Lincoln-electric IM10062 FLEXTEC 450 User Manual

Operator’s ManualFLEXTEC ™ 450Register your machine: www.lincolnelectric.com/registerAuthorized Service and Distributor Locator: www.lincolnelectric

A-4INSTALLATION A-4ELECTRIC SHOCK can kill. ONLY A QUALIFIED ELECTRICIANSHOULD CONNECT THE INPUTLEADS TO THE FLEXTEC™ 450.CONNECTIONS SHOULD BE

A-5INSTALLATION FLEXTEC™ 450A-5INPUT CONNECTION(See Figure A.1a) For codes 12038 and aboveUse a three-phase supply line. A 1.40 inch (36 mm)diameter

A-6INSTALLATION A-6FLEXTEC™ 450PinABCDEFWiring77 Remote potentiometer, 5K76 Remote potentiometer, wiper75 Remote potentiometer, commonTrigger, commo

A-7INSTALLATION FLEXTEC™ 450A-7RECOMMENDED ELECTRODE ANDWORK CABLE SIZES FOR ARC WELDINGGeneral GuidelinesConnect the electrode and work cables betw

A-8INSTALLATION FLEXTEC™ 450A-8CONNECTING LF-72 AND LF-74 TO THE FLEXTEC™ 450CONTROL SETTING14-PIN CONTROL CABLE K1797-XXWIRE FEEDERELECTRODEFLEXTEC

A-9INSTALLATION FLEXTEC™ 450A-9LN-10,DH-10 CONTROL SWITCHSETUPInitial set up of the LN-10, DH-10 control for the sys-tem components being used and f

A-10INSTALLATION FLEXTEC™ 450A-10CONNECTING LN-15(K1870-1) TO THE FLEXTEC™ 45014-PIN CONTROL CABLE K1819-XXELECTRODEFLEXTEC™-450WIRE FEEDERLN-15(K18

A-11INSTALLATION FLEXTEC™ 450A-11CONNECTING LN-25 PRO AND LN-25 PIPE TO THE FLEXTEC™ 450ELECTRODEFLEXTEC™-450WIRE FEEDERLN-25 PROLN-25 PIPEWORKWORK

B-1OPERATIONFLEXTEC™ 450B-1SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kill.•

B-2OPERATIONB-2FLEXTEC™ 450PRODUCT DESCRIPTIONThe Flextec™ 450 is a multi-process CC/CV DCinverter and is rated for 450 amps, 38 volts at a 60%duty cy

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELYWhen this equipment is ship

B-3OPERATIONB-3RECOMMENDED PROCESSES ANDEQUIPMENTRECOMMENDED PROCESSESThe Flextec™ 450 is designed for CC-SMAW, CC-GTAW(lift tig), CV-GMAW, CV-FCAW-S

B-4OPERATIONB-4CASE FRONT CONTROL DESCRIPTIONS(See Figure B.1)1. Power Switch2. Voltage Display Meter3. Amperage Display Meter4. Thermal LED5. Output

B-5OPERATIONB-5FLEXTEC™ 450CASE BACK CONTROL(See Figure B.2)1. Input Power Cord Access Hole.1FIGURE B.2COMMON WELDING PROCEDURESMAKING A WELDThe servi

B-6OPERATIONB-6FLEXTEC™ 450INTERNAL CONTROLS - ENABLING VRD™(For Code 11941 only)Internal Controls DescriptionThe Control PC Board has one bank of Dip

B-7OPERATIONB-7Amperage Display Meter• Prior to STICK or TIG operation (current flow), themeter displays preset current value.• Prior to CV operation,

B-8OPERATIONB-8FLEXTEC™ 450BASIC MODES OF OPERATIONSMAWThis weld mode is a constant current (CC) mode fea-turing continuous control from 15 – 500 amps

B-9OPERATIONB-9GTAWThis weld mode is a constant current (CC) mode featuring con-tinuous control from 10 – 500 amps. It is intended for the GTAWTIG wel

