Lincoln Electric IM10115 User Manual

For use with machines Code 11814

Safety Depends on You

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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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATORʼS MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

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.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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.

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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.

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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.

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

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

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.

SAFETY

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

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

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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

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

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

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

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

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

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

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

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

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

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

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

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

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

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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

)

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

)

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

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, 10K

76 Remote potentiometer, wiper

75 Remote potentiometer, common

Trigger, common

Trigger, input

Ground

115 VAC

Ground

Trigger, Common

Trigger input

77 Remote potentiometer, 10K

76 Remote potentiometer, wiper

75 Remote potentiometer, common

Voltage Sense (21)

Motor (42 VAC)

115 VAC

Motor (42 VAC)

L M N

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

100

30 40 60

100

40 60

100

60 60 80

100

60 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

A-7

POSITIVE

AT WWORK PPIECE

POSITIVE

AT WWORK PPIECE

POSITIVE

NEGATIVEVE

NEEGGAATTIIVEVE

TO GGROO

UND

ELECTRIC

CODE

PER

NATIONAL

GND

TO GGROUNUND

GND

PER NNATIONAL ELECTRICAL

ODE

BLOCK

655

)

INSTALLATION

A-7

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™ 650. 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 nonstandard 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.

FIGURE A.3

PARALLELING DIAGRAM

IINNPPUUT

TTEERRMMIINNAL

FFLLEEXXTTEECC 6

((MMAACCHHIINNEE #1#1)

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.

PARALLELING

FLEXTEC™ 650 power sources may be paralleled for increased output requirements. No kit is required for paralleling of FLEXTEC™ 650 power sources. The FLEXTEC™ 650 can only be paralleled for constant current processes (mode switch must be in the SMAW position). Connect the power sources as shown, and set the output control of each power source to one half of the desired arc current. (See Figure A.3)

IINNPPUUTT LLIINNES

AAL C

NNEEG

AATTIIVE

FFLLEEXXTTEEC

((MMAACCHHIINNEE #2#2)

IINNPPUUT

TTEERRMMIINNAL

BBLLOOCCK

66550

FLEXTEC™ 650

IINNPPUUTT LLIINNES

A-8

CONNECTING LF-72 AND LF-74 TO THE FLEXTEC™ 650

FLEXTEC™-650

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™ 650

A-9

INSTALLATION

CONNECTING LN-10 AND DH-10 TO THE FLEXTEC™ 650

WIRE FEEDER

A-9

14-PIN CONTROL CABLE K1501-XX

FLEXTEC™-650

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™ 650

Pwr Sources

12 3 4567 8

Head

Pwr Sources

12 345678

A-10

FLEXTEC™-650

INSTALLATION

CONNECTING LN-25 PRO, LN-25 PIPE, ACTIVE8 TO THE FLEXTEC™ 650

WIRE FEEDER

LN-25 PRO

ELECTRODE

WORK

CONTROL SETTING

WELD MODE

LN-25 PIPE ACTIVE8

WORK CLIP

CV, CV-INNERSHIELD

A-10

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

PROCESS DEPENDENT

LOCAL

CONNECTING LN-25 PRO DUAL POWER TO THE FLEXTEC™ 650

WIRE FEEDER

FLEXTEC™-650

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™ 650

CV, CV-INNERSHIELD

OFF

REMOTE

PROCESS DEPENDENT

A-11

FLEXTEC™-650

WELD MODE

INSTALLATION

CONNECTING LN-7 TO THE FLEXTEC™ 650

WIRE FEEDER

14-PIN CONTROL CABLE K1818-XX

ELECTRODE

WORK

CONTROL SETTING

CV, CV-INNERSHIELD

LN-7

A-11

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

CONNECTING LN-8 AND LN-9 TO THE FLEXTEC™ 650

FLEXTEC™-650

LOCAL

PROCESS DEPENDENT

14-PIN CONTROL CABLE K1820-XX

ELECTRODE

WORK

OFF

WIRE FEEDER

LN-8 LN-9

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

CONTROL SETTING

CV, CV-INNERSHIELD

OFF

REMOTE

PROCESS DEPENDENT

FLEXTEC™ 650

A-12

INSTALLATION

CONNECTING NA-3, NA-5 TO THE FLEXTEC™ 650

WIRE FEEDER

A-12

14-PIN CONTROL CABLE K1820-XX

FLEXTEC™-650

FOR NA-3, NA-4 WIRE FEEDERS ONLY:

- MOVE JUMPER LEAD ON VARIABLE VOLTAGE BOARD TO "L" PIN.

