................................40

8695 4496 / B
II FLEXCUT 125 CE INSTALLATION
INFORMATIONS
For operating instructions, adjustments, troubleshooting and spare parts see safety instructions for use and
maintenance
ISEE N°
ISUM
IM10375
Flexcut 125 CE Power Source
8695 4566
Tool Holder PO150D
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 02/19
DESIGNATION
PAGE
Creation in English language

8695 4496 / B
FLEXCUT 125 CE INSTALLATION A-1
A - IDENTIFICATION
1 - FLEXCUT 125 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 125 CE POWER SOURCE
(G)
TOOL HOLDER (P)
TORCH LC125M (T)
FLEXCUT 125 CE INSTALLATION
REFERENCE
DESCRIPTION
T
Torch LC125M + torch bundle
G
Flexcut 125 CE power source
P
Tool-Holder PO150D

A - IDENTIFICATION 8695 4496 / B
A-2 FLEXCUT 125 CE INSTALLATION
2 - TOOL HOLDER PO150D
Please refer to the document: 8695 4566.
3 - FLEXCUT 125 CE POWER SOURCE
Please refer to the document: IM10375.
4 - TORCH LC125M
Please refer to the document: IM10375.
5 - HMI FOR HPC INSTALLATION
Please refer to the document: 8695 4944.

8695 4496 / B
FLEXCUT 125 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: référence IM10375
In the operating phase, and also in the adjustment phase, appropriate personal protection is required (see
document IM10375 for more details).
Standard EN 169 requires the use of shade 10 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 125 CE installation, all metallic parts within the
operator’s reach must imperatively be linked to the ground.
MARKS
B
Shield
P
Tool holder
C
Cycle function
RA
Rail
D
Cutting table

B - SAFETY INSTRUCTIONS 8695 4496 / B
B-4 FLEXCUT 125 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 125 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 4496 / BB - SAFETY INSTRUCTIONS
FLEXCUT 125 CE INSTALLATION B-5
5 - ELECTROMAGNETIC POLLUTION
It is indispensable to protect the eyes from arc radiation
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 1m/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 - 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).

B - SAFETY INSTRUCTIONS 8695 4496 / B
B-6 FLEXCUT 125 CE INSTALLATION
8 - AIRBORNE NOISE
1 - MEASUREMENT SITE QUALIFICATION
2 - SOUND PRESSURE MEASUREMENTS
The machine was tested in the workshop of Pont
Sainte Maxence:
5 place Chatelier
60700 PONT SAINTE MAXENCE
FRANCE.
That qualification was the subject of Report
n°17563386/1
The values are given in equivalent weighted
sound level (LAeq)
The unit of measurement is the dB (A) :
weighted decibel "A"
The measurements were taken at a height of
1.6m above the ground with a sound-level meter,
type FUSION, nbr 10925, checked in an accredited
laboratory (LNE)
3 - MESURES
LC 125M
MEASUREMENT CONDITIONS
M1
M2
Current
85A
125 A
Materials
Mild steels:
8 mm
Mild steels:
20 mm
Gas
compressed air
compressed air
Level LAeq
dB(A)
Level LCpeak
dB(C)
Level LAeq
dB(A)
Level LCpeak
dB(C)
Distance
from
measure
point to
torch
1 m
101,2
114,3
95,2
108
2 m
96,2
109
90,6
103,6
3 m
93,2
106,3
89
103,8
4 m
90,8
103,8
85,9
98,6
5 m
89,7
102,6
84,4
98,8

8695 4496 / B
FLEXCUT 125 CE INSTALLATION C-7
C-DESCRIPTION
1 - CAPACITIES OF THE FLEXCUT 125 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 45A to 125A up to 30mm at middle sheet cutting start (40mm at
sheet edge cutting start), mainly with steel, stainless steel or aluminium, using the following gases: air, nitrogen and
argon-hydrogen. The installation can also do plasma markin from 12A up to 16A.
NOTE : The speed/quality ratio can be chosen according to the final use of the parts cut out.

