Lincoln Electric Welder FX450 User Manual

IM10094  
February, 2011  
RED-D-ARC  
FX450  
(
RETURN TO MAIN MENU  
For use with machines having Code Numbers:  
11789  
OPERATOR’S MANUAL  
Red-D-Arc Spec-Built Welding Equipment  
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty  
design specifications by Lincoln Electric.  
Safety Depends onYou  
This welder 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 READING THIS MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED THROUGHOUT.  
And, most importantly, think before you act and be careful.  
North America’s Largest Fleet of Welding Equipment  
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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.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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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 one of our QuALITY products. We want you to take  
pride in operating this product ••• as much pride as we have in  
bringing this product to you!  
Thank You  
CuSTOMER ASSISTANCE POLICY  
The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to  
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for  
advice or information about their use of our products. We respond to our customers based on the best informa-  
tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no  
liability, with respect to such information 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 informa-  
tion 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.  
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the  
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the  
results obtained in applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing.  
Please 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 (if available)______________________________________________________  
Serial Number (if available)__________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above.  
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  
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  
Input Voltage Selection ...................................................................................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-678 Series  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TEChNICAL SPECIFICATIONS - FX450  
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 / 27 / 22  
29 / 21 / 17  
K3073-1  
95%  
380 / 460 / 575 / 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)  
SMAW (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)  
(3)  
Maximum  
Input  
Amperes  
Type 75°C Copper  
Wire in Conduit  
Fuse (Super Lag) or  
(2)  
COPPER GROuNDING  
CONDuCTOR  
Cord Size  
AWG SIzES  
(mm)  
VOLTAGE  
50/60hz  
Breaker Size  
2
2
AWG (mm )  
AWG (mm )  
380/3/50  
460/3/60  
575/3/60  
42 A  
30 A  
25 A  
8 (10)  
10 (6)  
12 (4)  
50  
45  
35  
10 (6)  
10 (6)  
12 (4)  
8(10)  
8(10)  
10(6)  
(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.  
(3)  
Type SD cord or similar in 30°C ambient.  
FX450 (RED-D-ARC)  
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A-2  
A-2  
INSTALLATION  
WELDING PROCESS  
OuTPuT RANGE (AMPERES)  
OCV (uo)  
PROCESS  
40-500  
10-500  
15-500  
40-500  
40-500  
60  
24  
60  
60  
60  
GMAW (CV)  
GTAW (CC)  
SMAW (CC)  
FCAW-GS (CV)  
FCAW-SS (CV)  
PhYSICAL DIMENSIONS  
MODEL  
hEIGhT  
WIDTh  
WEIGhT  
125lbs (56.6kg)*  
DEPTh  
K3073-1  
26.66in (677mm)  
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.  
FX450 (RED-D-ARC)  
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A-3  
A-3  
INSTALLATION  
SAFETY PRECAuTIONS  
CAuTION  
Do not mount the FX450 over combustible sur-  
faces. Where there is a combustible surface  
directly under stationary or fixed electrical equip-  
ment, 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.  
WARNING  
ELECTRIC ShOCK can kill.  
ONLY QuALIFIED PERSONNEL  
ShOuLD PERFORM ThIS INSTALLA-  
TION.  
• TuRN OFF INPuT POWER TO ThE POWER  
SOuRCE AT ThE DISCONNECT SWITCh OR  
FuSE bOX bEFORE WORKING ON ThIS  
EQuIPMENT. TuRN OFF ThE INPuT POWER  
TO ANY OThER EQuIPMENT CONNECTED TO  
ThE WELDING SYSTEM AT ThE DISCONNECT  
SWITCh OR FuSE bOX bEFORE WORKING ON  
ThE EQuIPMENT.  
-----------------------------------------------------------------------  
INPuT AND GROuNDING CONNECTIONS  
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 ground-  
ing methods.  
• DO NOT TOuCh ELECTRICALLY hOT PARTS.  
• ALWAYS CONNECT ThE FX450 GROuNDING  
LuG (LOCATED INSIDE ThE RECONNECT  
INPuT ACCESS DOOR) TO A PROPER SAFETY  
(EARTh) GROuND.  
hIGh FREQuENCY PROTECTION  
----------------------------------------------------------------------  
Locate the FX450 away from radio controlled machin-  
ery. The normal operation of the FX450 may adverse-  
ly affect the operation of RF controlled equipment,  
which may result in bodily injury or damage to the  
equipment.  
