Lincoln Electric IM10062 User Manual

Operator’s Manual

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FLEXTEC ™ 450

For use with machines having Code Numbers:

11626, 11754, 11941, 12038

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10062-C | Issue D ate Oct-13

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIA L SI TUATIONS

Additional precautionary measures

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

Lincoln 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.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

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 Material Safety

Data Sheet (MSDS) 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.

WEAR 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

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.

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.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH 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 Lincoln 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.

SAFETY

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

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.

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 possible to the area being welded.

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

SAFETY

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

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.

between the

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. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) 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. In confined spaces or in some circumstances, outdoors, a respirator may 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 PEL and ACGIH TLV 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.

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

5.d. Shielding gases used for arc welding can displace air and

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 material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

SAFETY

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.

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 1235 Jefferson Davis Highway, Arlington, VA 22202.

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.

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.

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.

Welding Safety Interactive Web Guide for mobile devices

vi vi

TABLE OF CONTENTS

Page

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

Technical Specifications ........................................................................................A-1

Welding Process, Physical Dimensions ..........................................................A-2

Safety Precautions ..........................................................................................A-3

VRD™ (Voltage Reduction Device) ..............................................................................A-3

Select Suitable Location..................................................................................A-3

Lifting...............................................................................................................A-3

Stacking ..........................................................................................................A-3

Environmental Limitations ...............................................................................A-3

Input and Grounding Connections ..................................................................A-3

High Frequency Protection ....................................................................................A-3

Input Connection ............................................................................................A-4

Input Connection .............................................................................................A-5

Input Fuse and Supply Wire Considerations...................................................A-5

Input Voltage Selection ...................................................................................A-5

Cable Connections..........................................................................................A-6

Recommended Electrode and Work Cable for arc Welding ..................................A-7

Output Cable Guidelines........................................................................................A-7

Connection Diagrams Flextec 450 to Wire Feeders ..............................A-8 thru A-11

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1

Graphic Symbols............................................................................................B-1, B-2

Product Description ..............................................................................................B-2

Duty Cycle .............................................................................................................B-2

Design Features ....................................................................................................B-2

Recommended Processes and Equipment ...........................................................B-3

Case Front Controls...............................................................................................B-4

Power-Up Sequence..............................................................................................B-5

Case Back Controls...............................................................................................B-5

Common Welding Procedures, Weld Controls and Displays..................B-5, thru B-8

_______________________________________________________________________

Accessories .....................................................................................................Section C

Options / Accessories............................................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

ISUAL INSPECTION...................................................................................................D-1

OUTINE MAINTENANCE ............................................................................................D-1

ERIODIC MAINTENANCE ...........................................................................................D-1

________________________________________________________________________

Section E ..............................................................................................Troubleshooting

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Error Codes ............................................................................................E-3 Thru E-5

________________________________________________________________________

Wiring Diagram and Dimension Print ............................................................Section F

________________________________________________________________________

Parts List.........................................................................................P-652, P-732 Series

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS -

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K2882-2

Process

GMAW (CV)

GTAW (CC)

SMAW (CC)

FCAW-GS (CV)

Duty Cycle

60% rating

100% rating

Duty Cycle

60%

100%

60%

100%

60%

100%

60%

100%

Input Voltage ± 10%

380 / 460 / 575 / 3 / 50 / 60

Volts at Rated Amperes

FLEXTEC™ 450

Input Amperes

RATED OUTPUT

36.5V

34V

28V

26V

38V

36V

36.5V

34V

37 / 27 / 22

29 / 21 / 17

Idle Power

72 Watts

Max.

(fan on)

Amperes

450

400

450

400

450

400

450

400

Power Factor @

Rated Output

95%

60%

36.5V

450

FCAW-SS (CV)

100%

RECOMMENDED INPUT WIRE AND FUSE SIZES

VOLTAGE

50/60Hz

Maximum

Input

Cord Size AWG SIZES

Amperes

380/3/50 460/3/60 575/3/60

(1)

Cord and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.

(2)

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the magnitude of current increases.

(3)

Type SD cord or similar in 30°C ambient.

