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Lincoln Electric Flextec 500 Operator's Manual
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Lincoln Electric Flextec 500 Operator's Manual

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Operator's Manual
FLEXTEC
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10193-B
| Issue D ate Sep-16
© Lincoln Global, Inc. All Rights Reserved.
™
500
For use with machines having Code Numbers:
12175, 12564, 12606

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Summary of Contents for Lincoln Electric Flextec 500

  • Page 1 Operator’s Manual ™ FLEXTEC For use with machines having Code Numbers: 12175, 12564, 12606 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10193-B | Issue D ate Sep-16 ©...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 FLEXTEC™ 500 TABLE OF CONTENTS...
  • Page 7 FLEXTEC™ 500 TABLE OF CONTENTS...
  • Page 8 FLEXTEC™ 500 CHANGES AFTER INITIAL RELEASE CHANGES AFTER INITIAL RELEASE...
  • Page 9 PRODUCT DESCRIPTION PRODUCT DESCRIPTION Product Summary The Flextec™ 500 is a multi-process CC/CV DC inverter power source rated for 450 Amps, 38 Volts at 100% duty cycle. The Flextec™ 500 comes in a rugged case and is intended for either indoor or outdoor operation and comes with an IP23 environmental rating.
  • Page 10 CV-INNERSHIELD FCAW-SS ALUMINUM, STAINLESS, NR-203; NR-211, STEEL NR-440NI2 PROCESS LIMITATIONS COMMON EQUIPMENT PACKAGES The Flextec 500 is suitable only for the processes listed. LF-72 BASIC PACKAGE (K4093-1 READY PAK) K4091-1 FLEXTEC™ 500 K3056-2 LOCKING FOOT KIT EQUIPMENT LIMITATIONS K3883-13 FLEXFEED 74 HT Operating Temperature Range is -10°...
  • Page 11 FLEXTEC™ 500 PRODUCT DESCRIPTION COMMON OPTIONAL KITS & ACCESSORIES K3059-2 INVERTER CART K3056-2 BASE MOUNTING KIT K3091-1 MULTI-PROCESS SWITCH K2909-1 12-PIN TO 6-PIN ADAPTER K3127-1 WIRELESS FOOT PEDAL K857-2 REMOTE OUTPUT CONTROL WITH 12-PIN UNIVERSAL CONNECTOR (25 FEET) K870-2 FOOT AMPTROL K963-3 HAND AMPTROL K3975-1...
  • Page 12 FLEXTEC™ 500 NOTES...
  • Page 13 FLEXTEC™ 500 DESIGN DESIGN TECHNICAL SPECIFICATIONS POWER SOURCES - INPUT VOLTAGE AND CURRENT MODEL DUTY CYCLE INPUT VOLTAGE ± 10% INPUT AMPERES IDLE POWER (W) POWER FACTOR K4091-1 60% RATING 380 / 460 / 575 / 3 / 50 / 60 39 / 32 / 32 150W FAN ON 100% RATING...
  • Page 14 FLEXTEC™ 500 DESIGN AGENCY APPROVALS MODEL MARKET CONFORMITY MARK NOTES K4091-1 US AND CANADA C/US AUSTRALIA C-TICK / RCM REQUIRES K3975-1 EUROPE CE FILTER KIT DESIGN FEATURES • VRD – reduces OCV when not welding for added safety. • The Future is Now – You no longer have to pay a price premium to gain the advantages of inverter technology over conventional •...
  • Page 15 FLEXTEC™ 500 DESIGN CASE FRONT CONTROLS 8. Local/Remote Selector Toggle Switch: CASE FRONT CONTROLS DESCRIPTIONS. Sets the control of the output to local (output control knob) or remote (K857 hand amptrol or K870 foot amptrol through the 12- pin or 14-pin circular connectors). 1.
  • Page 16 FLEXTEC™ 500 DESIGN CASE BACK CONTROLS CASE BACK CONTROLS DESCRIPTIONS. 1. Input Power Cord Access Hole 2. Access Panel – Allows access for connecting input power and configuring the machine 3. Input Power Reconnect – Configures the machine for the input supply voltage 4.