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.  
hIGh TEMPERATuRE OPERATION  
WELDER OuTPuT RATINGS AT 55°C  
ELEVATED TEMPERATuRES  
LIFTING  
Both handles should be used when lifting the FX450.  
When using a crane or overhead device a lifting strap  
should be connected to both handles. Do not attempt  
to lift the FX450 with accessories attached to it.  
AMPS  
VOLTS  
DUTY CYCLE  
TEMPERATURES  
340  
375  
400  
450  
34VDC  
35VDC  
36VDC  
38VDC  
100%  
60%  
40%  
20%  
STACKING  
55°C  
The FX450 cannot be stacked.  
ENVIRONMENTAL LIMITATIONS  
The FX450 is IP23 rated for use in an outdoor envi-  
ronment. The FX450 should not be subjected to falling  
water during use nor should any parts of it be sub-  
merged in water. Doing so may cause improper oper-  
ation as well as pose a safety hazard. The best prac-  
tice is to keep the machine in a dry, sheltered area.  
FX450 (RED-D-ARC)  
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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 FX450. CONNEC-  
TIONS ShOuLD bE MADE IN ACCORDANCE  
WITh ALL LOCAL AND NATIONAL ELECTRI-  
CAL CODES AND ThE CONNECTION DIAGRAM  
LOCATED ON ThE INSIDE OF ThE RECON-  
NECT/INPuT ACCESS DOOR OF ThE  
MAChINE. FAILuRE TO DO SO MAY RESuLT  
IN bODILY INJuRY OR DEATh.  
----------------------------------------------------------------------  
INPuT VOLTAGE SELECTION  
INPuT CONNECTION  
(See Figure A.1)  
Welders are shipped connected for 460 Volt input  
voltage. To move this connection to a different input  
voltage, see the diagram located on the inside panel  
in the reconnect/input connection area, also illustrat-  
ed below. If the Auxiliary lead (indicated as ‘A’) is  
placed in the wrong position and power is applied to  
the machine, the machine will protect itself and dis-  
play an error message:  
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.  
• "Err" "058" will be shown on the display.  
• The control board and switch boards will blink out  
error 58 on their status leds.  
• The weld output will be turned off and the control  
board will force itself into an idle state.  
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.  
• The machine will need to have the misconnect  
condition removed before it will recover.  
FIGuRE A-1  
R
                                                                                                                                                                                                                                                               s
                                                                                                                                                                                                                                                                                                                                                                                                                           t
                                                                                                   s
                                          P
              L
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  t
e
                                                                                     a
P
t
                                                                                                   u
                                                                                                                                                                                                                                                                                                                                                    N
RECONNECT TERMINAL BLOCK  
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.)  
RECONNECT TERMINAL BLOCK  
• Reconnects auxiliary transformers  
for the proper input voltages  
FX450 (RED-D-ARC)  
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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 FX450.  
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  
FX450 (RED-D-ARC)  
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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 FX450 per the follow-  
ing 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 FX450. 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 starting), and low  
wire driving force (wire feeding problems). 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).  
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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  
FX450 (RED-D-ARC)  
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b-2  
b-2  
OPERATION  
GRAPhIC SYMbOLS ThAT  
APPEAR ON ThIS MAChINE  
OR IN ThIS MANuAL  
PRODuCT DESCRIPTION  
The FX450 is a multi-process CC/CV DC inverter and  
is rated for 450 amps, 38 volts at a 60% duty cycle.  
This machine is intended for both factory and field  
operation. It comes in a compact, rugged case that is  
designed for portability and outdoor use with an IP23  
environmental rating. The user interface of the FX450  
is simple and intuitive. Weld modes are selected by a  
4 position selector switch. Volts and Amps are dis-  
played 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 FX450  
operates on 380V, 460V, or 575V 50hz or 60hz  
power.  
OPEN CIRCuIT  
VOLTAGE  
u
0
u
u
I
INPuT VOLTAGE  
OuTPuT VOLTAGE  
INPuT CuRRENT  
OuTPuT CuRRENT  
1
2
DuTY CYCLE  
1
The FX450 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 maxi-  
mum output of the machine is 500 amps.  
I
2
PROTECTIVE  
GROuND  
The FX450 is also rated for Desert Duty, elevated  
temperature operation, in a 55°C(131°F) ambient.  
The machine is output de-rated for this application.  
DESIGN FEATuRES  
• Severe Duty Design for outdoor use (IP23 rating).  
• Passive Power Factor Correction – reliably gives  
95% power factor for lower installation costs.  
