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Lincoln Electric RED-D-ARC FX450 Operator's Manual

Lincoln electric welder user manual.
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For use with machines having Code Numbers:
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
And, most importantly, think before you act and be careful.
North America's Largest Fleet of Welding Equipment
February, 2011

   Summary of Contents for Lincoln Electric RED-D-ARC FX450

  • Page 1

    OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3

    3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation.

  • Page 4

    6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines.

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    PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6

    Thank You The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We respond to our customers based on the best informa- tion in our possession at that time.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Installation ...Section A Technical Specifications ...A-1 Welding Process, Physical Dimensions ...A-2 Safety Precautions ...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 Fuse and Supply Wire Considerations...A-4 Input Voltage Selection ...A-4 Cable Connections...A-5 Recommended Electrode and Work Cable for arc Welding ...A-6...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS - POWER SOURCE-INPUT VOLTAGE AND CURRENT Input Voltage ± 10% Model Duty Cycle 60% rating K3073-1 380 / 460 / 575 / 3 / 50 / 60 100% rating Process Duty Cycle GMAW (CV) 100% GTAW (CC) 100% SMAW (CC) 100% FCAW-GS (CV)

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    PROCESS GMAW (CV) GTAW (CC) SMAW (CC) FCAW-GS (CV) FCAW-SS (CV) MODEL HEIGHT K3073-1 18.80in (478mm) OPERATING TEMPERATURE RANGE Environmentally Hardened: 14°F to 131°F (-10°C to 55°C IP23 155º(F) Insulation Class Weight does not include input cord. Output De-rated at Temperatures above 40°C. INSTALLATION WELDING PROCESS OUTPUT RANGE (AMPERES)

  • Page 10: Safety Precautions, Select Suitable Location, Lifting, Stacking, Environmental Limitations, Input And Grounding Connections

    Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a mini- mum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

  • Page 11: Input Connection, Input Fuse And Supply Wire Considerations, Input Voltage Selection

    Using input wire sizes, fuses or circuit breakers smaller than recom- mended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents. INPUT VOLTAGE SELECTION Welders are shipped connected for 460 Volt input voltage.

  • Page 12: Cable Connections

    See FIGURE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FX450. 6 - P I N R E M O T E C O N T R O L C O N N E C T O R F O R W I R E F E E D E R 1 4 - P I N C O N N E C T O R 6-PIN REMOTE...

  • Page 13: Output Cable Guidelines

    RECOMMENDED ELECTRODE AND WORK CABLE SIZES FOR ARC WELDING General Guidelines Connect the electrode and work cables between the appropriate output studs of the FX450 per the follow- ing guidelines: • Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source.

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    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 electrically energized and could remain energized several seconds after the welding ceases.

  • Page 15: Product Description, Duty Cycle, Design Features

    • Simple user interface - designed with the operator in mind. Getting setup for the weld is several clicks away and even the most novice welder can be confi- dent he is setup properly. • F.A.N. (fan as needed). Cooling fan runs when the output is energized and for a 5 minute cool down period after output is disabled.

  • Page 16: Recommended Processes And Equipment

    RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The FX450 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 FX450 is suitable only for the processes listed. EQUIPMENT LIMITATIONS Operating Temperature Range is -10°...

  • Page 17: Case Front Controls

    CASE FRONT CONTROL DESCRIPTIONS (See Figure B.1) 1. Power Switch 2. Voltage Display Meter 3. Amperage Display Meter 4. Thermal LED 5. Output Control Dial 6. Weld Process Selector Switch 7. Hot Start Toggle Switch 8. Output Control Local/Remote Toggle Switch 9.

  • Page 18: Power-up Sequence, Case Back Controls

    The serviceability of a product or structure utiliz- ing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are...

  • Page 19

    Amperage Display Meter • Prior to STICK or TIG operation (current flow), the meter displays preset current value. • Prior to CV operation, the meter displays four dash- es indicating non-presettable AMPS. • During welding, this meter displays actual average amps.

  • Page 20

    GTAW This weld mode is a constant current (CC) mode featuring con- tinuous control from 10 – 500 amps. It is intended for the GTAW TIG welding processes. Hot Start - The Hot Start control regulates the starting current at arc initiation. Hot Start can be set to “Off” and no additional current is added at arc start.

  • Page 21

    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 22: Options / Accessories

    OPTIONS / ACCESSORIES General Options K2149-1 Work Lead Package. K1842-10 10ft. Weld Power Cable (Lug to Lug). Inverter and Wire Feeder Cart Rear-wheeled cart includes front casters and no-lift gas bottle platform. Convenient handles allow for easy cable storage while full length side trays store parts and tools.

  • Page 23: V Isual I Nspection, Safety Precautions, R Outine M Aintenance, P Eriodic M Aintenance

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ------------------------------------------------------------------------ See additional warning information throughout this Operatorʼs Manual...

  • Page 24: How To Use Troubleshooting Guide, Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by 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 25: Troubleshooting

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident when the sheet metal covers are removed. Machine wonʼt weld, canʼt get any output. Thermal symbol is lit. Wire feeder wonʼt work. Apparently no power to wire feeder If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

  • Page 26: Error Codes

    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.

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    • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE:

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