  • Page 17 FLEXTEC™ 500 DESIGN INTERNAL CONTROLS Internal Controls Description The User Interface pc board has one bank of dip switches (See Figure A.1). As shipped from the factory and under normal conditions, the dip switches are all in the ‘off’ position (Figure A.2). There are 2 instances that require a change of the dip switch.
  • Page 18 FLEXTEC™ 500 INSTALLATION INSTALLATION WARNING ELECTRIC SHOCK CAN KILL. ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION. • 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...
  • Page 19 FLEXTEC™ 500 INSTALLATION 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. Remove the reconnect access panel located on the case back and connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal.
  • Page 20 FLEXTEC™ 500 INSTALLATION INPUT VOLTAGE SELECTION Welders are shipped connected for 460V input voltage. 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 display an error message: •...
  • Page 21 FLEXTEC™ 500 INSTALLATION CONNECTION DIAGRAMS, CONTROL CABLES Analog Wire Feeder Connectivity Picture Function Wiring 14-pin Ground connector for Trigger, Common wire feeder Trigger input connectivity. 77 Remote potentiometer, 10V 76 Remote potentiometer, wiper 75 Remote potentiometer, common Work (21) 42 VAC 42 VAC...
  • Page 22 FLEXTEC™ 500 INSTALLATION ArcLink Wire Feeder & Digital Accessory Connectivity Picture Function Wiring ArcLink CAN 5-pin ArcLink CAN connector for Electrode Sense Lead wire feeder 40Vdc connectivity. 40Vdc Common Picture Function Wiring ArcLink CAN ArcLink CAN Remote Potentiometer Common 12-pin remote Remote Potentiometer Wiper control Remote Potentiometer +10V...
  • Page 23 FLEXTEC™ 500 INSTALLATION • Route all cables directly to the work and wire feeder, avoid RECOMMENDED ELECTRODE AND WORK excessive lengths and do not coil excess cable. Route the CABLE SIZES FOR ARC WELDING electrode and work cables in close proximity to one another to General Guidelines minimize the loop area and therefore the inductance of the weld circuit.
  • Page 24 FLEXTEC™ 500 INSTALLATION CONTROL CABLE AND VOLTAGE SENSING CONNECTIONS Electrode Voltage Sensing General Guidelines The remote ELECTRODE sense lead (67) is built into the 5-pin ArcLink Genuine Lincoln control cables should be used at all times (except control cable (K1543-xx) and is always connected to the wire drive where noted otherwise).
  • Page 25 Connect the power sources as shown on Figure B2, and set the output control of each power sources to one half of the desired arc current. Figure B.2 FLEXTEC 500 PARALLEL MACHINES MACHINE #1 SETUP WITH FLEXTEC 500...
  • Page 26 FLEXTEC™ 500 OPERATION OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL RATED REDUCED INPUT POWER NO-LOAD VOLTAGE OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE HIGH TEMPERATURE INPUT CURRENT MACHINE STATUS CIRCUIT BREAKER OUTPUT CURRENT PROTECTIVE WIRE FEEDER GROUND POSITIVE OUTPUT WARNING OR CAUTION...
  • Page 27 FLEXTEC™ 500 OPERATION POWER-UP SEQUENCE WARNING ELECTRIC SHOCK can kill. UNLESS USING COLD FEED FEATURE, WHEN FEEDING WITH GUN TRIGGER, THE ELEC- TRODE AND DRIVE MECHANISM ARE ALWAYS ELECTRICALLY ENERGIZED AND COULD REMAIN ENERGIZED SEVERAL SECONDS AFTER THE WELDING CEASES. -------------------------------------------------------- FUMES AND GASES can be dangerous to your health.
  • Page 28 FLEXTEC™ 500 OPERATION DUTY CYCLE The Flextec™ 500 is capable of welding at a 100% duty cycle (continuous welding) at 450 Amps rated output. The 60% duty cycle rating is 500 amps (based off of a ten minute DEFINITION OF WELDING MODES cycle –...
  • Page 29 FLEXTEC™ 500 OPERATION Output Control Dial Control - Local/Remote Toggle Switch Output control is conducted via a single turn potentiometer. • Set the switch to ‘local’ to control output at the Flextec™ via the Adjustment is indicated by the meters. Output Control dial.
