IM10124 FX 450.qxp_IM10124 FX450

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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.
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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to
stay a reasonable distance away
from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the 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 develop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area AT ALL
TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
SAFETY
1.d. Keep all equipment safety 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.
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
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.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and welding
machines
2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.
FOR ENGINE POWERED
EQUIPMENT.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
2.d.2. Never coil the electrode lead around your body.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with 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.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right 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.
2.d.5. Do not work next to welding power source.
3
SAFETY
ELECTRIC SHOCK
CAN KILL.
ARC RAYS CAN BURN.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
4.a.
Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
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 suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if
welding 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, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When welding with
electrodes which require special ventilation such
as stainless or hard facing (see instructions on
container or MSDS) or on lead or cadmium plated
steel and other metals or coatings which produce
highly toxic fumes, keep exposure as low as
possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or
mechanical ventilation. In confined spaces or in
some circumstances, outdoors, a respirator may
be required. Additional precautions are also
required when welding on galvanized steel.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage 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. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
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.
4
SAFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks 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 situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
7.c. Cylinders should be located:
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
•
Away from areas where they may be struck or subjected
to physical damage.
•
A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
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 will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society (see address
above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
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. Always wear
safety glasses with side shields when in a welding area.
FOR ELECTRICALLY
POWERED EQUIPMENT.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
6.h. Also see item 1.c.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes 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.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.j. Do not use a welding power source for pipe thawing.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety
Interactive Web Guide
for mobile devices
5
vi
vi
TABLE OF CONTENTS
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-9
_______________________________________________________________________
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-678 Series
________________________________________________________________________
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - FX450
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model
Duty Cycle
K3073-1
Input Voltage ± 10%
Input Amperes
60% rating
37 / 27 / 22
100% rating 380 / 460 / 575 / 3 / 50 / 60
29 / 21 / 17
Idle Power
Power Factor @
Rated Output
72 Watts
Max.
(fan on)
95%
RATED OUTPUT
Process
Duty Cycle
Volts at Rated Amperes
Amperes
60%
36.5V
450
100%
34V
400
60%
28V
450
100%
26V
400
60%
38V
450
100%
36V
400
60%
36.5V
450
100%
34V
400
60%
36.5V
450
100%
34V
400
GMAW (CV)
GTAW (CC)
SMAW (CC)
FCAW-GS (CV)
FCAW-SS (CV)
RECOMMENDED INPUT WIRE AND FUSE SIZES (1)
VOLTAGE Maximum
Input
50/60Hz
Amperes
380/3/50
460/3/60
575/3/60
42 A
30 A
25 A
Cord Size(3)
AWG SIZES
(mm)
8(10)
8(10)
10(6)
Type 75°C Copper COPPER GROUNDING
Wire in Conduit
CONDUCTOR
AWG (mm2)
AWG (mm2)
8 (10)
10 (6)
12 (4)
10 (6)
10 (6)
12 (4)
Fuse (Super Lag) or
Breaker Size (2)
50
45
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.
FX450 (RED-D-ARC)
A-2
A-2
INSTALLATION
WELDING PROCESS
PROCESS
OUTPUT RANGE (AMPERES)
OCV (Uo)
GMAW (CV)
GTAW (CC)
SMAW (CC)
FCAW-GS (CV)
FCAW-SS (CV)
40-500
10-500
15-500
40-500
40-500
60
24
60
60
60
OCV (Ur)
15
15
PHYSICAL DIMENSIONS
MODEL
HEIGHT
WIDTH
DEPTH
WEIGHT
K3073-1
18.80in (478mm)
14.14in (359mm)
26.66in (677mm)
125lbs (56.6kg)*
TEMPERATURE RANGES
STORAGE TEMPERATURE RANGE
OPERATING TEMPERATURE RANGE
**
Environmentally
Hardened: -40°F to 185°F (-40°C to 85°C)
Environmentally Hardened: 14°F to 131°F (-10°C to 55°C )
IP23
155º(F) Insulation Class
* Weight does not include input cord.
** Output De-rated at Temperatures above 40°C.
FX450 (RED-D-ARC)
A-3
A-3
INSTALLATION
SAFETY PRECAUTIONS
LIFTING
WARNING
Both handles should be used when lifting the FX450.
ELECTRIC SHOCK can kill.
