Instruction/ maintenance manual of the product FLEXTEC 450 CE Lincoln Electric
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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 .
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.
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.
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.
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.
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.
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ......................................................................
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.
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 TEMPE.
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.
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.
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.
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 (+).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
NOTES FLEXTEC™ 450 CE.
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.
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.
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However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric FLEXTEC 450 CE. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric FLEXTEC 450 CE along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
