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Lincoln Electric FLEXTEC 450 CE manual

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Table of contents for the manual

  • Page 1

    FLEXTEC ™ 450 CE OPERA T ORʼS MANUAL For use with machines Code 11776 IM1 0 091 April, 2011 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 TH[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC R A Y S can bur n. 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 s[...]

  • Page 4

    iii SAFETY iii FOR ELECTRIC ALL Y pow ered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 5

    iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

  • Page 6

    v v Thank Y ou 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pa[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Welding Process, Physical Dimensions ........................................[...]

  • Page 8

    FLEXTEC™ 450 CE A-1 INST ALLA TION A-1 TECHNICAL SPECIFICA TIONS - FLEXTEC™ 450 CE RA TED OUTPUT POWER SOURCE-INPUT VOL T AGE AND CURRENT Model K3065-1 Duty Cycle 60% rating 100% rating Volts at Rated Amperes 36.5V 34V 28V 26V 38V 36V 36.5V 34V 36.5V 34V Amperes 450 400 450 400 450 400 450 400 450 400 Duty Cycle 60% 100% 60% 100% 60% 100% 60% 1[...]

  • Page 9

    A-2 INST ALLA TION FLEXTEC™ 450 CE A-2 PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 18.80in (478mm) MODEL K3065-1 WIDTH 14.14in (359mm) DEPTH 26.66in (677mm) WEIGHT 130lbs (59kg) * OPERATING TEMPERATURE RANGE Environmentally Hardened: 14°F to 131°F (-10°C to 55°C ** ) STORAGE TEMPERATURE RANGE Environmentally Hardened: -40°F to 185°F (-40[...]

  • Page 10

    A-3 INST ALLA TION A-3 VRD™ (VOL T AGE REDUCTION DEVICE) The VRD™ feature provides additional safety in the CC- Stick mode. The VRD™ reduces the OCV (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 po[...]

  • Page 11

    A-4 INST ALLA TION A-4 INPUT FUSE AND SUPPL Y WIRE CONSIDERA TIONS 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[...]

  • Page 12

    A-5 INST ALLA TION A-5 FLEXTEC™ 450 CE Pin A B C D E F Wiring 77 Remote potentiometer, 5K 76 Remote potentiometer, wiper 75 Remote potentiometer, common Trigger, common Trigger, input Ground CABLE CONNECTIONS See FIGURE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FLEXTEC™ 450 CE. FIGURE A.2 Function 6-pin remote control c[...]

  • Page 13

    A-6 INST ALLA TION FLEXTEC™ 450 CE 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, conn[...]

  • Page 14

    B-1 OPERA TION FLEXTEC™ 450 CE B-1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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 [...]

  • Page 15

    B-2 OPERA TION B-2 FLEXTEC™ 450 CE PRODUCT DESCRIPTION The FLEXTEC™ 450 CE is a multi-process CC/CV DC inverter and is rated for 450 amps, 38 volts at a 60% 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 [...]

  • Page 16

    B-3 OPERA TION B-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 LIMIT A TIONS The Flextec™ 450 CE is suitable only for the processes listed. EQUIPME[...]

  • Page 17

    B-4 OPERA TION B-4 CASE FRONT CONTROL DESCRIPTIONS (See Figure B.1) 1. Power Switch 2. Voltage Display Meter 3. Amperage Display Meter 4. Thermal LED 5. Output Control Dial 6. Weld Process Selector Switch 7. Hot Start Toggle Switch 8. Output Control Local/Remote Toggle Switch 9. Arc Control Dial 10. W e l d T e r m i n a l s On/Remote toggle select[...]

  • Page 18

    B-5 OPERA TION B-5 FLEXTEC™ 450 CE CASE BACK CONTROL (See Figure B.2) 1. Input Power Cord Access Hole. 1 1 FIGURE B.2 COMMON WELDING PROCEDURES MAKING A 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 Ele[...]

  • Page 19

    B-6 OPERA TION B-6 FLEXTEC™ 450 CE 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 actu[...]

  • Page 20

    B-7 OPERA TION 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. GT A W 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 pr[...]

  • Page 21

    B-8 OPERA TION B-8 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 “ON” position to provide more energy during the start of a weld. Arc Control – The Arc Control regulates pinch effect. At the minimum sett[...]

  • Page 22

    C-1 ACCESSORIES C-1 OPTIONS / ACCESSORIES General Options K2149-1 Work Lead Package. 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. Convenient handles allow for easy cable storage while full length side trays store parts and tools. Shipped fully a[...]

  • Page 23

    D-1 MAINTENANCE D-1 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 [...]

  • Page 24

    E-1 TROUBLESHOOTING E-1 FLEXTEC™ 450 CE 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. CAUTION This Troubleshooting Guide is provided to help you locate and repai[...]

  • Page 25

    E-2 TROUBLESHOOTING E-2 FLEXTEC™ 450 CE Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBL[...]

  • Page 26

    E-3 TROUBLESHOOTING E-3 FLEXTEC™ 450 CE Observe all Safety Guidelines detailed throughout this manual 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. CAUTION USING[...]

  • Page 27

    F-1 DIAGRAMS F-1 FLEXTEC™ 450 CE 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 n[...]

  • Page 28

    F-2 DIMENSION PRINT F-2 FLEXTEC™ 450 CE L15698 A.01 26.66 18.78 14.14 26.51 13.06 L15698 A.01 26.66 18.78 14.14 26.51 13.06[...]

  • Page 29

    NOTES FLEXTEC™ 450 CE[...]

  • Page 30

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LA S INS TRUCCIONES DEL F ABRIC A[...]

  • Page 31

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INSTR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P ARTES DE USO , E SIG A AS PRÁTIC A S DE SEGUR ANÇA DO EMPREG ADOR. • Keep your head out of fumes. • Use ventilation or exhaust to r[...]

  • Page 32

    • 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 • World's Leader in Welding and Cutting Products •[...]