Lincoln Electric FLEXTEC 500 P, Operator'S Manual

Page 1: ...om register Authorized Service and Distributor Locator www lincolnelectric com locator IM10194 Issue Date 10 14 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12246 S...

Page 2: ...he general area IN 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...

Page 3: ...y guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e...

Page 4: ...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 suita...

Page 5: ...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 NFPA 51B Standard fo...

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

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

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

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

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

Page 11: ...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...

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

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

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

Page 15: ...rol Dial Sets the Output 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...

Page 16: ...r Cord Access Hole 2 Access Panel Allows access for connecting input power and configuring the machine 3 Input Power Reconnect Configures the machine for the input supply voltage 4 Input Power Fuse Pr...

Page 17: ...normal conditions the dip switches are all in the off position Figure A 2 There are 2 instances that require a change of the dip switch 1 Enter VRD Mode VRD Enabled a Turn switch 5 to the ON Position...

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

Page 19: ...panel located on the case back and connect L1 L2 L3 and ground according to the Input Supply Connection Diagram decal See Figure B 1 Input Fuse and Supply Wire Considerations Refer to Page A 1 for rec...

Page 20: ...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 con...

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

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

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

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

Page 25: ...processes Connect the power sources as shown on Figure B2 and set the output control of each power sources to one half of the desired arc current FLEXTEC 500 P MACHINE 1 NEGATIVE POSITIVE INPUT TERMI...

Page 26: ...B 9 NOTES FLEXTEC 500 P...

Page 27: ...VOLTAGE RATED REDUCED NO LOAD VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION EXPLOSION DANGEROUS VOLTAGE SHOCK HAZARD OFF HIGH TEMPERATURE CIRC...

Page 28: ...ers ARC RAYS can burn eyes and skin Wear eye ear and body protection SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS ON INSIDE OF FRONT COVER OF OPERATING MANUAL When power is...

Page 29: ...position is used to unlock synergic and basic pulse welding modes when combined with an ArcLink wire feeder The machine is also capable of gouging Gouging can be done in either the SMAW mode or the CV...

Page 30: ...so configures the 292 lead to the User Interface board to determine if voltage sensing needs to be configured for Electrode Negative Polarity operation in ArcLink mode Thermal Light This status light...

Page 31: ...holds the actual voltage value for 5 seconds Output adjustment while in the hold period results in the prior to operation characteristics stated above The displays blink indicating that the machine i...

Page 32: ...age LCD Display This display will display the pre set welding current when the machine is in the idle state After welding the meter holds the actual amperage value for 5 seconds Output adjustment whil...

Page 33: ...idle state This indicates that amperage is not settable in this weld mode While output is enabled the actual welding amperage will be displayed After welding the meter holds the actual amperage value...

Page 34: ...d the actual welding amperage will be displayed After welding the meter holds the actual amperage value for 5 seconds Output adjustment while in the hold period results in the prior to operation chara...

Page 35: ...ble in this weld mode While output is enabled the actual welding amperage will be displayed After welding the meter holds the actual amperage value for 5 seconds Output adjustment while in the hold pe...

Page 36: ...00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length See Figure C 2 All pulse welding programs in the Flextec 500 P are synergic As the wire fee...

Page 37: ...rent while increasing the peak current This results in a soft arc good for out of position welding The UltimArcTM Arc Control can be accessed through the ArcLink compatible wire feeder user interface...

Page 38: ...ng power source and the work clamp Weld Fume Control Solutions Lincoln Electric offers a wide variety of welding fume control solutions ranging from portable systems easily wheeled around the shop to...

Page 39: ...e in good condition to ensure that high voltage parts are protected and correct spacing is maintained throughout All external sheet metal screws must be in place to ensure case strength and electrical...

Page 40: ...r local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility...

Page 41: ...the error 36 Thermal Fault Machine shutoff output due to elevated internal temperature Check for material blocking intake or exhaust louvers Blow air in the rear louvers to clear dirt from the fan No...

Page 42: ...t refer to the thermal section 3 If the output terminals are in remote control switch to ON and check for output voltage If output voltage is now present check for correct remote control connection an...

Page 43: ...2021 78 INSERTION SIDE A B K J L M G H C D E F S3 J20 3 227 J20 11 228 J29 J46 51A J22 3 J4 6 J4 5 294 292 J2 10 J2 2 J3 12 J3 11 LEM CURRENT TRANSDUCER 216 217 215 218 1 2 3 4 220D 221D 306 306 J3 8...

Page 44: ...FLEXTEC 500 P L16790 A 01 FLEXTEC 500 P TO NEGATIVE STUD WORK PIECE WORK CLAMP TO POSITIVE STUD WELDING GUN ACTIV8 WIRE FEEDER WORK SENSE LEAD ACROSS THE ARC WIRE FEEDER SETUP WITH FLEXTEC 500 P CONNE...

Page 45: ...ORK CLAMP TO NEGATIVE STUD LN 10 or DH 10 WIRE FEEDER FLEXTEC 500 P CONTROL CABLE K1501 XX TO POSITIVE STUD S1 N O DIP SWITCH CONFIGURATION INSIDE CONTROL BOX 1 2 3 4 5 6 7 8 WELDING GUN LN10 DH10 SET...

Page 46: ...MS FLEXTEC 500 P L16790 WORK K1785 XXX CONTROL CABLE FLEXTEC 500 P FLEXFEED 74 HT WIRE FEEDER ELECTRODE TO NEGATIVE STUD WORK CLAMP MAGNUM PRO GUN FLEXFEED 74 HT SETUP WITH FLEXTEC 500 P CONNECTION DI...

Page 47: ...6790 TO POSITIVE STUD WORK PIECE GROUND CLAMP TO NEGATIVE STUD MAGNUM PRO GUN FLEXTEC 500 P LN25 PRO DUAL POWER OPTIONAL CONTROL CABLE K1797 XXX WORK SENSE LEAD LN25 PRO DUAL POWER SETUP WITH FLEXTEC...

Page 48: ...RAMS FLEXTEC 500 P L16790 MAGNUM PRO GUN WORK PIECE WORK CLAMP TO NEGATIVE STUD TO POSITIVE STUD CONTROL CABLE K1543 XX FLEXFEED 84 FLEXTEC 500 P FLEXFEED PF84 SETUP WITH FLEXTEC 500 P CONNECTION DIAG...

Page 49: ...s diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If...

Page 50: ...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...