42 A 30 A 25 A

(3)

(mm)

8(10) 8(10) 10(6)

34V

Type 75°C Copper

Wire in Conduit

AWG (mm

)

8 (10) 10 (6) 12 (4)

(1)

COPPER GROUNDING

CONDUCTOR

AWG (mm

)

10 (6) 10 (6) 12 (4)

400

Fuse (Super Lag) or

Breaker Size

50 45 35

(2)

FLEXTEC™ 450

A-2

PROCESS

INSTALLATION

WELDING PROCESS

OUTPUT RANGE (AMPERES)

A-2

OCV (Uo)

GMAW (CV)

GTAW (CC)

SMAW (CC) FCAW-GS (CV) FCAW-SS (CV)

40-500 10-500 15-500 40-500 40-500

PHYSICAL DIMENSIONS

MODEL

K2882-2

HEIGHT

18.80in (478mm)

14.14in (359mm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

Environmentally Hardened: 14°F to 131°F (-10°C to 55°C**)

IP23 155º(F) Insulation Class

* Weight does not include input cord. ** Output De-rated at Temperatures above 40°C.

60 24 60 60 60

WIDTH

STORAGE TEMPERATURE RANGE

Environmentally Hardened: -40°F to 185°F (-40°C to 85°C)

DEPTH

26.66in (677mm)

WEIGHT

125lbs (56.6kg)*

FLEXTEC™ 450

A-3

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

INSTALLATION

STACKING

The Flextec™ 450 cannot be stacked.

A-3

ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION.

• TURN OFF INPUT POWER TO THE

POWER SOURCE AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THIS EQUIPMENT. TURN OFF THE INPUT POWER TO ANY OTHER EQUIPMENT CONNECTED TO THE WELDING SYSTEM AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THE EQUIPMENT.

• DO NOT TOUCH ELECTRICALLY HOT PARTS.

• ALWAYS CONNECT THE FLEXTEC™ 450 GROUNDING LUG (LOCATED INSIDE THE RECONNECT INPUT ACCESS DOOR) TO A PROPER SAFETY (EARTH) GROUND.

----------------------------------------------------------------------

ENVIRONMENTAL LIMITATIONS

The Flextec™ 450 is IP23 rated for use in an outdoor environment. The Flextec™ 450 should not be subjected to falling water during use nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

Do not mount the Flextec™ 450 over combustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .060” (1.6mm) thick, which shall extend not less than 5.90” (150mm) beyond the

VRD™ (VOLTAGE REDUCTION DEVICE)

equipment on all sides.

-----------------------------------------------------------------------

(For Code 11941 only)

The VRD™ feature provides additional safety in the CC-

INPUT AND GROUNDING CONNECTIONS

Stick mode. The VRD™ reduces the OCV (Open Circuit Voltage) at the welding output terminals while not welding to less than 35VDC peak.

The VRD™ requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting. Having good electrical connections also limits the possibility of other safety issues such as heat-generated damage, burns and fires.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol shown is located inside the reconnect/input connection area for this purpose. See your local and national electrical codes for proper grounding methods.

CAUTION

The machine is shipped with VRD™ “Disabled”. The VRD™ function can be disabled or enabled via dip switches on the control P.C. board. Dip switch setting will differ depending on input voltage.

The control board and dip switches can be accessed by removing the case top and side as shown in the Operation

Section figure B.3.

HIGH FREQUENCY PROTECTION

Locate the Flextec™ 450 away from radio controlled machinery. The normal operation of the Flextec™ 450 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

SELECT SUITABLE LOCATION

LOCATION AND VENTILATION FOR COOLING

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

HIGH TEMPERATURE OPERATION

LIFTING

Both handles should be used when lifting the Flextec™ 450. When using a crane or overhead device a lifting strap should be connected to both handles. Do not attempt to lift the Flextec™ 450 with accessories attached to it.

WELDER OUTPUT RATINGS AT 55°C

ELEVATED TEMPERATURES

AMPS

340

375

400

450

DUTY CYCLE

100%

60%

40%

20%

VOLTS

34VDC

35VDC

36VDC

38VDC

TEMPERATURES

55°C

FLEXTEC™ 450

A-4

INSTALLATION

A-4

WARNING

ELECTRIC SHOCK can kill.

