Lincoln Electric 450 CE Welder User Manual
Contents
1. asna ve oo18 IVNIWE3 L ANANI O NMO ag O men on SNIQOO Qv31 men NAO any PES lauvoa o 4o3qls IN3NOdWOO d3M3I 4813 Hd SIOBNAS 1 Ee 3ON3n03S ALIAVO 0 ANIHOVW 40 5 30 14371 INVH9VIG ONIYIM OS 991 919 F 1 FLEXTEC 450 CE LINCOLN E 2 869911 DIMENSION PRINT F 2 FLEXTEC 450 CE LINCOLN LELECTRIC 5 FLEXTEC 450 LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG FA Donottouch electrically live parts or electrode with skin or wet clothing Insulate y2. 110091 FLEXTEC 450 For use with machines Code 11776 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ER 150 9001 lt ANSI CG E wi an Quality Pr by ET Inder y Copyright O Lincoln Global Inc LINCOLN 5 World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY P
3. VRD Voltage limit exceded If condition persists contact an authorized Machine needs to be turned off Lincoln Field Service Shop and back on to reset CAP bank over voltage or under If condition persists contact an authorized Machine needs to be turned off voltage Lincoln Field Service Shop and back on to reset Communication or Switch Board If condition persists contact an authorized Weld Terminals Remote Re Lincoln Field Service Shop trigger to recover from error Weld Terminals Local Toggle Remote Local Switch to recover from error 713 Input Power Misconnect Supply Verity the input supply voltage to the machine is Machine needs to be turned off Voltage too High within rated specifications and back on to reset 714 Input Power Misconnect Supply Verity the input supply voltage to the machine is Machine needs to be turned off Voltage too Low within rated specifications and back on to reset Switchboard Under voltage Lock Verify input voltage level Machine needs to be turned off and back on to reset If condition persists contact an authorized Lincoln Field Service Shop 717 Control Board Mis configuration Verify that the wiring to connector J5 on the Machine needs to be turned off control board matches the machine wiring dia land back on to reset gram If condition persists contact an authorized Lincoln Field Service Shop Internal Switchboard Error Cycle Power to the machine Machine needs to b
4. 2 8 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving n Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known 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 idler by pushing on the throttle control rods while the engine is running M 1 9 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 LINCOLN 8 All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrod
5. Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone ee WELDING SPARKS can cause or explosion Keep flammable material away Do not weld on containers that have held combustibles Wear eye ear and body protection 16 RAYS can burn NM Observe additional guidelines detailed in the beginning of this manual GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL lt OFF INPUT POWER HIGH TEMPERATURE 0 0 CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT ZE CY 3 PHASE INVERTER INPUT POWER po 3 THREE PHASE DIRECT CURRENT FLEXTEC 450 CE LINCOLN 8 2 OPERATION B 2 SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U OPEN CIRCUIT 0 VOLTAGE 01 INPUT VOLTAGE Us OUTPUT VOLTAGE l4 INPUT CURRENT gt OUTPUT CURRENT PROTECTIVE GROUND WARNING or CAUTION Explosion Dangerous Voltage Shock Hazard PRODUCT DESCRIPTION The FLEXTEC 450 CE is a multi process CC CV DC inverter and is rated for 450 amps 38 volts at a 6096 duty cycle The Flextec is intended for both fac tory and field operation It comes in a compact rugged case that is designed for portability and out door use with an IP23 environmental rating The use
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7. 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 3 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground t
8. Remote Output Conirol Consists of a control box with choice of two cable lengths Permits remote adjustment of out put Order K857 for 25 ft 7 6 m Order K857 1 for 100 ft 30 m TIG Options Pro Torch TIG Torches PTA Y 9 PTA 17 PTA 26 2 piece power cord FLEXTEC 450 CE LINCOLN 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 Operator s Manual VISUAL INSPECTION Clean interior of machine with a low pressure air stream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection 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
9. 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 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 SYMP TOMS 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 are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technica
