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Operator’s Manual

FLEXTEC

™

500 P

Register your machine:  

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:  

www.lincolnelectric.com/locator

IM10194-B

|   Issue D ate Sep-16

© Lincoln Global, Inc.  All Rights Reserved.

For use with machines having Code Numbers:

12246, 12565, 12607

Save for future reference  

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Summary of Contents for 12246

Page 1: ...ter Authorized Service and Distributor Locator www lincolnelectric com locator IM10194 B Issue Date Sep 16 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12246 12565...

Page 2: ...A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual s...

Page 3: ...hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and...

Page 4: ...m to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with s...

Page 5: ...nt passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow N...

Page 6: ...s B 3 High Frequency Protection B 3 Connection Diagrams Control Cables B 4 B 5 Analog Wire Feeder Connectivity B 4 ArcLink Wire Feeder Digital Accessory Connectivity B 5 Recommended Electrode and Work...

Page 7: ...Extracting Systems D 1 Stick Options D 1 TIG Welding Options Accessories D 1 Maintenance Section E Safety Precautions E 1 Visual Inspection E 1 Routine Maintenance E 1 Periodic Maintenance E 1 Troubl...

Page 8: ...8 CHANGES AFTER INITIAL RELEASE FLEXTEC 500 P CHANGES AFTER INITIAL RELEASE...

Page 9: ...merica and Export markets and operates on 380V 460V or 575V 50hz or 60hz three phase power Switching between voltages is made simple via a reconnect panel located on the case back The Flextec 500 P is...

Page 10: ...C 500 P K3328 13 POWER FEED 84 U I HVY DTY REEL USB K3059 2 INVERTER CART K3056 1 BASE MOUNTING KIT K2952 2 10 45 MAGNUM PRO CURVE 400 K1842 10 3 0 WELDING CABLE KIT K2149 1 WORK LEAD PACKAGE 3100211...

Page 11: ...ATIBLE WIRE FEEDERS ANALOG ARCLINK FEEDERS NORTH AMERICAN SEMI AUTOMATIC WIRE FEEDERS PF10M PF25M PF84 POWER FEED SERIES 40VDC INPUT LF 72 LF 74 LF SERIES 42VAC INPUT ALL MODELS FLEX FEED SERIES 42VAC...

Page 12: ...12 NOTES FLEXTEC 500 P...

Page 13: ...50 33 A 60 8 10 10 6 8 460 3 60 27 A 50 10 6 10 6 8 575 3 60 27 A 50 10 6 10 6 8 RATED OUTPUT PROCESS DUTY CYCLE VOLTS AT RATED AMPERES AMPERES EFFICIENCY AT RATED OUTPUT GMAW CV 60 39 V 500A 89 100...

Page 14: ...arance Procedure Control Utilize ArcLink Feeder capabilities such as user memories preference options and procedure lockouts Full Featured Remote Control Capability Use a foot pedal or hand control to...

Page 15: ...ut Current or Voltage for the selected Weld Process 8 Local Remote Selector Toggle Switch Sets the control of the output to local output control knob or remote K857 hand amptrol or K870 foot amptrol t...

Page 16: ...r 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 Input Power Fuse Pr...

Page 17: ...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 1 Enter VRD Mode VRD Enabled a Turn switch 5 to the ON Position...

Page 18: ...LOCATED INSIDE THE RECONNECT INPUT ACCESS DOOR TO A PROPER SAFETY EARTH GROUND ONLY A QUALIFIED ELECTRICIAN SHOULD CONNECT THE INPUT LEADS TO THE FLEXTEC MACHINE CONNECTIONS SHOULD BE MADE IN ACCORDAN...

Page 19: ...t and grounding wire size according to local or national electrical codes Using input wire sizes fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush...

Page 20: ...ne may topple over if this procedure is not followed Lifting The Flextec 500 P has two handles that can be used to lift the machine Both handles should be used when lifting the machine When using a cr...

Page 21: ...Wiring J A H B K I C L N D M E F G A B Ground C Trigger Common D Trigger input E 77 Remote potentiometer 10V F 76 Remote potentiometer wiper G 75 Remote potentiometer common H Work 21 I 42 VAC J K 42...

Page 22: ...Common Picture Function Pin Wiring 12 pin remote control connector for remote or hand foot amptrol and digital accessories A ArcLink CAN B ArcLink CAN C D E F ALPS connection G Trigger H Trigger J 40V...

Page 23: ...connections often result in unsatisfactory welding performance Always use the largest welding cables electrode and work that are practical and be sure all connections are clean and tight Note Excessi...

Page 24: ...to improve the accuracy of the arc voltage information supplied to the machine The electrode sense lead is integral to the ArcLink control cable General Guidelines for Voltage Sense Leads Sense leads...

