IM10062-A

FLEXTEC™ 450 September, 2010

For use with machines Code 11626, 11754

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

OPERATOR’ S MANUAL

Copyright © Lincoln Global Inc.

• 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: www.lincolnelectric.com
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 i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
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.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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 ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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 iii iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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 iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: 8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains. des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans 9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines. 11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de voir le code “Code for safety in welding and cutting” CSA
courant pour soudage semi-automatique, ces precautions Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, REDRESSEUR
donc:

a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

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 v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information 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 information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEb SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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 vi TAbLE OF CONTENTS vi
Page

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
Output Cable Guidelines........................................................................................A-6
________________________________________________________________________

Operation .........................................................................................................Section b
Safety Precautions ................................................................................................B-1
Graphic Symbols............................................................................................B-1, B-2
Product Description ..............................................................................................B-2
Duty Cycle .............................................................................................................B-2
Design Features ....................................................................................................B-2
Recommended Processes and Equipment ...........................................................B-3
Case Front Controls...............................................................................................B-4
Power-Up Sequence..............................................................................................B-5
Case Back Controls ...............................................................................................B-5
Common Welding Procedures, Weld Controls and Displays..................B-5, thru B-8
_______________________________________________________________________

Accessories .....................................................................................................Section C
Options / Accessories............................................................................................C-1
________________________________________________________________________

Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
VISUAL INSPECTION...................................................................................................D-1
ROUTINE MAINTENANCE ............................................................................................D-1
PERIODIC MAINTENANCE ...........................................................................................D-1
________________________________________________________________________

Section E ..............................................................................................Troubleshooting
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Error Codes ...........................................................................................................E-3
________________________________________________________________________

Wiring Diagram and Dimension Print ..............................................................Section F

________________________________________________________________________

Parts List ....................................................................................................P-652 Series

________________________________________________________________________

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 A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS - FLEXTEC™ 450

POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @
Rated Output

60% rating 37 / 27 / 22 72 Watts

K2882-1 380 / 460 / 575 / 3 / 50 / 60 Max. 95%
100% rating 29 / 21 / 17 (fan on)

RATED OUTPUT
Process Duty Cycle Volts at Rated Amperes Amperes

60% 36.5V 450

GMAW (CV)
100% 34V 400

60% 28V 450

GTAW (CC)
100% 26V 400

60% 38V 450

SMAW (CC)
100% 36V 400

60% 36.5V 450

FCAW-GS (CV)
100% 34V 400

60% 36.5V 450

FCAW-SS (CV)
100% 34V 400

RECOMMENDED INPUT WIRE AND FUSE SIzES (1)

VOLTAGE Maximum Cord Size(3) Type 75°C Copper COPPER GROUNDING Fuse (Super Lag) or
50/60Hz Input AWG SIzES Wire in Conduit CONDUCTOR Breaker Size (2)
Amperes (mm) AWG (mm )2 AWG (mm2)

380/3/50 42 A 8(10) 8 (10) 10 (6) 50

460/3/60 30 A 8(10) 10 (6) 10 (6) 45
575/3/60 25 A 10(6) 12 (4) 12 (4) 35
(1) Cord and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.
(2) Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the
magnitude of current increases.
(3) Type SD cord or similar in 30°C ambient.

FLEXTEC™ 450

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 A-2 INSTALLATION A-2

WELDING PROCESS
PROCESS OUTPUT RANGE (AMPERES) OCV (Uo)

GMAW (CV) 40-500 60

GTAW (CC) 10-500 24
SMAW (CC) 15-500 60
FCAW-GS (CV) 40-500 60
FCAW-SS (CV) 40-500 60
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT

K2882-1 18.80in (478mm) 14.14in (359mm) 26.66in (677mm) 125lbs (56.6kg)*

TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
**
Environmentally Hardened: 14°F to 131°F (-10°C to 55°C ) Environmentally Hardened: -40°F to 185°F (-40°C to 85°C)

IP23 155º(F) Insulation Class

* Weight does not include input cord.
** Output De-rated at Temperatures above 40°C.