10. 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 feed ers When set to the 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 is 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 The displays blink indicating that the machine is in the hold peri od Voltage Display Meter This display will display the pre set welding voltage when the machine is in the idle state While output is enabled the actual weld amperage is displayed After welding the meter holds the actual voltage value for 5 seconds Output adjust ment while in the hold period results in the prior to operation characteristics The displays blink indicat ing that the machine is in the hold period 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 con trolled through the Output Control Dial on the front of the Flextec 450 Set this switch to REMOTE wh
11. 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 e Route all cables directly to the work and wire feeder avoid excessive lengths and do not coil excess cable Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit Always weld in a direction away from the work ground connection CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times except where noted otherwise Lincoln cables are specifically designed for the communication and power needs of the FLEXTEC 450 CE Most designed to be connected end to end for ease of extension Generally it is recommended that the total length not exceed 100 feet 30 5 m The use of non standard cables especially in lengths greater than 25 feet can lead to communication problems system shutdowns poor motor acc
12. 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 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
13. 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 con dition 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 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 disable the machine output 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 FLEXTEC 450 CE LINCOLN E TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE WARNING
14. 7 SRACVHELTIBELTFAL e OER E 5 Fi f I8 S 202 e 7 e zyez 87 R Ash 71250712 552 8 SE ce Vua duly 4 6 lo auch Les 5 AA uu ze cial ue gWelsid g Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas AFFA YEARN 34 52412 e AHS Ale lh il A eh dell Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas exem amp S S E E e gdo SE yqz Sa Vae cus 13 al Uu 9 Ale Viel dl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese LEIA E COMPREENDA AS INS
15. ACEMAKER 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 amp 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 FOR ENGINE 4 Ges 1 h To avoid scalding do not remove the 9l 0 radiator pressure cap when the engine is powered equipment Kelte e OE ip S 9 1 a Turn the engine off before troubleshooting and maintenance x work unless the maintenance work requires to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes 5 outdoors 5 X ELECTRIC AND SR MAGNETIC FIELDS 1 c Do not add the fuel near an open flame Se dangerous welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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
16. AND GASES can be dangerous 5 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 circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 spe cific 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 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 prod ucts Shielding gase
17. AW This is a CC constant current weld mode used for the GTAW TIG welding process 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 4 CV Innershield This is a CV constant voltage weld mode used for welding the FCAW SS flux cored self shielded welding process The Flextec 450 CE is also capable of gouging Gouging can be done in the MMAW mode In addition to the weld process selector switch a hot start toggle output control dial and arc control dial are provided to setup and fine tune the welding procedure WELD CONTROLS AND DISPLAYS Weld Process Selector Switch 4 Position switch used to select the welding process Hot Start Toggle Switch The Hot Start control regulates the starting current at arc initiation Hot Start can be set to Off and no additional current is added at arc start When set to the position additional current relative to the preset current is added at arc initiation Arc Control Dial Full range selection of arc control from 10 to 10 In CV mode this control is an inductance control In stick mode the control adjusts the arc force Output Control Dial Output control is conducted by a single turn poten tiometer Adjustment is indicated by the meters When in Remote Mode this control sets the maximum welding current of the remote device For example