Page 25: ...processes 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 FLEXTEC 500 P MACHINE 1 NEGATIVE POSITIVE INPUT TERMI...

Page 26: ...VOLTAGE RATED REDUCED NO LOAD VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION EXPLOSION DANGEROUS VOLTAGE SHOCK HAZARD OFF HIGH TEMPERATURE CIRC...

Page 27: ...ers ARC RAYS can burn eyes and skin Wear eye ear and body protection SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS ON INSIDE OF FRONT COVER OF OPERATING MANUAL When power is...

Page 28: ...position is used to unlock synergic and basic pulse welding modes when combined with an ArcLink wire feeder The machine is also capable of gouging Gouging can be done in either the SMAW mode or the CV...

Page 29: ...so configures the 292 lead to the User Interface board to determine if voltage sensing needs to be configured for Electrode Negative Polarity operation in ArcLink mode Thermal Light This status light...

Page 30: ...holds the actual voltage value for 5 seconds Output adjustment while in the hold period results in the prior to operation characteristics stated above The displays blink indicating that the machine i...

Page 31: ...age LCD Display This display will display the pre set welding current when the machine is in the idle state After welding the meter holds the actual amperage value for 5 seconds Output adjustment whil...

Page 32: ...idle state This indicates that amperage is not settable in this weld mode While output is enabled the actual welding amperage will be displayed After welding the meter holds the actual amperage value...

Page 33: ...d the actual welding amperage will be displayed After welding the meter holds the actual amperage value for 5 seconds Output adjustment while in the hold period results in the prior to operation chara...

Page 34: ...ble in this weld mode While output is enabled the actual welding amperage will be displayed After welding the meter holds the actual amperage value for 5 seconds Output adjustment while in the hold pe...

Page 35: ...00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length See Figure C 2 All pulse welding programs in the Flextec 500 P are synergic As the wire fee...

Page 36: ...rent while increasing the peak current This results in a soft arc good for out of position welding The UltimArcTM Arc Control can be accessed through the ArcLink compatible wire feeder user interface...

Page 37: ...ng 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...

Page 38: ...e in good condition to ensure that high voltage parts are protected and correct spacing is maintained throughout All external sheet metal screws must be in place to ensure case strength and electrical...

Page 39: ...r local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility...

Page 40: ...the error 36 Thermal Fault Machine shutoff output due to elevated internal temperature Check for material blocking intake or exhaust louvers Blow air in the rear louvers to clear dirt from the fan No...

Page 41: ...t refer to the thermal section 3 If the output terminals are in remote control switch to ON and check for output voltage If output voltage is now present check for correct remote control connection an...

Page 42: ...E S12021 78 INSERTION SIDE A B K J L M G H C D E F S3 J20 3 227 J20 11 228 J29 J46 51A J22 3 J4 6 J4 5 294 292 J2 10 J2 2 J3 12 J3 11 LEM CURRENT TRANSDUCER 216 217 215 218 1 2 3 4 220D 221D 306 306...

Page 43: ...G 2 DIAGRAMS FLEXTEC 500 P L16790 A 01 FLEXTEC 500 P TO NEGATIVE STUD WORK PIECE WORK CLAMP TO POSITIVE STUD WELDING GUN ACTIV8 WIRE FEEDER WORK SENSE LEAD...

Page 44: ...ORK CLAMP TO NEGATIVE STUD LN 10 or DH 10 WIRE FEEDER FLEXTEC 500 P CONTROL CABLE K1501 XX TO POSITIVE STUD S1 N O DIP SWITCH CONFIGURATION INSIDE CONTROL BOX 1 2 3 4 5 6 7 8 WELDING GUN LN10 DH10 SET...

Page 45: ...MS FLEXTEC 500 P L16790 WORK K1785 XXX CONTROL CABLE FLEXTEC 500 P FLEXFEED 74 HT WIRE FEEDER ELECTRODE TO NEGATIVE STUD WORK CLAMP MAGNUM PRO GUN FLEXFEED 74 HT SETUP WITH FLEXTEC 500 P CONNECTION DI...

Page 46: ...6790 TO POSITIVE STUD WORK PIECE GROUND CLAMP TO NEGATIVE STUD MAGNUM PRO GUN FLEXTEC 500 P LN25 PRO DUAL POWER OPTIONAL CONTROL CABLE K1797 XXX WORK SENSE LEAD LN25 PRO DUAL POWER SETUP WITH FLEXTEC...

Page 47: ...RAMS FLEXTEC 500 P L16790 MAGNUM PRO GUN WORK PIECE WORK CLAMP TO NEGATIVE STUD TO POSITIVE STUD CONTROL CABLE K1543 XX FLEXFEED 84 FLEXTEC 500 P FLEXFEED PF84 SETUP WITH FLEXTEC 500 P CONNECTION DIAG...

Page 48: ...s diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If...

Page 49: ...Flextec 500P 12607...

