Lincoln Electric Flextec 650x Operator's Manual
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Lincoln Electric Flextec 650x Operator's Manual

Lincoln Electric Flextec 650x Operator's Manual

For use with machines having code numbers: 12596
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Operator's Manual
Flextec
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10373
| Issue D ate Jun-18
© Lincoln Global, Inc. All Rights Reserved.
650x
®
For use with machines having Code Numbers:
12596

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Summary of Contents for Lincoln Electric Flextec 650x

  • Page 1 Operator’s Manual Flextec 650x ® For use with machines having Code Numbers: 12596 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) IM10373 | Issue D ate Jun-18 ©...
  • 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, 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 High Temperature Operation......................A-3 Input Connection .........................A-4 Input Fuse and Supply Wire Considerations..................A-4 Input Voltage Selection.........................A-4 Cable Connections........................
  • Page 7 FLEXTEC 650x INSTALLATION TECHNICAL SPECIFICATIONS - FLEXTEC 650X POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Power Factor @ Idle Power Effective Rated Output 60% rating 61 / 50 / 40 230 MAX.( Fan On)
  • Page 8 FLEXTEC 650x INSTALLATION WELDING PROCESS OUTPUT RANGE (AMPERES) OCV (U OCV (U PROCESS GMAW (CV) 40-815 GTAW (CC) 10-815 SMAW (CC) 15-815 40-815 FCAW-G (CV) FCAW-S (CV) 40-815 SAW (CV) 40-815 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT 165lbs (74.8kg)* 29.33 in (745 mm)

  • Page 9: Installation

    INSTALLATION INSTALLATION WARNING LIFTING The FLEXTEC 650x has 2 lifting eyelets and 2 handles that can be used to lift the machine. Both handles or both eyelets should be ELECTRIC SHOCK can kill. used when lifting the FLEXTEC 650x. •...

  • Page 10: High Temperature Operation

    Only a qualified electrician should connect the input leads to Section. If the Auxiliary lead (indicated as ‘A’) is placed in the the Flextec 650x. connections should be made in wrong position and power is applied to the machine, the machine...

  • Page 11: Cable Connections

    FLEXTEC ® 650x INSTALLATION CABLE CONNECTIONS See FIGURE A.2 for locating 5, 12 and 14 pin connectors on the front of the FLEXTEC ® 650x. FIGURE A.2 12-PIN ACCESSORY CONNECTIVITY Function Wiring A ArcLink CAN B ArcLink CAN C Remote potentiometer, common 12-pin remote D Remote potentiometer wiper control...

  • Page 12: Output Cable Guidelines

    Connect the electrode and work cables between the appropriate practical, and be sure all connections are clean and tight. output studs of the FLEXTEC 650x per the following guidelines: Note: Excessive heat in the weld circuit indicates undersized • Most welding applications run with the electrode being cables and/or bad connections.