ONLY A QUALIFIED ELECTRICIAN SHOULD CONNECT THE INPUT

LEADS TO THE FLEXTEC™ 450. CONNECTIONS SHOULD BE MADE IN ACCORDANCE WITH ALL LOCAL AND NATIONAL ELECTRICAL CODES AND THE CONNECTION DIAGRAM LOCATED ON THE INSIDE OF THE RECONNECT/INPUT ACCESS DOOR OF THE MACHINE. FAILURE TO DO SO MAY RESULT IN BODILY INJURY OR DEATH.

----------------------------------------------------------------------

INPUT CONNECTION

(See Figure A.1) For codes 11941 and below

Use a three-phase supply line. A 1.40 inch (36 mm) diameter access hole for the input supply is located on the case back. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the internal horizontal panel.

INPUT VOLTAGE SELECTION

For codes 11941 and below

Welders are shipped connected for 460 Volt input voltage. To move this connection to a different input voltage, see the diagram located on the inside panel in the reconnect/input connection area, illustrated in Figure A.1. If the Auxiliary lead (indicated as ʻAʼ) is placed in the wrong position and power is applied to the machine, the machine will protect itself and display an error message:

• "Err" "713" or “714” will be shown on the display.

• The control board and switch boards will blink out error "713" or “714” on their status leds.

• The weld output will be turned off and the control board will force itself into an idle state.

• The machine will need to have the misconnect condition removed before it will recover.

To access the reconnect/input supply connection blocks, remove the 8 screws that secure the case top of the welder and remove the case top.

FIGURE A.1

POWER SUPPLY ACCESS HOLE

• Route input power cable through this hole.

RECONNECT TERMINAL BLOCK

• Reconnects auxiliary transformers for the proper input voltages

RECONNECT TERMINAL BLOCK

POWER SUPPLY TERMINAL BLOCK

• Line Cord/Cable attaches here.

• A ground terminal marked with the symbol shown is provided separate from this block for connecting the ground lead of the line cord. (See your local and national electrical codes for proper grounding methods.)

FLEXTEC™ 450

A-5

INSTALLATION

A-5

INPUT CONNECTION

(See Figure A.1a) For codes 12038 and above

To access the input supply connection blocks, remove the 8 screws that secure the case top of the welder and remove the case top.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to Specification in this Installation Section for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse time" or "thermal/magnetic" circuit breakers). Choose input and grounding wire size according to local or national electrical codes. Using input wire sizes, fuses or circuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents.

INPUT VOLTAGE SELECTION

For codes 12038 and above

Welders are shipped connected for 460 Volt input voltage. To move this connection to a different input voltage, reconnect the auxiliary lead (indicated as ʼAʼ) located at the back of the machine to the appropriate receptacle as shown in Figure A.1a. If the Auxiliary lead (indicated as ʻAʼ) is placed in the wrong position and power is applied to the machine, the machine will protect itself and display an error message:

• "Err" "713" or “714” will be shown on the display.

• The control board and switch boards will blink out error "713" or “714” on their status leds.

• The weld output will be turned off and the control board will force itself into an idle state.

• The machine will need to have the misconnect condition removed before it will recover.

FIGURE A.1a

POWER SUPPLY ACCESS HOLE

• Route input power cable through this hole.

POWER SUPPLY TERMINAL BLOCK

• Line Cord/Cable attaches here.

BACK OF MACHINE

RECONNECT TERMINAL BLOCK

• Reconnect auxiliary transformer for the proper input voltage.

L1 L2 L3

U V W

FLEXTEC™ 450

A-6

INSTALLATION

CABLE CONNECTIONS

See FIGURE A.2 for locating 6-pin and 14-pin connectors on the front of the FLEXTEC™ 450.

6-PIN REMOTE CONTROL CONNECTOR

A-6

Function

6-pin remote control connector for remote or hand/foot amptrol.

14-PIN CONNECTOR FOR WIRE FEEDER

Function

14 pin connector for wire feeder connectivity.

77 Remote potentiometer, 5K

76 Remote potentiometer, wiper

75 Remote potentiometer, common

Trigger, common

Trigger, input

Ground

Trigger, Common

Trigger input

77 Remote potentiometer, 5K

76 Remote potentiometer, wiper

75 Remote potentiometer, common

Voltage Sense (21)

Motor (42 VAC)

L M N

Wiring

FIGURE A.2

6-PIN REMOTE CONTROL CONNECTOR

FLEXTEC™ 450

14-PIN CONNECTOR FOR WIRE FEEDER

A-7

INSTALLATION

A-7

RECOMMENDED ELECTRODE AND WORK CABLE SIZES FOR ARC WELDING

General Guidelines

Connect the electrode and work cables between the appropriate output studs of the Flextec™ 450 per the following guidelines:

• Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source. Connect a work lead from the negative (-) power source output stud to the work piece.