FLEXTEC™ 450

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 A-3 INSTALLATION A-3
SAFETY PRECAUTIONS
CAUTION
WARNING
Do not mount the Flextec™ 450 over combustible
ELECTRIC SHOCK can kill.
surfaces. Where there is a combustible surface
directly under stationary or fixed electrical equip-
ONLY QUALIFIED PERSONNEL ment, that surface shall be covered with a steel
SHOULD PERFORM THIS INSTALLA- plate at least .060” (1.6mm) thick, which shall
TION. extend not less than 5.90” (150mm) beyond the
• TURN OFF INPUT POWER TO THE POWER equipment on all sides.
SOURCE AT THE DISCONNECT SWITCH OR -----------------------------------------------------------------------
FUSE bOX bEFORE WORKING ON THIS
EQUIPMENT. TURN OFF THE INPUT POWER INPUT AND GROUNDING CONNECTIONS
TO ANY OTHER EQUIPMENT CONNECTED TO
THE WELDING SYSTEM AT THE DISCONNECT MACHINE GROUNDING
SWITCH OR FUSE bOX bEFORE WORKING ON The frame of the welder must be grounded.
THE EQUIPMENT. A ground terminal marked with the symbol
shown is located inside the reconnect/input
• DO NOT TOUCH ELECTRICALLY HOT PARTS. connection area for this purpose. See your local and
• ALWAYS CONNECT THE FLEXTEC™ 450 national electrical codes for proper grounding meth-
GROUNDING LUG (LOCATED INSIDE THE ods.
RECONNECT INPUT ACCESS DOOR) TO A
PROPER SAFETY (EARTH) GROUND. HIGH FREQUENCY PROTECTION
----------------------------------------------------------------------
SELECT SUITAbLE LOCATION Locate the Flextec™ 450 away from radio controlled
machinery. The normal operation of the Flextec™ 450
LOCATION AND VENTILATION FOR COOLING may adversely affect the operation of RF controlled
Place the welder where clean cooling air can freely equipment, which may result in bodily injury or dam-
circulate in through the rear louvers and out through
age to the equipment.
the case sides. 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 HIGH TEMPERATURE OPERATION
in excessive operating temperatures and nuisance
shutdowns.
WELDER OUTPUT RATINGS AT 55°C
LIFTING ELEVATED TEMPERATURES
Both handles should be used when lifting the
Flextec™ 450. When using a crane or overhead
AMPS DUTY CYCLE VOLTS TEMPERATURES
device a lifting strap should be connected to both han-
dles. Do not attempt to lift the Flextec™ 450 with
340 100% 34VDC
accessories attached to it.
375 60% 35VDC
STACKING 55°C
400 40% 36VDC
The Flextec™ 450 cannot be stacked.
450 20% 38VDC
ENVIRONMENTAL LIMITATIONS
The Flextec™ 450 is IP23 rated for use in an outdoor
environment. The Flextec™ 450 should not be sub-
jected to falling water during use nor should any parts
of it be submerged in water. Doing so may cause
improper operation as well as pose a safety hazard.
The best practice is to keep the machine in a dry,
sheltered area.

FLEXTEC™ 450

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 A-4 INSTALLATION A-4
INPUT FUSE AND SUPPLY WIRE
WARNING CONSIDERATIONS
ELECTRIC SHOCK can kill.
Refer to Specification in this Installation Section for
ONLY A QUALIFIED ELECTRICIAN recommended fuse, wire sizes and type of the copper
SHOULD CONNECT THE INPUT wires. Fuse the input circuit with the recommended
LEADS TO THE FLEXTEC™ 450. super lag fuse or delay type breakers (also called
CONNECTIONS SHOULD bE MADE IN ACCOR- "inverse time" or "thermal/magnetic" circuit breakers).
DANCE WITH ALL LOCAL AND NATIONAL Choose input and grounding wire size according to
ELECTRICAL CODES AND THE CONNECTION local or national electrical codes. Using input wire
DIAGRAM LOCATED ON THE INSIDE OF THE sizes, fuses or circuit breakers smaller than recom-
RECONNECT/INPUT ACCESS DOOR OF THE mended may result in "nuisance" shut-offs from
MACHINE. FAILURE TO DO SO MAY RESULT welder inrush currents, even if the machine is not
IN bODILY INJURY OR DEATH. being used at high currents.
----------------------------------------------------------------------
INPUT VOLTAGE SELECTION
INPUT CONNECTION
(See Figure A.1) Welders are shipped connected for 460 Volt input
voltage. To move this connection to a different input
Use a three-phase supply line. A 1.40 inch (36 mm) voltage, see the diagram located on the inside panel
diameter access hole for the input supply is located on in the reconnect/input connection area, also illustrat-
the case back. Connect L1, L2, L3 and ground ed below. If the Auxiliary lead (indicated as ‘A’) is
according to the Input Supply Connection Diagram placed in the wrong position and power is applied to
decal located on the internal horizontal panel. the machine, the machine will protect itself and dis-
play an error message:
• "Err" "058" will be shown on the display.
To access the reconnect/input supply connection • The control board and switch boards will blink out
blocks, remove the 8 screws that secure the case top error 58 on their status leds.
of the welder and remove the case top. • The weld output will be turned off and the control
board will force itself into an idle state.
• The machine will need to have the misconnect
condition removed before it will recover.
FIGURE A-1
codes for proper grounding methods.)

for the proper input voltages • A ground terminal marked with the symbol shown
is provided separate from this block for connecting the ground
lead of the line cord. (See your local and national electrical

RECONNECT TERMINAL BLOCK

• Reconnects auxiliary transformers
POWER SUPPLY TERMINAL BLOCK
• Line Cord/Cable attaches here.

POWER SUPPLY ACCESS HOLE

• Route input power cable through this hole.

RECONNECT TERMINAL BLOCK

RECONNECT TERMINAL BLOCK

POWER SUPPLY ACCESS HOLE

• Route input power cable through this hole.

