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Lincoln Electric FlexCut 80 User Manual

Lincoln Electric FlexCut 80
64 pages
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Operator’s Manual
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www.lincolnelectric.com/locator
IM10197-B | Issue D ate Oct-16
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12249, 12589
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
FlexCut
80

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Lincoln Electric FlexCut 80 Specifications

General IconGeneral
Output Current Range20 - 80 A
Max Open Circuit Voltage300 VDC
Gas TypeAir or Nitrogen
Duty Cycle60% at 80 A
Rated Output80 A at 60% duty cycle
Gas Pressure65-75 psi (4.5-5.2 bar)

Summary

Safety Introduction and Precautions

Fume and Arc Exposure Prevention

Advises keeping head out of fumes and ensuring adequate ventilation during operation.

Personal Protective Equipment (PPE)

Details necessary eye, ear, and body protection for welding.

Section A: Major Warnings

Arc Welding Hazards and Precautions

Highlights dangers of arc welding and need for caution, especially for pacemaker wearers.

Electric and Magnetic Field Hazards

Warns about EMF fields and their potential impact on pacemakers and health.

Key Safety Hazard Categories

Electric Shock Prevention

Details measures to prevent electric shock, including insulation and proper grounding.

Arc Ray Protection

Advises on protective shields, clothing, and screening against arc rays.

Fumes and Gases Danger

Warns about hazardous fumes and gases produced during welding and ventilation needs.

Fire and Explosion Safety

Fire Prevention During Cutting

Instructions on removing fire hazards and using fire extinguishers during cutting.

Detailed Safety Procedures

General Precautions for Plasma Cutting

General safety advice for plasma cutting, emphasizing qualified personnel and safety decals.

Ultraviolet Radiation Protection

Details protection needed against UV radiation from plasma cutting, including eye and skin protection.

Toxic Fume Prevention

Discusses ventilation and breathing equipment for toxic fumes from various materials.

Electric Shock Prevention Measures

Comprehensive safety guidelines to prevent electric shock during operation and maintenance.

Operational Safety Focus

Fire Prevention Measures

Reinforces fire prevention steps, including material removal and extinguisher accessibility.

Explosion Prevention with Compressed Gases

Further details on safe handling and storage of compressed gas cylinders.

Technical Specifications Overview

Installation and Setup Guide

Safety Precautions During Installation

Critical warnings regarding electric shock and qualified personnel for installation.

Input Connection and Grounding

Details on proper input power connection, grounding, and electrical code compliance.

Power Input and Gas Supply Setup

Gas Supply Requirements and Warnings

Specifies clean, dry air or nitrogen, regulator use, and pressure limits.

Compressed Gas Cylinder Safety

Precautions for handling compressed gas cylinders to prevent damage and explosion.

Operational Safety Warnings

General Operation Safety Precautions

Key safety warnings for electric shock, fumes, sparks, and arc rays during operation.

Control Panel and Settings Guide

Output Current and Gas Pressure Adjustment

Explains how to set output current, adjust gas pressure, and use the purge function.

Selecting Cutting Operating Mode

Describes how to select between CUT, GRID, and GOUGE operating modes.

Performing Hand Cuts

Procedure for Hand Cutting

Step-by-step guide on how to perform a hand cutting operation.

Plasma Gouging Process

Technique for Plasma Gouging

Step-by-step instructions on how to perform plasma gouging.

Troubleshooting Gouging Issues

Addresses potential problems like electric shock and parts-in-place errors during gouging.

Mechanized Cutting Setup

Installing and Removing Torch Consumables

Steps for proper installation and removal of torch consumables.

Making a Cut: Step-by-Step

Setting Up a Cut

Step-by-step guide for preparing and initiating a plasma cut.

Consumable Life and Cut Quality Optimization

Achieving Optimum Cut Quality

Factors influencing cut quality and adjustments for improvement.

Routine Maintenance Schedule

Troubleshooting Guide Introduction

Electrical Safety During Troubleshooting

Emphasizes turning off power and observing safety precautions before troubleshooting.

Troubleshooting: Power and Indicator Issues

Circuit Breaker Tripping and No Status Indicators

Addresses issues with circuit breakers tripping and no status indicators lighting up.

Troubleshooting: Operational Faults

No Response When Trigger Pulled

Troubleshooting steps when the trigger is pulled but there is no response.

Trigger Locked Condition

Explains the trigger locked condition and how to restore normal operation.

Troubleshooting: Arc and Air Flow Problems

No Pilot Arc After Air Flow

Addresses issues where air flows but no pilot arc establishes.

Troubleshooting: Arc Transfer Failures

Pilot Arc Starts But Will Not Transfer

Solutions for when the pilot arc starts but fails to transfer to the workpiece.

Troubleshooting: Status Indicator Errors

Yellow Gas Pressure LED Steady

Checks for gas pressure issues indicated by a steady yellow LED.

Troubleshooting: Error Codes and Recovery

No Pilot Arc Established Error

Details errors related to no pilot arc establishment and restoration steps.

Trigger Locked Error Recovery

Explains the trigger locked error and how to recover from it.

Wiring Diagram Overview

FlexCut 80 Wiring Schematic

Provides the electrical wiring diagram for the FlexCut 80.

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