Page 50: ...ii THIS PAGE INTENTIONALLY LEFT BLANK...

Page 51: ...1068 C CASE FRONT ASSEMBLY AR 2 P 1068 D DIVIDER PANEL ASSEMBLY AR 3 P 1068 E BASE CENTER ASSEMBLY AR 4 P 1068 F CASE BACK ASSEMBLY AR 5 P 1068 G WRAPAROUND ASSEMBLY AR Index of Sub Assemblies 12607...

Page 52: ...P 1068 A jpg Index of Sub Assemblies 12607 2 Flextec 500P 12607 Printed 09 29 2016 at 13 26 01 Produced by Enigma...

Page 53: ...SL16656 MAIN CONTROL HARNESS 1 9A 9ST10812 119 POTENTIOMETER 3 9B 9SS16670 12 ROTARY SWITCH 1 10A 9SG6525 3 HANDLE 1 10B 9SM24996 FRONT HANDLE SUPPORT BRACKET 1 10C 9SS9225 66 SELF TAPPING SCREW 4 11A...

Page 54: ...E106A 15 LOCKWASHER 2 14E 9SCF000344 HEX HD SCREW 2 15 9SS30151 POSITIVE OUTPUT STUD LEAD 1 16 9SM22778 1 KNOB 1 0 2 17 9SM22778 2 KNOB 1 5 1 18 9SM22778 3 KNOB 1 19 9SS30408 2 LINE SWITCH LEAD ASBLY...

Page 55: ...P 1068 C jpg Case Front Assembly Flextec 500P 12607 5 Printed 09 29 2016 at 13 26 01 Produced by Enigma...

Page 56: ...T12380 4 BUSHING 1 7 9ST12380 8 BUSHING 1 8A 9ST13637 6 DIODE BRIDGE35A400VF W1 PH 2 8B 9SS9262 27 PLAIN WASHER 2 8C 9SE106A 1 LOCKWASHER 2 8D 9SCF000010 10 24HN 2 9A 9SS13490 157 CAPACITOR ALEL240001...

Page 57: ...ATOR 2 15 9ST10728 77 FUSE 1 16 9SS18491 1 MOV ASBLY 1 9SS18250 1074 PLUG LEAD ASBLY 1 9SL16767 AUX TRANSFORMER THERMOSTAT ASBLY 1 17A 9SS13000 129 AUXILIARY TRANSFORMER 1 17B 9ST13359 15 THERMOSTAT 1...

Page 58: ...P 1068 D jpg Divider Panel Assembly 8 Flextec 500P 12607 Printed 09 29 2016 at 13 26 01 Produced by Enigma...

Page 59: ...5B 9SS30871 LEM SUPPORT 1 5C 9SS8025 77 SELF TAPPING SCREW 1 5D 9SS9225 66 SELF TAPPING SCREW 1 9SL11452 8 PLUG LEAD ASBLY 1 6A 9SG7848 TRANSFORMER ASBLY 1 6B 9SS9225 66 SELF TAPPING SCREW 4 7A 9SM249...

Page 60: ...2 13C 9SE106A 3 LOCKWASHER 1 13D 9SCF000029 5 16 18HN 1 14A 9SCF000040 5 16 18X 75HHCS 1 14B 9SS9262 30 PLAIN WASHER 1 14C 9SE106A 3 LOCKWASHER 1 15A 9SG8122 SWITCHBOARD ASBLY 1 15B 9SS9225 66 SELF T...

Page 61: ...P 1068 E jpg Base Center Assembly Flextec 500P 12607 11 Printed 09 29 2016 at 13 26 01 Produced by Enigma...

Page 62: ...ASBLY 1 5A 9SS30907 RELAY SUPPORT 1 5B 9SS9262 3 PLAIN WASHER 2 5C 9ST4291 A LOCKWASHER 2 5D 9SCF000042 8 32HN 2 6 9SS22752 28 RATING PLATE 1 7A 9SS15122 15 RELAY 1 7B 9SS8025 98 SELF TAPPING SCREW 2...

Page 63: ...P 1068 F jpg Case Back Assembly Flextec 500P 12607 13 Printed 09 29 2016 at 13 26 01 Produced by Enigma...

Page 64: ...RIP NUT RETAINER 1 9SS9225 66 SELF TAPPING SCREW 2 9SS9225 68 THREAD FORMING SCREW CUTTING 3 9SS9262 183 PLAIN WASHER 2 3A 9SG7798 ROOF 1 3B 9SS9225 68 THREAD FORMING SCREW CUTTING 8 9SG8035 WIRING DI...

Page 65: ...P 1068 G jpg Wraparound Assembly Flextec 500P 12607 15 Printed 09 29 2016 at 13 26 01 Produced by Enigma...

Page 66: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...

Page 67: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 68: ...or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of in...

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