Lincoln Electric 11626 Operator's Manual
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Lincoln Electric 11626 Operator's Manual

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Operator's Manual
FLEXTEC
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10062-C
| Issue D ate Jun-15
© Lincoln Global, Inc. All Rights Reserved.
™
450
For use with machines having Code Numbers:
11626, 11754, 11941, 12038

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Summary of Contents for Lincoln Electric 11626

  • Page 1 Operator’s Manual FLEXTEC ™ For use with machines having Code Numbers: 11626, 11754, 11941, 12038 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) IM10062-C | Issue D ate Jun-15...
  • 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: Table Of Contents

    TABLE OF CONTENTS Page Installation .......................Section A Technical Specifications ..................A-1 Welding Process, Physical Dimensions ............A-2 Safety Precautions ..................A-3 VRD™ (Voltage Reduction Device) ................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 Connection .....................A-5 Input Fuse and Supply Wire Considerations...........A-5...

  • Page 7: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - FLEXTEC™ 450 POWER SOURCE-INPUT VOLTAGE AND CURRENT Input Amperes Input Voltage ± 10% Model Duty Cycle Power Factor @ Idle Power Rated Output 60% rating 72 Watts 37 / 27 / 22 K2882-2 Max. 380 / 460 / 575 / 3 / 50 / 60 100% rating 29 / 21 / 17 (fan on)
  • Page 8 INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U GMAW (CV) 40-500 GTAW (CC) 10-500 15-500 SMAW (CC) FCAW-GS (CV) 40-500 FCAW-SS (CV) 40-500 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH WEIGHT DEPTH 26.66in (677mm) 125lbs (56.6kg)* K2882-2 18.80in (478mm) 14.14in (359mm) TEMPERATURE RANGES STORAGE TEMPERATURE RANGE OPERATING TEMPERATURE RANGE...

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING WARNING Both handles should be used when lifting the Flextec™ 450. When using a crane or overhead ELECTRIC SHOCk can kill. device a lifting strap should be connected to both han- dles. Do not attempt to lift the Flextec™ 450 with ONLY QUALIFIED PERSONNEL SHOULD accessories attached to it.

  • Page 10: Input Connection

    INSTALLATION INPUT CONNECTION HIGH TEMPERATURE OPERATION (See Figure A.1) WELDER OUTPUT RATINGS AT 55°C For codes 11941 and below ELEVATED TEMPERATURES 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.

  • Page 11: Input Fuse And Supply Wire Considerations

    INSTALLATION INPUT VOLTAGE SELECTION INPUT CONNECTION For codes 12038 and above (See Figure A.1a) For codes 12038 and above Welders are shipped connected for 460 Volt input voltage. To move this connection to a different input Use a three-phase supply line. A 1.40 inch (36 mm) voltage, reconnect the auxiliary lead (indicated as ’A’) diameter access hole for the input supply is located on located at the back of the machine to the appropriate...

  • Page 12: Cable Connections

    INSTALLATION CABLE CONNECTIONS See FIGURE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FLEXTEC™ 450. 6-PIN REMOTE CONTROL CONNECTOR Function Wiring 6-pin remote 77 Remote potentiometer, 5K control con- 76 Remote potentiometer, wiper nector for 75 Remote potentiometer, common remote or Trigger, common...

  • Page 13: Recommended Electrode And Work Cable For Arc Welding

    INSTALLATION RECOMMENDED ELECTRODE AND • Route all cables directly to the work and wire WORk CABLE SIZES FOR ARC WELDING 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 General Guidelines loop area and therefore the inductance of the weld Connect the electrode and work cables between the...
  • Page 14 INSTALLATION CONNECTING LF-72 AND LF-74 TO THE FLEXTEC ™ WIRE FEEDER 14-PIN CONTROL CABLE K1797-XX LF-72 FLEXTEC™-450 LF-74 ELECTRODE WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS LOCAL REMOTE/LOCAL (REMOTE IF K2329-1 INSTALLED) VOLTMETER POLARITY PROCESS DEPENDENT FLEXTEC™ 450...
  • Page 15 INSTALLATION CONNECTING LN-10 AND DH-10 TO THE FLEXTEC ™ WIRE FEEDER 14-PIN CONTROL CABLE K1501-XX LN-10 FLEXTEC™-450 DH-10 ELECTRODE WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL REMOTE VOLTMETER POLARITY PROCESS DEPENDENT LN-10,DH-10 CONTROL SWITCH Setting the DIP Switches SETUP The DIP switches are each labeled with an “ON”...
  • Page 16 INSTALLATION A-10 A-10 CONNECTING LN-15(k1870-1) TO THE FLEXTEC ™ WIRE FEEDER LN-15 FLEXTEC™-450 ELECTRODE (K1870-1) WORK CLIP WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL LOCAL VOLTMETER POLARITY PROCESS DEPENDENT CONNECTING LN-15(k1871-1) TO THE FLEXTEC ™ WIRE FEEDER 14-PIN CONTROL CABLE K1819-XX LN-15 FLEXTEC™-450...
  • Page 17 INSTALLATION A-11 A-11 CONNECTING LN-25 PRO AND LN-25 PIPE TO THE FLEXTEC ™ WIRE FEEDER LN-25 PRO FLEXTEC™-450 LN-25 PIPE ELECTRODE WORK CLIP WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL LOCAL VOLTMETER POLARITY PROCESS DEPENDENT CONNECTING LN-25 PRO DUAL POWER TO THE FLEXTEC ™...
  • Page 18 OPERATION GRAPHIC SYMBOLS THAT SAFETY PRECAUTIONS APPEAR ON THIS MACHINE Read this entire section of operating instructions OR IN THIS MANUAL 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...