FOR NA-5 WIRE FEEDER ONLY:

- MOVE "BLUE" JUMPER LEAD ON VOLTAGE BOARD TO "AUTO " TERMINAL.

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

CONNECTING LT-7 TO THE FLEXTEC™ 650

ELECTRODE

WORK

CONTROL SETTING

CV- SAW

REMOTE

PROCESS DEPENDENT

NA-3 NA-5

OFF

FLEXTEC™-650

WELD MODE

WELD TERMINALS

REMOTE/LOCAL

VOLTMETER POLARITY

14-PIN CONTROL CABLE K1822-XX

ELECTRODE

WORK

CONTROL SETTING

CV- SAW

REMOTE

PROCESS DEPENDENT

FLEXTEC™ 650

TRACTOR

LT-7

OFF

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™ 650

B-2

OPERATION

B-2

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

PRODUCT DESCRIPTION

The FLEXTEC™ 650 is a multi-process CC/CV DC inverter and is rated for 650 amps, 44 volts at a 100% duty cycle. The FLEXTEC™ 650 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™ 650 is simple and intuitive. Weld modes are selected via a 5 position selector switch. Volts and Amps are displayed on an easy to view LED display, and the amps and volts are set via a large output control knob. A hot start and an arc control knob allow for finer tuning of the welding arc for the application.

REDUCED OPEN CIRCUIT VOLTAGE

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

The FLEXTEC™ 650 is designed for the North America and export markets and operates on 3 phase 380V, 460V, or 575V 50hz or 60hz power.

DUTY CYCLE

The FLEXTEC™ 650 is capable of welding at a 100% duty cycle (continuous welding) at 650 amps rated output. The 60% duty cycle rating is 750 amps (based off of a ten minute cycle – 6 minutes on time and 4 minutes off time). The maximum output of the machine is 815 amps.

The FLEXTEC™ 650 is also rated for Desert Duty, elevated temperature operation, in a 55°C ambient. The machine is de-rated for this application. (See Table in the Installation Section.

DESIGN FEATURES

• Severe Duty Design for outdoor use (IP23 rating)

• Passive Power Factor Correction – reliably gives 88% power factor for lower installation costs.

• 91% Efficiency rating – reduces electrical utility costs.

• Simple user interface - user interface is 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.

• Reversible handles for ease of lifting and transporting

• Multiple options for lifting / transporting: Reversible handles; eyelet lifting bolts; and single forklift fork access

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

• Electronic over current protection.

• Input voltage mis-connection protection.

• Utilizes digital signal processing and microprocessor control.

• VRD™ (Voltage Reduction Device)- Enable this function for reduced OCV in CC modes for added safety.

FLEXTEC™ 650

B-3

OPERATION

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The FLEXTEC™ 650 is designed for CC-SMAW, CCGTAW (lift tig), CV-GMAW, CV-FCAW-SS, CVFCAW-GS and CV-SAW welding processes. CAG

(arc gouging) is also supported.

PROCESS LIMITATIONS

The FLEXTEC™ 650 is suitable only for the processes listed.

Note: When used with K3091-1 Multi-Process Switch, the output is limited to 600A / 100% and 700A / 60%.

EQUIPMENT LIMITATIONS

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

B-3

COMMON EQUIPMENT PACKAGES

Basic Package

K3060-1 K2327-5 K2149-1

3100211

Common Optional Kits

K857

K857-1

K870

K963-3

K3091-1

Compatible Wire Feeders

All Models

Harris Regulator and gas hose

Remote Output Control (25 feet)

Remote Output Control (100 feet)

Flextec 650

LF-72 Bench Model

Work Cable

Foot Amptrol

Hand Amptrol

Multi-Process Switch

LF-72 LF-74

LN-10

DH-10

LN-25 Pro

LT-7 Tractor

LN-8 LN-9

NA SERIES

FLEXTEC™ 650

B-4

OPERATION

CASE FRONT CONTROL DESCRIPTIONS

(See Figure B.1)

1. Power Switch: Controls input power to the Flextec 650.

2. Voltage Display Meter

3. Amperage Display Meter

4. Thermal LED: A yellow light that comes on when an over temperature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled.