ONLY QUALIFIED PERSONNEL
SHOULD PERFORM THIS INSTALLATION.
• TURN OFF INPUT POWER TO THE POWER
SOURCE AT THE DISCONNECT SWITCH OR
FUSE BOX BEFORE WORKING ON THIS
EQUIPMENT. TURN OFF THE INPUT POWER
TO ANY OTHER EQUIPMENT CONNECTED TO
THE WELDING SYSTEM AT THE DISCONNECT
SWITCH OR FUSE BOX BEFORE WORKING ON
THE EQUIPMENT.
• DO NOT TOUCH ELECTRICALLY HOT PARTS.
• ALWAYS CONNECT THE FX450 GROUNDING
LUG (LOCATED INSIDE THE RECONNECT
INPUT ACCESS DOOR) TO A PROPER SAFETY
(EARTH) GROUND.
----------------------------------------------------------------------
VRD™ (VOLTAGE REDUCTION DEVICE)
The VRD™ feature provides additional safety in the CCStick mode. The VRD™ reduces the OCV (Open Circuit
Voltage) at the welding output terminals while not welding to
less than 35VDC peak.
The VRD™ requires that the welding cable connections be
kept in good electrical condition because poor connections
will contribute to poor starting. Having good electrical connections also limits the possibility of other safety issues
such as heat-generated damage, burns and fires.
The machine is shipped with VRD™ “Disabled”. The VRD™
function can be disabled or enabled via dip switches on the
control P.C. board. Dip switch setting will differ depending
on input voltage.
The control board and dip switches can be accessed by
removing the case top and side as shown in the Operation
Section figure B.3.
SELECT SUITABLE LOCATION
When using a crane or overhead device a lifting strap
should be connected to both handles. Do not attempt
to lift the FX450 with accessories attached to it.
STACKING
The FX450 cannot be stacked.
ENVIRONMENTAL LIMITATIONS
The FX450 is IP23 rated for use in an outdoor environment. The FX450 should not be subjected 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.
CAUTION
Do not mount the FX450 over combustible surfaces. Where there is a combustible surface
directly under stationary or fixed electrical equipment, that surface shall be covered with a steel
plate at least .060” (1.6mm) thick, which shall
extend not less than 5.90” (150mm) beyond the
equipment on all sides.
-----------------------------------------------------------------------
INPUT AND GROUNDING CONNECTIONS
MACHINE GROUNDING
The frame of the welder must be grounded.
A ground terminal marked with the symbol
shown is located inside the reconnect/input connection area for this purpose. See your local and national
electrical codes for proper grounding methods.
HIGH FREQUENCY PROTECTION
Locate the FX450 away from radio controlled machinery. The normal operation of the FX450 may adversely affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the
equipment.
HIGH TEMPERATURE OPERATION
LOCATION AND VENTILATION FOR COOLING
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through
the case sides. Dirt, dust, or any foreign material that
can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shutdowns.
TILTING
Place the machine directly on a secure, level surface
or on a recommended undercarriage. The machine
may topple over if this procedure is not followed.
WELDER OUTPUT RATINGS AT 55°C
ELEVATED TEMPERATURES
AMPS DUTY CYCLE
VOLTS TEMPERATURES
340
100%
34VDC
375
60%
35VDC
400
40%
36VDC
450
20%
38VDC
55°C
FX450 (RED-D-ARC)
A-4
A-4
INSTALLATION
INPUT FUSE AND
CONSIDERATIONS
WARNING
SUPPLY
WIRE
ELECTRIC SHOCK can kill.
ONLY A QUALIFIED ELECTRICIAN
SHOULD CONNECT THE INPUT
LEADS TO THE FX450. CONNECTIONS SHOULD BE MADE IN ACCORDANCE
WITH ALL LOCAL AND NATIONAL ELECTRICAL CODES AND THE CONNECTION DIAGRAM
LOCATED ON THE INSIDE OF THE RECONNECT/INPUT ACCESS DOOR OF THE
MACHINE. FAILURE TO DO SO MAY RESULT
IN BODILY INJURY OR DEATH.
----------------------------------------------------------------------
Refer to Specification in this Installation Section for
recommended fuse, wire sizes and type of the copper
wires. Fuse the input circuit with the recommended
super lag fuse or delay type breakers (also called
"inverse time" or "thermal/magnetic" circuit breakers).
