Lincoln Electric 12719 User manual

O erator’s Manual
Flextec ®650x
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10415 | Issue D ate May-17
© Lincoln Glo al, Inc. All Rights Reserved.
For use with machines having Code Num ers:
12719
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
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 Safety Data
Sheet (SDS) 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.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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 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.
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.
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.
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.
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.
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.
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.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
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.
2.d.2. Never coil the electrode lead around your body.
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 pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
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.
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.
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.
• 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.
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.
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.
ARC RAYS CAN BURN.
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 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.
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
hardfacing (see instructions on container or SDS)
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
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
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.
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.
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
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
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.
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.
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.
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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
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.
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.
6.h. Also see item 1.c.
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.
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.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• 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.
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 from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED 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. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

Page
Installation....................................................................................................... Section A
Technical Specifications.......................................................................................................A-1, A-2
Safety Precautions................................................................................................................A-3
VRD™ (Voltage Reduction Device)........................................................................................................ A-3
Select Suitable Location....................................................................................................... A-3
Lifting...................................................................................................................................A-3
Stacking...............................................................................................................................A-3
Environmental Limitations.................................................................................................... A-3
Input and Grounding Connections......................................................................................... A-3
igh Frequency Protection....................................................................................................A-3
igh Temperature Operation........................................................................................................ 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
Control Cable Connections, Paralleling......................................................................................... A-7
Connection Diagrams Flextec 650 to Wire Feeders and Tractor.................................... A-8 thru A-12
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
Case Back Controls......................................................................................................................B-5
Internal Controls.......................................................................................................................... B-6
Power-Up Sequence.................................................................................................................... B-7
Common Welding Procedures, Weld Controls and Displays.......................................... B-7 thru B-10
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
Current Calibration.......................................................................................................................D-1
Voltage Calibration.......................................................................................................................D-2
To Restore Factory Current Calibration.........................................................................................D-2
To Restore Factory Voltage Calibration.........................................................................................D-2
Section E...............................................................................................Troubleshooting
ow to Use Troubleshooting Guide............................................................................................... E-1
Troubleshooting Guide................................................................................................................. E-2
Error Codes.......................................................................................................................... E-3, E-4
Wiring Diagram and Dimension Print...............................................................Section F
Parts List .........................................................................................................................parts.li col electric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
2
TABLE OF CONTENTS

A-1
INSTALLATION
FLEXTEC®650x
TECHNICAL SPECIFICATIONS - FLEXTEC
®
650X
RATED OUTPUT*
Model
K4376-1
Duty Cycle
60% rating
100% rating
Volts at Rated Amperes
44V
34V
44V
Amperes
750
650
750
650
750
650
750
650
750
650
750
650
Duty Cycle
60%
100%
60%
100%
60%
100%
60%
100%
60%
100%
60%
100%
Process
GMAW (CV)
GTAW (CC)
SMAW (CC)
FCAW-G (CV)
FCAW-S (CV)
SAW (CV)
Input Amperes
Effective
61 / 50 / 40
57 / 47 / 38
Idle Power
(W)
230 MAX.( Fan On)
100 MAX. (Fan Off)
Power Factor @
Rated Output
88%
Input Voltage ± 10%
380 / 460 / 575 / 3 / 50 / 60
(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 SJ cord or similar in 30°C ambient.
VOLTAGE
50/60 z
380/3/50
460/3/60
575/3/60
Maximum
Input
Amperes
70 A
58 A
46 A
Cord Size(3)
AWG SIZES
(mm2)
4(21)
4(21)
6(13)
Fuse (Super Lag) or
Breaker Size (2)
90
80
60
COPPER GROUNDING
CONDUCTOR
AWG (mm2)
8(8)
8(8)
10(5)
Type 75°C Copper
Wire in Conduit
AWG (mm2)
4(21)
6(13)
8(8)
RECOMMENDED INPUT WIRE AND FUSE SIZES (1)
*
*
*
*
*
*
*
*
*
*
* Output is limited to 600A / 100% and 700A / 60% when used with K3091-1 Multi-Process Switch.
POWER SOURCE-INPUT VOLTAGE AND CURRENT