• 89% Efficiency rating – reduces electrical utility  
costs.  
WARNING or CAUTION  
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.  
• 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.  
Dangerous Voltage  
• Thermal protection by thermostats with Thermal  
Indicator LED.  
• Error Codes display on LED screen for ease of trou-  
ble shooting.  
• Electronic over current protection.  
Shock hazard  
• Input voltage misconnection protection.  
• Utilizes digital signal processing and microprocessor  
control.  
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b-3  
b-3  
OPERATION  
RECOMMENDED PROCESSES AND  
EQuIPMENT  
RECOMMENDED PROCESSES  
The FX450 is designed for CC-SMAW, CC-GTAW (lift tig),  
CV-GMAW, CV-FCAW-SS and CV-FCAW-GS welding  
processes. CAG (arc gouging) is also supported.  
PROCESS LIMITATIONS  
The FX450 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  
FX450  
LF-72 Bench Model  
Work Lead Package  
10 Ft. Weld Power Cable  
Harris Regulator and gas hose  
K3073-1  
K2327-5  
K2149-1  
K1842-10  
3100211  
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 FX450 is not compatible with 115V Wire Feeders.  
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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  
10. Weld Terminals On/Remote toggle selector  
switch  
FIGuRE b.1  
1
14  
8
1320  
9
4
3
2
1
2
3
1
4
5
6
7
9
10  
11  
12  
8
13  
14  
15  
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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 FX450 is also capable of gouging. Gouging can  
be done in either the SMAW mode or the CV and CV-  
Innershield modes.  
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 FX450, the displays will  
illuminate and display the voltage and/or amperage  
settings.  
Arc Control Dial  
COMMON WELDING PROCEDuRES  
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.  
WARNING  
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 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 Dial  
Output control is conducted by a single turn poten-  
tiometer. (Adjustment is indicated by the meters.)  
When in Remote Mode, this control sets the maximum  
welding current of the remote device. For example, 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 FX450 is a multi-process inverter welder. The  
Weld Process Selector Switch is used to set the  
desired weld mode. The FX450 has 4 selectable  
welding modes:  
1. SMAW This is a CC (constant current) weld  
mode used for the SMAW stick welding process.  
• Output adjustment while in the "hold" period results in  
the "prior to operation" characteristics.  
2. GTAW This is a CC (constant current) weld  
mode used for the GTAW TIG welding process.  
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b-6  
b-6  
OPERATION  
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.  
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.  
Weld Terminals On/Remote – Set to “On” so the  
machine is in the ready to weld state.  
• 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  
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.  
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.  
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.  
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.  
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 FX450. Set this switch to “REMOTE” when an  
external potentiometer/control is connected.  
• When a remote potentiometer is connected, the out-  
put control on the FX450 and the remote act as a  
master/slave configuration. Use the control dial on  
the FX450 to pre-set the maximum welding current.  
The remote will control output from minimum to the  
pre-set maximum.  
Thermal Light  
• This status light indicates when the power source  
has been driven into thermal overload. If the output  
terminals were "ON", the output will be turned back  
on once the unit cools down to an acceptable tem-  
perature level. If the unit was operating in the  
"REMOTE" mode, the trigger will need to be  
opened before or after the thermal has cleared and  
closed after the machine has cooled down to an  
acceptable temperature to establish output.  
bASIC MODES OF OPERATION  
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. The remote  
potentiometer than controls the amperage from min-  
imum to this pre-set maximum.  
SMAW  
This weld mode is a constant current (CC) mode fea-  
turing continuous control from 15 – 500 amps. It is  
intended for the SMAW stick welding processes and  
arc gouging.  
hot Start - The Hot Start control regulates the starting  
current at arc initiation. Hot Start can be set to “Off”  
and no additional current is added at arc start. When  
set to the “On” position, additional current (relative to  
the preset current) at arc initiation.  
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b-7  
b-7  
OPERATION  
CV-GAS  
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.  
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 and arc gouging.  
hot Start - The Hot Start control regulates the starting current  
at arc initiation. Hot Start can be set to “Off” and no additional  
current is added at arc start. When set to the “On” position,  
additional current (relative to the preset current) at arc initiation.  
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  
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.  
2
• When set to the “REMOTE” position, output is enabled  
through a remote trigger.  
and GMAW with CO .  
Weld Terminals On/Remote  
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.  
• 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.  
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.  
Voltage Display Meter – This display will display the pre-set  
welding voltage when the machine is in the idle state. While out-  
put is enabled, the actual weld amperage is displayed. After  
welding, the meter holds the actual voltage value for 5 seconds.  
Output adjustment while in the "hold" period results in the "prior  
to operation" characteristics. The displays blink indicating that  
the machine is in the "hold" period.  
Output Control Local/Remote – When the control is set to  
local (no remote potentiometer/control plugged into the 6-pin or  
14-pin connectors), the output is controlled through the Output  
Control Dial on the front of the FX450. Set this switch to  
“REMOTE” when an external potentiometer/control is connect-  
ed.  
• When a remote potentiometer is connected, the output control  
on the FX450 and the remote act as a master/slave configura-  
tion. Use the control dial on the FX450 to pre-set the maxi-  
mum welding current. The remote will control output from  
minimum to the pre-set maximum.  
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 FX450. Set this switch to  
“REMOTE” when an external potentiometer/control is connect-  
ed.  
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 voltage.  
• When the Local/Remote is set to Remote, this dial is disabled.  
The remote potentiometer controls the amperage from minimum  
to this pre-set maximum.  
FX450 (RED-D-ARC)  
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b-8  
b-8  
OPERATION  
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 and arc  
gouging.  
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.  
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.  
• 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 indicates that amperage is not settable in  
this weld mode. While output is enabled, the actual  
welding amperage is displayed. After welding, the  
meter holds the actual amperage value for 5 seconds.  
Output adjustment while in the "hold" period results in  
the "prior to operation" characteristics. The displays  
blink indicating that the machine is in the "hold" peri-  
od.  
Voltage Display Meter – This display will display the  
pre-set welding voltage when the machine is in the  
idle state. While output is enabled, the actual weld  
amperage is displayed. After welding, the meter holds  
the actual voltage value for 5 seconds. Output adjust-  
ment while in the "hold" period results in the "prior to  
operation" characteristics. The displays blink indicat-  
ing that the machine is in the "hold" period.  
Output Control Local/Remote – When the control is  
set to local (no remote potentiometer/control plugged  
into the 6-pin or 14-pin connectors), the output is con-  
trolled through the Output Control Dial on the front of  
the FX450. Set this switch to “REMOTE” when an  
external potentiometer/control is connected.  
Output Control Dial  
• When the Local/Remote is set to Local, this dial sets  
the welding voltage.  
• When the Local/Remote is set to Remote, this dial is  
disabled  
FX450 (RED-D-ARC)  
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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.  
FX450 (RED-D-ARC)  
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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  
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.  
FX450 (RED-D-ARC)  
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E-1  
E-1  
TROubLEShOOTING  
hOW TO uSE TROubLEShOOTING GuIDE  
WARNING  
Service and Repair should only be performed by 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 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 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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
FX450 (RED-D-ARC)  
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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.  
Field Service facility 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 Authorized  
stopped.  
Field Service Facility.  
2. Welding output ratings may have  
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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
FX450 (RED-D-ARC)  
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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 FX450  
Corrective Action  
Error  
Code#  
Description  
31 Primary Over Current  
Machine needs to be turned  
off and back on to reset.  
Check the input power (voltage and fre-  
quency). Verify the primary reconnect is  
properly configured for the input voltage.  
If condition persists contact an authorized  
Field Service Shop.  
711 Capacitor over-or-under volt-  
age.  
Machine needs to be turned  
off and back on to reset.  
Check input power (voltage and frequency)  
while welding. Verify the primary reconnect  
is properly configured for the input voltage.  
712 Communication error between  
P.C. boards or P.C. board  
fatal.  
Weld Terminals Remote:  
Re-trigger to recover from  
error.  
Re-trigger to recover from error.  
If condition persists contact an authorized  
Field Service Shop.  
Weld Terminals Local:  
Toggle Remote/Local Switch  
to recover from error.  
713 Input Power Misconnect  
Supply Voltage is too high.  
Verify the primary reconnect is properly  
configured for the input voltage.  
Machine needs to be turned  
off and back on to reset.  
714 Input Power Misconnect  
Supply Voltage is too low.  
If condition persists contact an authorized  
Field Service Shop.  
715 Supply Voltage to the switch  
Printed Circuit Board is too  
low.  
Machine needs to be turned  
off and back on to reset.  
If condition persists contact an authorized  
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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
FX450 (RED-D-ARC)  
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F-1  
F-1  
DIAGRAMS  
FX450 (RED-D-ARC)  
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F-2  
F-2  
DIMENSION PRINT  
FX450 (RED-D-ARC)  
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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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