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FLEXTEC™ 500
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
cycle – 6 minutes on time and 4 minutes off time). The maximum
output of the machine is 500 amps.
The Flextec™ 500 is also rated for Desert Duty, elevated
temperature operation, in a 55°C ambient. The machine is de-rated
for this application.
COMMON WELDING PROCEDURES
MAKING A WELD
The Flextec™ 500 is a multi-process inverter welder. The Weld
Process Selector Switch is used to set the desired weld mode. The
Flextec™ 500 has 5 selectable welding modes:
1. SMAW – This is a CC (constant current) weld mode used for the
SMAW stick welding process.
2. GTAW – This is a CC (constant current) weld mode used for the
GTAW tig welding process.
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.
4. CV-Innershield – This is a CV (constant voltage) weld mode used
for welding the FCAW-SS, flux cored self shielded welding
process
5. ArcLink – This weld mode position is used to unlock synergic
modes when combined with an ArcLink wire feeder.
6. Constant Current Test Mode – When the switch is in the
ArcLink position with no ArcLink feeder present, the Flextec™
will go into constant current test mode. This can be used to
verify the calibration of the Flextec™.
The machine 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 Mode Selector switch, a hot start dial, output
control dial and arc control dial are provided to setup and fine tune
the welding procedure.
DEFINITION OF WELDING MODES
NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all welding process
variables to be set by the operator.
SYNERGIC WELDING MODES
• A Synergic welding mode offers the simplicity of single knob
control. The machine will select the correct voltage and amperage
based on the wire feed speed (WFS) set by the operator.
WELD CONTROLS AND DISPLAYS
Weld Process Selector Switch
5 Position switch used to select the welding process
Hot Start Dial
The Hot Start control regulates the starting current at arc initiation.
Hot Start can be set to '0" and no additional current is added at arc
start. Increasing from 0 to 10 will increase the additional current
(relative to the preset current) that is added at arc initiation.
Arc Control Dial
Full range selection of arc control from -10 to +10. In CV mode, this
control is an inductance control. In stick mode, the control adjusts
the arc force.
C-3
OPERATION
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