A-2
INSTALLATION
FLEXTEC®650x
P YSICAL DIMENSIONS
TEMPERATURE RANGES
EIG T
21.8 in (554 mm)
MODEL
K4376-1
WIDT
16.14 in (410 mm)
DEPT
29.33 in (745 mm)
WEIG T
165lbs (74.8kg)*
OPERATING TEMPERATURE RANGE
Environmentally ardened: 14°F to 131°F (-10°C to 55°C
**
)
STORAGE TEMPERATURE RANGE
Environmentally ardened: -40°F to 185°F (-40°C to 85°C)
PROCESS
GMAW (CV)
GTAW (CC)
SMAW (CC)
FCAW-G (CV)
FCAW-S (CV)
SAW (CV)
OUTPUT RANGE (AMPERES)
40-815
10-815
15-815
40-815
40-815
40-815
OCV (Uo)
60
24
60
60
60
60
OCV (Ur)
---
15
15
---
---
---
WELDING PROCESS
IP23 180º( ) Insulation Class
*Weight does not include input cord.
** Power Source is de-rated at temperatures above 40C.
"A" LEAD
POSITION
380 Volt
Reconnect
460 Volt
Reconnect
575 Volt
Reconnect
VRD
Enabled
Low Limit - 340 Vac
igh Limit - 420 Vac
Low Limit - 390 Vac
igh Limit - 505 Vac
Low Limit - 485 Vac
igh Limit - 620 Vac
VRD
Disabled
Low Limit - 340 Vac
igh Limit - 455 Vac
Low Limit - 390 Vac
igh Limit - 520 Vac
Low Limit - 485 Vac
igh Limit - 655 Vac
AUXILIARY RECONNECT INPUT RANGES

A-3
INSTALLATION
FLEXTEC®650x
INSTALLATION
ELECTRIC S OCK 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.
• To not touch electrically hot parts.
• Always connect the flextec™ 650 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 CC-Stick
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
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.
LIFTING
The FL XT C®650x has 2 lifting eyelets and 2 handles that can be
used to lift the machine. Both handles or both eyelets should be
used when lifting the FL XT C®650x.
When using a crane or overhead device to lift using the handles, a
lifting strap should be connected to both handles. Do not attempt
to lift the FLEXTEC®650x with accessories attached to it.
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.
STACkING
Multiple FL XT C®650x’s cannot be stacked.
ENVIRONmENTAL LImITATIONS
The FL XT C®650x is IP23 rated for use in an outdoor
environment. The FL XT C®650x 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.
Do not mount the FLEXTEC
®
650x 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 FL XT C®650x away from radio controlled machinery.
The normal operation of the FL XT C®650x may adversely affect
the operation of RF controlled equipment, which may result in
bodily injury or damage to the equipment.
WARNING
CAUTION

A-4
INSTALLATION
FLEXTEC®650x
HIGH TEmPERATURE OPERATION
ELECTRIC S OCK can kill.
Only a qualified electrician should connect the input leads to
the Flextec
®
650x. 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.
INPUT CONNECTION
(See Figure A.1)
Use a three-phase supply line. A 1.75 inch (45 mm) diameter
access hole for the input supply is located on the case back.
Remove the reconnect access panel located on the case back and
connect W, V, U and ground according to the Input Supply
Connection Diagram decal.
INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS
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
Welders are shipped connected for 460 Volt input voltage. To
accomodate different input voltages, move the reconnect lead to
the corresponding voltage (see Figure A.1) Refer to Auxiliary
Reconnect Input Ranges table in the Technical Specification
Section. 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:
• " rr" "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. Power must be removed prior
to changing reconnect position.
WARNING
WELDER OUTPUT RATINGS AT 55°C
ELEVATED TEMPERATURES
A PS Duty Cycle Volts Temperatures
600 100%
44V 55°C650 50%
750 30%
POWER SUPPLY ACCESS HOLE
• Route input power cable through this hole.
• Strain relief required. See your local and
National Electrical codes for proper strain relief.
REMOVE FOUR SCREWS
AND ACCESS PANEL
• Reconnects auxiliary
transformer for the
proper input voltage.
RECONNECT TERMINAL BLOCK
POWER SUPPLY TERMINAL
BLOCK
• Line Cord/Cable attaches here.
• 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.)
FIGURE A.1

A-5
INSTALLATION
FLEXTEC®650x
CAbLE CONNECTIONS
See FIGUR A.2 for locating 5, 12 and 14 pin connectors on the
front of the FL XT C®650x.
FIGURE A.2
G
F
E
M
N
DB
A
J
I
L
K
C
H
14-Pin Connector for
Wire Feeder
5-Pin Connector for
ArcLink Wire Feeder
12-Pin ArcLink Wire
Feeder & Digital
Accessory Connectivity
5-PIN CONNECTOR FOR WIRE FEEDER
Function Pin Wiring
5-pin connec-
tor for wire
feeder connec-
tivity
AArcLink CAN
BArcLink CAN
CElectrode Sense Lead
D40Vdc
E40Vdc Common
12-PIN ACCESSORY CONNECTIVITY
Function Pin Wiring
12-pin remote
control
connector for
remote or
hand/foot
amptrol and
digital
accessories.
A ArcLink CAN
B ArcLink CAN
C Remote potentiometer, common
D Remote potentiometer wiper
Remote potentiometer +10V
F ALPS connection
G Trigger
H Trigger
J 40Vdc Common
K 40Vdc
L Not used
M Not used
14-PIN CONNECTOR FOR WIRE FEEDER
Function Pin Wiring
14 pin connec-
tor for wire
feeder connec-
tivity.
A 115 VAC
B
Ground
C
Trigger, Common
D
Trigger input
77 Remote potentiometer, 5K
F
76 Remote potentiometer, wiper
G
75 Remote potentiometer, common
H
Voltage Sense (21)
I
42 VAC
J 40Vdc
K
42 VAC
L
M
N

