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Lincoln Electric Flextec 500X Operator's Manual

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Operator's Manual
Flextec
Register your machine:
www.lincolnelectric.com/register
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www.lincolnelectric.com/locator
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10500-A
| Issue D ate Jan-22
© Lincoln Global, Inc. All Rights Reserved.
®
500X
For use with machines having Code Numbers:
12806
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric Flextec 500X

  • Page 1 Operator’s Manual ® Flextec 500X For use with machines having Code Numbers: 12806 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...

  • Page 2: Safety Depends On You

    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 P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 4: Electric Shock Can Kill

    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 Efficiency and idle power consumption: Efficiency when max power Name consumption / Idle power Equivalent model consumption Flextec 500x CE Flextec 500x CE/RCM 89.5% / 75 W Construction with K3129 filter with K3129 filter idle state, set the Weld Terminals to off and Local/Remote to remote and wait until the fan is off. The fan will be off when the units are powered up, or will turn off after a delay of (up to) 5 minutes if the welding output was just disabled.
  • Page 7 Item Component Material for recovery Selective treatment Enclosure Steel Heat sink Aluminum Si, 20 g Mg, 34 g Enclosure Aluminum Si, 9 g Mg, 181 g Handle Aluminum Si, 118 g Mg, 1 g Output terminal Brass PC board Required Choke Copper Transformers...
  • Page 8 FLEXTEC ® 500X TABLE OF CONTENTS...

  • Page 9: Agency Approvals

    FLEXTEC ® 500X INSTALLATION AGENCY APPROVALS MODEL MARKET CONFORMITY MARK NOTES K3607-1 US AND CANADA C/US REQUIRES K3129-2 AUSTRALIA C-TICK / RCM EUROPE CE FILTER KIT DESIGN FEATURES PRODUCT DESCRIPTION • The Future is Now – You no longer have to pay a price premium The Flextec ®...

  • Page 10: Technical Specifications

    FLEXTEC ® 500X INSTALLATION INSTALLATION TECHNICAL SPECIFICATIONS POWER SOURCES - INPUT VOLTAGE AND CURRENT MODEL DUTY CYCLE INPUT VOLTAGE ± 10% INPUT AMPERES IDLE POWER (W) POWER FACTOR K3607-1 60% RATING 380 / 460 / 575 / 3 / 50 / 60 39 / 32 / 32 150W FAN ON 33 / 27 / 27...

  • Page 11: Recommended Processes

    FLEXTEC ® 500X PRODUCT DESCRIPTION RECOmmENDED PROCESSES COmmON EqUIPmENT PACKAGES The Flextec ® 500X is designed for CC-SMAW, CC-GTAW (Touch FLEX FEED 84 READY-PAK Start tig), CV-GMAW, CV-GMAW-P, CV-FCAW-SS and ® K3607-1 FLEXTEC 500X CV-FCAW-GS welding processes. CAG arc gouging is also supported.
  • Page 12 FLEXTEC ® 500X PRODUCT DESCRIPTION COmmON OPTIONAL KITS & ACCESSORIES K4345-1 CROSSLINC REMOTE K3059-4 INVERTER CART ® K3056-2 LOCKING FOOT KIT - FLEXTEC 500X K3091-1 MULTI-PROCESS SWITCH K2909-1 12-PIN TO 6-PIN ADAPTER K4217-1 WIRELESS FOOT PEDAL K857-2 REMOTE OUTPUT CONTROL WITH 12-PIN UNIVERSAL CONNECTOR (25 FEET) K857-3 REMOTE OUTPUT CONTROL WITH 12-PIN UNIVERSAL CONNECTOR (100 FEET) K870-2...
  • Page 13 FLEXTEC ® 500X MAINTENANCE GTAW bASIC mODES OF OPERATION This weld mode is a constant current (CC) mode featuring continuous control from 10 –500 amps. SMAW It is intended for the GTAW TIG welding processes. This weld mode is a constant current (CC) mode featuring continuous control from 15 –...
  • Page 14 FLEXTEC ® 500X MAINTENANCE CV-Gas CV-Innershield This weld mode is a constant voltage (CV) mode featuring This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts. continuous control from 10 to 45 volts. It is intended for the GMAW, FCAW-GS, MCAW welding processes It is intended for the FCAW-SS welding process and arc gouging.
  • Page 15 FLEXTEC ® 500X MAINTENANCE ArcLink CrossLinc ® This weld mode is intended to unlock basic GMAW pulse and CrossLinc is a new welding system communication technology. synergic modes intended for use with a compatible ArcLink wire When using a CrossLinc-enabled power source such as the feeders.