B-4

8. Local/Remote Selector Toggle Switch: Sets the control of the output to local (output control knob) or remote (K857 hand amptrol or K870 foot amptrol).

9. Arc Force Control Dial

10. Weld Terminals On/Remote selector switch.

11. 14 pin wire feeder circular connector.

12. 115V or 42V wire feeder selector switch.

13. Circuit breaker reset buttons for the 14 pin

wire feeder connector.

5. Weld Process Selector Switch: A rotary switch that toggles through the five available weld modes for the Flextec 650 – CC-SMAW; CCGTAW; CV; CV-Innershield; CV-SAW.

6. Hot Start Control Dial

7. Output Control Dial: Sets the output current or voltage for the selected weld process.

FIGURE B.1

14. 6 pin remote circular connector.

15. Positive and negative welding output studs.

16. Wire Feeder Voltmeter Polarity Selection Switch.

17. VRD™ (Voltage Reduction Device) Indicator Lights

172

FLEXTEC™ 650

B-5

OPERATION

CASE BACK CONTROLS

(See Figure B.2)

1. Input Power Cord Access Hole.

2. Access Panel – Allows access for connecting input power and configuring the machine.

3. Input Power Reconnect – Configures the machine for the input supply voltage.

4. OPTION – GFCI protection for the 115V auxiliary output.

5. 115 volt, 15 amp auxiliary output duplex with protective environmental cover.

6. 15 Amp Circuit Breaker for the 115V auxiliary power.

FIGURE B.2

B-5

FLEXTEC™ 650

B-6

OPERATION

B-6

INTERNAL CONTROLS -

Internal Controls Description

The Control PC Board has one bank of Dip Switches. As shipped from the factory VRD™ mode is disabled and the Dip Switches are all in the “off” position. For proper operation ensure that the ”A” lead is connected properly according to the Auxiliary Reconnect Input Ranges table see Technical Specification Section.

ENABLING VRD™

1 2 3 4 5 6 7 8

ON OFF

To Enter VRD™ Mode (VRD™ Enabled)

a. For 380V input: Switch #5 in the “ON”

Position.

1 2 3 4 5 6 7 8

ON OFF

b. For 460V input: Switch #6 in the “ON”

Position.

1 2 3 4 5 6 7 8

ON OFF

c. For 575V input: Switch #5 and #6 in the

“ON” Position

CONTROL PCB LOCATION

1 2 3 4 5 6 7 8

ON OFF

FIGURE B.3

CONTROL PCB

FLEXTEC™ 650

DIP SWITCH LOCATION

B-7

OPERATION

B-7

POWER-UP SEQUENCE

When power is applied to the FLEXTEC™ 650, 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™ 650 is a multi-process inverter welder. The Weld Process Selector Switch is used to set the desired weld mode. The FLEXTEC™ 650 has 5 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.

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.

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

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

5. CV-SAW – This is a CV (constant voltage) weld

mode used for welding the SAW submerged arc welding process

The FLEXTEC™ 650 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 control dial, 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

5 Position switch used to select the welding process.

Hot Start Control Dial

• The Hot Start control regulates the starting current at

arc initiation. Hot Start can be set to “0” and no additional current is added at arc start. Increasing from 0 to 10 will increase the additional current (relative to the preset current) that 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 via a single turn potentiometer.

• Adjustment is indicated by the meters.

• When in REMOTE modes, this control sets the maximum welding current. 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 (+/- .5V).

• Prior to STICK or TIG operation, the meter displays the Open Circuit Voltage of the Power Source or three 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.

Amperage Display Meter

• Prior to STICK or TIG operation (current flow), the meter displays preset current value (either 2 amps or +/- 3% (e.g. 3 amps on 100), whichever is greater).

• Prior to CV operation, the meter displays three dashes indicating non-presettable AMPS.

• During welding, this meter displays actual average amps.