RECOmmENDED ELECTRODE AND WORk CAbLE
SIZES FOR ARC WELDING
General Guidelines
Connect the electrode and work cables between the appropriate
output studs of the FL XT C®650x 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). xcessive 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.
Note: xcessive heat in the weld circuit indicates undersized
cables and/or bad connections.
•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.
A-6
INSTALLATION
FLEXTEC®650x
** 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).
OUTPUT CABLE GUIDELINES
CABLE SIZES FOR COMBINED LENGT S OF ELECTRODE AND WORK CABLES
(RUBBER COVERED COPPER - RATED 167°F or 75°C)**
AMPERES
200
200
250
250
250
250
300
300
350
400
400
500
600
600
600
650
650
700
800
800
PERCENT
DUTY
CYCLE
60
100
30
40
60
100
60
100
40
60
100
60
60
80
100
60
80
100
80
100
0 to 50Ft.
(0 to15m)
2
2
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
3/0
2-1/0
2-1/0
3/0
2-1/0
2-2/0
3-1/0
2-3/0
50 to 100Ft.
(15 to 30m)
2
2
3
2
1
1
1
2/0
1/0
2/0
3/0
2/0
3/0
2-1/0
2-1/0
3/0
2-1/0
2-2/0
3-1/0
2-3/0
100 to 150 Ft.
(30 to 46m)
2
2
2
1
1
1
1
2/0
2/0
2/0
3/0
3/0
3/0
2-1/0
2-1/0
4/0
2-1/0
2-3/0
3-1/0
2-3/0
150 to 200 Ft.
(46 to 61m)
1
1
1
1
1
1
1/0
2/0
2/0
3/0
3/0
3/0
4/0
2-2/0
2-2/0
2-2/0
2-2/0
2-3/0
2-3/0
2-3/0
200 to 250 Ft.
(61 to 76m)
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0
2-3/0
2-3/0
2-3/0
2-3/0
2-3/0
2-4/0
2-4/0
2-4/0
TABLE A.1

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 FL XT C®650x.
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 commu-
nication 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.
PARALLELING
FL XT C®650x power sources may be paralleled for increased
output requirements. No kit is required for paralleling of
FL XT C®650x power sources. The FL XT C®650X can only be
paralleled for constant current processes (mode switch must be in
the SMAW position). Connect the power sources as shown, and
set the output control of each power source to one half of the
desired arc current. (See Figure A.3)
A-7
INSTALLATION
FLEXTEC®650x
PPOOSSIITTIIVVEE
AATTWWOORRKKPPIIEECCEE
PPOOSSIITTIIVVEE
AATTWWOORRKKPPIIEECCEE
PPOOSSIITTIIVVEE
A
A
NNEEGGAATTIIVEVE
WW
PARALLELING DIAGRAM
VV
UU
IINNPPUUTT
TTEERRMMIINNALAL VV
WW
IINNPPUUTTLLIINNESES
A
A
N
NEEGGAATTIIVEVE
TTOOGGRROOUNUNDD
EELLEECCTTRRIICCAALLCCOODDEE
PEPERRNNAATTIIOONNAALL
UU
GGNNDD
NNEEGGAATTIIVEVE
TTOOGGRROOUNUNDD
GGNNDD
PPEERRNNAATTIIOONNAALL
EELLEECCTTRRIICCAALLCCOODDEE
BBLLOOCCKK
FFlexteclextec 66550x0x
((MMAACCHHIINNEE#1#1))
FFlexteclextec 66550x0x
((MMAACCHHIINNEE#2#2))
IINNPPUUTT
TTEERRMMIINNALAL
BBLLOOCCKK
WW
VV
UU
VV
WW
IINNPPUUTTLLIINNESES
UU
FIGURE A.3

A-8
INSTALLATIONFLEXTEC TM 650
CONNECTING LF-72 AND LF-74 TO T E FLEXTEC®650x
CONTROL SETTING
14-PIN CONTROL CABLE K1797-XX
WIRE FEEDER
ELECTRODE
WORK
LF-72
LF-74
Flextec 650x
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV, CV-INNERS IELD
OFF
LOCAL
(REMOTE IF K2329-1 INSTALLED)
PROCESS DEPENDENT