  • Page 30 FLEXTEC™ 500 OPERATION • When the Local/Remote is set to Remote, this dial sets the BASIC MODES OF OPERATION maximum welding amperage. The remote potentiometer than controls the amperage from minimum to this pre-set maximum. SMAW This weld mode is a constant current (CC) mode featuring continuous control from 15 –...
  • Page 31 FLEXTEC™ 500 OPERATION GTAW This weld mode is a constant current (CC) mode featuring continuous control from 10 –500 amps. It is intended for the GTAW TIG welding processes. Hot Start - Hot start regulates the arc initiation current. A setting of +10 results in the most positive arc initiation.
  • Page 32 FLEXTEC™ 500 OPERATION CV-GAS This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. It is intended for the GMAW, FCAW-GS, MCAW welding processes and arc gouging. Hot Start – Rotate from the ‘0’ position to the ‘10’ position to provide more energy during the start of a weld.
  • Page 33 FLEXTEC™ 500 OPERATION CV-INNERSHIELD This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. It is intended for the FCAW-SS welding process and arc gouging. Hot Start – Toggle from the ‘0’ position to the ‘10’ position to provide more energy during the start of a weld.
  • Page 34 FLEXTEC™ 500 OPERATION ARCLINK This weld mode is intended to unlock basic non-synergic and synergic modes intended for use with a compatible ArcLink wire feeders. All of the Flextec™ 500 user interface controls are disabled in this mode and controlling the power source is accomplished from the wire feeder user interface.
  • Page 35 DC welding power source and the work clamp. Weld Fume Control Solutions. Lincoln Electric offers a wide variety of welding fume control solutions, ranging from portable systems easily wheeled around the shop to shop-wide central systems servicing many dedicated welding stations.
  • Page 36 FLEXTEC™ 500 MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE WARNING Thermal Protection Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of ELECTRIC SHOCK can kill. cooling air or operating the machine beyond the duty cycle and output •...
  • Page 37 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 38 FLEXTEC™ 500 TROUBLE SHOOTING ERROR CODES The status lights on the User Interface board and the Switch board are Errors are displayed on the user interface. In addition, there are status dual-color LED’s. Normal operation for each is steady green. lights on the User Interface PC board and the Switch PC board that contain error sequences.
  • Page 39 COURSE OF ACTION Major physical or electrical damage 1. Contact your local authorized is evident when the sheet metal Lincoln Electric Field Service facility covers are removed. for technical assistance. Machine won’t weld, can’t get any 1. If the displays show an Err ### output.
  • Page 40 FLEXTEC™ 500 DIAGRAMS FRONT OF MACHINE ~575V ~42V ~460V ~380V ~52V ~115V...
  • Page 41 FLEXTEC™ 500 DIAGRAMS...
  • Page 42 FLEXTEC™ 500 DIAGRAMS...
  • Page 43 FLEXTEC™ 500 DIAGRAMS...
  • Page 44 FLEXTEC™ 500 DIAGRAMS...
  • Page 45 FLEXTEC™ 500 DIAGRAMS...
  • Page 46 FLEXTEC™ 500 DIAGRAMS...
  • Page 47 Index of Sub Assemblies - 12606 PART NUMBER DESCRIPTION P-1067-A INDEX OF SUB ASSEMBLIES P-1067-C CASE FRONT ASSEMBLY P-1067-D DIVIDER PANEL ASSEMBLY P-1067-E BASE & CENTER ASSEMBLY P-1067-F CASE BACK ASSEMBLY P-1067-G WRAPAROUND ASSEMBLY Flextec 500 - 12606...
  • Page 48 Index of Sub Assemblies - 12606 P-1067-A.jpg Flextec 500 - 12606...
  • Page 49 9SG8041 MAIN CONTROL HARNESS 9SS12021-73 BOX RECEPTACLE SOLID SHELL 9SS12021-78 CABLE CONNECTOR 9SS12021-70 BOX RECEPTACLE SOLID SHELL 9SS8025-96 SELF TAPPING SCREW 9SS17062-10 CABLE CONNECTOR CAP 9SS17062-11 CABLE CONNECTOR CAP 9SS17062-12 CONNECTOR CAP 9SCF000339 #4-40X.375PPNHS 9ST9695-2 LOCKWASHER Flextec 500 - 12606...