RECONNECT TERMINAL BLOCK POWER SUPPLY TERMINAL BLOCK

• Reconnects auxiliary transformers • Line Cord/Cable attaches here.
for the proper input voltages • A ground terminal marked with the symbol shown
is provided separate from this block for connecting the ground
lead of the line cord. (See your local and national electrical
codes for proper grounding methods.)

FLEXTEC™ 450

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 A-5 INSTALLATION A-5
CAbLE CONNECTIONS
See FIGURE A.2 for locating 6-pin and 14-pin con-
nectors on the front of the FLEXTEC™ 450.
C
B

6-PIN REMOTE CONTROL CONNECTOR

D
A
E F

Function Pin Wiring

E F
A 6-pin remote A 77 Remote potentiometer, 5K
control con- B 76 Remote potentiometer, wiper
D nector for C 75 Remote potentiometer, common
B remote or D Trigger, common
C
hand/foot E Trigger, input
amptrol. F Ground

14-PIN CONNECTOR FOR WIRE FEEDER

Function Pin Wiring
E

F
D

G
L
M
C B

H
I
A

14 pin con- A
nector for B Ground
wire feeder C Trigger, Common
G H connectivity. D Trigger input
F I E 77 Remote potentiometer, 5K
N F 76 Remote potentiometer, wiper
J
M G 75 Remote potentiometer, common
K
E L A H Voltage Sense (21)
I Motor (42 VAC)
D C B
J
K Motor (42 VAC)
L
M
N

FIGURE A.2
CONTROL CONNECTOR
6-PIN REMOTE FOR WIRE FEEDER
14-PIN CONNECTOR

14-PIN CONNECTOR
6-PIN REMOTE FOR WIRE FEEDER
CONTROL CONNECTOR
FLEXTEC™ 450

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 A-6 INSTALLATION A-6

RECOMMENDED ELECTRODE AND • Route all cables directly to the work and wire
WORK CAbLE SIzES FOR ARC WELDING feeder, avoid excessive lengths and do not coil
excess cable. Route the electrode and work cables
General Guidelines in close proximity to one another to minimize the
Connect the electrode and work cables between the loop area and therefore the inductance of the weld
appropriate output studs of the Flextec™ 450 per the circuit.
following guidelines:
• Always weld in a direction away from the work
• Most welding applications run with the electrode (ground) connection.
being positive (+). For those applications, connect
the electrode cable between the wire drive feed CONTROL CAbLE CONNECTIONS
plate and the positive (+) output stud on the power
source. Connect a work lead from the negative (-) General Guidelines
power source output stud to the work piece. Genuine Lincoln control cables should be used at all
times (except where noted otherwise). Lincoln cables
• When negative electrode polarity is required, such are specifically designed for the communication and
as in some Innershield applications, reverse the out- power needs of the Flextec™ 450. Most are designed
put connections at the power source (electrode to be connected end to end for ease of extension.
cable to the negative (-) stud, and work cable to the Generally, it is recommended that the total length not
positive (+) stud). exceed 100 feet (30.5 m). The use of non-standard
cables, especially in lengths greater than 25 feet, can
lead to communication problems (system shutdowns),
The following recommendations apply to all output poor motor acceleration (poor arc starting), and low
polarities and weld modes: wire driving force (wire feeding problems). Always use
the shortest length of control cable possible, and DO
• Select the appropriate size cables per the NOT coil excess cable.
“Output Cable Guidelines” (See Table A.1).
Excessive voltage drops caused by undersized Regarding cable placement, best results will be
welding cables and poor connections often result in obtained when control cables are routed separate
unsatisfactory welding performance. Always use the from the weld cables. This minimizes the possibility of
largest welding cables (electrode and work) that are interference between the high currents flowing
practical, and be sure all connections are clean and through the weld cables, and the low level signals in
tight. the control cables.

Note: Excessive heat in the weld circuit indicates

undersized cables and/or bad connections.

TAbLE A.1
OUTPUT CAbLE GUIDELINES
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
AMPERES PERCENT (RUBBER COVERED COPPER - RATED 167°F or 75°C)**
DUTY 0 to 50Ft. 50 to 100Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.
(0 to15m) (15 to 30m) (30 to 46m) (46 to 61m) (61 to 76m)
CYCLE
200 60 2 2 2 1 1/0
200 100 2 2 2 1 1/0
250 30 3 3 2 1 1/0
250 40 2 2 1 1 1/0
250 60 1 1 1 1 1/0
250 100 1 1 1 1 1/0
300 60 1 1 1 1/0 2/0
300 100 2/0 2/0 2/0 2/0 3/0
350 40 1/0 1/0 2/0 2/0 3/0
400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 3/0 3/0 4/0

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).

FLEXTEC™ 450

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 b-1 OPERATION b-1
SAFETY PRECAUTIONS GRAPHIC SYMbOLS THAT
Read this entire section of operating instructions APPEAR ON THIS MACHINE
before operating the machine.
OR IN THIS MANUAL
WARNING
INPUT POWER
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the
ON
electrode and drive mechanism are
always electrically energized and
could remain energized several OFF
seconds after the welding ceases.
• Do not touch electrically live parts or electrodes
with your skin or wet clothing. HIGH TEMPERATURE
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
CIRCUIT bREAKER
FUMES AND GASES can be
dangerous.
WIRE FEEDER
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
POSITIVE OUTPUT

WELDING SPARKS can cause

fire or explosion. NEGATIVE OUTPUT
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
3 PHASE INVERTER

ARC RAYS can burn. INPUT POWER

• Wear eye, ear, and body protection.