  • Page 16: Input Fuse And Supply Wire Considerations

    FLEXTEC ® 500X INSTALLATION WARNING ELECTRIC SHOCK CAN KILL. INPUT AND GROUND CONNECTIONS Only qualified personnel should perform this MACHINE GROUNDING installation. The frame of the welder must be grounded. A • Turn off input power to the power source ground terminal marked with the symbol shown is at the disconnect switch or fuse box located inside the reconnect/input connection area...
  • Page 17 FLEXTEC ® 500X INSTALLATION VRD™ (VOLTAGE REDUCTION DEVICE) INPUT VOLTAGE SELECTION The VRD™ feature provides additional safety in the CC-Stick Welders are shipped connected for 460V input voltage. If the mode. The VRD™ reduces the OCV (Open Circuit Voltage) at the Auxiliary lead (indicated as ‘A’) is placed in the wrong position and welding output terminals while not welding to less than 35VDC power is applied to the machine, the machine will protect itself...
  • Page 18 FLEXTEC ® 500X 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 19 FLEXTEC ® 500X 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...

  • Page 20: Recommended Electrode And Work Cable Sizes For Arc Welding

    FLEXTEC ® 500X INSTALLATION • Route all cables directly to the work and wire feeder, avoid excessive lengths and do not coil excess cable. Route the RECOmmENDED ELECTRODE AND wORK CAbLE electrode and work cables in close proximity to one another to SIZES FOR ARC wELDING minimize the loop area and therefore the inductance of the weld General Guidelines...
  • Page 21 FLEXTEC ® 500X INSTALLATION CONTROL CAbLE AND VOLTAGE SENSING CONNEC- TIONS General Guidelines Electrode Voltage Sensing Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed The remote ELECTRODE sense lead (67) is built into the 5-pin for the communication and power needs of the Flextec ®...
  • Page 22 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 500X PARALLEL MACHINES MACHINE #1 SETUP WITH...

  • Page 23: Power-Up Sequence

    FLEXTEC ® 500X OPERATION OPERATION POwER-UP SEqUENCE When power is applied to the Flextec ® 500X, the displays will SAFETY PRECAUTIONS illuminate and the machine electronics will complete a power up sequence indicated by a scrolling bar across each seven segment Read this entire section of operating instructions display.
  • Page 24 FLEXTEC ® 500X 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 25: Case Front Controls

    ® FLEXTEC 500X OPERATION CASE FRONT CONTROLS 1. Power Switch: 8. Local/Remote Selector Toggle Switch: Controls input power to the Flextec ® 500X. Sets the control of the output to local (output control knob) or remote (K857 hand amptrol or K870 foot amptrol through the 2.

  • Page 26: Case Back Controls

    ® FLEXTEC 500X OPERATION CASE bACK CONTROLS 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 27: Internal Controls

    ® FLEXTEC 500X OPERATION 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 28: Duty Cycle

    FLEXTEC ® 500X OPERATION DUTY CYCLE DEFINITION OF wELDING mODES NON-SYNERGIC WELDING MODES The Flextec ® 500X is capable of welding at a 100% duty cycle (continuous welding) at 450 Amps rated output. • A Non-synergic welding mode requires all welding process The 60% duty cycle rating is 500 amps (based off of a ten minute variables to be set by the operator.
  • Page 29 User Interface P.C. board. When VRD is active, a green light indicates the open circuit voltage is less than 35V peak, a red • The Flextec 500X automatically recognizes when a CrossLinc light indicates the OCV is at or above 35V peak, Both lights will equipped accessory is connected to it.

  • Page 30: Tig Options

    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 31: Periodic Maintenance

    FLEXTEC ® 500X MAINTENANCE MAINTENANCE PERIODIC mAINTENANCE Thermal Protection WARNING Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and ELECTRIC SHOCK can kill. output rating.
  • Page 32 TROUBLESHOOTING 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 33: Error Codes

    FLEXTEC ® 500X TROUBLE SHOOTING ERROR CODES The status lights on the User Interface board and the Switch board Errors are displayed on the user interface. In addition, there are are dual-color LED’s. Normal operation for each is steady green. status lights on the User Interface PC board and the Switch PC board that contain error sequences.
  • Page 34 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 35 FLEXTEC ® 500X DIAGRAMS FRONT OF MACHINE ~575V ~42V ~460V ~380V ~52V ~115V H3...
  • Page 36 FLEXTEC ® 500X DIAGRAMS...
  • Page 37 FLEXTEC ® 500X DIAGRAMS...
  • Page 38 FLEXTEC ® 500X DIAGRAMS...
  • Page 39 FLEXTEC ® 500X DIAGRAMS...
  • Page 40 FLEXTEC ® 500X DIAGRAMS...
  • Page 41 FLEXTEC ® 500X DIAGRAMS...
  • Page 42 FLEXTEC ® 500X NOTES...
  • Page 44 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 45 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 46 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.

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