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Lincoln Electric RED-D-ARC FX450 manual

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Table of contents for the manual

  • Page 1

    RED-D-ARC FX450 IM10094 February, 2011 Red-D-Arc Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful opera[...]

  • Page 2

    FOR ENGINE powered equipment. 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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC R A Y S can bur n. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your s[...]

  • Page 4

    iii SAFETY iii FOR ELECTRIC ALL Y pow er ed equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nat[...]

  • Page 5

    iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

  • Page 6

    v v Thank Y ou for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! 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 safet[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Welding Process, Physical Dimensions ........................................[...]

  • Page 8

    FX450 (RED-D-ARC) A-1 INST ALLA TION A-1 TECHNICAL SPECIFICA TIONS - FX450 RA TED OUTPUT POWER SOURCE-INPUT VOL T AGE AND CURRENT Model K3073-1 Duty Cycle 60% rating 100% rating Volts at Rated Amperes 36.5V 34V 28V 26V 38V 36V 36.5V 34V 36.5V 34V Amperes 450 400 450 400 450 400 450 400 450 400 Duty Cycle 60% 100% 60% 100% 60% 100% 60% 100% 60% 100%[...]

  • Page 9

    A-2 INST ALLA TION FX450 (RED-D-ARC) A-2 PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 18.80in (478mm) MODEL K3073-1 WIDTH 14.14in (359mm) DEPTH 26.66in (677mm) WEIGHT 125lbs (56.6kg) * OPERATING TEMPERATURE RANGE Environmentally Hardened: 14°F to 131°F (-10°C to 55°C ** ) STORAGE TEMPERATURE RANGE Environmentally Hardened: -40°F to 185°F (-[...]

  • Page 10

    A-3 INST ALLA TION A-3 SELECT SUIT ABLE LOCA TION 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 mini- mum. Failure to observe these precautions can[...]

  • Page 11

    A-4 INST ALLA TION A-4 INPUT FUSE AND SUPPL Y WIRE CONSIDERA TIONS 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[...]

  • Page 12

    A-5 INST ALLA TION A-5 FX450 (RED-D-ARC) Pin A B C D E F Wiring 77 Remote potentiometer, 5K 76 Remote potentiometer, wiper 75 Remote potentiometer, common Trigger, common Trigger, input Ground CABLE CONNECTIONS See FIGURE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FX450. FIGURE A.2 Function 6-pin remote control con- nector f[...]

  • Page 13

    A-6 INST ALLA TION FX450 (RED-D-ARC) A-6 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 follow- ing guidelines: • Most welding applications run with the electrode being positive (+). For those applications, connect the el[...]

  • Page 14

    B-1 OPERA TION FX450 (RED-D-ARC) B-1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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 [...]

  • Page 15

    B-2 OPERA TION B-2 FX450 (RED-D-ARC) PRODUCT DESCRIPTION The FX450 is a multi-process CC/CV DC inverter and 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 use[...]

  • Page 16

    B-3 OPERA TION B-3 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 LIMIT A TIONS The FX450 is suitable only for the processes listed. EQUIPMENT LIMIT A TIONS Operating Temperature Range [...]

  • Page 17

    B-4 OPERA TION B-4 CASE FRONT CONTROL DESCRIPTIONS (See Figure B.1) 1. Power Switch 2. Voltage Display Meter 3. Amperage Display Meter 4. Thermal LED 5. Output Control Dial 6. Weld Process Selector Switch 7. Hot Start Toggle Switch 8. Output Control Local/Remote Toggle Switch 9. Arc Control Dial 10. W e l d Te r m i n a l s On/Remote toggle selecto[...]

  • Page 18

    B-5 OPERA TION B-5 FX450 (RED-D-ARC) CASE BACK CONTROL (See Figure B.2) 1. Input Power Cord Access Hole. 1 1 FIGURE B.2 COMMON WELDING PROCEDURES MAKING A WELD The serviceability of a product or structure utiliz- ing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Ele[...]

  • Page 19

    B-6 OPERA TION B-6 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 dash- es indicating non-presettable AMPS. • During welding, this meter displays actual average amps. • After welding, the meter holds the actual current value f[...]

  • Page 20

    B-7 OPERA TION B-7 GT A W This weld mode is a constant current (CC) mode featuring con- tinuous control from 10 – 500 amps. It is intended for the GTAW TIG welding processes. 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 s[...]

  • Page 21

    B-8 OPERA TION 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 [...]

  • Page 22

    C-1 ACCESSORIES C-1 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 a[...]

  • Page 23

    D-1 MAINTENANCE D-1 PERIODIC MAINTENANCE 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 [...]

  • Page 24

    E-1 TROUBLESHOOTING E-1 FX450 (RED-D-ARC) 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair possib[...]

  • Page 25

    E-2 TROUBLESHOOTING E-2 FX450 (RED-D-ARC) 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. Machine wonʼt weld, canʼt get any output. Thermal symbol is lit. Wire feeder wonʼt work. Ap[...]

  • Page 26

    E-3 TROUBLESHOOTING E-3 FX450 (RED-D-ARC) Observe all Safety Guidelines detailed throughout this manual USING THE ST A TUS 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 info[...]

  • Page 27

    F-1 DIAGRAMS F-1 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 n[...]

  • Page 28

    F-2 DIMENSION PRINT F-2 FX450 (RED-D-ARC) L15698 A.01 26.66 18.78 14.14 26.51 13.06 L15698 A.01 26.66 18.78 14.14 26.51 13.06[...]

  • Page 29

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERS T AND THE MANUF A CTURER’S INS TRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LA S INSTR UCCIONES DEL F ABRIC[...]

  • Page 30

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INSTR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P AR TES DE USO , E SIGA AS PRÁTIC A S DE SEGUR ANÇA DO EMPREGADOR. • Keep your head out of fumes. • Use ventilation or exhaust to re[...]

  • Page 31

    • 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 • World's Leader in Welding and Cutting Products •[...]