Lincoln Electric IM10115 User Manual

For use with machines Code 11814

Safety Depends on You

RETURN TO MAIN MENU

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.

IM10115

March 2013

FLEXTEC™650

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

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 Above For Diesel Engines

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.

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

The Above For Gasoline Engines

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.

____________________________________________________

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.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

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.

___________________________________________________

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.

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.

ii

SAFETY

ii

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

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
between the 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.

3.j. Also see Items 6.c. and 8.

skin or wet clothing. Wear dry, hole-free

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

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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

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

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

ventilation and/or exhaust at the arc to keep

vapors

to

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.

iii

SAFETY

iii

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

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code 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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Thank You

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

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.

vi vi

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

High Temperature Operation.................................................................................A-3

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

Input Fuse and Supply Wire Considerations .........................................................A-4

Input Voltage Selection..........................................................................................A-4

Cable Connections ................................................................................................A-5

Recommended Electrode and Work Cable for Arc Welding..................................A-6

Output Cable Guidelines........................................................................................A-6

Control Cable Connections, Paralleling.................................................................A-7

Connection Diagrams Flextec 650 to Wire Feeders and Tractor...........A-8 thru A-12

________________________________________________________________________

TABLE OF CONTENTS

Page

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

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

Internal Controls ....................................................................................................B-6

Power-Up Sequence..............................................................................................B-7

Common Welding Procedures, Weld Controls and Displays.................B-7 thru B-10

_______________________________________________________________________

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

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

________________________________________________________________________

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

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

Visual Inspection ...................................................................................................D-1

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

________________________________________________________________________

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

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

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

Error Codes....................................................................................................E-3, E-4

________________________________________________________________________

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

________________________________________________________________________

Parts List .....................................................................................................P-686 Series

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS -

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K3060-1

GMAW (CV)

GTAW (CC)

SMAW (CC)

FCAW-GS (CV)

FCAW-SS (CV)

Duty Cycle

60% rating

100% rating

Process

Input Voltage ± 10%

380 / 460 / 575 / 3 / 50 / 60

Duty Cycle

60%

100%

60%

100%

60%

100%

60%

100%

60%

100%

FLEXTEC™ 650

Input Amperes

61 / 50 / 40

57 / 47 / 38

RATED OUTPUT*

Amperes

750

*

650

*

750

650

750

*

650

*

750

*

650

*

750

*

650

*

Idle Power

(W)

230 MAX.( Fan On)

100 MAX. (Fan Off)

Volts at Rated Amperes

44V

34V

44V

Power Factor @

Rated Output

88%

60%

SAW (CV)

100%

750

650

*

*

* Output is limited to 600A / 100% and 700A / 60% when used with K3091-1 Multi-Process Switch.

RECOMMENDED INPUT WIRE AND FUSE SIZES

(mm)

4(25)
4(25)
6(16)

(3)

Type 75°C Copper

Wire in Conduit

AWG (mm

4(25)
6(16)

8 (10)

COPPER GROUNDING

CONDUCTOR

2

)

AWG (mm

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

VOLTAGE

50/60Hz

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 SJ cord or similar in 30°C ambient.

Maximum

Input

Amperes

70 A
58 A
46 A

Cord Size
AWG SIZES

(1)

Fuse (Super Lag) or

2

)

Breaker Size

90
80
60

(2)

FLEXTEC™ 650

A-2

PROCESS

INSTALLATION

WELDING PROCESS

OUTPUT RANGE (AMPERES)

OCV (Uo)

A-2

OCV (Ur)

GMAW (CV)

GTAW (CC)

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

SAW (CV)

40-815
10-815
15-815
40-815
40-815
40-815

PHYSICAL DIMENSIONS

MODEL

K3060-1

HEIGHT

21.8 in (554 mm)

WIDTH

16.14 in (410 mm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

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

IP23 180º(H) Insulation Class

* Weight does not include input cord.
** Power Source is de-rated at temperatures above 40C.

AUXILIARY RECONNECT INPUT RANGES

"A" LEAD
POSITION

VAC INPUT

LIMITS (VOLTS)

60
24
60
60
60
60

DEPTH

29.33 in (745 mm)

STORAGE TEMPERATURE RANGE

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

VRD

Disabled

165lbs (74.8kg)*

Enabled

--­15
15

---

---

---

WEIGHT

VRD

380 Volt

Reconnect

460 Volt

Reconnect

575 Volt

Reconnect

Low Limit

High Limit

Low Limit

High Limit

Low Limit

High Limit

340 Vac
420 Vac

390 Vac
505 Vac

485 Vac
620 Vac

340 Vac
455 Vac

390 Vac
520 Vac

485 Vac
655 Vac

FLEXTEC™ 650

A-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

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™ 650

GROUNDING LUG (LOCATED INSIDE THE
RECONNECT INPUT ACCESS DOOR) TO A
PROPER SAFETY (EARTH) GROUND.