B-10OPERATIONB-10CV-INNERSHIELDThis weld mode is a constant voltage (CV) mode fea-turing continuous control from 10 to 45 volts. It isintended for the

C-1ACCESSORIESC-1OPTIONS / ACCESSORIESGeneral OptionsK2149-1 Work Lead Package.K1842-10 10ft. Weld Power Cable (Lug to Lug).Fume Extracting SystemsAcc

D-1MAINTENANCED-1PERIODIC MAINTENANCEThermal ProtectionThermostats protect the machine from excessiveoperating temperatures. Excessive temperatures ma

SECTION A:WARNINGS CALIFORNIA PROPOSITION 65 WARNINGSDiesel EnginesDiesel engine exhaust and some of its constituents are known to the State of Calif

E-1TROUBLESHOOTINGE-1FLEXTEC™ 450If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contac

E-2TROUBLESHOOTINGE-2FLEXTEC™ 450Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

E-3TROUBLESHOOTINGE-3FLEXTEC™ 450If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contac

E-4TROUBLESHOOTINGE-4FLEXTEC™ 450Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

E-5TROUBLESHOOTINGE-5FLEXTEC™ 450Suivre les instructions de Sécurité détaillées tout au long de ce manuel.If for any reason you do not understand the

F-1DIAGRAMSF-1FLEXTEC™ 450NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific di

F-2DIAGRAMSF-2FLEXTEC™ 450NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific di

F-3DIAGRAMSF-3FLEXTEC™ 450NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific di

F-4DIAGRAMSF-4FLEXTEC™ 450NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific di

F-5DIMENSION PRINTF-5FLEXTEC™ 450L15698A.0126.6618.7814.1426.5113.06

ELECTRIC SHOCK CAN KILL.3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts wi

FLEXTEC™450NOTES

FLEXTEC™450P-652P-652PARTS LIST FORFlextec™450This parts list is provided as an informative guide only.It was accurate at the time of printing. These

08-15-2012FLEXTEC™450P-652-AP-652-AILLUSTRATION OF SUB-ASSEMBLIES54123

08-15-2012FLEXTEC™450Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers not

08-15-2012FLEXTEC™450P-652-CP-652-CCase Front Assembly & Door146161616169D9D9E9E2A2A24A24A3A3A1111121221A21A222214A14A14B14B14C14C131313138A8A8B8B

Case Front Assembly (G6447), Includes: NSS 1X•Case Front Assembly (G6447-4), Includes: NSS 1•X1 Case Front G6456 1 X •1 Case Front G6456-1 1 • X2A Out

24C Plain Washer (Not Shown) S9262-120 2 X X24D Lock Washer (Not Shown) E106A-16 2 X X08-15-2012FLEXTEC™450Use only the parts marked “x” in the column

FLEXTEC™450NOTES

08-15-2012FLEXTEC™450P-652-DP-652-DDivider Panel Assembly1177810A10A21A21A24B24B24A24A10B10B3A3A13135A5A5B5B5C5C11116A6A9A9A23A23A23C23C23C23C23D23D22

Divider Panel Assembly, (G6458), Includes: NSS 1 XXX1 Divider Panel G6459 1 X X X3A Rectifier Module T13637-6 1 X X X3B Thread Forming Screw (Not Show

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the

08-15-2012FLEXTEC™450P-652-EP-652-EBase & Center Assembly112A2A3A3A10A10A3A3A3B3B3D3D3E3E3F3F2B2B2C2C15A15A15B15B8A8A8B8B11A11A13A13A13D13D6A6A7A7

Base & Center Assembly, Includes: G6490 1 X •Base & Center Assembly, Includes: G6490-4 1 • X1 Base G6446 1 X X2A Corner Cap L13138 4 X X2B Pla

08-15-2012FLEXTEC™450P-652-FP-652-FCase Back Assembly4A4A4B4B312B2B8A8A121211112A2A8B8B

Case Back Assembly (G6885), Includes: NSS1 Case Back G6455 1 X X2A Fan M22071 1 X X2B Thread Forming Screw S9225-68 4 X X3 Handle Support Bracket M224

08-15-2012FLEXTEC™450P-652-GP-652-GWraparound Assembly1C1C1D1D1A1A1F1F10102A2A96587

1A Case Side (Left) G6450 1 X X X1B Nut Retainer (Not Shown) T10097-3 2 X X X1C Self Tapping Screw S9225-68 6 X X X1D Self Tapping Screw S9225-66 4 X

FLEXTEC™450NOTES

FLEXTEC™450P-732P-732PARTS LIST FORFlextec™450This parts list is provided as an informative guide only.It was accurate at the time of printing. These

02-04-2013FLEXTEC™450P-732-AP-732-AILLUSTRATION OF SUB-ASSEMBLIES54123

02-04-2013FLEXTEC™450Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers not

vi vi TABLE OF CONTENTSPageInstallation ...Sectio

02-04-2013FLEXTEC™450P-732-CP-732-CCase Front Assembly & Door1271818181810D10D10E10E4A4A26A26A5A5A1212131324A24A25253A3A3C3C3B3B141414149A9A9B9B5B

Case Front Assembly (G6447-4), Includes: NSS 1X1 Case Front G6456-1 1 X2Nameplate (Display Decal) (G7539-1) (Part of G7539)NSS 1X3A Handle G6525-3 1 X

02-04-2013FLEXTEC™450P-732-DP-732-DDivider Panel Assembly117710A10A34B34B34A34A10B10B13133A3A5B5B5C5C5A5A111189A9A18A18A18C18C18D18D6A6A27274A4A4B4B31

Divider Panel Assembly, (G6458-2), Includes: NSS 1X1 Divider Panel G6459-1 1 X3A Rectifier Module T13637-6 1 X3B Thread Forming Screw (Not Shown) S922

02-04-2013FLEXTEC™450P-732-EP-732-EBase & Center Assembly112A2A3A3A10A10A3A3A3B3B3D3D3E3E3F3F2B2B2C2C15A15A15B15B8A8A8B8B11A11A13A13A13D13D6A6A7A7

Base & Center Assembly, Includes: G6490-4 1 X1 Base G6446 1 X2A Corner Cap L13138 4 X2B Plain Washer S9262-183 6 X2C Self Tapping Screw S9225-66 6

02-04-2013FLEXTEC™450P-732-FP-732-FCase Back Assembly4A4A4B4B3113132A2A10B10B10A10A11A11A11B11B

Case Back Assembly (G6885-2), Includes: NSS1 Case Back G6455-1 1 X2A Fan M22071 1 X2B Thread Forming Screw (Not Shown) S9225-68 4 X3 Handle Support Br

02-04-2013FLEXTEC™450P-732-GP-732-GWraparound Assembly1C1C1D1D1A1A1F1F10102A2A96587

1A Case Side (Left) G6450 1 X1B Nut Retainer (Not Shown) T10097-3 2 X1C Self Tapping Screw S9225-68 6 X1D Self Tapping Screw S9225-66 4 X1E Plain Wash

FLEXTEC™ 450A-1INSTALLATION A-1TECHNICAL SPECIFICATIONS - FLEXTEC™ 450RATED OUTPUTPOWER SOURCE-INPUT VOLTAGE AND CURRENTModelK2882-2Duty Cycle60% ra

FLEXTEC™450NOTES

FLEXTEC™450NOTES

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cu

A-2INSTALLATION FLEXTEC™ 450A-2PHYSICAL DIMENSIONSTEMPERATURE RANGESHEIGHT18.80in (478mm)MODELK2882-2WIDTH14.14in (359mm)DEPTH26.66in (677mm)WEIGHT1

A-3INSTALLATION A-3VRD™ (VOLTAGE REDUCTION DEVICE)(For Code 11941 only)The VRD™ feature provides additional safety in the CC-Stick mode. The VRD™ re