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Operator’s Manual

FLEXTEC

™

500

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10193-B

| Issue D ate Sep-16

For use with machines having Code Numbers:

12175, 12564, 12606

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Содержание Flextec 500

Страница 1: ...er Authorized Service and Distributor Locator www lincolnelectric com locator IM10193 B Issue Date Sep 16 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12175 12564 1...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...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 C...

Страница 7: ...tems D 1 Stick Options D 1 TIG Options D 1 Maintenance Section E Safety Precautions E 1 Visual Inspection E 1 Routine Maintenance E 1 Periodic Maintenance E 1 Troubleshooting Section F Safety Precauti...

Страница 8: ...8 CHANGES AFTER INITIAL RELEASE FLEXTEC 500 CHANGES AFTER INITIAL RELEASE...

Страница 9: ...North America 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 5...

Страница 10: ...EADY PAK K4091 1 FLEXTEC 500 K3056 2 LOCKING FOOT KIT K2327 7 LF 72 BENCH MODEL K2952 2 10 45 MAGNUM PRO CURVE 400 K1842 10 3 0 WELDING CABLE KIT K2149 1 WORK LEAD PACKAGE 3100211 HARRIS FLOWMETER K30...

Страница 11: ...TIBLE 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...

Страница 12: ...12 NOTES FLEXTEC 500...

Страница 13: ...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 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K4091 1 18 8 IN 477 MM 14 IN 356 MM 26 5 IN 673 MM 120 LBS 54 43 KG TEMPERATURE...

Страница 14: ...ductance to control spatter fluidity and bead appearance Procedure Control Utilize ArcLink Feeder capabilities such as user memories preference options and procedure lockouts Full Featured Remote Cont...

Страница 15: ...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 thro...

Страница 16: ...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 Pro...

Страница 17: ...ormal 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 S...

Страница 18: ...OCATED 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 ACCORDANC...

Страница 19: ...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 c...

Страница 20: ...500 has two handles that can be used to lift the machine Both handles should be used when lifting the machine When using a crane or overhead device to lift using the handles a lifting strap should be...

Страница 21: ...iring 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 V...

Страница 22: ...ommon 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 40Vd...

Страница 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...

Страница 24: ...nse lead is used 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 L...

Страница 25: ...or constant current 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 WORK PIECE FLEXTEC 500 MACHINE 1 F...

Страница 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 CIRCU...

Страница 27: ...rs 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 a...

Страница 28: ...rrent Test Mode When the switch is in the ArcLink position with no ArcLink feeder present the Flextec will go into constant current test mode This can be used to verify the calibration of the Flextec...

Страница 29: ...also 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 ligh...

Страница 30: ...er 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...

Страница 31: ...erage 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 wh...

Страница 32: ...e 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 valu...

Страница 33: ...led 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 cha...

Страница 34: ...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 perio...

Страница 35: ...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...

Страница 36: ...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...

Страница 37: ...ur 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 Facilit...

Страница 38: ...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 Not...

Страница 39: ...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 and...

Страница 40: ...1 2 3 4 220D 221D 306 306 J3 8 280A 280A U I BOARD HOT START 301 302 303 R5 OUTPUT CONTROL R4 S7 MODE SELECT 308 WELD TERMINALS 212 210 S6 ARC CONTROL R3 252 281 251 253 280 282 LOCAL REMOTE 289 290...

Страница 41: ...MS FLEXTEC 500 L16790 A 01 FLEXTEC 500 TO NEGATIVE STUD WORK PIECE WORK CLAMP TO POSITIVE STUD WELDING GUN ACTIV8 WIRE FEEDER WORK SENSE LEAD ACROSS THE ARC WIRE FEEDER SETUP WITH FLEXTEC 500 CONNECTI...

Страница 42: ...WORK CLAMP TO NEGATIVE STUD LN 10 or DH 10 WIRE FEEDER FLEXTEC 500 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 SETU...

Страница 43: ...GRAMS FLEXTEC 500 L16790 WORK K1785 XXX CONTROL CABLE FLEXTEC 500 FLEXFEED 74 HT WIRE FEEDER ELECTRODE TO NEGATIVE STUD WORK CLAMP MAGNUM PRO GUN FLEXFEED 74 HT SETUP WITH FLEXTEC 500 CONNECTION DIAGR...