Choose input 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 currents, even if the machine is not
being used at high currents.
INPUT VOLTAGE SELECTION
INPUT CONNECTION
(See Figure A.1)
Use a three-phase supply line. A 1.40 inch (36 mm)
diameter access hole for the input supply is located on
the case back. Connect L1, L2, L3 and ground
according to the Input Supply Connection Diagram
decal located on the internal horizontal panel.
To access the reconnect/input supply connection
blocks, remove the 8 screws that secure the case top
of the welder and remove the case top.
Welders are shipped connected for 460 Volt input
voltage. To move this connection to a different input
voltage, see the diagram located on the inside panel
in the reconnect/input connection area, also illustrated below. If the Auxiliary lead (indicated as ‘A’) is
placed in the wrong position and power is applied to
the machine, the machine will protect itself and display an error message:
• "Err" “713” or “714” will be shown on the display.
• The control board and switch boards will blink out
error 713 or 714 on their status leds.
• 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
FX450 (RED-D-ARC)
A-5
INSTALLATION
CABLE CONNECTIONS
See FIGURE A.2 for locating 3-pin and 14-pin connectors on the front of the FX450.
3-PIN REMOTE CONTROL CONNECTOR
Function
Wiring
Pin
3-pin remote
control connector for
remote.
A 75 Remote potentiometer, common
B 76 Remote potentiometer, wiper
C 77 Remote potentiometer, 5K
14-PIN CONNECTOR FOR WIRE FEEDER
Function
Wiring
Pin
14 pin connector for
wire feeder
connectivity.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Ground
Trigger, Common
Trigger input
77 Remote potentiometer, 5K
76 Remote potentiometer, wiper
75 Remote potentiometer, common
Voltage Sense (21)
Motor (42 VAC)
Motor (42 VAC)
FIGURE A.2
FX450 (RED-D-ARC)
A-5
A-6
A-6
INSTALLATION
RECOMMENDED ELECTRODE AND
WORK CABLE SIZES FOR ARC WELDING
General Guidelines
Connect the electrode and work cables between the
appropriate output studs of the FX450 per the following guidelines:
• Most welding applications run with the electrode
being positive (+). For those applications, connect
the electrode cable between the wire drive feed
plate and the positive (+) output stud on the power
source. Connect a work lead from the negative (-)
power source output stud to the work piece.
• When negative electrode polarity is required, such
as in some Innershield applications, reverse the output connections at the power source (electrode
cable to the negative (-) stud, and work cable to the
positive (+) stud).
The following recommendations apply to all output
polarities and weld modes:
• Select the appropriate size cables per the
“Output Cable Guidelines” (See Table A.1).
Excessive voltage drops caused by undersized
welding cables and poor 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.
• Route all cables directly to the work and wire
feeder, avoid excessive lengths and do not coil
excess cable. Route the electrode and work cables
in close proximity to one another to minimize the
loop area and therefore the inductance of the weld
circuit.
• Always weld in a direction away from the work
(ground) connection.
CONTROL CABLE CONNECTIONS
General Guidelines
Genuine Lincoln control cables should be used at all
times (except where noted otherwise). Lincoln cables
are specifically designed for the communication and
power needs of the FX450. Most are designed to be
connected end to end for ease of extension.
Generally, it is recommended that the total length not
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),
poor motor acceleration (poor arc starting), and low
wire driving force (wire feeding problems). Always use
the shortest length of control cable possible, and DO
NOT coil excess cable.
Regarding cable placement, best results will be
obtained when control cables are routed separate
from the weld cables. This minimizes the possibility of
interference between the high currents flowing
through the weld cables, and the low level signals in
the control cables.
Note: Excessive heat in the weld circuit indicates
undersized cables and/or bad connections.
TABLE A.1
OUTPUT CABLE GUIDELINES
AMPERES PERCENT
DUTY
CYCLE
200
200
250
250
250
250
300
300
350
400
400
500
60
100
30
40
60
100
60
100
40
60
100
60
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
(RUBBER COVERED COPPER - RATED 167°F or 75°C)**
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
2
2
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
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).
FX450 (RED-D-ARC)
B-1
B-1
OPERATION
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
electrode and drive mechanism are
always electrically energized and
could remain energized several
seconds after the welding ceases.