THREE PHASE
Observe additional guidelines detailed in the
beginning of this manual.

DIRECT CURRENT

FLEXTEC™ 450

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 b-2 OPERATION b-2

GRAPHIC SYMbOLS THAT PRODUCT DESCRIPTION

APPEAR ON THIS MACHINE
The Flextec™ 450 is a multi-process CC/CV DC
OR IN THIS MANUAL inverter and is rated for 450 amps, 38 volts at a 60%
duty cycle. The Flextec is intended for both factory
and field operation. It comes in a compact, rugged
U0 OPEN CIRCUIT case that is designed for portability and outdoor use
VOLTAGE with an IP23 environmental rating. The user interface
of the Flextec™ 450 is simple and intuitive. Weld
modes are selected by a 4 position selector switch.
U1 INPUT VOLTAGE Volts and Amps are displayed on an easy to view LED
display, and the amps and volts are set by a large out-
put control knob. A hot start toggle selector switch
and an arc control knob allow for finer tuning of the
U2 OUTPUT VOLTAGE welding arc. The Flextec™ 450 operates on 380V,
460V, or 575V 50hz or 60hz power.

I1 INPUT CURRENT DUTY CYCLE

The Flextec™ 450 is capable of welding at a 100%

duty cycle (continuous welding) at 400 amps rated
I2 OUTPUT CURRENT output. The 60% rating is 450 amps base off of a 10
minute cycle - 6 minutes on time and 4 minutes off
time. The maximum output of the machine is 500
PROTECTIVE amps.
GROUND
The Flextec™ 450 is also rated for Desert Duty, ele-
vated temperature operation, in a 55°C(131°F) ambi-
ent. The machine is output de-rated for this applica-
tion.

DESIGN FEATURES
WARNING or CAUTION
• Severe Duty Design for outdoor use (IP23 rating).
• Passive Power Factor Correction – reliably gives
95% power factor for lower installation costs.
Explosion • 89% Efficiency rating – reduces electrical utility
costs.
• Simple user interface - designed with the operator in
mind. Getting setup for the weld is several clicks
Dangerous Voltage 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.
Shock Hazard • Thermal protection by thermostats with Thermal
Indicator LED.
• Error Codes display on LED screen for ease of trou-
ble shooting.
• Electronic over current protection.
• Input voltage misconnection protection.
• Utilizes digital signal processing and microprocessor
control.

FLEXTEC™ 450

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 b-3 OPERATION b-3

RECOMMENDED PROCESSES AND

EQUIPMENT

RECOMMENDED PROCESSES

The Flextec™ 450 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 Flextec™ 450 is suitable only for the processes listed.

EQUIPMENT LIMITATIONS
Operating Temperature Range is -10° C to + 55° C.
Output De-rated at Temperatures above 40°C.

COMMON EQUIPMENT PACKAGES

basic Package
K2882-1 Flextec™ 450
K2327-5 LF-72 Bench Model
K2149-1 Work Lead Package
K1842-10 10 Ft. Weld Power Cable
3100211 Harris Regulator and gas hose

Common Optional Kits

K857 Remote Output Control (25 feet)
K857-1 Remote Output Control (100 feet)
K870 Foot Amptrol
K963-3 Hand Amptrol

Compatible Wire Feeders

LF-72
LF-74
All Models LN-10
DH-10
LN-25 Pro

Note: The Flextec™ 450 is not compatible with 115V Wire Feeders.

FLEXTEC™ 450

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 b-4 OPERATION b-4
CASE FRONT CONTROL DESCRIPTIONS
(See Figure B.1) 11. Wire feeder voltmeter polarity selection toggle
switch
1. Power Switch
12. Circuit breaker reset button for the 14-pin wire
2. Voltage Display Meter feeder connector

3. Amperage Display Meter 13. 14-pin wire feeder circular connector

4. Thermal LED 14. 6-pin remote circular connector

5. Output Control Dial 15. Positive and negative welding output studs

6. Weld Process Selector Switch

7. Hot Start Toggle Switch

8. Output Control Local/Remote Toggle Switch

9. Arc Control Dial

10. Weld Terminals On/Remote toggle selector

switch

FIGURE b.1
15 14

13

12
8
11

7 10

9
6

4
3 2 1

3 2 1
4

6
9

7 10

11
8
12

13

15 14
FLEXTEC™ 450

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 b-5 OPERATION b-5
CASE bACK CONTROL 3. CV – This is CV (constant voltage) weld mode used
(See Figure B.2) for welding the GMAW MIG welding process and
the FCAW-GS, flux cored gas shielded welding
1. Input Power Cord Access Hole. process.