  • Page 19: Operation

    OPERATION GRAPHIC SYMBOLS THAT PRODUCT DESCRIPTION APPEAR ON THIS MACHINE OR IN THIS MANUAL The Flextec™ 450 is a multi-process CC/CV DC inverter and is rated for 450 amps, 38 volts at a 60% duty cycle. The Flextec is intended for both factory and field operation.

  • Page 20: Recommended Processes And Equipment

    OPERATION RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Flextec™ 450 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 Flextec™ 450 is suitable only for the processes listed. EQUIPMENT LIMITATIONS Operating Temperature Range is -10°...
  • Page 21 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 2. Voltage Display Meter feeder connector 3. Amperage Display Meter 13. 14-pin wire feeder circular connector 4.

  • Page 22: Power-Up Sequence

    Output control is conducted by a single turn poten- responsibility of the builder/user. Many variables tiometer. (Adjustment is indicated by the meters.) beyond the control of The Lincoln Electric When in Remote Mode, this control sets the maximum Company affect the results obtained in applying welding current of the remote device.
  • Page 23 OPERATION INTERNAL CONTROLS - ENABLING VRD To Enter VRD™ Mode (VRD™ Enabled) ™ (For Code 11941 only) a. For 380V input: Switch #5 in the “ON” Internal Controls Description Position. The Control PC Board has one bank of Dip Switches. As shipped from the factory VRD™...
  • Page 24 OPERATION VRD™ (VOLTAGE REDUCTION DEVICE) Amperage Display Meter INDICATOR LIGHT • Prior to STICK or TIG operation (current flow), the meter displays preset current value. (For Code 11941 only) • Prior to CV operation, the meter displays four dash- es indicating non-presettable AMPS. There are 2 indicator lights on the case front of the •...
  • Page 25 OPERATION BASIC MODES OF OPERATION Output Control Dial • When the Local/Remote is set to Local, this dial sets the welding amperage. SMAW • When the Local/Remote is set to Remote, this dial This weld mode is a constant current (CC) mode fea- sets the maximum welding amperage.
  • Page 26 OPERATION GTAW CV-GAS This weld mode is a constant current (CC) mode featuring con- This weld mode is a constant voltage (CV) mode featuring con- tinuous control from 10 – 500 amps. It is intended for the GTAW tinuous control from 10 to 45 volts. TIG welding processes.
  • Page 27 OPERATION B-10 B-10 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.

  • Page 28: Accessories

    ACCESSORIES OPTIONS / ACCESSORIES Hand Amptrol® - Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug con- General Options nection). Order k963-3 k2149-1 Work Lead Package. Arc Start Switch - May be used in place of the Foot or Hand Amptrol®.

  • Page 29: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS PERIODIC MAINTENANCE WARNING Thermal Protection Thermostats protect the machine from excessive ELECTRIC SHOCk can kill. operating temperatures. Excessive temperatures may • Only Qualified personnel should perform this maintenance. be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating.

  • Page 30: How To Use Troubleshooting Guide

    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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 31 COURSE OF ACTION Major physical or electrical damage 1. Contact your local authorized is evident when the sheet metal Lincoln Electric Field Service facil- covers are removed. ity for technical assistance. Machine won’t weld, can’t get any 1. If the displays show an Err ### output.
  • Page 32 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. (For Codes 11626, 11754 only) Error Codes for the FLEXTEC™ 450 Corrective Action...
  • Page 33 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.

  • Page 34: Error Codes

    TROUBLESHOOTING Suivre les instructions de Sécurité détaillées tout au long de ce manuel. (For Code 11941 and above) FLEXTEC™ 450 Fault Codes Error Description Possible Cause Corrective Action Code# Input Power Misconnect. Verify the primary reconnect Occurs upon power up when the supply Supply Voltage is too high.
  • Page 35 DIAGRAMS FLEXTEC™ 450...
  • Page 36 DIAGRAMS FLEXTEC™ 450...
  • Page 37 DIAGRAMS FLEXTEC™ 450...
  • Page 38 DIAGRAMS FLEXTEC™ 450...
  • Page 39 DIMENSION PRINT FLEXTEC™ 450...
  • Page 40 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 41 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 42 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:

Flextec 450117541194112038

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