• After welding, the meter holds the actual current 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™ 650

B-8

OPERATION

B-8

Weld Terminals On/Remote Toggle Switch

• This switch determines the trigger location.

• When set to the “ON” position, the weld terminals are at OCV (open circuit voltage) and ready to weld.

• When set to the “REMOTE” position, output is enabled through a remote trigger.

Control - Local/Remote Toggle Switch

• Set the switch to “LOCAL” to control output at the Flextec via the Output Control dial.

• Set the switch to “REMOTE” to control output via a remote device (K857 hand amptrol or K870 foot amptrol) connected to the 6-pin remote connector or a wire feeder connected to the 14-pin connector.

Wire Feeder Selector Switch

• This switch configures wire feeder supply voltage in the 14 pin connector to either 42 volt or 115 volt.

• If the switch is in the incorrect position for the attached wire feeder, there will be no power supplied to the wire feeder.

Wire Feeder Voltmeter Polarity Switch

• The switch provides a work connection for wire feeder voltmeters. Place the switch in the position of the electrode polarity indicated by the decal. The switch does not change the welding polarity.

Thermal Light

• This status light indicates when the power source has been driven into thermal overload. If the output terminals were "ON", the output will be turned back on once the unit cools down to an acceptable temperature level. If the unit was operating in the "REMOTE" mode, the trigger will need to be opened before or after the thermal has cleared and closed after the machine has cooled down to an acceptable temperature to establish output.

VRD™ (VOLTAGE REDUCTION DEVICE) INDICATOR LIGHT

There are 2 indicator lights on the case front of the Flextec™ 650 above the Voltage LED Display to indicate the status of VRD™ operation. As shipped, the VRD™ function is disabled. VRD™ is enabled by setting dip switches on the Control P.C. board (See Internal Controls Figure B.3 in this Operation Section). When VRD™ is active:

• A green light indicates the OCV (open circuit voltage) is less than 35V peak.

• A red light indicates the OCV is at or above 35V peak.

• Both lights will illuminate for 5 seconds at power up.

For each weld mode, the VRD™ lights function as shown in Table B.1:

BASIC MODES OF OPERATION

SMAW

This weld mode is a constant current (CC) mode featuring continuous control from 15 – 815 amps. It is intended for the SMAW stick welding processes and arc gouging.

Output Control Local/Remote – When the control is set to “LOCAL” (no remote potentiometer/control plugged into the 6 pin or 14 pin connectors), the output is controlled through the Output Control Dial on the front of the FLEXTEC™ 650. Set this switch to “REMOTE” when an external potentiometer/control is connected.

• When a remote potentiometer is connected, the output con-

trol on the FLEXTEC™ 650 and the remote act as a master/slave configuration. Use the control dial on the FLEXTEC™ 650 to set the maximum welding current. The remote will control output from minimum to the pre-set maximum.

TABLE B.1

VRD™ Indicator Lights

Mode

CC-SMAW CC-GTAW CV-GAS CV-Innershield

CV-SAW

* It is normal for the lights to alternate between colors while welding.

OCV While welding OCV

While welding

Green (OCV reduced) Green or Red (depends on weld voltage)* Red (OCV Not Reduced)

Weld Terminals ʻONʼ Red (OCV Not Reduced) Weld Terminals Remotely Controlled Gun Trigger Closed Green (NO OCV) Weld Terminals Remotely Controlled Gun Trigger Open

Green or Red (depends on weld voltage)*

FLEXTEC™ 650

VRD™ “ON”

VRD™ “OFF”

No lights are

active

B-9

Hot Start - The Hot Start control regulates the starting current

at arc initiation. Hot Start can be set to “0” and no additional current is added at arc start. Increasing from 0 to 10 will increase the additional current (relative to the preset current) that is added at arc initiation.

Arc Control - The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting (-10) will produce a "soft" arc and will produce minimal spatter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking.

Weld Terminals On/Remote – Set to “ON” and the machine is in the ready to weld state.

Voltage Display Meter – This display will display three dashed lines when the machine is in the idle state. This indicates that voltage is not settable in this weld mode. While output is enabled, the actual welding voltage will be displayed. After welding, the meter holds the actual voltage value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "hold" period.