FIGURE b.2 4. CV-Innershield – This is a CV (constant voltage)

weld mode used for welding the FCAW-SS, flux
1

1 cored self shielded welding process

The Flextec™ 450 is also capable of gouging.

Gouging can be done in either the SMAW mode or the
CV and CV-Innershield modes.

In addition to the weld process selector switch, a hot

start toggle, output control dial and arc control dial are
provided to setup and fine tune the welding procedure.

WELD CONTROLS AND DISPLAYS

Weld Process Selector Switch

4 Position switch used to select the welding process.

Hot Start Toggle Switch

The Hot Start control regulates the starting current at
POWER-UP SEQUENCE arc initiation. Hot Start can be set to “Off” and no
additional current is added at arc start. When set to
When power is applied to the Flextec™ 450, the the “On” position, additional current (relative to the
displays will illuminate and display the voltage and/or preset current) is added at arc initiation.
amperage settings.
Arc Control Dial
COMMON WELDING PROCEDURES Full range selection of arc control from -10 to +10. In
CV mode, this control is an inductance control. In
WARNING stick mode, the control adjusts the arc force.
MAKING A WELD
The serviceability of a product or structure utiliz- Output Control Dial
ing the welding programs is and must be the sole Output control is conducted by a single turn poten-
responsibility of the builder/user. Many variables tiometer. (Adjustment is indicated by the meters.)
beyond the control of The Lincoln Electric When in Remote Mode, this control sets the maximum
Company affect the results obtained in applying welding current of the remote device. For example, full
these programs. These variables include, but are depression of a foot or hand amptrol results in the pre-
not limited to, welding procedure, plate chemistry set level of current.
and temperature, weldment design, fabrication
methods and service requirements. The available Voltage Display Meter
range of a welding program may not be suitable • Prior to CV operation (current flow), the meter dis-
for all applications, and the build/user is and must plays desired preset voltage value.
be solely responsible for welding program selec- • Prior to STICK or TIG operation, the meter displays
tion. the Open Circuit Voltage of the Power Source or four
The Flextec™ 450 is a multi-process inverter welder. dashes if the output has not been turned on.
The Weld Process Selector Switch is used to set • During welding, this meter displays actual average
the desired weld mode. The Flextec™ 450 has 4 volts.
selectable welding modes: • After welding, the meter holds the actual voltage
value for 5 seconds. The displays blink indicating that
1. SMAW – This is a CC (constant current) weld the machine is in the "hold" period.
mode used for the SMAW stick welding process. • Output adjustment while in the "hold" period results in
the "prior to operation" characteristics.
2. GTAW – This is a CC (constant current) weld
mode used for the GTAW TIG welding process.

FLEXTEC™ 450

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 b-6 OPERATION b-6
Amperage Display Meter Arc Control - The Arc Control regulates the Arc Force
• Prior to STICK or TIG operation (current flow), the to adjust the short circuit current. The minimum setting
meter displays preset current value. (-10) will produce a "soft" arc and will produce minimal
• Prior to CV operation, the meter displays four dash- spatter. The maximum setting (+10) will produce a
es indicating non-presettable AMPS. "crisp" arc and will minimize electrode sticking.
• During welding, this meter displays actual average
amps. Weld Terminals On/Remote – Set to “On” so the
• After welding, the meter holds the actual current machine is in the ready to weld state.
value for 5 seconds. The displays blink indicating
that the machine is in the "hold" period. Voltage Display Meter – This display will display
•Output adjustment while in the "hold" period results three dashed lines when the machine is in the idle
in the "prior to operation" characteristics state. This indicates that voltage is not settable in this
weld mode. While output is enabled, the actual weld-
Weld Terminals On/Remote Toggle Switch ing voltage is displayed. After welding, the meter
• This switch determines the trigger location. holds the actual voltage value for 5 seconds. Output
• When set to the “ON” position, the weld terminals adjustment while in the "hold" period results in the
are at OCV (open circuit voltage) and ready to weld. "prior to operation" characteristics. The displays blink
• When set to the “REMOTE” position, output is indicating that the machine is in the "hold" period.
enabled through a remote trigger.
Amperage Display Meter – This display will display
Control - Local/Remote Toggle Switch the pre-set welding current when the machine is in the
• Set the switch to “Local” to control output at the idle state. While output is enabled, the actual weld
machine by the Output Control dial. amperage is displayed. After welding, the meter holds
• Set the switch to “REMOTE” to control output via a the actual amperage value for 5 seconds. Output
remote device (K857 hand amptrol or K870 foot adjustment while in the "hold" period results in the
amptrol) connected to the 6-pin remote connector "prior to operation" characteristics. The displays blink
or a wire feeder connected to the 14-pin connector. indicating that the machine is in the "Hold" period.