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

VRD™ (VOLTAGE REDUCTION DEVICE)

The VRD™ feature provides additional safety in the CC­Stick mode. The VRD™ reduces the OCV (Open Circuit
Voltage) at the welding output terminals while not welding to
less than 35VDC peak.

A-3

When using a crane or overhead device to lift using
the handles, a lifting strap should be connected to
both handles. Do not attempt to lift the FLEXTEC™
650 with accessories attached to it.

STACKING

Multiple FLEXTEC™ 650ʼs cannot be stacked.

ENVIRONMENTAL LIMITATIONS

The FLEXTEC™ 650 is IP23 rated for use in an out­door environment. The FLEXTEC™ 650 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.

CAUTION

Do not mount the FLEXTEC™ 650 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
equipment on all sides.

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

INPUT AND GROUNDING CONNECTIONS

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.

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.

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.

LIFTING

The FLEXTEC™ 650 has 2 lifting eyelets and 2 han­dles that can be used to lift the machine. Both handles
or both eyelets should be used when lifting the FLEX­TEC™ 650.

FLEXTEC™ 650

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.

HIGH FREQUENCY PROTECTION

Locate the FLEXTEC™ 650 away from radio con­trolled machinery. The normal operation of the FLEX­TEC™ 650 may adversely affect the operation of RF
controlled equipment, which may result in bodily injury
or damage to the equipment.

HIGH TEMPERATURE OPERATION

WELDER OUTPUT RATINGS AT 55°C

ELEVATED TEMPERATURES

AMPS

600

650

750

DUTY CYCLE

100%

50%

30%

VOLTS

44V

TEMPERATURES

55°C

A-4

INSTALLATION

WARNING

ELECTRIC SHOCK can kill.

ONLY A QUALIFIED ELECTRICIAN
SHOULD CONNECT THE INPUT

LEADS TO THE FLEXTEC™ 650.
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)

Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the case back. Remove the reconnect access panel
located on the case back and connect W, V, U and
ground according to the Input Supply Connection
Diagram decal.

A-4

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

Welders are shipped connected for 460 Volt input
voltage. To move this connection to a different input
voltage, see Figure A.1 which is illustrated below.
Refer to Auxiliary Reconnect Input Ranges table in
the Technical Specification Section. 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. Power
must be removed prior to changing reconnect posi­tion.

REMOVE FOUR SCREWS
AND ACCESS PANEL

FIGURE A.1

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™ 650

POWER SUPPLY ACCESS HOLE

• Route input power cable through this hole.

• Strain relief required. See your local and
National Electrical codes for proper strain relief.

RECONNECT TERMINAL BLOCK

• Reconnects auxiliary
transformer for the
proper input voltage.

A-5

INSTALLATION

CABLE CONNECTIONS

See FIGURE A.2 for locating 6-pin and 14-pin con­nectors on the front of the FLEXTEC™ 650.

6-PIN REMOTE CONTROL CONNECTOR

A-5

F

E

A

D

C

G

F

M

E

L

D

B

H

I

N

J

K

A

B

C

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.

Pin

77 Remote potentiometer, 10K

A

76 Remote potentiometer, wiper

B

75 Remote potentiometer, common

C

Trigger, common

D

Trigger, input

E

Ground

F

Pin

115 VAC

A

Ground

B

Trigger, Common

C

Trigger input

D

77 Remote potentiometer, 10K

E

76 Remote potentiometer, wiper

F

75 Remote potentiometer, common

G

Voltage Sense (21)

H

Motor (42 VAC)

I

115 VAC

J

Motor (42 VAC)

K

L
M
N

Wiring

Wiring

FIGURE A.2

14-PIN CONNECTOR
FOR WIRE FEEDER

FLEXTEC™ 650

6-PIN REMOTE
CONTROL CONNECTOR

A-6

INSTALLATION

A-6

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™ 650 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.

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

• 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.

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
600
600
600
650
650
700
800
800

** 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

60

100

30
40
60

100

60

100

40
60

100

60
60
80

100

60
80

100

80

100

0 to 50Ft.
(0 to15m)

2
2
3
2
1
1

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

2-1/0
2-1/0

3/0

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

(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
3/0

2-1/0
2-1/0

3/0

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

100 to 150 Ft.

(30 to 46m)

2
2
2
1
1
1

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

2-1/0
2-1/0

4/0

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

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
4/0

2-2/0
2-2/0
2-2/0
2-2/0
2-3/0
2-3/0
2-3/0

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
2-3/0
2-3/0
2-3/0
2-3/0
2-3/0
2-4/0
2-4/0
2-4/0

FLEXTEC™ 650