18. Error GODS EE 3 Wiring Diagram and Dimension Print Section Parts one aussi P 674 Series A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS FLEXTEC 450 CE POWER SOURCE INPUT VOLTAGE AND CURRENT Duty Cycle Input Voltage 10 Input Amperes Power Power Factor Rated Output 60 rating 37 35 34 72 Watts A 1380 400 415 3 50 60 95 100 rating 29 28 27 fan on RATED OUTPUT 36 5V Duty Cycle 60 GMAW CV 100 34 60 28 100 26V diii 400 400 450 00 100 36V 60 36 5V FCAW GS CV 100 34V 60 36 5V RECOMMENDED INPUT WIRE AND FUSE SIZES 4 CONDUCTOR FCAW SS CV Fuse Super Lag or SOOW or similar Cord in 40 C 104 F Ambient Breaker Size 2 380 3 50 400 3 60 8 AWG or 10mm 415 3 60 1 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 FLEXTEC 450 CE LINCOLN 8 2 INSTALLATION A 2 WELDING PROCESS PROCESS OUTPUT RANGE AMPERES GMAW CV GTAW CC PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT 14 14in 359mm 26 66in 677mm 130lbs 59kg K3065 1 18 80in 478mm TEMPERATURE RANGES STORAGE TEMPERATURE RA
19. LN B 8 OPERATION 8 The remote potentiometer controls the amperage from minimum to this pre set maximum CV GAS This weld mode is a constant voltage CV mode featuring con tinuous control from 10 to 45 volts It is intended for the GMAW FCAW GS MCAW welding processes Hot Start Toggle to ON position to provide more energy during the start of a weld Arc Control The Arc Control regulates pinch effect Inductance At the minimum setting 10 minimizes pinch and results in a soft arc Low pinch settings are preferable for weld ing with gas mixes containing mostly inert gases At the maxi mum setting 10 maximizes pinch effect and results in a crisp arc High pinch settings are preferable for welding FCAW GS and GMAW with CO2 Weld Terminals On Remote When set to the ON position the weld terminals are at OCH 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 indi cates that amperage is not settable in this weld mode While output is enabled the actual welding amperage is 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 The di
20. N we I ENN 4 D 4 LIE N C o m N 1 SEINS VI CC Co do I n ZEN ER 1 N EESTI 25 E 9 JZ LUE lt SZ N 1 IS m N NE N NI bas CS LII 9 Co T e SFILA N 4 N E 9 i POWER UP SEQUENCE When power is applied to the Flextec 450 CE the displays will illuminate and display the voltage and or amperage settings COMMON WELDING PROCEDURES WARNING MAKING WELD The serviceability of a product or structure utiliz ing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selec tion The Flextec 450 CE is a multi process inverter welder The Weld Process Selector Switch is used to set the desired weld mode The Flextec 450 CE has 4 selectable welding modes 1 MMAW This is a CC constant current weld mode used for the MMAW stick welding process 2 GT
21. NGE OPERATING TEMPERATURE RANGE Environmentally Hardened 40 F to 185 F 40 C to 85 Environmentally Hardened 14 F to 131 F 10 C to 55 C IP23 155 F Insulation Class Weight does not include input cord Output De rated at Temperatures above 40 FLEXTEC 450 CE LINCOLN 3 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill 09 ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLA TION TURN OFF INPUT POWER TO THE POWER SOURCE AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THIS EQUIPMENT TURN OFF THE INPUT POWER TO ANY OTHER EQUIPMENT CONNECTED TO THE WELDING SYSTEM AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THE EQUIPMENT DO NOT TOUCH ELECTRICALLY HOT PARTS ALWAYS CONNECT THE FLEXTEC 450 CE 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 CC Stick mode The VRD reduces the OCH Open Circuit Voltage at the welding output terminals while not welding to less than 35VDC 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 con nections also limits the possibility of other safety issues such as heat generated damage burns and fires The machine is shipped with VRD enable
22. S Jui W 2 il dl Sall Gea 6 AL 6 dis de de L y eat lu dra slay JANN pu oec SS PLI 4 4 aal dus tog 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 ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 45074
23. TRU OES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR GK 5 BA 4900773 LTRHOREMEI 6 EE E E EN L EA S R 0 o 0 SSH 265 HAS HYR 55 ETS aisect an casual QU dl ail Aal gail sl 3 candy LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
24. 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 WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration 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 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 TABLE OF CONTENTS Page Installation EiN Section A Technical Specifications n csetera deest A 1 Welding Process Physical Dimensions A 2 Safety Precaution RR A 3 VRD Voltage Reduction Device A 3 Select Suitable 00 81104 A 3 sis si
25. ave configuration Use the control dial on the FLEXTEC 450 CE to pre set the maximum welding current The remote will con trol output from minimum to the pre set maximum Output Control Dial When the Local Remote is set to Local this dial sets the welding amperage OPERATION B 7 When the Local Remote is set to Remote this dial sets the maximum welding amperage The remote potentiometer than controls the amperage from min imum to this pre set maximum GTAW This weld mode is a constant current CC mode featuring con tinuous control from 10 500 amps It is intended for the GTAW TIG welding processes Hot Start The Hot Start control regulates the starting current at arc initiation Hot Start can be set to Off and no additional current is added at arc start When set to the On position additional current relative to the preset current at 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 is displayed After welding the meter holds the actual voltag