• When negative electrode polarity is required, such as in some Innershield applications, reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud).

The following recommendations apply to all output polarities and weld modes:

• Select the appropriate size cables per the “Output Cable Guidelines” (See Table A.1).

Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance. Always use the largest welding cables (electrode and work) that are practical, and be sure all connections are clean and tight.

• Route all cables directly to the work and wire

feeder, avoid excessive lengths and do not coil excess cable. Route the electrode and work cables

in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit.

• Always weld in a direction away from the work (ground) connection.

CONTROL CABLE CONNECTIONS

General Guidelines

Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the Flextec™ 450. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 100 feet (30.5 m). The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving force (wire feeding problems). Always use the shortest length of control cable possible, and DO NOT coil excess cable.

Regarding cable placement, best results will be obtained when control cables are routed separate from the weld cables. This minimizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the control cables.

Note: Excessive heat in the weld circuit indicates undersized cables and/or bad connections.

TABLE A.1

OUTPUT CABLE GUIDELINES

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPERES

200 200 250 250 250 250 300 300 350 400 400 500

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables

larger than recommended, or cables rated higher than 167°F(75°C).

PERCENT

DUTY

CYCLE

100

30 40 60

100

40 60

100

0 to 50Ft. (0 to15m)

2 2 3 2 1 1

1 2/0 1/0 2/0 3/0 2/0

(RUBBER COVERED COPPER - RATED 167°F or 75°C)**

50 to 100Ft. (15 to 30m)

2 2 3 2 1 1

1 2/0 1/0 2/0 3/0 2/0

100 to 150 Ft.

(30 to 46m)

2 2 2 1 1 1

1 2/0 2/0 2/0 3/0 3/0

150 to 200 Ft.

(46 to 61m)

1 1 1 1 1

1 1/0 2/0 2/0 3/0 3/0 3/0

200 to 250 Ft.

(61 to 76m)

1/0 1/0 1/0 1/0 1/0 1/0 2/0 3/0 3/0 4/0 4/0 4/0

FLEXTEC™ 450

A-8

CONNECTING LF-72 AND LF-74 TO THE FLEXTEC™ 450

FLEXTEC™-450

WELD MODE

INSTALLATION

14-PIN CONTROL CABLE K1797-XX

ELECTRODE

WORK

CONTROL SETTING

CV, CV-INNERSHIELD

A-8

WIRE FEEDER

LF-72 LF-74

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

OFF

LOCAL

(REMOTE IF K2329-1 INSTALLED)

PROCESS DEPENDENT

FLEXTEC™ 450

A-9

INSTALLATION

CONNECTING LN-10 AND DH-10 TO THE FLEXTEC™ 450

WIRE FEEDER

A-9

14-PIN CONTROL CABLE K1501-XX

FLEXTEC™-450

ELECTRODE

WORK

CONTROL SETTING

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

LN-10,DH-10 CONTROL SWITCH SETUP

Initial set up of the LN-10, DH-10 control for the system components being used and for general operator preferences is done using a pair of 8-pole DIP switches located inside the LN-10, DH-10 control box.

LN-10 DH-10

CV, CV-INNERSHIELD

OFF

REMOTE

PROCESS DEPENDENT

Setting the DIP Switches

The DIP switches are each labeled with an “ON” arrow showing the on direction for each of the 8 individual switches in each DIP switch (S1 and S2). The functions of these switches are also labeled and set as described below:

Setup DIP Switch Access

1) Shut off the input power to the LN-10, DH-10 control by turning off the power at the welding power source it is connected to.

2) Remove the two screws on the top of the LN-10, DH-10 control box door and swing the door down to open.

3) Locate the two 8-pole DIP switches, near the top left corner of the LN-10, DH-10 Control P.C. board, labeled S1 and S2.

4) Switch settings are only programmed during input power-up restoration.

