6
TABLE OF CONTENTS
FLEXTEC™ 500
Page
Changes After Initial Release .................................................................................................................................8
Product Description ................................................................................................................................................9
Recommended Processes and Equipment ..........................................................................................................10
Recommended Processes ......................................................................................................................10
Process Limitations ................................................................................................................................10
Equipment Limitations............................................................................................................................10
Common Equipment Packages ...............................................................................................................10
Common Optional Kits & Accessories .....................................................................................................11
Compatible Wire Feeders .......................................................................................................................11
Design........................................................................................................................................................Section A
Specifications ...............................................................................................................................................A-1
Agency Approvals .........................................................................................................................................A-2
Design Features ............................................................................................................................................A-2
Case Front Controls.......................................................................................................................................A-3
Case Back Controls .......................................................................................................................................A-4
Internal Controls............................................................................................................................................A-5
Installation ................................................................................................................................................Section B
Input and Ground Connections ......................................................................................................................B-1
Input Fuse and Supply Wire Considerations...................................................................................................B-2
Input Voltage Selection..................................................................................................................................B-3
Location........................................................................................................................................................B-3
Location and Ventilation for Cooling ......................................................................................................B-3
Lifting...................................................................................................................................................B-3
Stacking ...............................................................................................................................................B-3
Environmental Limitations ....................................................................................................................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 Cable Sizes for Arc Welding ...................................................................B-6
Output Cable Guidelines .......................................................................................................................B-6
Control Cable and Voltage Sensing Connections ............................................................................................B-7
Paralleling Machines.....................................................................................................................................B-8
Operation ..................................................................................................................................................Section C
Graphic Symbols that Appear in this Machine or in this Manual.....................................................................C-1
Power Up Sequence......................................................................................................................................C-2
Safety Warnings............................................................................................................................................C-2
Duty Cycle ....................................................................................................................................................C-3
Common Welding Procedures .......................................................................................................................C-3
Making a Weld .....................................................................................................................................C-3
Definition of Welding Modes..........................................................................................................................C-3
Non-Synergic Welding Modes...............................................................................................................C-3
Synergic Welding Modes ......................................................................................................................C-3
Weld Controls and Displays...........................................................................................................................C-3
Weld Processor Selector Switch............................................................................................................C-3
Hot Start Dial ........................................................................................................................................C-3
Arc Control Dial ....................................................................................................................................C-3
Output Control Dial ...............................................................................................................................C-4
Volt Display Meter.................................................................................................................................C-4
Amperage Display Meter.......................................................................................................................C-4
Weld Terminals On/Remote Toggle Switch............................................................................................C-4
Control - Local/Remote Toggle Switch ..................................................................................................C-4