26. c 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c 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 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 7 Use only compressed gas cylinders
27. d The VRD function can be disabled or enabled via a dip switch on the control P C board The control board and dip switch can be accessed by removing the case top 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 mini mum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns LIFTING Both handles should be used when lifting the FLEX 450 CE When using a crane or overhead device a lifting strap should be connected to both han des Do not attempt to lift the FLEXTEC 450 CE with accessories attached to it INSTALLATION STACKING The FLEXTEC 450 CE cannot be stacked ENVIRONMENTAL LIMITATIONS The FLEXTEC 450 CE is IP23 rated for use in an outdoor environment The FLEXTEC 450 CE 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 450 CE over bustible surfaces Where there is a combustible surface directly under stationary or fixed electrical eq
28. e and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode
29. e turned off and back on to reset If condition persists contact an authorized Lincoln Field Service Shop CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed FLEXTEC 450 CE LINCOLN Jequinu epoo jueuudinbe e 10 eu si eui sjaued einsojoue y euo uo LL eu episui paysed si epoo e 104 4 eu siy seuruoeui 10 eq jou AJUO 10 S 541 310 c 06895 NOLLISOd GHVOG NO HOLIMS 410 9NIOV 1d QUA NO 1 NO SI GUA 3ALLOV 38V 5 931 ON OVA SLHr 0BE JO 318V4VO SI 3NIHOVIN ON ANIHOVN 3GIS LHOIH 19008 037 30 ALIHM ANNHS vx ISS d SN3103140 3903 DNH 3HL 1S38V3N Nid 162 x 90 ox 1 T d Di Ko SE 1nd1no 1097135 D 30419313 2022 esz zu az EE E Sever 1 3e Seer gt her See E nisi 7
30. e value for 5 seconds Output adjustment while in the hold period results in the prior to operation characteristics 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 While output is enabled the actual weld amperage is displayed 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 The displays blink indicating that the machine is in the hold period 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 450 Set this switch to REMOTE when an external potentiometer control is connected When a remote potentiometer is connected the output control on the FLEXTEC 450 CE and the remote act as a master slave configuration Use the control dial on the FLEX 450 CE to pre set the maximum welding current The remote will control output from minimum to the pre set maxi mum Output Control Dial When the Local Remote is set to Local this dial sets the welding amperage When the Local Remote is set to Remote this dial sets the maximum welding amperage FLEXTEC 450 CE LINCO
31. electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 8 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 287 standards 4 b Use suitable clothing made from durable flame resistant 54 LINCOLN 8 material to protect your skin and that of your helpers from the arc rays 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
32. eleration poor arc start ing and low wire driving force wire feeding prob lems Always use the shortest length of control cable possible and DO NOT coil excess cable Regarding cable placement best results will be obtained when control cables are routed separate from the weld cables This minimizes the possibility of interference between the high currents flowing through the weld cables and the low level signals in the control cables TABLE A 1 OUTPUT CABLE GUIDELINES 200 60 200 100 0 250 3 250 40 250 60 100 CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES AMPERES PERCENT RUBBER COVERED COPPER RATED 167 F 75 200 to 250 Ft 61 to 76m 1 0 1 0 1 0 1 0 1 0 3 0 4 0 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 FLEXTEC 450 CE LINCOLN 8 1 OPERATION B 1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING e 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
33. en an external potentiometer control is connected 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 450 CE LINCOLN e ACCESSORIES 1 OPTIONS ACCESSORIES Foot Amptrol amp Provides 25 ft 7 6 m of remote current control for TIG welding 6 pin plug connection zi Order K870 4 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 con nection 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 Arc Start Switch May be used Convenient handles allow for easy cable storage while in place of the Foot or Hand full length side trays store parts and tools Shipped Amptrol Comes with a 25 ft fully assembled Small footprint fits through 30 762 7 6m cable Attaches to the TIG mm door torch for convenient finger control Order K2945 1 to start and stop the weld cycle at the current set on the machine Order K814 Fume Extracting Systems Accessory Kit For stick weld ing 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 ee holder 400 amp capacity Order K704