Страница 44: ...16790 TO POSITIVE STUD WORK PIECE GROUND CLAMP TO NEGATIVE STUD MAGNUM PRO GUN FLEXTEC 500 LN25 PRO DUAL POWER OPTIONAL CONTROL CABLE K1797 XXX WORK SENSE LEAD LN25 PRO DUAL POWER SETUP WITH FLEXTEC 5...

Страница 45: ...6 DIAGRAMS FLEXTEC 500 L16790 MAGNUM PRO GUN WORK PIECE WORK CLAMP TO NEGATIVE STUD TO POSITIVE STUD CONTROL CABLE K1543 XX FLEXFEED 84 FLEXTEC 500 PF84 SETUP WITH FLEXTEC 500 CONNECTION DIAGRAM A 01...

Страница 46: ...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 t...

Страница 47: ...P 1067 C CASE FRONT ASSEMBLY AR 2 P 1067 D DIVIDER PANEL ASSEMBLY AR 3 P 1067 E BASE CENTER ASSEMBLY AR 4 P 1067 F CASE BACK ASSEMBLY AR 5 P 1067 G WRAPAROUND ASSEMBLY AR Index of Sub Assemblies 12606...

Страница 48: ...P 1067 A jpg Index of Sub Assemblies 12606 2 Flextec 500 12606 Printed 09 29 2016 at 13 26 56 Produced by Enigma...

Страница 49: ...9SL16656 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 1...

Страница 50: ...HER 2 17E 9SCF000344 HEX HD SCREW 2 18 9SS30151 POSITIVE OUTPUT STUD LEAD 1 19 9SM22778 1 KNOB 1 0 2 20 9SM22778 2 KNOB 1 5 1 21 9SM22778 3 KNOB 1 22 9SS30408 2 LINE SWITCH LEAD ASBLY 1 9ST10082 30 SE...

Страница 51: ...P 1067 C jpg Case Front Assembly Flextec 500 12606 5 Printed 09 29 2016 at 13 26 56 Produced by Enigma...

Страница 52: ...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...

Страница 53: ...9ST11267 B INSULATOR 2 15 9ST10728 77 FUSE 1 16 9SS18491 1 MOV ASBLY 1 9SL16767 AUX TRANSFORMER THERMOSTAT ASBLY 1 17A 9SS13000 129 AUXILIARY TRANSFORMER 1 17B 9ST13359 15 THERMOSTAT 1 17C 9SS9225 32...

Страница 54: ...P 1067 D jpg Divider Panel Assembly 8 Flextec 500 12606 Printed 09 29 2016 at 13 26 56 Produced by Enigma...

Страница 55: ...8HN 1 5A 9SCF000040 5 16 18X 75HHCS 1 5B 9SS9262 30 PLAIN WASHER 1 5C 9SE106A 3 LOCKWASHER 1 6A 9SL16500 CHOKE ASBLY 1 6B 9SS9225 66 SELF TAPPING SCREW 3 6C 9SS9262 98 PLAIN WASHER 3 9SS23730 3 SPACER...

Страница 56: ...SWITCHBOARD ASBLY 1 13B 9SS9225 66 SELF TAPPING SCREW 2 14A 9SS18504 10 CURRENT TRANSDUCER 1 14B 9SS30871 LEM SUPPORT 1 14C 9SS8025 77 SELF TAPPING SCREW 1 14D 9SS9225 66 SELF TAPPING SCREW 1 9SL1145...

Страница 57: ...P 1067 E jpg Base Center Assembly Flextec 500 12606 11 Printed 09 29 2016 at 13 26 56 Produced by Enigma...

Страница 58: ...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...

Страница 59: ...P 1067 F jpg Case Back Assembly Flextec 500 12606 13 Printed 09 29 2016 at 13 26 56 Produced by Enigma...

Страница 60: ...GRIP 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 3 9SG8035 WIRING D...

Страница 61: ...P 1067 G jpg Wraparound Assembly Flextec 500 12606 15 Printed 09 29 2016 at 13 26 56 Produced by Enigma...

Страница 62: ...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...

Страница 63: ...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...

Страница 64: ...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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