FLEXTEC™ 450

Pwr Sources

12 3 4567 8

Head

Pwr Sources

12 3 4567 8

A-10

INSTALLATION

CONNECTING LN-15(K1870-1) TO THE FLEXTEC™ 450

WIRE FEEDER

A-10

FLEXTEC™-450

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

ELECTRODE

WORK

LN-15 (K1870-1)

CONTROL SETTING

CV, CV-INNERSHIELD

OFF

LOCAL

PROCESS DEPENDENT

CONNECTING LN-15(K1871-1) TO THE FLEXTEC™ 450

WORK CLIP

FLEXTEC™-450

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

14-PIN CONTROL CABLE K1819-XX

ELECTRODE

WORK

CONTROL SETTING

CV, CV-INNERSHIELD

OFF

REMOTE

PROCESS DEPENDENT

FLEXTEC™ 450

WIRE FEEDER

LN-15 (K1871-1)

A-11

INSTALLATION

CONNECTING LN-25 PRO AND LN-25 PIPE TO THE FLEXTEC™ 450

WIRE FEEDER

A-11

FLEXTEC™-450

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

CONNECTING LN-25 PRO DUAL POWER TO THE FLEXTEC™ 450

ELECTRODE

WORK

CONTROL SETTING

LN-25 PRO LN-25 PIPE

WORK CLIP

CV, CV-INNERSHIELD

OFF

LOCAL

PROCESS DEPENDENT

WIRE FEEDER

FLEXTEC™-450

CONTROL CABLE K1797-XX

ELECTRODE

WORK

LN-25 PRO

DUAL POWER

CONTROL SETTING

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

*CONTROL CABLE SETUP SHOWN. REFER TO LN-25 PRO CONNECTION DIAGRAM IF SETTING UP

"ACROSS-THE-ARC" FEEDER.

FLEXTEC™ 450

CV, CV-INNERSHIELD

OFF

REMOTE

PROCESS DEPENDENT

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions

before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several

seconds after the welding ceases.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

INPUT POWER

OFF

HIGH TEMPERATURE

CIRCUIT BREAKER

WIRE FEEDER

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have

held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning of this manual.

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

FLEXTEC™ 450

B-2

OPERATION

B-2

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

PRODUCT DESCRIPTION

The Flextec™ 450 is a multi-process CC/CV DC inverter and is rated for 450 amps, 38 volts at a 60% duty cycle. The Flextec is intended for both factory and field operation. It comes in a compact, rugged case that is designed for portability and outdoor use with an IP23 environmental rating. The user interface of the Flextec™ 450 is simple and intuitive. Weld modes are selected by a 4 position selector switch. Volts and Amps are displayed on an easy to view LED display, and the amps and volts are set by a large output control knob. A hot start toggle selector switch and an arc control knob allow for finer tuning of the welding arc. The Flextec™ 450 operates on 380V, 460V, or 575V 50hz or 60hz power.

DUTY CYCLE

The Flextec™ 450 is capable of welding at a 100% duty cycle (continuous welding) at 400 amps rated output. The 60% rating is 450 amps base off of a 10 minute cycle - 6 minutes on time and 4 minutes off time. The maximum output of the machine is 500 amps.

The Flextec™ 450 is also rated for Desert Duty, elevated temperature operation, in a 55°C(131°F) ambient. The machine is output de-rated for this application.

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

DESIGN FEATURES

• Severe Duty Design for outdoor use (IP23 rating).

• Passive Power Factor Correction – reliably gives 95% power factor for lower installation costs.

• 89% Efficiency rating – reduces electrical utility costs.

• Simple user interface - designed with the operator in mind. Getting setup for the weld is several clicks away and even the most novice welder can be confident he is setup properly.

• F.A.N. (fan as needed). Cooling fan runs when the output is energized and for a 5 minute cool down period after output is disabled.

• Thermal protection by thermostats with Thermal Indicator LED.

• Error Codes display on LED screen for ease of trouble shooting.

• Electronic over current protection.

• Input voltage misconnection protection.

• Utilizes digital signal processing and microprocessor control.

FLEXTEC™ 450

B-3

OPERATION

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The Flextec™ 450 is designed for CC-SMAW, CC-GTAW (lift tig), CV-GMAW, CV-FCAW-SS and CV-FCAW-GS

welding processes. CAG (arc gouging) is also supported.