34. ent EM A 3 LACKING M A 3 3 Input and Grounding Connections A 3 High Frequency ProteCtlOn EE A 3 Input Connection et UR A 4 Input Fuse and Supply Wire A 4 Cable A 5 Recommended Electrode and Work Cable for arc Welding A 6 Output Cable Guidelines sise A 6 Section B Safety Precautions uices cit m ENEE B 1 Graphic Gvmbols ss B 1 B 2 Product Description 2 D 2 Design Lu B 2 Recommended Processes and Equipment sse B 3 Case Front Controls d ritiene sa We Ce Ete soda EE ined ue B 4 Power Up Geouence iii B 5 Case Back Control eieiei coercet tie ERR iere B 5 Common Welding Procedures Weld Controls and Displays B 5 thru B 8 Section C Options Accessorles sis C 1 Section D Safety Precautions iii D 1 Visual INSPOCHOM E D 1 Routine Maintenance see D 1 eeler ae D 1 Section X Troubleshooting Safety 0 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide 2
35. eux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de Soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement to
36. full depression of a foot or hand amptrol results in the pre set level of current Voltage Display Meter Prior to CV operation current flow the meter dis plays desired preset voltage value Prior to STICK or TIG operation the meter displays the Open Circuit Voltage of the Power Source or four dashes if the output has not been turned on e During welding this meter displays actual average volts After welding the meter holds the actual voltage value for 5 seconds The displays blink indicating that the machine is in the hold period Output adjustment while in the hold period results in the prior to operation characteristics FLEXTEC 450 CE LINCOLN B 6 OPERATION B 6 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 dash es 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 Weld Terminals On Remote Toggle Switch This switch determines the trigger location When set to the position the weld terminals are at OCV open circuit voltage and ready to weld When set to the REMOTE
37. h Thermal Indicator LED Error Codes display on LED screen for ease of trou ble shooting Electronic over current protection Input voltage misconnection protection Utilizes digital signal processing and microprocessor control e VRD Voltage Reduction Device Enable this func tion for reduced OCV in CC modes for added safety FLEXTEC 450 CE LINCOLN 3 RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Flextec 450 CE is designed for CC MMAW CC GTAW lift tig CV GMAW CV FCAW SS and CV FCAW GS welding processes CC CAG arc gouging is also supported in the MMAW mode PROCESS LIMITATIONS The Flextec 450 CE 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 COMMON EQUIPMENT PACKAGES Basic Package K3065 1 Flextec 450 CE K2327 5 LF 72 Bench Model K2149 1 Work Lead Package K1842 10 10 Ft Weld Power Cable 3100211 Harris Regulator and gas hose Common Optional Kits K857 Remote Output Control 25 feet K857 1 Remote Output Control 100 feet K870 Foot Amptrol K963 3 Hand Amptrol All Models LN 25 Pro Note The Flextec 450 is not compatible with 115V Wire Feeders FLEXTEC 450 CE LINCOLN B 4 OPERATION B 4 CASE FRONT CONTROL DESCRIPTIONS See Figure B 1 11 Wire feeder voltmeter polarity selection toggle sw
38. he 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 LINCOLN 8 SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 6 S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les d
39. hods FLEXTEC 450 CE LINCOLN 5 5 INSTALLATION CABLE CONNECTIONS See FIGURE A 2 for locating 6 pin and 14 pin con nectors on the front of the FLEXTEC 450 CE 6 PIN REMOTE CONTROL CONNECTOR 77 Remote potentiometer 5 6 Remote potentiometer wiper AJ 8 Ground Trigger opt EN M Motor 42 VAC pO Motor 42 VAC FIGURE 2 4 4 IN 4 TN A 5 2 e e IN 2 IN R A IN FEIN 1 U 14 PIN CONNECTOR 6 PIN REMOTE FOR WIRE FEEDER CONTROL CONNECTOR FLEXTEC 450 LINCOLN 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 450 CE 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 out put connections at the power source electrode cable to
40. icit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Thank 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 equip ment 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 posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration
41. itch 1 Power Switch 12 Circuit breaker reset button for the 14 pin wire 2 Voltage Display Meter 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 16 VRD Voltage Reduction Device Indicator lights 7 Hot Start Toggle Switch 8 Output Control Local Remote Toggle Switch 9 Arc Control Dial 10 Weld Terminals On Remote toggle selector switch FIGURE B 1 FLEXTEC 450 CE LINCOLN B 5 CASE BACK CONTROL See Figure B 2 1 Input Power Cord Access Hole Fr 7 cw H o H 9 LAT MLC 1 d 2 8 N ZRSE CASE FO 7 DE 1 ONE A NET E