  • Page 13: Control Cable Connections, Paralleling

    Genuine Lincoln control cables should be used at all times (except control cables. where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the FLEXTEC 650x. Most are designed to be connected end to end for ease of PARALLELING extension.
  • Page 14 FLEXTEC INSTALLATION CONNECTING LF-72 AND LF-74 TO THE FLEXTEC 650x WIRE FEEDER 14-PIN CONTROL CABLE K1797-XX LF-72 ELECTRODE LF-74 Flextec 650x WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS LOCAL REMOTE/LOCAL (REMOTE IF K2329-1 INSTALLED) VOLTMETER POLARITY PROCESS DEPENDENT...
  • Page 15 FLEXTEC INSTALLATION CONNECTING LN-10 AND DH-10 TO THE FLEXTEC 650x WIRE FEEDER 14-PIN CONTROL CABLE K1501-XX LN-10 DH-10 Flextec 650x ELECTRODE WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL REMOTE VOLTMETER POLARITY PROCESS DEPENDENT LN-10,DH-10 CONTROL SWITCH SETUP...
  • Page 16 FLEXTEC INSTALLATION CONNECTING LN-25 PRO, LN-25 PIPE, ACTIV8 TO THE FLEXTEC 650x WIRE FEEDER LN-25 PRO LN-25 PIPE Flextec 650x ELECTRODE ACTIV8 WORK CLIP WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL LOCAL PROCESS DEPENDENT VOLTMETER POLARITY CONNECTING LN-25 PRO DUAL POWER TO THE FLEXTEC 650x...
  • Page 17 ELECTRODE WORK CONTROL SETTING CV, CV-INNERSHIELD WELD MODE WELD TERMINALS REMOTE/LOCAL LOCAL VOLTMETER POLARITY PROCESS DEPENDENT CONNECTING LN-8 AND LN-9 TO THE FLEXTEC 650x WIRE FEEDER 14-PIN CONTROL CABLE K1820-XX LN-8 LN-9 ELECTRODE Flextec 650x WORK CONTROL SETTING WELD MODE...
  • Page 18 FLEXTEC INSTALLATION CONNECTING NA-3, NA-5 TO THE FLEXTEC 650x WIRE FEEDER 14-PIN CONTROL CABLE K1820-XX NA-3 NA-5 Flextec 650x ELECTRODE WORK FOR NA-3, NA-4 WIRE FEEDERS ONLY: - MOVE JUMPER LEAD ON VARIABLE VOLTAGE BOARD TO "L" PIN. FOR NA-5 WIRE FEEDER ONLY: - MOVE "BLUE"...

  • Page 19: Operation

    FLEXTEC 650x OPERATION OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always...

  • Page 20: Graphic Symbols

    FLEXTEC 650x OPERATION GRAPHIC SYmbOLS THAT APPEAR ON THIS mACHINE OR IN THIS mANUAL REDUCED OPEN INPUT POWER CIRCUIT VOLTAGE OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE HIGH TEMPERATURE INPUT CURRENT CIRCUIT BREAKER OUTPUT CURRENT PROTECTIVE WIRE FEEDER GROUND WARNING or CAUTION POSITIVE OUTPUT Read &...

  • Page 21: Product Description

    Output De-rated at Temperatures above 40°C. DUTY CYCLE COmmON EQUIPmENT PACkAGES The FLEXTEC 650x is capable of welding at a 100% duty cycle (continuous welding) at 650 amps rated output. The 60% duty BASIC PACKAGE cycle rating is 750 amps (based off of a ten minute cycle – 6...
  • Page 22 18. Local/Remote Selector Toggle Switch: Sets the control of the output to local (output control knob) or remote through the six available weld modes for the Flextec 650X – (K857-2 hand amptrol, K870-2 foot amptrol or 14-pin wire CC-SMAW; CC-GTAW; CV; CV-Innershield; CV-SAW; Arc Link feeder) 7.

  • Page 23: Case Back Controls

    FLEXTEC 650x OPERATION CASE bACk CONTROLS (See Figure B.2) 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.

  • Page 24: Internal Controls

    FLEXTEC 650x OPERATION INTERNAL CONTROLS - ENAbLING VRD, mULTI-WELD AND CURRENT/VOLTAGE CALIbRATION Internal Controls Description The User Interface pc board has one bank of dip switches (See Figure B.3 Item 1). As shipped from the factory and under normal conditions, dip switch #2 is ‘on’ position and all others are in the ‘off’...

