Lincoln Electric FLEXTEC 450 CE Bedienungsanleitung

IM2059

04/2014

REV01

FLEXTEC™ 450&650 CE

OPERATOR’S MANUAL

ENGLISH

THE LINCOLN ELECTRIC COMPANY

22801 St. Clair Ave., Cleveland Ohio 44117-1199 USA

www.lincolnelectric.eu

English English

THE LINCOLN ELECTRIC COMPANY

EC DECLARATION OF CONFORMITY FOR

FLEXTEC™450 CE

Manufacturer and technical documentation

holder:

The Lincoln Electric Company

Address:

22801 St. Clair Ave.

Cleveland Ohio 44117-1199 USA

EC Company:

Lincoln Electric Europe S.L.

Address:

c/o Balmes, 89 - 802a

08008 Barcelona

SPAIN

Hereby declare that welding equipment:

Flextec™ 450 CE, including options and accessories

Product numbers:

K3065

(Product numbers may also contain prefixes and suffixes)

Is in conformity with Council Directives

and amendments:

Electromagnetic Compatibility (EMC) Directive

2004/108/EC

Low Voltage Directive (LVD) 2006/95/EC

Standards: EN 60974-10 Arc Welding Equipment – Part 10:

Electromagnetic compatibility (EMC) requirements, 2003

EN 60974-1, Arc Welding Equipment – Part 1: Welding

Power Sources, 2005

CE marking affixed in ’11

Frank Stupczy, Manufacturer Dario Gatti, European Community Representative

Compliance Engineering Manager European Engineering Director Machines

03 March 2013 04 March 2013

MCD361a

English English

THE LINCOLN ELECTRIC COMPANY

EC DECLARATION OF CONFORMITY FOR

FLEXTEC™650 CE

Manufacturer and technical documentation

holder:

The Lincoln Electric Company

Address:

22801 St. Clair Ave.

Cleveland Ohio 44117-1199 USA

EC Company:

Lincoln Electric Europe S.L.

Address:

c/o Balmes, 89 - 802a

08008 Barcelona

SPAIN

Hereby declare that welding equipment:

Flextec™ 650 with CE marking and installed CE filter.

Product numbers:

K3060 and K3129

(Product numbers may also contain prefixes and suffixes)

Is in conformity with Council Directives

and amendments:

Electromagnetic Compatibility (EMC) Directive

2004/108/EC

Low Voltage Directive (LVD) 2006/95/EC

Standards: EN 60974-10 Arc Welding Equipment – Part 10:

Electromagnetic compatibility (EMC) requirements, 2007

EN 60974-1, Arc Welding Equipment – Part 1: Welding

Power Sources, 2005

CE marking affixed in ’13

Frank Stupczy, Manufacturer Dario Gatti, European Community Representative

Compliance Engineering Manager European Engineering Director Machines

25 September 2013 1 October 2013

MCD390

English English

III

12/05

THANKS! For having chosen the QUALITY of the Lincoln Electric products.

Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Technical Specifications .................................................................................................................................................. 1

Electromagnetic Compatibility (EMC) .............................................................................................................................. 3

Safety .............................................................................................................................................................................. 4

Installation and Operator Instructions .............................................................................................................................. 5

WEEE............................................................................................................................................................................ 16

Spare Parts.................................................................................................................................................................... 16

Electrical Schematic ...................................................................................................................................................... 16

Suggested Accessories ................................................................................................................................................. 16

English English

Technical Specifications

FLEXTEC™ 650

POWER SOURCE

–

INPUT VOLTAGE AND CURRENT

Model Duty Cycle Input Voltage ±10% Input

Amperes Idle Power (W)

Power

Factor@ Rated

Input

K3060-2 60% rating 380/460/575/3/50/60 61/50/40 230 MAX (Fan On) 88%

100% rating 57/47/38 100 MAX. (Fan Off)

RATED OUTPUT

Process Duty Cycle Amperes Volts at Rated Amperes

GMAW (CV) 60% 750 * 44V

100% 650 *

GTAW (CC) 60% 750 34V

100% 650

SMAW (CC) 60% 750 *

44V

100% 650 *

FCAW-GS (CV) 60% 750 *

100% 650 *

FCAW-SS (CV) 60% 750 *

100% 650 *

SAW (CV) 60% 750 *

100% 650 *

RECOMMENDED INPUT WIRE AND FUSES SIZES

(1)

VOLTAGE

50/60Hz Maximum Input Amperes

Cord Size (3)

AWG SIZES

(mm)

Type 75°C

Copper Wire in

Conduit AWG

(mm2)

COPPER

GROUNDING

CONDUCTOR

AWG (mm2)

Fuse (Super

Lag)or Breaker

Sizes(2)

380/3/50

460/3/60

575/3/60

70A

58A

46A

4 (25)

6 (16)

4 (25)

6 (16)

8 (10)

10 (6)

* Output is limited to 600A/100% and 700A/60% when used with K3091-1 Multi-Process Swith.