42. l troubleshooting assistance before you proceed FLEXTEC 450 CE LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Major physical or electrical damage is evident when the sheet metal covers are removed Machine won t weld can t get any output Thermal symbol is lit Wire feeder won t work Apparently no power to wire feeder Contact your local authorized Lincoln Electric Field Service facil ity for technical assistance If the displays show an Err see the fault section for corrective action 2 If the thermal symbol is lit refer to the thermal section 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 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 Welding output ratings may have been exceeded Allow the machine to cool down and reset Check circuit breakers by the wire feeder receptacles on the rear of the machine Reset Check the control cable between the power source and the wire feeder for continuity 1 If all recommended possible areas of misadjustment have been checked and the problem persists Contact y
43. ode the VRD lights function as shown in Table B 1 TABLE B 1 VRD Indicator Lights VRD ON VRD OFF Green OCV reduced While welding Green or Red depends on weld voltage OCV C V Innershield Weld Terminals Remotely Controlled Gun Trigger Closed Green NO OCV Weld Terminals Remotely Controlled Gun Trigger Open While welding Green or Red depends on weld voltage It is normal for the lights to alternate between colors while welding Hed Not Reduced Weld Terminals ON Red OCV Not Reduced No lights are active FIGURE B 3 lt Location of Control P C Board VRD Mode Setting Switch 5 in the ON Position ON OFF FLEXTEC 450 CE LINCOLN B 7 BASIC MODES OF OPERATION MMAW This weld mode is a constant current CC mode fea turing continuous control from 15 500 amps It is intended for the MMAW stick welding processes and arc gouging Hot Start The Hot Start control regulates the starting current at arc initiation Hot Start can be set to Off and no additional current is added at arc start When set to the On position additional current relative to the preset current 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 s
44. our 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 450 CE LINCOLN E 3 TROUBLESHOOTING E 3 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 The status lights on the main control board and the switch pc board are dual color LED s Normal operation for each is steady green Error Codes for the FLEXTEC 450 CE Error Description Corrective Action Code Internal Control Board Error Cycle power to the machine Machine needs to be turned off and back on to reset If condition persists contact an authorized Lincoln Field Service Shop Primary Over Current Check the input power voltage and frequency Machine needs to be turned off Verify the primary reconnect is properly config land back on to reset ured for the input voltage If condition persists contact an authorized Lincoln Field Service Shop 45
45. ourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e solieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas electro dos com a pele ou roupa molhada sole se da pe a e terra 888 950 8888 08865 1 5568 5 98 97 54 Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos efmiet os60o00PcomitEs 4A Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e SESMHMSEGSEmA 5585 st B Oo 213 548 82 AIX ez at 29 S225 48511 58 8 SE au FS su ya qye ij AA
46. position output is enabled through a remote trigger Control Local Remote Toggle Switch Set the switch to Local to control output at the machine by 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 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 tem perature 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 450 CE above the Voltage LCD Display to indicate the status of VRD operation A green light indicates the open circuit volt age is less than 35V A red light indicates the OCV is at or above 35V VRD is enabled via a dip switch on the Control P C board see Figure B 3 This switch must be in the On position for the VRD function to be active and the lights to be enabled If VRD is enabled both lights will illuminate for 5 seconds at power up For each weld m