  • Page 25: Power-Up Sequence

    POWER-UP SEQUENCE WELD CONTROLS AND DISPLAYS Weld Process Selector Switch When power is applied to the FLEXTEC 650x, the displays will illuminate and display the voltage and/or amperage settings. 6 Position switch used to select the welding process. Hot Start Control Dial COmmON WELDING PROCEDURES •...
  • Page 26 Output Control pin connector to either 42 volts or 115 volts. Dial on the front of the Flextec 650x. Set this switch to “Remote” • If the switch is in the incorrect position for the attached wire when an external potentiometer/control is connected.
  • Page 27 Output Control welding voltage when the machine is in the idle state. After Dial on the front of the Flextec 650x. Set this switch to “Remote” welding, the meter holds the actual voltage value for 5 seconds.
  • Page 28 Output Control indicating that the machine is in the "hold" period. Dial on the front of the Flextec 650x. Set this switch to “Remote” Output Control Local/Remote – When the control is set to “local”...
  • Page 29 When using a CrossLinc™ enabled power source such as the feeders. All of the Flextec 650x user interface controls are Flextec 650x and a CrossLinc™ enabled wire feeder such as the disabled in this mode and controlling the power source is accom- LN-25X, welding voltage can be controlled remotely without the plished from the wire feeder user interface.

  • Page 30: Accessories

    FLEXTEC 650x ACCESSORIES OPTIONS / ACCESSORIES TIG Options General Options Pro-Torch™ TIG Torches – PTA-9, PTA- K2149-1 Work Lead Package. 17, PTA-26 – 2 piece power cord. Foot Amptrol - Provides 25 ft. (7.6 m) of K1842-10 10ft. Weld Power Cable (Lug to Lug).

  • Page 31: Maintenance

    FLEXTEC 650x MAINTENANCE MAINTENANCE PERIODIC  mAINTENANCE WARNING Safety Precautions 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 rating.

  • Page 32: Voltage Calibration

    FLEXTEC 650x MAINTENANCE VOLTAGE CALIbRATION TO RESTORE FACTORY CURRENT CALIbRATION 1. Connect a resistive load bank to the machine configured for 1. Connect the resistive load bank and test voltmeter to the 300A/20V (750A/50V equivalent). welding output terminals. 2. Connect a certified calibrated voltmeter to the output circuit.