GTAW

This weld mode is a constant current (CC) mode featuring continuous control from 10 – 815 amps. It is intended for the GTAW tig welding processes.

OPERATION

Output Control Local/Remote – When the control is set to

“LOCAL” (no remote potentiometer/control plugged into the 6 pin or 14 pin connectors), the output is controlled through the Output Control Dial on the front of the FLEXTEC™ 650. Set this switch to “REMOTE” when an external potentiometer/control is connected.

• When a remote potentiometer is connected, the output con-

Output Control Dial

• When the Local/Remote is set to “LOCAL”, this dial sets the

• When the Local/Remote is set to “REMOTE”, this dial sets

CV-Gas

This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. It is intended for the GMAW, FCAW-GS, MCAW welding processes and arc gouging.

Hot Start – Rotate from the “0” position to the “10” position to provide more energy during the start of a weld.

B-9

welding amperage.

the maximum welding amperage. The remote potentiometer controls the amperage from minimum to this pre-set maximum.

Hot Start - Hot start regulates the arc initiation current. A setting of +10 results in the most positive arc initiation.

Arc Control – This control is not used in the GTAW mode.

Weld Terminals On/Remote

• When set to the “ON” position, the weld terminals are at OCV (open circuit voltage) and ready to weld.

• When set to the “remote” position, output is enabled through a remote trigger.

Voltage Display Meter – This display will display three dashed

lines when the machine is in the idle state. This indicates that voltage is not settable in this weld mode. While output is enabled, the actual welding voltage will be displayed. After welding, the meter holds the actual voltage value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "hold" period.

Amperage Display Meter – This display will display the pre-

set welding current when the machine is in the idle state. After

welding, the meter holds the actual amperage value for 5 sec-

onds. Output adjustment while in the "hold" period results in the

"prior to operation" characteristics stated above. The displays

blink indicating that the machine is in the "hold" period.

Arc Control – The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and results in a soft arc. Low pinch settings are preferable for welding with gas mixes containing mostly inert gases. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc. High pinch settings are preferable for welding FCAW and GMAW with CO

Weld Terminals On/Remote

• When set to the “ON” position, the weld terminals are at OCV (open circuit voltage) and ready to weld. This selection is used for across the arc wire feeders.

• When set to the “REMOTE” position, output is enabled through a remote trigger.

Amperage Display Meter – This display will display three dashed lines when the machine is in the idle state. mode. While output is enabled, the actual welding amperage will be displayed. After welding, the meter holds the actual amperage value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics

stated above. The displays blink indicating that the machine is in the "hold" period.

This indicates that amperage is not settable in this weld

FLEXTEC™ 650

B-10

Voltage Display Meter – This display will display the pre-set

welding voltage when the machine is in the idle state. After welding, the meter holds the actual voltage value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "hold" period.

OPERATION

Output Control Local/Remote – When the control is set to

B-10

Output Control Local/Remote – When the control is set to

Output Control Dial

• When the Local/Remote is set to “LOCAL”, this dial sets the welding voltage.

• When the Local/Remote is set to “REMOTE”, this dial is disabled.

CV-Innershield

This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. It is intended for the FCAWSS welding process and arc gouging.

Hot Start – Toggle from the “0” position to the “10” position to provide more energy during the start of a weld.

Arc Control – The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and results in a soft arc. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc.

Weld Terminals On/Remote

• When set to the “ON” position, the weld terminals are at OCV (open circuit voltage) and ready to weld. This selection is used for across the arc wire feeders.

• When set to the “REMOTE” position, output is enabled through a remote trigger.

Amperage Display Meter – This display will display three dashed lines when the machine is in the idle state. This indicates that amperage is not settable in this weld mode. While output is enabled, the actual welding amperage will be displayed. After welding, the meter holds the actual amperage value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "hold" period.

Voltage Display Meter – This display will display the pre-set welding voltage when the machine is in the idle state. After welding, the meter holds the actual voltage value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "hold" period.

Output Control Dial

• When the Local/Remote is set to “LOCAL”, this dial sets the welding voltage.

• When the Local/Remote is set to “REMOTE”, this dial is disabled.

CV-SAW

This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. It is intended for the CVSAW submerged arc welding process.

Hot Start – Not used for this welding process.