Thermal Light Output Control Local/Remote – When the control is

• This status light indicates when the power source set to local (no remote potentiometer/control plugged
has been driven into thermal overload. If the output into the 6-pin or 14-pin connectors), the output is con-
terminals were "ON", the output will be turned back trolled through the Output Control Dial on the front of
on once the unit cools down to an acceptable tem- the Flextec™ 450. Set this switch to “REMOTE”
perature level. If the unit was operating in the when an external potentiometer/control is connected.
"REMOTE" mode, the trigger will need to be • When a remote potentiometer is connected, the out-
opened before or after the thermal has cleared and put control on the Flextec™ 450 and the remote act
closed after the machine has cooled down to an as a master/slave configuration. Use the control
acceptable temperature to establish output. dial on the Flextec™ 450 to pre-set the maximum
welding current. The remote will control output from
bASIC MODES OF OPERATION minimum to the pre-set maximum.

SMAW Output Control Dial

This weld mode is a constant current (CC) mode fea- • When the Local/Remote is set to Local, this dial
turing continuous control from 15 – 500 amps. It is sets the welding amperage.
intended for the SMAW stick welding processes and • When the Local/Remote is set to Remote, this dial
arc gouging. sets the maximum welding amperage. The remote
potentiometer than controls the amperage from min-
Hot Start - The Hot Start control regulates the starting imum to this pre-set maximum.
current at arc initiation. Hot Start can be set to “Off”
and no additional current is added at arc start. When
set to the “On” position, additional current (relative to
the preset current) at arc initiation.

FLEXTEC™ 450

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 b-7 OPERATION b-7
GTAW CV-GAS

This weld mode is a constant current (CC) mode featuring con- This weld mode is a constant voltage (CV) mode featuring con-
tinuous control from 10 – 500 amps. It is intended for the GTAW tinuous control from 10 to 45 volts.
TIG welding processes. It is intended for the GMAW, FCAW-GS, MCAW welding
processes and arc gouging.
Hot Start - The Hot Start control regulates the starting current
at arc initiation. Hot Start can be set to “Off” and no additional Hot Start – Toggle to “ON” position to provide more energy
current is added at arc start. When set to the “On” position, during the start of a weld.
additional current (relative to the preset current) at arc initiation.
Arc Control – The Arc Control regulates pinch effect
Arc Control – This control is not used in the GTAW mode. (Inductance). At the minimum setting (-10), minimizes pinch and
results in a soft arc. Low pinch settings are preferable for weld-
Weld Terminals On/Remote ing with gas mixes containing mostly inert gases. At the maxi-
• When set to the “ON” position, the weld terminals are at OCV mum setting (+10), maximizes pinch effect and results in a crisp
(open circuit voltage) and ready to weld. arc. High pinch settings are preferable for welding FCAW-GS
• When set to the “REMOTE” position, output is enabled and GMAW with CO2.
through a remote trigger.
Weld Terminals On/Remote
Voltage Display Meter – This display will display three dashed • When set to the “ON” position, the weld terminals are at OCV
lines when the machine is in the idle state. This indicates that (open circuit voltage) and ready to weld. This selection is
voltage is not settable in this weld mode. While output is used for across the arc wire feeders.
enabled, the actual welding voltage is displayed. After welding, • When set to the “REMOTE” position, output is enabled
the meter holds the actual voltage value for 5 seconds. Output through a remote trigger.
adjustment while in the "hold" period results in the "prior to
operation" characteristics. The displays blink indicating that the Amperage Display Meter – This display will display three
machine is in the "hold" period. dashed lines when the machine is in the idle state. This indi-
cates that amperage is not settable in this weld mode. While
Amperage Display Meter – This display will display the pre-set output is enabled, the actual welding amperage is displayed.
welding current when the machine is in the idle state. While After welding, the meter holds the actual amperage value for 5
output is enabled, the actual weld amperage is displayed. After seconds. Output adjustment while in the "hold" period results in
welding, the meter holds the actual amperage value for 5 sec- the "prior to operation" characteristics. The displays blink indi-
onds. Output adjustment while in the "hold" period results in the cating that the machine is in the "hold" period.
"prior to operation" characteristics. The displays blink indicating
that the machine is in the "hold" period. Voltage Display Meter – This display will display the pre-set
welding voltage when the machine is in the idle state. While out-
Output Control Local/Remote – When the control is set to put is enabled, the actual weld amperage is displayed. After
local (no remote potentiometer/control plugged into the 6-pin or welding, the meter holds the actual voltage value for 5 seconds.
14-pin connectors), the output is controlled through the Output Output adjustment while in the "hold" period results in the "prior
Control Dial on the front of the Flextec™ 450. Set this switch to to operation" characteristics. The displays blink indicating that
“REMOTE” when an external potentiometer/control is connect- the machine is in the "hold" period.
ed.
• When a remote potentiometer is connected, the output control Output Control Local/Remote – When the control is set to
on the Flextec™ 450 and the remote act as a master/slave local (no remote potentiometer/control plugged into the 6-pin or
configuration. Use the control dial on the Flextec™ 450 to 14-pin connectors), the output is controlled through the Output
pre-set the maximum welding current. The remote will control Control Dial on the front of the Flextec™ 450. Set this switch to
output from minimum to the pre-set maximum. “REMOTE” when an external potentiometer/control is connect-
ed.
Output Control Dial
• When the Local/Remote is set to Local, this dial sets the Output Control Dial
welding amperage. • When the Local/Remote is set to Local, this dial sets the
• When the Local/Remote is set to Remote, this dial sets the welding voltage.
maximum welding amperage. • When the Local/Remote is set to Remote, this dial is disabled.

