Lincoln Electric IM10132 User Manual

Operator’s Manual

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FLEXTEC ™650

For use with machines having Code Numbers:

11936

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10132 | Issue D ate Sept- 13

© Lincoln Global, Inc. All Rights Reserved.

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon
receipt by the carrier. Consequently, Claims for material damaged in
shipment must be made by the purchaser against the transportation
company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with
safety in mind. However, your overall safety can be increased by
proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

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

CAUTION

This statement appears where the information must be followed to
avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to
stay a reasonable distance away
from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly
toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

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

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

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

Read and understand the following safety highlights. For additional
safety information, it is strongly recommended that you purchase a
copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the
American Welding Society, P.O. Box 351040, Miami, Florida 33135 or
CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”
booklet E205 is available from the Lincoln Electric Company, 22801
St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.

1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.

1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is

hot.

ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS

2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and welding
machines

FOR ENGINE POWERED
EQUIPMENT.

1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.

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

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.

2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos­sible to the area being welded.

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

3

SAFETY

ELECTRIC SHOCK
CAN KILL.

3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.

In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.

3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage

two can be the total of the open circuit voltage of both
welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation
such as stainless or hard facing (see instructions
on container or MSDS) or on lead or cadmium
plated steel and other metals or coatings which
produce highly toxic fumes, keep exposure as low
as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or
mechanical ventilation. In confined spaces or in
some circumstances, outdoors, a respirator may
be required. Additional precautions are also
required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.

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

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

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

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s
safety practices. MSDS forms are available from your welding
distributor or from the manufacturer.

5.f. Also see item 1.b.

4

cause

SAFETY

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society (see address
above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF
DAMAGED.

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected
to physical damage.

• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in

Cylinders,” available
from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.

FOR ELECTRICALLY
POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.

8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety
Interactive Web Guide
for mobile devices

5

vi vi

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

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

________________________________________________________________________

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

________________________________________________________________________

TABLE OF CONTENTS

Page

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-711 Series

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS -

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K3060-2

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

TECHNICAL SPECIFICATIONS -

PROCESS

OUTPUT RANGE (AMPERES)

INSTALLATION

FLEXTEC™ 650

WELDING PROCESS

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

K3060-2

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

VRD

Enabled

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)

165lbs (74.8kg)*

VRD

Disabled

--­15
15

---

---

---

WEIGHT

380 Volt

Reconnect

460 Volt

Reconnect

575 Volt

Reconnect

Low Limit - 340 Vac

High Limit - 420 Vac

Low Limit - 390 Vac

High Limit - 505 Vac

Low Limit - 485 Vac

High Limit - 620 Vac

Low Limit - 340 Vac

High Limit - 455 Vac

Low Limit - 390 Vac

High Limit - 520 Vac

Low Limit - 485 Vac

High Limit - 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, 5K

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, 5K

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

A-7

POSITIVE

AT WWORK PPIECE

POSITIVE

AT WWORK PPIECE

POSITIVE

A

NEGATIVEVE

W

V

U

T

AL

V

W

ES

A

NEEGGAATTIIVEVE

TO GGROUNUND

ELECTRICAL

CODE

PER NNATIONAL

U

GND

VE

GROUNUND

GND

PER NNATIOONAL
ELECTRICAL

CODE

BLOCK

0

E

)

0

INN

)

T

AL

BLL

K

W

V

U

V

W

U

ES

U

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 66550

((MMAACCHHIINNE

#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)

W

U

A

PE

IINNPPUUTT LLIINNES

W

V

C

NNEEGGAATTIIVE

N

FFLLEEXXTTEECC 66550

((MMAACCHHI

IINNPPUUT

TTEERRMMIINNAL

B

OOCCK

EE #2#2)

FLEXTEC™ 650

W

U

IINNPPU

TT LLIINNES

A

TTO G

W

V

U

G

C

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

ON

12 3 456 7 8

S1

Head

S1

Pwr Sources

ON

12 345678

S1

S1

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

ON

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