Arc Control – Not used for this welding process .

Weld Terminals On/Remote

• When set to the “ON” position, the weld terminals are at OCV (open circuit voltage) and ready to weld. This selection is used for across the arc wire feeders.

• When set to the “REMOTE” position, output is enabled through a remote trigger.

Output Control Dial

• When the Local/Remote is set to “LOCAL”, this dial sets the welding voltage.

• When the Local/Remote is set to “REMOTE”, this dial is disabled.

FLEXTEC™ 650

C-1

ACCESSORIES

C-1

OPTIONS / ACCESSORIES

General Options

K2149-1 Work Lead Package.

K1842-10 10ft. Weld Power Cable (Lug to Lug).

K3091-1 Multi-Process

Switch

Inverter and Wire Feeder Cart

Rear-wheeled cart with front casters and gas bottle platform. Convenient handles allow for easy cable storage. Small footprint fits through 30 in. (762 mm) door. Not intended for use with double head wire feeders.

Order K3059-1

Fume Extracting Systems

TIG Options

Pro-Torch™ TIG Torches – PTA9, PTA-17, PTA-26 – 2 piece power cord.

Foot Amptrol®

Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug connection).

Order K870

Hand Amptrol® - Provides 25 ft.

(7.6 m) of remote current control for TIG welding. (6-pin plug connection).

Order K963-3

Arc Start Switch - May be used

in place of the Foot or Hand Amptrol®. Comes with a 25 ft. (7.6m) cable. Attaches to the TIG torch for convenient finger control to start and stop the weld cycle at the current set on the machine.

Order K814

GFCI KIT - Order K3157-1

Accessory Kit For stick welding. Includes 35 ft. (10.7 m) 2/0

electrode cable with lug, 30 ft. (9.1 m) 2/0 work cable with lugs, headshield, filter plate, cover plate, work clamp and electrode holder. 400 amp capacity. Order

K704

Remote Output Control Consists of a control box with

choice of two cable lengths. Permits remote adjustment of output.

Order K857 for 25 ft. (7.6 m) Order K857-1 for 100 ft. (30 m)

Dual Cylinder Inverter and Wire Feeder Cart - Rear-wheeled cart

with front casters and dual gas bottle platform. Convenient handles allow for easy cable storage. Small footprint fits through 30in. (762 mm) door. Can be used with dual head wire feeders.

Order K3059-3

FLEXTEC™ 650

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only Qualified personnel should perform this maintenance.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

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

See additional warning information throughout this Operatorʼs Manual

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

VISUAL INSPECTION

Clean interior of machine with a low pressure air stream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or other obvious problems. Many problems can be uncovered with a good visual inspection.

PERIODIC MAINTENANCE

Thermal Protection

Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will prevent output voltage or current. The meter will remain energized during this time. Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period.

ROUTINE MAINTENANCE

VRD™ Functionality should be checked once per day or once per shift. VRD™ functionality can be verified by the indicator lights on the front of the power source. One of the lights will be illuminated at all times when VRD™ is enabled. No lights will be illuminated when VRD™ is disabled. VRD™ can be verified by cycling power as well. When VRD™ is enabled, the VRD™ indicator lights will illuminate for 5 seconds at power

up and one light will remain illuminated.

1. Every 6 months or so the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas:

• All printed circuit boards

• Power switch

• Main transformer

• Heatsink fins

• Input rectifier

• Auxiliary transformer

• Reconnect switch area

• Fan (blow air through the rear louvers)

2. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity.

FLEXTEC™ 650

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

FLEXTEC™ 650

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Major physical or electrical damage is evident when the sheet metal covers are removed.

Machine wonʼt weld, canʼt get any output.

Thermal LED is lit.

1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance.

1. If the displays show an Err ### see the fault section for corrective action.

2 If the thermal LED is lit refer to the

thermal section.

3 If the output terminals are in

remote control switch to "ON" and check for output voltage. If output voltage is now present check for correct remote control connection and operation.

1. Check for proper fan operation.

• Check for material blocking

intake or exhaust louvers.

• Blow air in the rear louvers to

clear dirt from the fan.

Note: The Fan As Needed circuitry

automatically shuts off the fan 5 minutes after welding has stopped.