• Do not touch electrically live parts or electrodes
with your skin or wet clothing.
ON
OFF
HIGH TEMPERATURE
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
CIRCUIT BREAKER
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
WIRE FEEDER
POSITIVE OUTPUT
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
FX450 (RED-D-ARC)
B-2
B-2
OPERATION
GRAPHIC SYMBOLS THAT PRODUCT DESCRIPTION
APPEAR ON THIS MACHINE
The FX450 is a multi-process CC/CV DC inverter and
OR IN THIS MANUAL
is rated for 450 amps, 38 volts at a 60% duty cycle.
This machine is intended for both factory and field
operation. It comes in a compact, rugged case that is
designed for portability and outdoor use with an IP23
environmental rating. The user interface of the FX450
is simple and intuitive. Weld modes are selected by a
4 position selector switch. Volts and Amps are displayed on an easy to view LED display, and the amps
and volts are set by a large output control knob. A hot
start toggle selector switch and an arc control knob
allow for finer tuning of the welding arc. The FX450
operates on 380V, 460V, or 575V 50hz or 60hz
power.
Ur
REDUCED OPEN
CIRCUIT VOLTAGE
U0
OPEN CIRCUIT
VOLTAGE
U1
INPUT VOLTAGE
U2
OUTPUT VOLTAGE
DUTY CYCLE
I1
INPUT CURRENT
The FX450 is capable of welding at a 100% duty cycle
(continuous welding) at 400 amps rated 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 amps.
I2
OUTPUT CURRENT
The FX450 is also rated for Desert Duty, elevated
temperature operation, in a 55°C(131°F) ambient.
The machine is output de-rated for this application.
PROTECTIVE
GROUND
DESIGN FEATURES
WARNING or CAUTION
Explosion
Dangerous Voltage
Shock Hazard
• Severe Duty Design for outdoor use (IP23 rating).
• Passive Power Factor Correction – reliably gives
95% power factor for lower installation costs.
• 89% Efficiency rating – reduces electrical utility
costs.
• Simple user interface - designed with the operator in
mind. Getting setup for the weld is several clicks
away and even the most novice welder can be confident 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.
• Thermal protection by thermostats with Thermal
Indicator LED.
• Error Codes display on LED screen for ease of trouble shooting.
• Electronic over current protection.
• Input voltage misconnection protection.
• Utilizes digital signal processing and microprocessor
control.
• VRD™ (Voltage Reduction Device)- Enable this
function for reduced OCV in CC modes for added
safety.
FX450 (RED-D-ARC)
B-3
OPERATION
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
The FX450 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 FX450 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
K3073-1
K2327-5
K2149-1
K1842-10
3100211
FX450
LF-72 Bench Model
Work Lead Package
10 Ft. Weld Power Cable
Harris Regulator and gas hose
Compatible Wire Feeders
All Models
LF-72
LF-74
LN-10
DH-10
LN-25 Pro
Note: The FX450 is not compatible with 115V Wire Feeders.
FX450 (RED-D-ARC)
B-3
B-4
OPERATION
B-4
CASE FRONT CONTROL DESCRIPTIONS
(See Figure B.1)
11. Wire feeder voltmeter polarity selection toggle
switch
1. Power Switch
2. Voltage Display Meter
12. Circuit breaker reset button for the 14-pin wire
feeder connector
3. Amperage Display Meter
13. 14-pin wire feeder circular connector
4. Thermal LED
14. 3-pin remote circular connector
5. Output Control Dial
15. Positive and negative welding output studs
6. Weld Process Selector Switch
16. VRD™ (Voltage Reduction Device) Indicator
Lights
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
FX450 (RED-D-ARC)
B-5
OPERATION
B-5
3. CV – This is CV (constant voltage) weld mode used
for welding the GMAW MIG welding process and
the FCAW-GS, flux cored gas shielded welding
process.
CASE BACK CONTROL
(See Figure B.2)
FIGURE B.2
4. CV-Innershield – This is a CV (constant voltage)
weld mode used for welding the FCAW-SS, flux
cored self shielded welding process
The FX450 is also capable of gouging. Gouging can
be done in either the SMAW mode or the CV and CVInnershield 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.
POWER-UP SEQUENCE
When power is applied to the FX450, the displays will
illuminate and display the voltage and/or amperage
settings.