47. put and grounding wire size according to ELECTRICAL CODES AND THE CONNECTION local or national electrical codes Using input wire DIAGRAM LOCATED ON THE INSIDE OF THE sizes fuses or circuit breakers smaller than recom RECONNECT INPUT ACCESS DOOR OF THE mended may result in nuisance shut offs from MACHINE FAILURE TO DO SO MAY RESULT welder inrush currents even if the machine is not IN BODILY INJURY OR DEATH being used at high currents INPUT CONNECTION See Figure A 1 Use a three phase supply line A 1 40 inch 36 mm diameter access hole for the input supply is located on the case back Connect L1 L2 13 and ground according to the Input Supply Connection Diagram decal located on the internal horizontal panel To access the reconnect input supply connection blocks remove the 8 screws that secure the case top of the welder and remove the case top FIGURE A 1 POWER SUPPLY ACCESS HOLE Route input power cable through this hole RECONNECT PROCEDURE 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 grounc lead of the line cord See your local and national electrical codes for proper grounding met
48. r interface of the FLEXTEC 450 CE is simple and intuitive Weld modes are selected by a 4 position selector switch Volts and Amps are displayed on an easy to view LED display and the amps and volts are set by a large output control knob A hot start toggle selector switch and an arc control knob allow for finer tuning of the welding arc The FLEXTEC 450 CE operates on 380V 400V or 415V 50hz or 60hz power DUTY CYCLE The FLEXTEC 450 CE is capable of welding at a 10096 duty cycle continuous welding at 400 amps rated output The 6096 rating is 450 amps base off of a 10 minute cycle 6 minutes on time and 4 minutes off time The maximum output of the machine is 500 amps The FLEXTEC 450 is also rated for Desert Duty elevated temperature operation in a 55 C 131 F ambient The machine is output de rated for this application DESIGN FEATURES Severe Duty Design for outdoor use IP23 rating Passive Power Factor Correction reliably gives 95 power factor for lower installation costs 8996 Efficiency rating reduces electrical utility costs Simple user interface designed with the operator in mind Getting setup for the weld is several clicks away and even the most novice welder can be confi dent 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 wit
49. s 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 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 Also see item 1 b SAFETY D WELDING and CUTTING gt 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 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 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 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 toxi
50. splays blink indi cating 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 While out put is enabled the actual weld amperage is 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 The displays blink indicating that the machine is in the hold period 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 450 CE Set this switch to REMOTE when an external potentiometer control is connected 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 fea turing continuous control from 10 to 45 volts It is intended for the FCAW SS welding process Hot Start Toggle to 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
51. ticking Weld Terminals On Remote Set to so 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 weld ing voltage is 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 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 While output is enabled the actual weld amperage is 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 The displays blink indicating that the machine is in the Hold period 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 con trolled through the Output Control Dial on the front of the FLEXTEC 450 CE Set this switch to REMOTE when an external potentiometer control is connected When a remote potentiometer is connected the out put control on the FLEXTEC 450 CE and the remote act as a master sl
52. uipment 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 MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with the symbol D shown is located inside the reconnect input connection area for this purpose See your local and national electrical codes for proper grounding meth ods HIGH FREQUENCY PROTECTION Locate the FLEXTEC 450 CE away from radio con trolled machinery The normal operation of the FLEX 450 CE 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 ELEVATED TEMPERATURES AMPS DUTY CYCLE VOLTS TEMPERATURES 55 FLEXTEC 450 LINCOLN 5 A 4 INSTALLATION 4 INPUT FUSE AND SUPPLY WIRE WARNING CONSIDERATIONS 09 ELECTRIC SHOCK can kill Refer to Specification in this Installation Section for ONLY A QUALIFIED ELECTRICIAN recommended fuse wire sizes and type of the copper SHOULD CONNECT THE INPUT wires Fuse the input circuit with the recommended LEADS TO THE FLEXTEC 450 CE super lag fuse or delay type breakers also called CONNECTIONS SHOULD BE MADE IN ACCOR inverse time or thermal magnetic circuit breakers DANCE WITH ALL LOCAL AND NATIONAL Choose in
53. xique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret 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 prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectr
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