PROCESS LIMITATIONS

The Flextec™ 450 is suitable only for the processes listed.

EQUIPMENT LIMITATIONS

Operating Temperature Range is -10° C to + 55° C. Output De-rated at Temperatures above 40°C.

COMMON EQUIPMENT PACKAGES

B-3

Basic Package

K2882-2 K2327-5 K2149-1

K1842-10

3100211

Common Optional Kits

K857

K857-1

K870

K963-3

Compatible Wire Feeders

All Models

Note: The

Flextec™ 450 is not compatible with 115V Wire Feeders.

Harris Regulator and gas hose

Remote Output Control (25 feet)

Remote Output Control (100 feet)

Flextec™ 450

LF-72 Bench Model

Work Lead Package

10 Ft. Weld Power Cable

Foot Amptrol

Hand Amptrol

LF-72 LF-74 LN-10

DH-10

LN-25 Pro

FLEXTEC™ 450

B-4

OPERATION

CASE FRONT CONTROL DESCRIPTIONS

(See Figure B.1)

1. Power Switch

2. Voltage Display Meter

B-4

11. Wire feeder voltmeter polarity selection toggle

switch

12. Circuit breaker reset button for the 14-pin wire

feeder connector

3. Amperage Display Meter

4. Thermal LED

5. Output Control Dial

6. Weld Process Selector Switch

7. Hot Start Toggle Switch

8. Output Control Local/Remote Toggle Switch

9. Arc Control Dial

10. Weld Terminals On/Remote toggle selector switch

FIGURE B.1

13. 14-pin wire feeder circular connector

14. 6-pin remote circular connector

15. Positive and negative welding output studs

16. VRD™ (Voltage Reduction Device) Indicator Lights (For Code 11941 only)

FLEXTEC™ 450

B-5

CASE BACK CONTROL

(See Figure B.2)

1. Input Power Cord Access Hole.

OPERATION

3. CV – This is CV (constant voltage) weld mode used

for welding the GMAW MIG welding process and the FCAW-GS, flux cored gas shielded welding process.

B-5

FIGURE B.2

POWER-UP SEQUENCE

When power is applied to the Flextec™ 450, the displays will illuminate and display the voltage and/or amperage settings.

COMMON WELDING PROCEDURES

WARNING

MAKING A WELD The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selec-

tion.

The Flextec™ 450 is a multi-process inverter welder. The Weld Process Selector Switch is used to set the desired weld mode. The Flextec™ 450 has 4 selectable welding modes:

1. SMAW – This is a CC (constant current) weld

mode used for the SMAW stick welding process.

2. GTAW – This is a CC (constant current) weld

mode used for the GTAW TIG welding process.

4. CV-Innershield – This is a CV (constant voltage)

weld mode used for welding the FCAW-SS, flux cored self shielded welding process

The Flextec™ 450 is also capable of gouging. Gouging can be done in either the SMAW mode or the CV and CV-Innershield modes.

In addition to the weld process selector switch, a hot start toggle, output control dial and arc control dial are provided to setup and fine tune the welding procedure.

WELD CONTROLS AND DISPLAYS

Weld Process Selector Switch

4 Position switch used to select the welding process.

Hot Start Toggle Switch

The Hot Start control regulates the starting current at arc initiation. Hot Start can be set to “Off” and no additional current is added at arc start. When set to the “On” position, additional current (relative to the preset current) is added at arc initiation.

Arc Control Dial

Full range selection of arc control from -10 to +10. In CV mode, this control is an inductance control. In stick mode, the control adjusts the arc force.

Output Control Dial

Output control is conducted by a single turn potentiometer. (Adjustment is indicated by the meters.) When in Remote Mode, this control sets the maximum welding current of the remote device. For example, full depression of a foot or hand amptrol results in the preset level of current.

Voltage Display Meter

• Prior to CV operation (current flow), the meter displays desired preset voltage value.

• Prior to STICK or TIG operation, the meter displays the Open Circuit Voltage of the Power Source or four dashes if the output has not been turned on.

• During welding, this meter displays actual average volts.

• After welding, the meter holds the actual voltage value for 5 seconds. The displays blink indicating that the machine is in the "hold" period.

• Output adjustment while in the "hold" period results in the "prior to operation" characteristics.

FLEXTEC™ 450

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