The remote potentiometer controls the amperage from minimum

to this pre-set maximum.

FLEXTEC™ 450

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 b-8 OPERATION b-8

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.

Arc Control – The Arc Control regulates pinch effect.

At the minimum setting (-10), minimizes pinch and
results in a soft arc. At the maximum setting (+10),
maximizes pinch effect and results in a crisp arc.

Weld Terminals On/Remote

• When set to the “ON” position, the weld terminals
are at OCV (open circuit voltage) and ready to weld.
This selection is used for across the arc wire feed-
ers.
• When set to the “REMOTE” position, output is
enabled through a remote trigger.

Amperage Display Meter – This display will display

three dashed lines when the machine is in the idle
state. This indicates that amperage is not settable in
this weld mode. While output is enabled, the actual
welding amperage is 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" characteristics. The displays
blink indicating that the machine is in the "hold" peri-
od.

Voltage Display Meter – This display will display the

pre-set welding voltage when the machine is in the
idle state. While output is enabled, the actual weld
amperage is displayed. After welding, the meter holds
the actual voltage value for 5 seconds. Output adjust-
ment while in the "hold" period results in the "prior to
operation" characteristics. The displays blink indicat-
ing that the machine is in the "hold" period.

Output Control Local/Remote – When the control is

set to local (no remote potentiometer/control plugged
into the 6-pin or 14-pin connectors), the output is con-
trolled through the Output Control Dial on the front of
the Flextec™ 450. Set this switch to “REMOTE”
when an external potentiometer/control is connected.

Output Control Dial

• When the Local/Remote is set to Local, this dial sets
the welding voltage.
• When the Local/Remote is set to Remote, this dial is
disabled

FLEXTEC™ 450

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 C-1 ACCESSORIES C-1

OPTIONS / ACCESSORIES
Foot Amptrol®
General Options Provides 25 ft. (7.6 m) of remote
current control for TIG welding.
K2149-1 Work Lead Package. (6-pin plug connection).
Order K870

Hand Amptrol® - Provides 25 ft.

K1842-10 10ft. Weld Power Cable (Lug to Lug). (7.6 m) of remote current control
for TIG welding. (6-pin plug con-
nection).
Order K963-3
Inverter and Wire Feeder Cart Rear-wheeled cart
includes front casters and no-lift gas bottle platform. Arc Start Switch - May be used
Convenient handles allow for easy cable storage while in place of the Foot or Hand
full length side trays store parts and tools. Shipped Amptrol®. Comes with a 25 ft.
fully assembled. Small footprint fits through 30" (762 (7.6m) cable. Attaches to the TIG
mm) door. torch for convenient finger control
Order K2945-1. to start and stop the weld cycle at
the current set on the machine.
Order K814
Fume Extracting Systems

Accessory Kit For stick weld-

ing. Includes 35 ft. (10.7 m) 2/0
electrode cable with lug, 30 ft.
(9.1 m) 2/0 work cable with lugs,
headshield, filter plate, cover
plate, work clamp and electrode
holder. 400 amp capacity. Order
K704

Remote Output Control

Consists of a control box with
choice of two cable lengths.
Permits remote adjustment of out-
put.
Order K857 for 25 ft. (7.6 m)
Order K857-1 for 100 ft. (30 m)

TIG Options

Pro-Torch™ TIG Torches – PTA-

9, PTA-17, PTA-26 – 2 piece
power cord.

FLEXTEC™ 450

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 D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS PERIODIC MAINTENANCE

WARNING Thermal Protection

ELECTRIC SHOCK can kill. Thermostats protect the machine from excessive
• Only Qualified personnel should operating temperatures. Excessive temperatures may
perform this maintenance. be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
• Turn the input power OFF at the excessive operating temperature should occur, the
disconnect switch or fuse box before thermostat will disable the machine output. The meter
working on this equipment.
• Do not touch electrically hot parts. will remain energized during this time. Thermostats
------------------------------------------------------------------------ are self-resetting once the machine cools sufficiently.
If the thermostat shutdown was caused by excessive
See additional warning information output or duty cycle and the fan is operating normally,
throughout this Operator’s Manual the Power Switch may be left on and the reset should
occur within a 15 minute period.
-----------------------------------------------------------

VISUAL INSPECTION

Clean interior of machine with a low pressure air

stream. Make a thorough inspection of all compo-
nents. Look for signs of overheating, broken leads or
other obvious problems. Many problems can be
uncovered with a good visual inspection.

ROUTINE MAINTENANCE

1. Every 6 months or so the machine should be

cleaned with a low pressure airstream. Keeping
the machine clean will result in cooler operation
and higher reliability. Be sure to clean these areas:

• All printed circuit boards

• Power switch
• Main transformer
• Heatsink Fins
• Input rectifier
• Auxiliary Transformer
• Reconnect Switch Area
• Fan (Blow air through the rear louvers)

2. Examine the sheet metal case for dents or breakage.

Repair the case as required. Keep the case in good con-
dition to insure that high voltage parts are protected and
correct spacings are maintained. All external sheet
metal screws must be in place to insure case strength
and electrical ground continuity.