  • Page 33: How To Use Troubleshooting Guide

    FLEXTEC 650x TROUBLESHOOTING 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.
  • Page 34 FLEXTEC 650x TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Major physical or electrical damage is 1. Contact your local authorized Lincoln evident when the sheet metal covers are Electric Field Service facility for technical removed.
  • Page 35 In addition, there are status lights on the control pc board and the board are dual-color LED’s. Normal operation for each is steady switch pc board that contain error sequences. green. FLEXTEC 650X FAULT CODES Error Description Possible Cause Corrective Action...
  • Page 36 FLEXTEC 650x DIAGRAMS FRONT OF MACHINE...
  • Page 37 FLEXTEC 650x DIAGRAMS...
  • Page 38 Flextec 650x- 12596...
  • Page 39 Index of Sub Assemblies - 12596 PART NUMBER DESCRIPTION P-1101-A INDEX OF SUB ASSEMBLIES P-1101-C CASE FRONT ASSEMBLY P-1101-D DIVIDER PANEL ASSEMBLY P-1101-E BASE ASSEMBLY P-1101-F CASE BACK ASSEMBLY P-1101-G COVERS ASSEMBLY Flextec 650x- 12596...
  • Page 40 Index of Sub Assemblies - 12596 P-1101-A.jpg Flextec 650x- 12596...
  • Page 41 SELF TAPPING SCREW 9SCF000339 #4-40X.375PPNHS 9ST9695-2 LOCKWASHER 9SCF000002 #4-40HN 9SS17062-12 CONNECTOR CAP 9SS17062-11 CABLE CONNECTOR CAP 9SS17062-10 CABLE CONNECTOR CAP 9SCF000010 #10-24HN 9SE106A-1 LOCKWASHER 9SL17083-1 POTTED CONTROL HARNESS 9ST10812-119 POTENTIOMETER 9SS16670-24 ROTARY SWITCH 9SS32071-1 UI BOARD ASSEMBLY Flextec 650x- 12596...
  • Page 42 9SS20030-1 LINE SWITCH 9SS25384-1 SWITCH COVER - WEATHER RESISTANT 9SCF000373 #10-32X.50PRHS-FULL-GR2-4265 9ST9695-1 LOCKWASHER 9SS28393-5 NOISE SUPPRESSOR 9SS9262-1 PLAIN WASHER 9SE106A-15 LOCKWASHER 9SCF000021 1/2-13X1.00HHCS 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS9262-183 PLAIN WASHER 9SS9225-66 SELF TAPPING SCREW 9ST4550-5 EYEBOLT Flextec 650x- 12596...
  • Page 43 Case Front Assembly P-1101-C.jpg Flextec 650x- 12596...
  • Page 44 GROUND LUG 9ST9695-17 LOCKWASHER 9SCF000412 1/4-20 X .50 HHCS 9ST13260-4 DECAL-EARTH GROUND CONN 9ST12386 FUSE HOLDER 9ST9447-91 SOCKET HEAD CAP SCREW #8-32X.50 SS 9ST10728-72 FUSE - 7.5A 9SS28930 FUSE DECAL 9SM22714 TRANSFORMER BAFFLE 9SS8025-68 SELF TAPPING SCREW Flextec 650x- 12596...
  • Page 45 1/4-20HN 9SS18504-6 CURRENT TRANSDUCER 9SS28515 TRANSDUCER SPACER 9SS9225-36 THREAD FORMING SCREW (CUTTING) 9ST14605 INSULATOR 9ST11267-B INSULATOR 9SS31808 INSULATION 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS18491-1 MOV ASBLY 9SL10033-12 AUXILIARY TRANSFORMER ASSEMBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SE106A-2 LOCKWASHER Flextec 650x- 12596...
  • Page 46 Divider Panel Assembly P-1101-D.jpg Flextec 650x- 12596...
  • Page 47 DIODE MODULE ASBLY 9SCF000013 1/4-20X.625HHCS 9SS9262-98 PLAIN WASHER 9ST12735-4 SPRING WASHER 9ST9447-91 SOCKET HEAD CAP SCREW #8-32X.50 SS 9SS28865 HEATSINK SUPPORT 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000013 1/4-20X.625HHCS 9SS22168 HEAT SINK HOLDER 9SS9225-68 THREAD FORMING SCREW (CUTTING) Flextec 650x- 12596...
  • Page 48 SELF TAPPING SCREW 9SS23224 BUS BAR 9SCF000028 5/16-18X1.25HHCS 9SS9262-30 PLAIN WASHER 9SE106A-3 LOCKWASHER 9SCF000029 5/16-18HN 9SM22858-1 DIVIDER SUPPORT 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM25001 RESISTOR ASSEMBLY 9SS10404-139 RESISTORWW225W5010% 9ST11827-59 CARRIAGE BOLT 9ST9764-6 INSULATOR 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN Flextec 650x- 12596...
  • Page 49 Base Assembly P-1101-E.jpg Flextec 650x- 12596...
  • Page 50 HANDLE SUPPORT BRACKET 9SG6525-3 HANDLE 9SS9225-66 SELF TAPPING SCREW 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS9262-183 PLAIN WASHER 9SS9225-66 SELF TAPPING SCREW 9SS22752-43 RATING PLATE 9SM22683 RECONNECT DOOR 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9ST4550-5 EYEBOLT 9ST13259-2 GROUNDING DECAL Flextec 650x- 12596...
  • Page 51 Case Back Assembly P-1101-F.jpg Flextec 650x- 12596...
  • Page 52 THREAD FORMING SCREW (CUTTING) 9SG7027-2 CASE SIDE 9SG7030 CASE TOP WRAPAROUND 9SS9225-66 SELF TAPPING SCREW 9SG8737 WIRING DIAGRAM 9SL8064-1 WARNING DECAL (INTERNATIONAL) 9SS30277-2 WARRANTY DECAL 9SM22461 FAMILY NAME DECAL 9SS27368-4 DECAL LE LOGO 9SS28039-2 DECAL GREEN INITIATIVE Flextec 650x- 12596...
  • Page 53 Covers Assembly P-1101-G.jpg Flextec 650x- 12596...
  • Page 54 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 55 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 56 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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