Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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 4 - Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Welding Process, Physical Di...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS -; RATED OUTPUT; RECOMMENDED INPUT WIRE AND FUSE SIzES
FLEXTEC™ 450 A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - FLEXTEC™ 450 RATED OUTPUT POWER SOURCE-INPUT VOLTAGE AND CURRENT Model K2882-1 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 Cycl...
Page 9 - PHYSICAL DIMENSIONS
A-2 INSTALLATION FLEXTEC™ 450 A-2 PHYSICAL DIMENSIONS TEMPERATURE RANGES HEIGHT 18.80in (478mm) MODEL K2882-1 WIDTH 14.14in (359mm) DEPTH 26.66in (677mm) WEIGHT 125lbs (56.6kg) * OPERATING TEMPERATURE RANGE Environmentally Hardened: 14°F to 131°F (-10°C to 55°C ** ) STORAGE TEMPERATURE RANGE Environ...
Page 10 - CAUTION
A-3 INSTALLATION A-3 SELECT SUITAbLE LOCATION LOCATION AND VENTILATION FOR COOLING Place the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe case sides. Dirt, dust, or any foreign material thatcan be drawn into the welder should be kept at a mini-mum...
Page 11 - INPUT VOLTAGE SELECTION; INPUT CONNECTION
A-4 INSTALLATION A-4 I N P U T F U S E A N D S U P P LY W I R ECONSIDERATIONS Refer to Specification in this Installation Section forrecommended fuse, wire sizes and type of the copperwires. Fuse the input circuit with the recommendedsuper lag fuse or delay type breakers (also called"inverse tim...
Page 12 - CAbLE CONNECTIONS
A-5 INSTALLATION A-5 FLEXTEC™ 450 Pin AB CD E F Wiring 77 Remote potentiometer, 5K76 Remote potentiometer, wiper75 Remote potentiometer, commonTrigger, commonTrigger, inputGround CAbLE CONNECTIONS See FIGURE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FLEXTEC™ 450. FIGURE A.2 ...
Page 13 - CONTROL CAbLE CONNECTIONS
A-6 INSTALLATION FLEXTEC™ 450 A-6 R E C O M M E N D E D E L E C T R O D E A N DWORK CAbLE SIzES FOR ARC WELDING General Guidelines Connect the electrode and work cables between theappropriate output studs of the Flextec™ 450 per thefollowing guidelines: • Most welding applications run with the elect...
Page 14 - OPERATION; SAFETY PRECAUTIONS
b-1 OPERATION FLEXTEC™ 450 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 f e e d i n g w i t h g u n t r i g g e r , t h eelectrode and drive mechanism area l w a y s e l e c t r...
Page 15 - PRODUCT DESCRIPTION
b-2 OPERATION b-2 FLEXTEC™ 450 PRODUCT DESCRIPTION T h e F l e x t e c ™ 4 5 0 i s a m u l t i - p r o c e s s C C / C V D Cinverter and is rated for 450 amps, 38 volts at a 60%duty cycle. The Flextec is intended for both factoryand field operation. It comes in a compact, ruggedcase that is designed...
Page 16 - RECOMMENDED PROCESSES; EQUIPMENT LIMITATIONS; COMMON EQUIPMENT PACKAGES
b-3 OPERATION b-3 RECOMMENDED PROCESSES ANDEQUIPMENT RECOMMENDED PROCESSES The Flextec™ 450 is designed for CC-SMAW, CC-GTAW(lift tig), CV-GMAW, CV-FCAW-SS and CV-FCAW-GSwelding processes. CAG (arc gouging) is also supported. PROCESS LIMITATIONS The Flextec™ 450 is suitable only for the processes li...
Page 17 - CASE FRONT CONTROL DESCRIPTIONS
b-4 OPERATION 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. ...
Page 18 - CASE bACK CONTROL; COMMON WELDING PROCEDURES; WELD CONTROLS AND DISPLAYS
b-5 OPERATION b-5 FLEXTEC™ 450 CASE bACK CONTROL (See Figure B.2) 1. Input Power Cord Access Hole. 1 1 FIGURE b.2 COMMON WELDING PROCEDURES MAKING A WELDThe serviceability of a product or structure utiliz-ing the welding programs is and must be the soleresponsibility of the builder/user. Many variab...
Page 19 - bASIC MODES OF OPERATION
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, t...
Page 20 - GTAW
b-7 OPERATION b-7 GTAW This weld mode is a constant current (CC) mode featuring con-tinuous control from 10 – 500 amps. It is intended for the GTAWTIG welding processes. Hot Start - The Hot Start control regulates the starting current at arc initiation. Hot Start can be set to “Off” and no additiona...
Page 22 - ACCESSORIES; OPTIONS / ACCESSORIES
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 whilefull length s...
Page 23 - MAINTENANCE; PERIODIC MAINTENANCE; VISUAL INSPECTION
D-1 MAINTENANCE D-1 PERIODIC MAINTENANCE Thermal Protection Thermostats protect the machine from excessiveoperating temperatures. Excessive temperatures maybe caused by a lack of cooling air or operating themachine beyond the duty cycle and output rating. Ifexcessive operating temperature should occ...
Page 24 - TROUbLESHOOTING; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 FLEXTEC™ 450 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 G...
Page 25 - PRObLEMS
E-2 TROUbLESHOOTING E-2 FLEXTEC™ 450 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...
Page 26 - Error Codes for the FLEXTECTM 450
E-3 TROUbLESHOOTING E-3 FLEXTEC™ 450 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...
Page 27 - DIAGRAMS
F-1 DIAGRAMS F-1 FLEXTEC™ 450 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...
Page 29 - DIMENSION PRINT
F-3 DIMENSION PRINT F-3 FLEXTEC™ 450 L1 56 98 A.0 1 26 .6 6 18 .7 8 14 .1 4 26 .5 1 13 .0 6 L 1 5 6 9 8 A .0 1 2 6 .6 6 1 8 .7 8 1 4 .1 4 2 6 .5 1 1 3 .0 6
Page 30 - NOTES