COMMON WELDING PROCEDURES
WARNING
MAKING A WELD
The serviceability of a product or structure utilizing the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
these programs. These variables include, but are
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication
methods and service requirements. The available
range of a welding program may not be suitable
for all applications, and the build/user is and must
be solely responsible for welding program selection.
The FX450 is a multi-process inverter welder. The
Weld Process Selector Switch is used to set the
desired weld mode. The FX450 has 4 selectable
welding modes:
1. SMAW – This is a CC (constant current) weld
mode used for the SMAW stick welding process.
Hot Start Toggle Switch
The Hot Start control regulates the starting 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) is added at arc initiation.
Arc Control Dial
Full range selection of arc control from -10 to +10. In
CV mode, this control is an inductance control. In
stick mode, the control adjusts the arc force.
Output Control Dial
Output control is conducted by a single turn potentiometer. (Adjustment is indicated by the meters.)
When in Remote Mode, this control sets the maximum
welding current of the remote device. For example, full
depression of a foot or hand amptrol results in the preset level of current.
Voltage Display Meter
• Prior to CV operation (current flow), the meter displays desired preset voltage value.
• Prior to STICK or TIG operation, the meter displays
the Open Circuit Voltage of the Power Source or four
dashes if the output has not been turned on.
• During welding, this meter displays actual average
volts.
• After welding, the meter holds the actual voltage
value for 5 seconds. The displays blink indicating that
the machine is in the "hold" period.
• 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.
FX450 (RED-D-ARC)
B-6
OPERATION
Amperage Display Meter
• Prior to STICK or TIG operation (current flow), the
meter displays preset current value.
• Prior to CV operation, the meter displays four dashes indicating non-presettable AMPS.
• During welding, this meter displays actual average
amps.
• After welding, the meter holds the actual current
value for 5 seconds. The displays blink indicating
that the machine is in the "hold" period.
•Output adjustment while in the "hold" period results
in the "prior to operation" characteristics
Weld Terminals On/Remote Toggle Switch
• This switch determines the trigger location.
• When set to the “ON” position, the weld terminals
are at OCV (open circuit voltage) and ready to weld.
• When set to the “REMOTE” position, output is
enabled through a remote trigger.
Control - Local/Remote Toggle Switch
• Set the switch to “Local” to control output at the
machine by the Output Control dial.
• Set the switch to “REMOTE” to control output via a
remote device (hand amptrol or foot amptrol) connected to the 3-pin remote connector or a wire feeder connected to the 14-pin connector.
Thermal Light
• This status light indicates when the power source
has been driven into thermal overload. If the output
terminals were "ON", the output will be turned back
on once the unit cools down to an acceptable temperature level. If the unit was operating in the
"REMOTE" mode, the trigger will need to be
opened before or after the thermal has cleared and
closed after the machine has cooled down to an
acceptable temperature to establish output.
BASIC MODES OF OPERATION
SMAW
This weld mode is a constant current (CC) mode featuring continuous control from 15 – 500 amps. It is
intended for the SMAW stick 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 current is added at arc start. When
set to the “On” position, additional current (relative to
the preset current) at arc initiation.
B-6
Arc Control - The Arc Control regulates the Arc Force
to adjust the short circuit current. The minimum setting
(-10) will produce a "soft" arc and will produce minimal
spatter. The maximum setting (+10) will produce a
"crisp" arc and will minimize electrode sticking.
Weld Terminals On/Remote – Set to “On” so the
machine is in the ready to weld state.
Voltage Display Meter – This display will display
three dashed lines when the machine is in the idle
state. This indicates that voltage is not settable in this
weld mode. While output is enabled, the actual welding voltage is displayed. After welding, the meter
holds the actual voltage 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" period.
Amperage Display Meter – This display will display
the pre-set welding current 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 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" period.
Output Control Local/Remote – When the control is
set to local (no remote potentiometer/control plugged
into the 3-pin or 14-pin connectors), the output is controlled through the Output Control Dial on the front of
the FX450. Set this switch to “REMOTE” when an
external potentiometer/control is connected.
• When a remote potentiometer is connected, the output control on the FX450 and the remote act as a
master/slave configuration. Use the control dial on
the FX450 to pre-set the maximum welding current.
The remote will control output from minimum to the
pre-set maximum.