FLEXTEC™ 450

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 E-1 TROUbLESHOOTING E-1

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. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

FLEXTEC™ 450

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 E-2 TROUbLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual
PRObLEMS POSSIbLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal Lincoln Electric Field Service facil-
covers are removed. ity for technical assistance.

Machine won’t weld, can’t get any 1. If the displays show an Err ###
output. see the fault section for corrective
action.
2 If the thermal symbol is lit 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 operation.

Thermal symbol is lit. 1. Check for proper fan operation.

• Check for material blocking
intake or exhaust louvers.
• Blow air in the rear louvers to
clear dirt from the fan. 1.If all recommended possible areas
Note: The Fan As Needed circuitry of misadjustment have been
automatically shuts off the fan checked and the problem persists,
5 minutes after welding has Contact your local Lincoln
stopped. Authorized Field Service
2. Welding output ratings may have Facility.
been exceeded. Allow the
machine to cool down and reset.

Wire feeder won’t work. Apparently 1. Check circuit breakers by the wire
no power to wire feeder feeder receptacles on the rear of
the machine. Reset
2. Check the control cable between
the power source and the wire
feeder for continuity.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
FLEXTEC™ 450

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 E-3 TROUbLESHOOTING E-3
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.

The status lights on the main control board and the switch pc board are dual-color LED’s. Normal operation for
each is steady green.
Error Codes for the FLEXTEC™ 450
Error Description Corrective Action
Code#
31 Primary Over Current Check the input power (voltage and fre- Machine needs to be turned
quency). Verify the primary reconnect is off and back on to reset.
properly configured for the input voltage.

If condition persists contact an authorized

Lincoln Field Service Shop.

711 Capacitor over-or-under volt- Check input power (voltage and frequency) Machine needs to be turned
age. while welding. Verify the primary reconnect off and back on to reset.
is properly configured for the input voltage.

712 Communication error between Re-trigger to recover from error. Weld Terminals Remote:
P.C. boards or P.C. board Re-trigger to recover from
fatal. If condition persists contact an authorized error.
Lincoln Field Service Shop.
Weld Terminals Local:
Toggle Remote/Local Switch
to recover from error.

713 Input Power Misconnect

Supply Voltage is too high. Verify the primary reconnect is properly
configured for the input voltage. Machine needs to be turned
off and back on to reset.
714 Input Power Misconnect If condition persists contact an authorized
Supply Voltage is too low. Lincoln Field Service Shop.

715 Supply Voltage to the switch If condition persists contact an authorized Machine needs to be turned
Printed Circuit Board is too Lincoln Field Service Shop. off and back on to reset.
low.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
FLEXTEC™ 450

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 F-1

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FLEXTEC™ 450
DIAGRAMS

NOTE: This 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 the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
 F-2

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FLEXTEC™ 450
DIAGRAMS

NOTE: This 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 the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
 F-3 DIMENSION PRINT F-3

41.41

15.62

66.62
60.31

87.81

10.A

89651L

L15698
A.01
18.78
13.06
26.51

26.66
14.14

FLEXTEC™ 450

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 NOTES

FLEXTEC™ 450

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 NOTES

FLEXTEC™ 450

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 • Do not touch electrically live parts or • Keep flammable materials away. • Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

• Insulate yourself from work and
ground.
Spanish
• No toque las partes o los electrodos • Mantenga el material combustible • Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION • Aislese del trabajo y de la tierra.

French • Ne laissez ni la peau ni des vête- • Gardez à l’écart de tout matériel • Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
• Isolez-vous du travail et de la terre.

German • Berühren Sie keine stromführenden • Entfernen Sie brennbarres Material! • Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
• Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
• Não toque partes elétricas e electro- • Mantenha inflamáveis bem guarda- • Use proteção para a vista, ouvido e
dos com a pele ou roupa molhada. dos. corpo.
ATENÇÃO • Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE

ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT

ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.

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 • Keep your head out of fumes. • Turn power off before servicing. • Do not operate with panel open or
• Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
• Los humos fuera de la zona de res- Spanish
• Desconectar el cable de ali- • No operar con panel abierto o
piración.
• Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
• Gardez la tête à l’écart des fumées. • Débranchez le courant avant l’entre- • N’opérez pas avec les panneaux French
• Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
• Vermeiden Sie das Einatmen von • Strom vor Wartungsarbeiten • Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öffnen; oder Innenschutzverkleidung in
• Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Maschine anhalten!) Betrieb setzen! WARNUNG
• Não opere com as tampas removidas. Portuguese
• Mantenha seu rosto da fumaça. • Mantenha-se afastado das partes
• Use ventilação e exhaustão para • Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço.
• Não toque as partes elétricas nuas.
• Não opere com os paineis abertos ATENÇÃO
ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES

DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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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: www.lincolnelectric.com
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