C - DESCRIPTION 8695 4496 / B
C-8 FLEXCUT 125 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 4496 / BC - DESCRIPTION
FLEXCUT 125 CE INSTALLATION C-9
FLEXCUT 125 CE INSTALLATION
Mark
Designation
Reference
B
Detection cabinet
0708 5608
C
Cycle function assembly
-
P
Tool Holder
0708 5505NG
I
Programming interface
-
T
Torch LC125M + torch bundle
07085711NG (15m)
07085712NG (22m)
G
Flexcut 125 CE power source
K4811-2
G1
Cutting gas (Air)
FT
Transverse chain
FL
Longitudinal chain
1
Torch harness
07085711NG (15m)
07085712NG (22m)
2
Power source / cycle control harness
0708 5719
3
Motor bundles
- TH motor moteur L = 10m
- TH control bundle L = 10.5m
- TH stepper encoder L = 13m
0708 5106
0708 5107
0708 5108
4
Detection 1 bundle
0708 5622
5
Detection 2 bundle
0708 5627
6
Power source earth / working place bundle, L=10 M :
Power source earth / working place bundle, L=20 M :
Power source earth / working place bundle, L=40 M :
0708 5730NG
0708 5731NG
0708 5732NG

C - DESCRIPTION 8695 4496 / B
C-10 FLEXCUT 125 CE INSTALLATION
3 - DETECTION BOX
It is usually mounted on the beam of the thermal
cutting machine. When choosing the location of this
unit, make sure that the distance is compatible with
the length of the detection cable.
CHARACTERISTICS :
Reference:
0708 5608
Dimensions:
131mm x 176mm x 65mm

8695 4496 / BC - DESCRIPTION
FLEXCUT 125 CE INSTALLATION C-11
4 - TOOL HOLDER AND TORCH IMPACT SAFETY
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 4566
5 - TORCH LC125M+ BUNDLE
The Flexcut 125 CE installation is designed to operate with the LC125M 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 via its bundle. It is fixed to the machine via the torch impact safety
system of the tool holder.
The torch is cooled by cutting air.
Space taken up by the equipment :
Please refer to the document: IM10375
6 - POWER SOURCE
The function of Flexcut 125 CE power source is to regulate the cutting current according to the required setpoints
The Flexcut 125 CE can deliver a maximum of 125A.
The power source is generally located close to the installation.
Space taken up by the equipment :
Please refer to the document: IM10375.

C - DESCRIPTION 8695 4496 / B
C-12 FLEXCUT 125 CE INSTALLATION

8695 4496 / B
FLEXCUT 125 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.
Never exceed the pressure value of 8 bars.
Starting up the gas sources
Please refer to section :
"6-2 CYLINDER CHANGE PROCEDURE"
in the safety booklet 8695 7050

D - ASSEMBLY AND INSTALLATION 8695 4496 / B
D-14 FLEXCUT 125 CE INSTALLATION
Conditions for gas types
CUTTING 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
260 l/mn
Compressed air
Compressed air
ISO 8573-1:2010,
Class 1.4.1
7.2 bar +/-1
260 l/mn
* 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.

8695 4496 / BD - ASSEMBLY AND INSTALLATION
FLEXCUT 125 CE INSTALLATION D-15
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 machines, refer to the machine instructions.

D - ASSEMBLY AND INSTALLATION 8695 4496 / B
D-16 FLEXCUT 125 CE INSTALLATION
Consumption of Flexcut 125 CE power source
Alimentation
3 phases + terre
400 V
I eff (125A-175VDC)
40A
Fuse rating
40 A aM
Fuse rating
10*38
Power supply cable
section
4*6 mm²
Cable part number
.5519035NG
The consumption values are stated for working
with 125 A - 175 VDC for cutting
Sectioning box
3-phase power supply +
ground
400 V
Flexcut 125 CE
Single torch
06942318NG
Dual torch
06942322NG
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.