Output Control Dial
• When the Local/Remote is set to Local, this dial
sets the welding amperage.
• When the Local/Remote is set to Remote, this dial
sets the maximum welding amperage. The remote
potentiometer than controls the amperage from minimum to this pre-set maximum.
FX450 (RED-D-ARC)
B-7
OPERATION
INTERNAL CONTROLS - ENABLING VRD™
B-7
To Enter VRD™ Mode (VRD™ Enabled)
a. For 380V input: Switch #5 in the “ON”
Position.
Internal Controls Description
The Control PC Board has one bank of Dip Switches.
As shipped from the factory VRD™ mode is disabled
and the Dip Switches are all in the “off” position.
b. For 460V input: Switch #6 in the “ON”
Position.
c. For 575V input: Switch #5 and #6 in the
“ON” Position
FIGURE B.3
FX450 (RED-D-ARC)
B-8
OPERATION
B-8
GTAW
CV-GAS
This weld mode is a constant current (CC) mode featuring continuous control from 10 – 500 amps. It is intended for the GTAW
TIG welding processes.
This weld mode is a constant voltage (CV) mode featuring continuous control from 10 to 45 volts.
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
current is added at arc start. When set to the “On” position,
additional current (relative to the preset current) at arc initiation.
Arc Control – This control is not used in the GTAW mode.
Weld Terminals On/Remote
• When set to the “ON” position, the weld terminals are at OCV
(open circuit voltage) and ready to weld.
• When set to the “REMOTE” position, output is enabled
through a remote trigger.
Voltage Display Meter – This display will display three dashed
lines when the machine is in the idle state. This indicates that
voltage is not settable in this weld mode. While output is
enabled, the actual welding voltage is displayed. After welding,
the meter holds the actual voltage 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" period.
Amperage Display Meter – This display will display the pre-set
welding current 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 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" period.
Output Control Local/Remote – When the control is set to
local (no remote potentiometer/control plugged into the 3-pin or
14-pin connectors), the output is controlled through the Output
Control Dial on the front of the FX450. Set this switch to
“REMOTE” when an external potentiometer/control is connected.
• When a remote potentiometer is connected, the output control
on the FX450 and the remote act as a master/slave configuration. Use the control dial on the FX450 to pre-set the maximum welding current. The remote will control output from
minimum to the pre-set maximum.
Output Control Dial
• When the Local/Remote is set to Local, this dial sets the
welding amperage.
• When the Local/Remote is set to Remote, this dial sets the
maximum welding amperage.
Hot Start – Toggle to “ON” position to provide more energy
during the start of a weld.
Arc Control – The Arc Control regulates pinch effect
(Inductance). At the minimum setting (-10), minimizes pinch and
results in a soft arc. Low pinch settings are preferable for welding with gas mixes containing mostly inert gases. At the maximum setting (+10), maximizes pinch effect and results in a crisp
arc. High pinch settings are preferable for welding FCAW-GS
and GMAW with CO2.
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 feeders.
• 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" period.
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 adjustment while in the "hold" period results in the "prior
to operation" characteristics. The displays blink indicating 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 3-pin or
14-pin connectors), the output is controlled through the Output
Control Dial on the front of the FX450. 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.
The remote potentiometer controls the amperage from minimum
to this pre-set maximum.
FX450 (RED-D-ARC)
B-9
OPERATION
CV-INNERSHIELD
This weld mode is a constant voltage (CV) mode featuring 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 feeders.
• 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" period.
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 adjustment while in the "hold" period results in the "prior to
operation" characteristics. The displays blink indicating 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 3-pin or 14-pin connectors), the output is controlled through the Output Control Dial on the front of
the FX450. 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
FX450 (RED-D-ARC)
B-9
C-1
ACCESSORIES
OPTIONS / ACCESSORIES
General Options
K2149-1 Work Lead Package.
K1842-10 10ft. Weld Power Cable (Lug to Lug).
Inverter and Wire Feeder Cart Rear-wheeled cart
includes front casters and no-lift gas bottle platform.
Convenient handles allow for easy cable storage while
full length side trays store parts and tools. Shipped
fully assembled. Small footprint fits through 30" (762
mm) door.
Order K2945-1.