2. Welding output ratings may have been exceeded. Allow the machine to cool down and reset.

1.I

f all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Wire feeder wonʼt work. Apparently no power to wire feeder

1. Check the 115/42V wire feeder switch (located on the case front) to make sure it is properly set for the input voltage requirement of the wire feeder.

2. Check circuit breakers by the wire feeder receptacles on the front of the machine. Reset if required.

3. Check the control cable between the power source and the wire feeder for continuity.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

FLEXTEC™ 650

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

Errors are displayed on the amperage and voltage display meters. In addition, there are status lights on the control pc board and the switch pc board that contain error sequences.

Included in this section is information about the fault codes indicated on the status lights and some basic troubleshooting charts for both machine and weld performance.

The status lights on the main control board and the switch pc board are dual-color LEDʼs. Normal operation for each is steady green.

FLEXTEC™ 650 Fault Codes

Error

Code#

Description

Device that controls sequence of the welding operation halted due to an error.

Primary Over Current.

Possible Cause

Check the input power (voltage and frequency). Verify the primary reconnect is properly configured for the input voltage.

Corrective Action

Weld Terminals Remote: Re-trigger to recover from error.

Weld Terminals Local: Toggle Remote/Local Switch to recover from error.

Machine needs to be turned off and back on to reset.

Thermal Fault

VRD™ Voltage limit exceeded.

Communication Fault

712

Machine shut off output due to elevated internal temperatures.

OCV

During able VRD™ levels.

• Verify dip switch settings are correct for the input voltage.

CAN communication between the control pcb and switch pcb has been interrupted.

, the voltage exceeded allow-

1. Check for material blocking intake or exhaust louvers.

• Blow air in the rear louvers to clear dirt from the fan.

Note: The Fan As Needed circuitry automatically shuts off the fan 5 minutes after welding has stopped.

2. Welding output ratings may have been exceeded. Allow the machine to cool down and reset.

Machine needs to be turned off and back on to reset.

Inspect harness for damage / loose connections.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

FLEXTEC™ 650

E-4

Error

Code#

713

714

715

719

Observe all Safety Guidelines detailed throughout this manual

Description

Input Power Misconnect. Supply Voltage is too high.

Input Power Misconnect. Supply Voltage is too low.

Under Voltage Lockout.

Switch PCB Error.

TROUBLESHOOTING

FLEXTEC™ 650 Fault Codes

Possible Cause

Occurs upon power up when the supply voltage to the switch pcb exceeded acceptable levels.

Occurs upon power up when the supply voltage to the switch pcb is below acceptable levels.

The supply voltage to the switch pcb is below acceptable levels

E-4

Corrective Action

Verify the primary reconnect is properly configured for the input voltage.

Machine needs to be turned off and back on to reset.

Verify the primary reconnect is properly configured for the input voltage.

Machine needs to be turned off and back on to reset.

If any of these conditions persist contact an authorized Lincoln Field Service Shop.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

FLEXTEC™ 650

F-1

ENHANCED DIAGRAM

FLEXTEC 650 WIRING DIAGRAM

CAVITY NUMBERING SEQUENCE

ELECTRICAL SYMBOLS PER E1537.

GENERAL INFORMATION

LEFT SIDE OF MACHINE

DIAGRAMS

613

J1 ,J22

J3, J24

J5, J10

J6 ,J20,

J26

J21

R - RED

B - BLACK

N- BROWN

U - BLUE

V - VIOLET

G - GREEN

SWITCH

ALIGNS WITH WHITE LEAD OF LED SOCKET.

PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)

S12021-73 (INSERTION SIDE)

)

(

L1A

L2A

L3A

(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

LEAD COLOR CODING

EARTH GROUND

GROUND BOND CIRCUIT

HORIZONTAL

DIVIDER PANEL

115V RECEPTACLE

RED LED

N.A, N.D.

VRD STATUS

298

297

N.A, N.D.

GREEN LED

VRD STATUS

32C

J26-1

FAN

BASE

AUX XFR 1

CASE BACK

299

32A

J26-4

J26-2

J26-3

AUX XFR 2

CASE FRONT

-1

DISPLAY BOARD

N.A.