  • Page 50 POSITIVE OUTPUT STUD LEAD 9SM22778-1 KNOB 1.0" 9SM22778-2 KNOB 1.5" 9SM22778-3 KNOB 9SS30408-2 LINE SWITCH & LEAD ASBLY 9ST10082-30 SEMS SCREW 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS9262-183 PLAIN WASHER 9SS9225-66 SELF TAPPING SCREW Flextec 500 - 12606...
  • Page 51 Case Front Assembly P-1067-C.jpg Flextec 500 - 12606...
  • Page 52 SET SCREW 9SS18250-955 PLUG & LEAD ASBLY 9SS9262-23 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000198 1/4-28HN 9SS22745-3 CAPACITOR INSULATION 9SS27974 CAPACITOR BRACKET 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SCF000010 #10-24HN 9SE106A-1 LOCKWASHER 9SM24994 RECONNECT PANEL ASBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) Flextec 500 - 12606...
  • Page 53 9SL16423-1 40 V BUS PC BD ASBLY 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9ST11267-A INSULATOR 9ST11267-B INSULATOR 9ST10728-77 FUSE 9SS18491-1 MOV ASBLY 9SL16767 AUX TRANSFORMER THERMOSTAT ASBLY 9SS13000-129 AUXILIARY TRANSFORMER 9ST13359-15 THERMOSTAT 9SS9225-32 THREAD FORMING SCREWS 9SS9262-98 PLAIN WASHER Flextec 500 - 12606...
  • Page 54 Divider Panel Assembly P-1067-D.jpg Flextec 500 - 12606...
  • Page 55 9SS23730-3 SPACER 9SCF000015 1/4-20X1.00HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SM24999 OUTPUT RECTIFIER ASBLY 9SS9225-66 SELF TAPPING SCREW 9SG7848 TRANSFORMER ASBLY 9SS9225-66 SELF TAPPING SCREW 9SCF000040 5/16-18X.75HHCS 9SS9262-30 PLAIN WASHER 9SE106A-3 LOCKWASHER 9SCF000028 5/16-18X1.25HHCS 9SS9262-30 PLAIN WASHER Flextec 500 - 12606...
  • Page 56 9SE106A-2 LOCKWASHER 9SG7908 SWITCHBOARD ASBLY 9SS9225-66 SELF TAPPING SCREW 9SS18504-10 CURRENT TRANSDUCER 9SS30871 LEM SUPPORT 9SS8025-77 SELF TAPPING SCREW 9SS9225-66 SELF TAPPING SCREW 9SL11452-8 PLUG & LEAD ASBLY 9SS28206-13 BRAIDED LEAD 9SS18250-1074 PLUG & LEAD ASBLY Flextec 500 - 12606...
  • Page 57 Base & Center Assembly P-1067-E.jpg Flextec 500 - 12606...
  • Page 58 RELAY SUPPORT 9SS9262-3 PLAIN WASHER 9ST4291-A LOCKWASHER 9SCF000042 #8-32HN 9SS22752-28 RATING PLATE 9SS15122-15 RELAY 9SS8025-98 SELF TAPPING SCREW 9SS19999 CORD GRIP CONNECTOR 9ST14370-3 CONDUIT LOCKNUT 9SS29938 RECONNECT PANEL COVER 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9ST13259-2 GROUNDING DECAL Flextec 500 - 12606...
  • Page 59 Case Back Assembly P-1067-F.jpg Flextec 500 - 12606...
  • Page 60 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS9262-183 PLAIN WASHER 9SG7798 ROOF 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG8035 WIRING DIAGRAM 9SS30277-2 WARRANTY DECAL 9SS27368-4 DECAL LE LOGO 9SM22461 FAMILY NAME DECAL 9SS28039-2 DECAL GREEN INITIATIVE 9SS20601-5 WARNING DECAL Flextec 500 - 12606...
  • Page 61 Wraparound Assembly P-1067-G.jpg Flextec 500 - 12606...
  • Page 62 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 63 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 64 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

This manual is also suitable for:

K4091-1