(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 SJ cord or similar in 30°C ambient

WELDING PROCESS

Process Output Range (A) OCV (U0) OCV (Ur)

GMAW (CV) 40-815 60 --

GTAW (CC) 10-815 24 15

SMAW (CC) 15-815 60 15

FCAW-GS (CV) 40-815 60 --

FCAW-SS (CV) 40-815 60 --

SAW (CV) 40-815 60 --

PHYSICAL DIMENSIONS

Model Height Width Depth Weight

K3060-2 554 mm 410mm 754mm 74.8kg*

TEMPERATURE RANGES

Operating Temperature Range Storage Temperature Range

Environmentally Hardened: 14°F to 131°F (-10°C to 55°C**)

Environmentally

Hardened: -40°F to 185°F (-40°C to 85°C)

IP23 180º(H) Insulation Class

*Weight does not include input cord.

**Power Source is derated at Temperatures above 40°C.

English English

FLEXTEC™ 450

POWER SOURCE

–

INPUT VOLTAGE AND CURRENT

Model Duty Cycle Input Voltage ±10% Input

Amperes Idle Power

Power

Factor@ Rated

Input

K3065-1 60% rating 380/400/415/3/50/60

37/35/34 72 W Max. (fan on) 95%

100% rating 29/28/27

RATED OUTPUT

Process Duty Cycle Volts at rated Amperes Amperes

GMAW (CV) 60% 36.5V 450

100% 34V 400

GTAW (CC) 60% 28V 450

100% 26V 400

MMAW (CC) 60% 38V 450

100% 36V 400

FCAW-GS (CV) 60% 36.5V 450

100% 34V 400

FCAW-SS (CV) 60% 36.5V 450

100% 34V 400

RECOMMENDED INPUT WIRE AND FUSES SIZES

(1)

VOLTAGE

50/60Hz Maximum Input Amperes 4 CONDUCTOR

SOOW or similar Cord in 40°C (104°F) Ambient

Fuse (Super

Lag)or Breaker

Sizes(2)

380/3/50

400/3/60

415/3/60

42A

40A

39A

8 AWG or 10 mm250

(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.

WELDING PROCESS

Process Output Range (A) OCV (U0) OCV (Ur)

GMAW (CV) 40-500 60 --

GTAW (CC) 10-500 24 15

MMAW (CC) 15-500 35 15

FCAW-GS (CV) 40-500 60 --

FCAW-SS (CV) 40-500 60 --

PHYSICAL DIMENSIONS

Model Height Width Depth Weight

K3065-1 478 mm 359mm 677mm 59kg*

TEMPERATURE RANGES

Operating Temperature Range Storage Temperature Range

Environmentally Hardened: 14°F to 131°F (-10°C to 55°C**)

Environmentally

Hardened: -40°F to 185°F (-40°C to 85°C)

IP23 155º(F) Insulation Class

*Weight does not include input cord.

**Power Source is derated at Temperatures above 40°C.

English English

Electromagnetic Compatibility (EMC)

11/04

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate

electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or

other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand

this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

This machine has been designed to operate in an industrial area. The operator must install and operate

this equipment as described in this manual. If any electromagnetic disturbances are detected the operator

must put in place corrective actions to eliminate these disturbances with, if necessary, assistance from

Lincoln Electric. The Class A equipment is not intended for use in residential locations where the electrical

power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring

electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances. This equipment

does not comply with IEC 61000-3-12. If it is connected to a public low-voltage system, it is responsibility of the installer

or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the

equipment may be connected.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.

Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

machine.

Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

Safety and control equipment for industrial processes. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure

that all equipment in the area is compatible. This may require additional protection measures.

The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

The output cables should be kept as short as possible and should be positioned together. If possible connect the

work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting

the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

Only for Flextec™ 650: CE input filter kit K3129-1 must be installed. Instructions how to install the CE filter kit are

provided with the kit.

English English

Safety

11/04

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair

procedures are performed only by qualified person. Read and understand this manual before operating this equipment.

Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this

equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible

for damages caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,

loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or

death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating

this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could

cause serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the

electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from

the electrode, work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the

fuse box before working on this equipment. Ground this equipment in accordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If any insulation damage exists replace the cable immediately. Do not place the electrode

holder directly on the welding table or any other surface in contact with the work clamp to avoid the

risk of accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any

conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some

pacemakers, and welders having a pacemaker shall consult their physician before operating this

equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to

health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use

enough ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: 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. Use suitable clothing made from durable

flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel

with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to

the arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding

area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding

process can easily go through small cracks and openings to adjacent areas. Do not weld on any

tanks, drums, containers, or material until the proper steps have been taken to insure that no

flammable or toxic vapors will be present. Never operate this equipment when flammable gases,

vapors or liquid combustibles are present.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and

materials in work area can cause serious burns. Use gloves and pliers when touching or moving

materials in the work area.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in

an environment with increased hazard of electric shock.

English English

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the

correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do

not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,

electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders

must be located away from areas where they may be subjected to physical damage or the welding

process including sparks and heat sources.

NOISE APPEARES DURING WELDING CAN BE HARMFUL: Welding arc can cause noise with high

level of 85dB for 8-hour week day. Welders operating welding machines are obligated to wear the

proper ear protectors /appendix No. 2 for the Decree of the Secretary of Labor and Social Policy from

17.06 1998 – Dz.U. No. 79 pos. 513/. According to the Decree the Secretary of Health and Social

Welfare from 09.07.1996 /Dz.U. No. 68 pos. 194/, employers are obligated to carry examinations and

measurements of health harmful factors.

MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which

can cause serious injury. Keep your hands, body and clothing away from those parts during machine

starting, operating and servicing.

EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another

person. Lifting may be dangerous for your physical health.

The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time

the operator’s manual.

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

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 minimum.

Failure to observe these precautions can result in

excessive operating temperatures and nuisance

shutdowns.

Lifting

The FLEXTEC™ 650 has 2 lifting eyelets and 2 handles

that can be used to lift the machine. Both handles or

both eyelets should be used when lifting the FLEXTEC™

650.

Both handles should be used when lifting the FLEX-

TEC™ 450 CE

When using a crane or overhead device to lift using the

handles, a lifting strap should be connected to both

handles. Do not attempt to lift the FLEXTEC™ 650&450

with accessories attached to it

Stacking

The FLEXTEC™ 650&450 cannot be stacked.

Environmental Limatations

The FLEXTEC™ 650&450 are IP23 rated for use in an

outdoor environment. The FLEXTEC™ 650&450 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.

WARNING

Do not mount the FLEXTEC™ 650&450 over

combustible 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 1.6mm thick, which shall extend not less

than 150mm beyond the equipment on all sides.

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 grounding

methods.

Duty Cycle

The FLEXTEC™ is capable of welding at a 100% duty

cycle (continuous welding) at 650 (for Flextec 650) amps

rated output, and at 450 (for Flextec 450) amps rated

output. The 60% duty cycle rating is 750 amps (for

Flextec 650) and 38volts (for Flextec 450) (based off of a

ten minute cycle – 6 minutes on time and 4 minutes off

time). The maximum output of the Flextec 650 is 815

amps, and for Flextec 450 is 500 amps.

English English

Example: 40% Duty Cycle:

Welding for 4 minutes. Break for 6 minutes.

Minutes or decrease

Duty Cycle

The FLEXTEC™ 650&450 are also rated for Desert

Duty, elevated temperature operation, in a 55°C

ambient. The machine is de-rated for this application.

(See Table below).

High Temperature Operation

FLEXTEC™ 650

WELDER OUTPUT RATINGS AT 55°C ELEVATED

TEMPERATURES

AMPS DUTY CYCLE VOLTS TEMPERATURES

600 100%

44V 55°C

650 50%

750 30%

FLEXTEC™ 450

WELDER OUTPUT RATINGS AT 55°C ELEVATED

TEMPERATURES

AMPS DUTY CYCLE VOLTS TEMPERATURES

340 100% 34VDC

55°C

375 60% 35VDC

400 40% 36VDC

450 20% 38VDC

High Frequency Protection

Locate the FLEXTEC™ 650&450 away from radio

controlled machinery. The normal operation of the

FLEXTEC™ 650&450 may adversely affect the

operation of RF controlled equipment, which may result

in bodily injury or damage to the equipment.

WARNING

ELECTRIC SHOCK can kill. Only a qualified eletrician

should connect the input leads to the Flextec™

650&450. Connections should be made in accordance

with 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

Use a three-phase supply line.

For Flextec™ 650 (see figure #1): a 45 mm diameter

access hole for the input supply is located on the case

back. Remove the reconnect access panel located on

the case back and connect W, V, U and ground

according to the Input Supply Connection Diagram

decal.

For Flextec™ 450 (see figure #2): a 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.

For CE markets (only for Flextec™ 650): CE input

filter kit (K3129-1) must be installed. Instructions how to

install the CE filter kit are provided with the kit.

Input Voltage Selection (Only for

Flextec™650)

Welders are shipped connected for 460 Volt input

voltage. To move this connection to a different input

voltage, see Figure #1 which is illustrated above. Refer

to Auxiliary Reconnect Input Ranges table in the

Technical Specification Section.

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