YELLOW

THERMAL LED

SWITCH BOARD

207

209

284

283

207

226

-1

201

204

201

227

J22-6

J22-5

J22-1

J22-4

J22-3

J22-2

221

83C

204

82A

83A

220A

CONNECTOR

WIRE FEEDER

10A

CB1

42A

FRONT OF MACHINE

32B

412176

4/4A

2/2A

31B

WIRE FEEDER

CB3

3.5A

41A

420

J1-4

J1-5

J1-3

J1-2

J1-1

J4-12 J4-11 J4-10

J4-9

297

J4-8 J4-7 J4-6 J4-5 J4-4

J4-3

298

J4-2

299

J4-1

225 W

50 OHM

319

REMOTE

CONNECTOR

ARC CONTROL

WELD TER MINALS

212

210

281

282

280

282A

SWITCH

276G277

275

OUTPUT

VOLTAGE

252

251

METER POLARITY

320

HOT START

LOCAL / REMOTE

289

290

253

317 316

282A

220D

221D

225 W

ELECTRODE

50 OHM

220B

220C

220A

MODE SELECT

308

301

305

303

302

319

WORK

221B

221C

SHUNT

83C 22 1

83B

J1-6

J8-2

J8-1

225

281

282

377

360

378

359

J5-2

J5-1

J5-3

J5-5

J5-4

CONTROL BOARD

J8-5

J8-4

J8-3

224

280

379

317

J5-8

J5-9

J5-6

J5-7

J5-10

J5-11

J5-13

J5-14

J5-15

J5-16

J5-12

316

-1

J10-9

308

J10-8 J10-7 J10-6

305

J10-5 J10-4

303

J10-3 J10-2 J10-1

J8-8

J8-7

J8-6

225

302

301

OUTPUT CHOKE

220

J3-10

252

J3-9

J3-8

J3-7

J3-6

251

J3-5

J3-4

J3-3

J3-2

J3-1

253

212

210

277 276

J J

290

289

J J

275

J J

J6-4 J6-3 J6-2

284

283

J6-1

283

284

RIGHT SIDE OF MACHINE

F-1

G7148

BASE

TO EARTH

GROUND

PER THE

NATIONAL

ELECTRIC

CODE

207

209

L1B

INPUT

RECTIFIER

600V

7.5 AMP,

(LOCATED IN RE-

CONNECT AREA)

N.B.

BLOCK

INPUT TERMINAL

~460V

~380V

~575V

H2H3H4

PANEL

RECONNECT

L1A

L2A

L3A

N.C.

THERMOSTAT

X14

~42V

X13

X16

~36V

X15

AUX.

TRANSFORMER

X12

~115V

X11

X12A

32D

CB2

BREAKER

15A CIRCUIT

31F

REAR OF MACHINE

41A

4 1 X

X12B

X11B

31B

31E

31F

32B

32A

42A

X11

82A

X12

31C

31F

X12A

X13

X11A

31A

X11A

31C

115V

RECEPTACLE

TO A SYSTEM

GROUND PER

NATIONAL

ELECTRICAL

CODE

AC AC

X16

X15

31E

32C

31C

83B

83A

RECTIFIER

Main

Transformer

RECTIFIER

COIL 2

COIL 1

203

202

201

204

THERMOSTAT

224

N.D. LED'S ARE ONLY ACTIVE IF VRD IS TURNED ON.

Output Rectifier Heatsink Assembly

THERMOSTAT

FAN

OUTPUT OR SET THERMAL FAULT WHEN OPEN.

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS

ALIGNS WITH WHITE LEAD OF LED SOCKET.

N.C. THERMOSTAT 3 TURNS FAN ON BUT DOES NOT DISABLE WELDING

NOTES:

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 575V

N.B. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR

OPERATION.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

FLEXTEC™ 650

F-2

DIMENSION PRINT

29.33

F-2

A.02

L16096

21.16

21.85

23.64

15.09

16.13

FLEXTEC™ 650

NOTES

FLEXTEC™ 650

NOTES

FLEXTEC™ 650

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

 Keep your head out of fumes.  Use ventilation or exhaust to

remove fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

 Gardez la tête à l’écart des fumées.  Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.  Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

 Não opere com as tampas removidas.  Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IM10115 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual