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IM10091
January, 2011
FLEXTEC™ 450 CE
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
Copyright © Lincoln Global Inc.
• 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 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. 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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. 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.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
5.c. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases 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.
5.e. 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.
5.f. Also see item 1.b.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. 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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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 toxic 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. 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.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. 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.
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. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. 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.
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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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!
Thank 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, 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.
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 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 WEbꢀSITE 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:
WARNING
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.
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TAbLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Welding Process, Physical Dimensions..........................................................A-2
Safety Precautions..........................................................................................A-3
VRD™ (Voltage Reduction Device) ..............................................................................A-3
Select Suitable Location..................................................................................A-3
Lifting...............................................................................................................A-3
Stacking ..........................................................................................................A-3
Environmental Limitations...............................................................................A-3
Input and Grounding Connections ..................................................................A-3
High Frequency Protection ....................................................................................A-3
Input Connection ............................................................................................A-4
Input Fuse and Supply Wire Considerations...................................................A-4
Cable Connections..........................................................................................A-5
Recommended Electrode and Work Cable for arc Welding ..................................A-6
Output Cable Guidelines........................................................................................A-6
________________________________________________________________________
Operation .........................................................................................................Section b
Safety Precautions ................................................................................................B-1
Graphic Symbols............................................................................................B-1, B-2
Product Description ..............................................................................................B-2
Duty Cycle .............................................................................................................B-2
Design Features ....................................................................................................B-2
Recommended Processes and Equipment ...........................................................B-3
Case Front Controls...............................................................................................B-4
Power-Up Sequence..............................................................................................B-5
Case Back Controls...............................................................................................B-5
Common Welding Procedures, Weld Controls and Displays..................B-5, thru B-8
_______________________________________________________________________
Accessories.....................................................................................................Section C
Options / Accessories............................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Visual Inspection ...................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
________________________________________________________________________
Section E ..............................................................................................Troubleshooting
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Error Codes ...........................................................................................................E-3
________________________________________________________________________
Wiring Diagram and Dimension Print ..............................................................Section F
________________________________________________________________________
Parts List ....................................................................................................P-674 Series
________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - FLEXTEC™ 450 CE
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Input Amperes
Input Voltage ± 10%
Model
Duty Cycle
Power Factor @
Rated Output
Idle Power
60% rating
72 Watts
Max.
(fan on)
37 / 35 / 34
29 / 28 / 27
K3065-1
95%
380 / 400 / 415 / 3 / 50 / 60
100% rating
RATED OUTPUT
Volts at Rated Amperes
Process
Duty Cycle
60%
Amperes
36.5V
34V
450
400
450
400
450
400
450
400
450
400
GMAW (CV)
100%
60%
28V
GTAW (CC)
MMAW (CC)
100%
60%
26V
38V
100%
60%
36V
36.5V
34V
FCAW-GS (CV)
FCAW-SS (CV)
100%
60%
36.5V
34V
100%
RECOMMENDED INPUT WIRE AND FUSE SIzES (1)
Maximum
Input
Amperes
4 CONDUCTOR
SOOW or similar Cord in 40°C(104°F) Ambient
Fuse (Super Lag) or
(2)
VOLTAGE
50/60Hz
breaker Size
380/3/50
400/3/60
415/3/60
42 A
40 A
39 A
2
8 AWG or 10mm
50
(1)
Cord 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
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A-2
A-2
INSTALLATION
WELDING PROCESS
OUTPUT RANGE (AMPERES)
OCV (Uo)
PROCESS
OCV (Ur)
40-500
10-500
15-500
40-500
40-500
60
24
35
60
60
GMAW (CV)
GTAW (CC)
MMAW (CC)
FCAW-GS (CV)
FCAW-SS (CV)
--
15
15
--
--
PHYSICAL DIMENSIONS
MODEL
HEIGHT
WIDTH
WEIGHT
DEPTH
26.66in (677mm)
130lbs (59kg)*
K3065-1
18.80in (478mm)
14.14in (359mm)
TEMPERATURE RANGES
STORAGE TEMPERATURE RANGE
Environmentally Hardened: -40°F to 185°F (-40°C to 85°C)
OPERATING TEMPERATURE RANGE
Environmentally Hardened: 14°F to 131°F (-10°C to 55°C**)
IP23
155º(F) Insulation Class
* Weight does not include input cord.
** Output De-rated at Temperatures above 40°C.
FLEXTEC™ 450 CE
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A-3
A-3
INSTALLATION
SAFETY PRECAUTIONS
STACKING
WARNING
ELECTRIC SHOCK can kill.
The FLEXTEC™ 450 CE cannot be stacked.
ENVIRONMENTAL LIMITATIONS
ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THIS INSTALLA-
TION.
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.
• 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.
CAUTION
Do not mount the FLEXTEC™ 450 CE over com-
bustible surfaces. Where there is a combustible
surface directly under stationary or fixed electrical
equipment, 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.
• 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)
INPUT AND GROUNDING CONNECTIONS
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.
MACHINE GROUNDING
The frame of the welder must be grounded.
A ground terminal marked with the symbol
shown is located inside the reconnect/input
connection area for this purpose. See your local and
national electrical codes for proper grounding meth-
ods.
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.
HIGH FREQUENCY PROTECTION
The machine is shipped with VRD™ “enabled”. The VRD™
function can be disabled or enabled via a dip switch on the
control P.C. board.
Locate the FLEXTEC™ 450 CE away from radio con-
trolled machinery. The normal operation of the FLEX-
TEC™ 450 CE may adversely affect the operation of
RF controlled equipment, which may result in bodily
injury or damage to the equipment.
The control board and dip switch can be accessed by
removing the case top as shown in the Operation Section
figure B.3.
HIGH TEMPERATURE OPERATION
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.
WELDER OUTPUT RATINGS AT 55°C
ELEVATED TEMPERATURES
AMPS
VOLTS
DUTY CYCLE
TEMPERATURES
340
375
400
450
34VDC
35VDC
36VDC
38VDC
100%
60%
40%
20%
LIFTING
55°C
Both handles should be used when lifting the FLEX-
TEC™ 450 CE. When using a crane or overhead
device a lifting strap should be connected to both han-
dles. Do not attempt to lift the FLEXTEC™ 450 CE
with accessories attached to it.
FLEXTEC™ 450 CE
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A-4
A-4
INSTALLATION
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
WARNING
ELECTRIC SHOCK can kill.
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).
Choose input and grounding wire size according to
local or national electrical codes. Using input wire
sizes, fuses or circuit breakers smaller than recom-
mended may result in "nuisance" shut-offs from
welder inrush currents, even if the machine is not
being used at high currents.
ONLY A QUALIFIED ELECTRICIAN
SHOULD CONNECT THE INPUT
LEADS TO THE FLEXTEC™ 450 CE.
CONNECTIONS SHOULD bE MADE IN ACCOR-
DANCE WITH ALL LOCAL AND NATIONAL
ELECTRICAL CODES AND THE CONNECTION
DIAGRAM LOCATED ON THE INSIDE OF THE
RECONNECT/INPUT ACCESS DOOR OF THE
MACHINE. FAILURE TO DO SO MAY RESULT
IN bODILY INJURY OR DEATH.
----------------------------------------------------------------------
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, L3 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
•
L
o
e
P
P
L
t
POWER SUPPLY ACCESS HOLE
• Route input power cable through this hole.
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 ground
lead of the line cord. (See your local and national electrical
codes for proper grounding methods.)
FLEXTEC™ 450 CE
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A-5
A-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.
C
B
D
A
E
F
6-PIN REMOTE CONTROL CONNECTOR
Function
Wiring
Pin
F
E
6-pin remote
control con-
nector for
remote or
hand/foot
amptrol.
A 77 Remote potentiometer, 5K
B 76 Remote potentiometer, wiper
C 75 Remote potentiometer, common
D Trigger, common
E Trigger, input
F Ground
A
D
B
C
14-PIN CONNECTOR FOR WIRE FEEDER
Function
Wiring
Pin
E
F
D
M
C
K
B
I
A
J
N
G
H
14 pin con-
nector for
A
B Ground
wire feeder
connectivity.
C Trigger, Common
D Trigger input
E 77 Remote potentiometer, 5K
F 76 Remote potentiometer, wiper
G 75 Remote potentiometer, common
H Voltage Sense (21)
H
N
G
I
F
E
J
M
L
K
A
I
Motor (42 VAC)
B
D
C
J
K Motor (42 VAC)
L
M
N
FIGURE A.2
C
P
M
ROL
OTE
O
N
C
O
R
F
-
I
C
N
E
T
OR
14-PIN CONNECTOR
FOR WIRE FEEDER
6-PIN REMOTE
CONTROL CONNECTOR
FLEXTEC™ 450 CE
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A-6
A-6
INSTALLATION
• 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.
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:
• Always weld in a direction away from the work
(ground) connection.
• 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.
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 are
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 acceleration (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.
• When negative electrode polarity is required, such
as in some Innershield applications, reverse the out-
put connections at the power source (electrode
cable to 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.
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.
Note: Excessive heat in the weld circuit indicates
undersized cables and/or bad connections.
TAbLE A.1
OUTPUT CAbLE GUIDELINES
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
(RUBBER COVERED COPPER - RATED 167°F or 75°C)**
AMPERES PERCENT
DUTY
CYCLE
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
2
2
3
2
1
2
2
2
1
1
200
200
250
250
250
250
300
300
350
400
400
500
60
100
30
40
60
100
60
100
40
2
2
3
2
1
1
1
1
1
1
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
1
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
2/0
1/0
2/0
3/0
2/0
2/0
2/0
2/0
3/0
3/0
2/0
1/0
2/0
3/0
2/0
60
100
60
** 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
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b-1
b-1
OPERATION
SAFETY PRECAUTIONS
GRAPHIC SYMbOLS THAT
APPEAR ON THIS MACHINE
OR IN THIS MANUAL
Read this entire section of operating instructions
before operating the machine.
WARNING
INPUT POWER
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the
electrode and drive mechanism are
always electrically energized and
could remain energized several
seconds after the welding ceases.
ON
OFF
• Do not touch electrically live parts or electrodes
with your skin or wet clothing.
HIGH TEMPERATURE
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
CIRCUIT bREAKER
WIRE FEEDER
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
INPUT POWER
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
THREE PHASE
Observe additional guidelines detailed in the
beginning of this manual.
DIRECT CURRENT
FLEXTEC™ 450 CE
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b-2
b-2
OPERATION
GRAPHIC SYMbOLS THAT
APPEAR ON THIS MACHINE
OR IN THIS MANUAL
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 rating. The user
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.
OPEN CIRCUIT
VOLTAGE
U
0
U
U
I
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
1
2
1
DUTY CYCLE
The FLEXTEC™ 450 CE is capable of welding at a
100% duty cycle (continuous welding) at 400 amps
rated output. The 60% 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.
I
2
PROTECTIVE
GROUND
The FLEXTEC™ 450 CE 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.
WARNING or CAUTION
DESIGN FEATURES
• Severe Duty Design for outdoor use (IP23 rating).
• Passive Power Factor Correction – reliably gives
95% power factor for lower installation costs.
• 89% Efficiency rating – reduces electrical utility
costs.
Explosion
• 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.
Dangerous Voltage
• 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.
Shock Hazard
• Thermal protection by thermostats with 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.
• VRD™ Voltage Reduction Device - Enable this func-
tion for reduced OCV in CC modes for added safety.
FLEXTEC™ 450 CE
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b-3
b-3
OPERATION
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°C.
COMMON EQUIPMENT PACKAGES
basic Package
Flextec™ 450 CE
LF-72 Bench Model
Work Lead Package
K3065-1
K2327-5
K2149-1
K1842-10
3100211
10 Ft. Weld Power Cable
Harris Regulator and gas hose
Common Optional Kits
Remote Output Control (25 feet)
K857
Remote Output Control (100 feet)
Foot Amptrol
Hand Amptrol
K857-1
K870
K963-3
Compatible Wire Feeders
LF-72
LF-74
LN-10
All Models
DH-10
LN-25 Pro
Note: The Flextec™ 450 CE is not compatible with 115V Wire Feeders.
FLEXTEC™ 450 CE
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b-4
b-4
OPERATION
CASE FRONT CONTROL DESCRIPTIONS
(See Figure B.1)
11. Wire feeder voltmeter polarity selection toggle
switch
1. Power Switch
12. Circuit breaker reset button for the 14-pin wire
feeder connector
2. Voltage Display Meter
3. Amperage Display Meter
4. Thermal LED
13. 14-pin wire feeder circular connector
14. 6-pin remote circular connector
5. Output Control Dial
15. Positive and negative welding output studs
6. Weld Process Selector Switch
7. Hot Start Toggle Switch
8. Output Control Local/Remote Toggle Switch
9. Arc Control Dial
16. VRD™ (Voltage Reduction Device) Indicator
lights
10. Weld Terminals On/Remote toggle selector
switch
FIGURE b.1
15
14
8
1320
9
4
3
2
16
1
16
2
3
1
4
5
6
7
9
10
11
12
8
13
14
15
FLEXTEC™ 450 CE
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b-5
b-5
OPERATION
3. CV – This is CV (constant voltage) weld mode used
for welding the GMAW MIG welding process and
the FCAW-GS, flux cored gas shielded welding
process.
CASE bACK CONTROL
(See Figure B.2)
1. Input Power Cord Access Hole.
FIGURE b.2
4. CV-Innershield – This is a CV (constant voltage)
weld mode used for welding the FCAW-SS, flux
cored self shielded welding process
1
1
The Flextec™ 450 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 “On” position, additional current (relative to the
preset current) is added at arc initiation.
POWER-UP SEQUENCE
When power is applied to the Flextec™ 450 CE, the
displays will illuminate and display the voltage and/or
amperage settings.
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.
COMMON WELDING PROCEDURES
WARNING
MAKING A WELD
Output Control Dial
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.
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, 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.
• 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.
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:
• Output adjustment while in the "hold" period results in
the "prior to operation" characteristics.
1. MMAW – This is a CC (constant current) weld
mode used for the MMAW stick welding process.
2. GTAW – This is a CC (constant current) weld
mode used for the GTAW TIG welding process.
FLEXTEC™ 450 CE
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b-6
b-6
OPERATION
Thermal Light
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.
• 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.
• 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
VRD™ (VOLTAGE REDUCTION DEVICE)
INDICATOR LIGHT
Weld Terminals On/Remote Toggle Switch
• This switch determines the trigger location.
• 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.
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 OCV (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.
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.
For each weld mode, the VRD™ lights function as
shown in Table B.1:
TAbLE b.1
VRD Indicator Lights
VRD “ON”
Green (OCV reduced)
Mode
VRD “OFF”
CC-MMAW
CC-GTAW
CV-GAS
OCV
While welding
OCV
Green or Red (depends on weld voltage)*
Red (OCV Not Reduced)
Weld Terminals ‘ON’
Red (OCV Not Reduced)
Weld Terminals Remotely Controlled
Gun Trigger Closed
C V-Innershield
No lights are
active
Green (NO OCV)
Weld Terminals Remotely Controlled
Gun Trigger Open
Green or Red (depends on weld voltage)*
While welding
* It is normal for the lights to alternate between colors while welding.
FIGURE b.3
D
L
o
l
d
L
P
V
5
8
Location of Control P.C. Board
VRD Mode Setting
- Switch #5 in the “ON” Position
1
2
3
4
5
6
7
8
ON
OFF
Dip Switch Location on Control P.C. Board
FLEXTEC™ 450 CE
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b-7
b-7
OPERATION
bASIC MODES OF OPERATION
• 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.
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.
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 - 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 sticking.
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.
Weld Terminals On/Remote – Set to “On” 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.
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 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 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.
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 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.
• 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-
TEC™ 450 CE to pre-set the maximum welding current. The
remote will control output from minimum to the pre-set maxi-
mum.
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/slave 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.
• When the Local/Remote is set to Remote, this dial sets the
maximum welding amperage.
Output Control Dial
• When the Local/Remote is set to Local, this dial
sets the welding amperage.
FLEXTEC™ 450 CE
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b-8
OPERATION
The remote potentiometer controls the amperage from minimum
to this pre-set maximum.
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.
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.
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.
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
Weld 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.
2
• When set to the “REMOTE” position, output is
enabled through a remote trigger.
and GMAW with CO .
Weld Terminals On/Remote
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.
• 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 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 displays 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 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.
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 con-
trolled through the Output Control Dial on the front of
the Flextec™ 450. Set this switch to “REMOTE”
when an external potentiometer/control is connected.
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.
Output Control Dial
• When the Local/Remote is set to Remote, this dial is
disabled
• 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
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C-1
C-1
ACCESSORIES
OPTIONS / ACCESSORIES
Foot Amptrol®
General Options
Provides 25 ft. (7.6 m) of remote
current control for TIG welding.
(6-pin plug connection).
Order K870
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).
K1842-10 10ft. Weld Power Cable (Lug to Lug).
Order K963-3
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 assembled. Small footprint fits through 30" (762
mm) door.
Arc Start Switch - May be used
in place of the Foot or Hand
Amptrol®. Comes with a 25 ft.
(7.6m) cable. Attaches to the TIG
torch for convenient finger control
to start and stop the weld cycle at
the current set on the machine.
Order K814
Order K2945-1.
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
holder. 400 amp capacity. Order
K704
Remote Output Control
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-
9, PTA-17, PTA-26 – 2 piece
power cord.
FLEXTEC™ 450 CE
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
PERIODICꢀMAINTENANCE
Thermal Protection
WARNING
ELECTRIC SHOCK can kill.
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.
• 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 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.
FLEXTEC™ 450 CE
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E-1
E-1
TROUbLESHOOTING
HOW TO USE TROUbLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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.
Step 1. LOCATE PROBLEMꢀ(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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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
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E-2
E-2
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS
(SYMPTOMS)
POSSIbLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal
covers are removed.
Lincoln Electric Field Service facil-
ity for technical assistance.
Machine won’t weld, can’t get any
output.
1. If the displays show an Err ###
see the fault section for corrective
action.
2 If the thermal symbol is lit refer to
the thermal section.
3 If 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.
Thermal symbol is lit.
1. 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.
1.If all recommended possible areas
Note: The Fan As Needed circuitry of misadjustment have been
automatically shuts off the fan checked and the problem persists,
5 minutes after welding has Contact your local Lincoln
stopped.
Authorized Field Service
2. Welding output ratings may have Facility.
been exceeded. Allow the
machine to cool down and reset.
Wire feeder won’t work. Apparently 1. Check circuit breakers by the wire
no power to wire feeder
feeder receptacles on the rear of
the machine. Reset
2. Check the control cable between
the power source and the wire
feeder for continuity.
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
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E-3
E-3
TROUbLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
USING THE STATUS LED TO TROUbLESHOOT SYSTEM PRObLEMS
Errors are displayed on the user interface. In addition, there are status lights on the control pc board and the
switch pc board that contain error sequences.
Included in this section is information about the Status Lights and some basic troubleshooting charts for both
machine and weld performance.
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
Corrective Action
Error
Code#
21
Description
Internal Control Board Error.
Machine needs to be turned off
and back on to reset.
Cycle power to the machine.
24
716
718
If condition persists contact an authorized
Lincoln Field Service Shop.
31
Primary Over Current.
Machine needs to be turned off
and back on to reset.
Check the input power (voltage and frequency).
Verify the primary reconnect is properly config-
ured for the input voltage.
If condition persists contact an authorized
Lincoln Field Service Shop.
45
VRD™ Voltage limit exceded.
Machine needs to be turned off
and back on to reset.
If condition persists contact an authorized
Lincoln Field Service Shop.
711 CAP bank over-voltage or under-
voltage.
Machine needs to be turned off
and back on to reset.
If condition persists contact an authorized
Lincoln Field Service Shop.
712 Communication or Switch Board
Fatal.
Weld Terminals Remote: Re-
trigger to recover from error.
If condition persists contact an authorized
Lincoln Field Service Shop.
Weld Terminals Local: Toggle
Remote/Local Switch to recover
from error.
713 Input Power Misconnect – Supply
Voltage too High.
Machine needs to be turned off
and back on to reset.
Verify the input supply voltage to the machine is
within rated specifications.
714 Input Power Misconnect – Supply
Voltage too Low.
Machine needs to be turned off
and back on to reset.
Verify the input supply voltage to the machine is
within rated specifications.
715 Switchboard Under-voltage Lock
Out.
Machine needs to be turned off
and back on to reset.
Verify input voltage level.
If condition persists contact an authorized
Lincoln Field Service Shop.
717 Control Board Mis-configuration.
Machine needs to be turned off
and back on to reset.
Verify that the wiring to connector J5 on the
control board matches the machine wiring dia-
gram.
If condition persists contact an authorized
Lincoln Field Service Shop.
719 Internal Switchboard Error.
Machine needs to be turned off
and back on to reset.
Cycle Power to the machine.
If condition persists contact an authorized
Lincoln Field Service Shop.
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
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F-1
F-1
DIAGRAMS
FLEXTEC™ 450 CE
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F-2
F-2
DIMENSION PRINT
FLEXTEC™ 450 CE
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NOTES
FLEXTEC™ 450 CE
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•
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
•
•
Keep flammable materials away.
•
•
Wear eye, ear and body protection.
WARNING
Spanish
•
No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
Mantenga el material combustible
fuera del área de trabajo.
Protéjase los ojos, los oídos y el
cuerpo.
AVISO DE
PRECAUCION
French
•
•
Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
•
•
Gardez à l’écart de tout matériel
inflammable.
•
•
Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
•
•
German
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Entfernen Sie brennbarres Material!
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
•
Elektroden und dem Erdboden!
Portuguese
•
•
Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
Isole-se da peça e terra.
•
Mantenha inflamáveis bem guarda-
dos.
•
Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPOY 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
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•
•
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
•
•
Turn power off before servicing.
•
•
Do not operate with panel open or
guards off.
WARNING
Spanish
•
•
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
•
•
Débranchez le courant avant l’entre-
tien.
•
•
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
•
•
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ATTENTION
German
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
•
•
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
•
•
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
•
•
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
•
•
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
•
Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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 WEBꢀSITE: www.lincolnelectric.com
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