Fume Extracting Systems
Accessory Kit For stick welding. 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
TIG Options
Pro-Torch™ TIG Torches – PTA-9,
PTA-17, PTA-26 – 2 piece power
cord.
FX450 (RED-D-ARC)
C-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
D-1
PERIODIC MAINTENANCE
WARNING
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box before
working on this equipment.
• Do not touch electrically hot parts.
------------------------------------------------------------------------
See additional warning information
throughout this Operator’s Manual
-----------------------------------------------------------
Thermal Protection
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostat will disable the machine output. The meter
will remain energized during this time. Thermostats
are self-resetting once the machine cools sufficiently.
If the thermostat shutdown was caused by excessive
output or duty cycle and the fan is operating normally,
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 components. 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 condition 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.
FX450 (RED-D-ARC)
E-1
TROUBLESHOOTING
E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by 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
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Authorized Field Service Facility.
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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
FX450 (RED-D-ARC)
E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Major physical or electrical damage
is evident when the sheet metal
covers are removed.
1. Contact your local authorized
Field Service facility for technical
assistance.
Machine won’t weld, can’t get any
output.
1. If the displays show an Err ###
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
1.If all recommended possible areas
clear dirt from the fan.
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 Authorized
Field Service Facility.
stopped.
2. Welding output ratings may have
been exceeded. Allow the
machine to cool down and reset.
Wire feeder won’t work. Apparently
no power to wire feeder
1. Check circuit breakers by the wire
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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
FX450 (RED-D-ARC)
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS
Errors are displayed on the amperage and voltage display meters. 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 fault codes indicated on 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 FX450
Error
Description
Code#
21 Device that controls sequence
of the welding operation halted due to an error.
Possible Cause
Corrective Action
Weld Terminals Remote:
Re-trigger to recover from
error.
Weld Terminals Local:
Toggle Remote/Local Switch
to recover from error.
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.
36
Thermal Fault
Machine shut off output due to elevated 1. Check for material blocking intake or exhaust louinternal temperatures.
vers.
• Blow air in the rear louvers to clear dirt from the
fan.
Note: The Fan As Needed
circuitry automatically
shuts off the fan 5 minutes
after welding has stopped.
2. Welding output ratings
may have been exceeded.
Allow the machine to cool
down and reset.
45
712
VRD™ Voltage limit exceeded.
During OCV, the voltage exceeded allow- Machine needs to be turned off
and back on to reset.
able VRD™ levels.
• Verify dip switch settings are correct for
the input voltage.
Communication Fault
CAN communication between the control Inspect harness for damage /
pcb and switch pcb has been interrupted. loose connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
FX450 (RED-D-ARC)
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
Error Codes for the FX450
Error
Corrective Action
Description
Possible Cause
Code#
713 Input Power Misconnect. Occurs upon power up when the supply Verify the primary reconnect
Supply Voltage is too high.
voltage to the switch pcb exceeded accept- is properly configured for the
input voltage.
able levels.
Machine needs to be turned
off and back on to reset.
714
Input Power Misconnect. Occurs upon power up when the supply Verify the primary reconnect
Supply Voltage is too low.
voltage to the switch pcb is below accept- is properly configured for the
input voltage.
able levels.
Machine needs to be turned
off and back on to reset.
715
Under Voltage Lockout.
719
Switch PCB Error.
The supply voltage to the switch pcb is Machine needs to be turned
off and back on to reset.
below acceptable levels
Machine needs to be turned
off and back on to reset.
If any of these conditions persist contact an authorized Field Service Shop.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
FX450 (RED-D-ARC)
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
DIAGRAMS
FX450 (RED-D-ARC)
F-1
F-2
DIMENSION PRINT
FX450 (RED-D-ARC)
F-2
NOTES
FX450 (RED-D-ARC)
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
● Do not touch electrically live parts or
● Keep flammable materials away.
● Wear eye, ear and body protection.
● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
fuera del área de trabajo.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
cuerpo.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Mantenha inflamáveis bem guarda-
dos.
● Use proteção para a vista, ouvido e
corpo.
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 ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes.
● Use ventilation or exhaust to
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Strom vor Wartungsarbeiten
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
● Mantenha-se afastado das partes
serviço.
● Não toque as partes elétricas nuas.
● Não opere com os paineis abertos
moventes.
ou guardas removidas.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
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.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. 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 possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information 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.
Download PDF

advertising