RETURN TO MAIN MENU IM10062-A FLEXTEC™ 450 September, 2010 For use with machines Code 11626, 11754 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.
i i 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 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 ARC WELDING CAN bE HAzARDOUS.
ii ii 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.
iii iii 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.
iv 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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v 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! CUSTOMER ASSISTANCE POLICY 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.
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Welding Process, Physical Dimensions ..........................................................A-2 Safety Precautions ..........................................................................................A-3 Select Suitable Location.
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - FLEXTEC™ 450 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% 60% rating K2882-1 100% rating Input Amperes Power Factor @ Rated Output 72 Watts Max. (fan on) 37 / 27 / 22 380 / 460 / 575 / 3 / 50 / 60 Idle Power 29 / 21 / 17 95% RATED OUTPUT Process Duty Cycle Volts at Rated Amperes Amperes 60% 36.5V 450 100% 34V 400 60% 28V 450 100% 26V 400 60% 38V 450 100% 36V 400 60% 36.
A-2 A-2 INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (Uo) GMAW (CV) GTAW (CC) SMAW (CC) FCAW-GS (CV) FCAW-SS (CV) 40-500 10-500 15-500 40-500 40-500 60 24 60 60 60 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2882-1 18.80in (478mm) 14.14in (359mm) 26.66in (677mm) 125lbs (56.
A-3 A-3 INSTALLATION SAFETY PRECAUTIONS CAUTION 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.
A-4 A-4 INSTALLATION INPUT FUSE AND CONSIDERATIONS WARNING SUPPLY WIRE ELECTRIC SHOCK can kill. ONLY A QUALIFIED ELECTRICIAN SHOULD CONNECT THE INPUT LEADS TO THE FLEXTEC™ 450. CONNECTIONS SHOULD bE MADE IN ACCORDANCE WITH ALL LOCAL AND NATIONAL ELECTRICAL CODES AND THE CONNECTION DIAGRAM LOCATED ON THE INSIDE OF THE RECONNECT/INPUT ACCESS DOOR OF THE MACHINE. FAILURE TO DO SO MAY RESULT IN bODILY INJURY OR DEATH.
A-5 INSTALLATION CAbLE CONNECTIONS See FIGURE A.2 for locating 6-pin and 14-pin connectors on the front of the FLEXTEC™ 450. C B 6-PIN REMOTE CONTROL CONNECTOR D A E F Function F E A D B C 6-pin remote control connector for remote or hand/foot amptrol.
A-6 A-6 INSTALLATION RECOMMENDED ELECTRODE AND WORK CAbLE SIzES FOR ARC WELDING General Guidelines Connect the electrode and work cables between the appropriate output studs of the Flextec™ 450 per the following guidelines: • Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source.
b-1 b-1 OPERATION SAFETY PRECAUTIONS GRAPHIC SYMbOLS THAT Read this entire section of operating instructions APPEAR ON THIS MACHINE before operating the machine. OR IN THIS MANUAL WARNING INPUT POWER 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.
b-2 b-2 OPERATION GRAPHIC SYMbOLS THAT PRODUCT DESCRIPTION APPEAR ON THIS MACHINE The Flextec™ 450 is a multi-process CC/CV DC OR IN THIS MANUAL inverter and is rated for 450 amps, 38 volts at a 60% U0 OPEN CIRCUIT VOLTAGE U1 INPUT VOLTAGE U2 OUTPUT VOLTAGE I1 INPUT CURRENT I2 duty cycle. The Flextec is intended for both factory and field operation. It comes in a compact, rugged case that is designed for portability and outdoor use with an IP23 environmental rating.
b-3 OPERATION RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Flextec™ 450 is designed for CC-SMAW, CC-GTAW (lift tig), CV-GMAW, CV-FCAW-SS and CV-FCAW-GS welding processes. CAG (arc gouging) is also supported. PROCESS LIMITATIONS The Flextec™ 450 is suitable only for the processes listed. EQUIPMENT LIMITATIONS Operating Temperature Range is -10° C to + 55° C. Output De-rated at Temperatures above 40°C.
b-4 b-4 OPERATION CASE FRONT CONTROL DESCRIPTIONS (See Figure B.1) 11. Wire feeder voltmeter polarity selection toggle switch 1. Power Switch 2. Voltage Display Meter 12. Circuit breaker reset button for the 14-pin wire feeder connector 3. Amperage Display Meter 13. 14-pin wire feeder circular connector 4. Thermal LED 14. 6-pin remote circular connector 5. Output Control Dial 15. Positive and negative welding output studs 6. Weld Process Selector Switch 7. Hot Start Toggle Switch 8.
b-5 OPERATION b-5 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. CASE bACK CONTROL (See Figure B.2) 1. Input Power Cord Access Hole. FIGURE b.2 4. CV-Innershield – This is a CV (constant voltage) weld mode used for welding the FCAW-SS, flux cored self shielded welding process 1 1 The Flextec™ 450 is also capable of gouging.
b-6 OPERATION Amperage Display Meter • Prior to STICK or TIG operation (current flow), the meter displays preset current value. • Prior to CV operation, the meter displays four 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.
b-7 OPERATION b-7 GTAW CV-GAS This weld mode is a constant current (CC) mode featuring continuous control from 10 – 500 amps. It is intended for the GTAW TIG welding processes. 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 - The Hot Start control regulates the starting current at arc initiation.
b-8 OPERATION CV-INNERSHIELD This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. It is intended for the FCAW-SS welding process and arc gouging. Hot Start – Toggle to “ON” 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.
C-1 ACCESSORIES OPTIONS / ACCESSORIES Foot Amptrol® Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug connection). Order K870 General Options K2149-1 Work Lead Package. Hand Amptrol® - Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug connection). Order K963-3 K1842-10 10ft. Weld Power Cable (Lug to Lug). Inverter and Wire Feeder Cart Rear-wheeled cart includes front casters and no-lift gas bottle platform.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 PERIODIC MAINTENANCE 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.
E-1 TROUbLESHOOTING E-1 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-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Major physical or electrical damage is evident when the sheet metal covers are removed. 1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. Machine won’t weld, can’t get any output. 1. If the displays show an Err ### see the fault section for corrective action.
E-3 E-3 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual USING THE STATUS LED TO TROUbLESHOOT SYSTEM PRObLEMS Errors are displayed on the user interface. 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 Status Lights and some basic troubleshooting charts for both machine and weld performance.
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.
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.
14.14 FLEXTEC™ 450 26.66 26.51 13.06 18.78 A.01 L15698 10.A 89651L 87.81 60.31 66.62 15.62 41.
NOTES FLEXTEC™ 450
NOTES FLEXTEC™ 450
• Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO • Keep flammable materials away. • Wear eye, ear and body protection. • Mantenga el material combustible • Protéjase los ojos, los oídos y el 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 your head out of fumes. • Use ventilation or exhaust to • Turn power off before servicing. • Do not operate with panel open or guards off. remove fumes from breathing zone. • 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- • Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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