A-9
INSTALLATIONFLEXTEC TM 650
LN-10,DH-10 CONTROL SWITCH SETUP
Initial set up of the LN-10, DH-10 control for the system
components being used and for general operator preferences
is done using a pair of 8-pole DIP switches located inside the
LN-10, DH-10 control box.
Setup DIP Switch Access
1) Shut off the input power to the LN-10, DH-10 control by
turning off the power at the welding power source it is
connected to.
2) Remove the two screws on the top of the LN-10, DH-10
control box door and swing the door down to open.
3) Locate the two 8-pole DIP switches, near the top left
corner of the LN-10, DH-10 Control P.C. board, labeled
S1 and S2.
4) Switch settings are only programmed during input
power-up restoration.
Setting the DIP Switches
The DIP switches are each labeled with an “ON” arrow
showing the on direction for each of the 8 individual switches
in each DIP switch (S1 and S2). The functions of these
switches are also labeled and set as described below:
Pwr Sources
S1
ON
S1
1 2 3 4 5 6 7 8
CONNECTING LN-10 AND D -10 TO T E FLEXTEC®650x
CONTROL SETTING
14-PIN CONTROL CABLE K1501-XX
ELECTRODE
WIRE FEEDER
LN-10
DH-10
WORK
Flextec 650x
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV, CV-INNERS IELD
OFF
REMOTE
PROCESS DEPENDENT

A-10
INSTALLATIONFLEXTEC TM 650
CONNECTING LN-25 PRO, LN-25 PIPE, ACTIV8 TO T E FLEXTEC®650x
ELECTRODE
WIRE FEEDER
LN-25 PRO
ACTIV8
LN-25 PIPE
WORK
WORK CLIP
ELECTRODE
WIRE FEEDER
*LN-25 PRO
DUAL POWER
WORK
CONTROL CABLE K1797-XX
Flextec 650x
Flextec 650x
CONTROL SETTING
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV, CV-INNERS IELD
ON
LOCAL
PROCESS DEPENDENT
CONTROL SETTING
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV, CV-INNERS IELD
OFF
REMOTE
PROCESS DEPENDENT
CONNECTING LN-25 PRO DUAL POWER TO T E FLEXTEC®650x
*CONTROL CABLE SETUP S OWN. REFER TO LN-25 PRO CONNECTION DIAGRAM IF SETTING UP "ACROSS-T E-ARC" FEEDER.

A-11
INSTALLATIONFLEXTEC TM 650
CONNECTING LN-7 TO T E FLEXTEC®650x
14-PIN CONTROL CABLE K1818-XX
ELECTRODE
WIRE FEEDER
LN-7
WORK
14-PIN CONTROL CABLE K1820-XX
ELECTRODE
WIRE FEEDER
LN-8
LN-9
WORK
Flextec 650x
Flextec 650x
CONTROL SETTING
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV, CV-INNERS IELD
OFF
LOCAL
PROCESS DEPENDENT
CONTROL SETTING
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV, CV-INNERS IELD
OFF
REMOTE
PROCESS DEPENDENT
CONNECTING LN-8 AND LN-9 TO T E FLEXTEC®650x

A-12
INSTALLATIONFLEXTEC TM 650
CONNECTING NA-3, NA-5 TO T E FLEXTEC®650x
14-PIN CONTROL CABLE K1820-XX
ELECTRODE
WIRE FEEDER
NA-3
NA-5
WORK
FOR NA-3, NA-4 WIRE FEEDERS ONLY:
- MOVE JUMPER LEAD ON VARIABLE VOLTAGE BOARD TO "L" PIN.
FOR NA-5 WIRE FEEDER ONLY:
- MOVE "BLUE" JUMPER LEAD ON VOLTAGE BOARD TO "AUTO " TERMINAL.
Flextec 650x
14-PIN CONTROL CABLE K1822-XX
ELECTRODE
TRACTOR
LT-7
WORK
Flextec 650x
CONTROL SETTING
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV- SAW
OFF
REMOTE
PROCESS DEPENDENT
CONTROL SETTING
WELD MODE
WELD TERMINALS
REMOTE/LOCAL
VOLTMETER POLARITY
CV- SAW
OFF
REMOTE
PROCESS DEPENDENT
CONNECTING LT-7 TO T E FLEXTEC®650x

B-1
OPERATION
FLEXTEC®650x
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
ELECTRIC S OCK 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.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be danger-
ous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire
or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the
beginning of this manual.
WARNING

B-2
OPERATION
FLEXTEC®650x
GRAPHIC SYmbOLS THAT APPEAR ON THIS
mACHINE OR IN THIS mANUAL
INPUT POWER
ON
OFF
IG TEMPERATURE
CIRCUIT BREAKER
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 P ASE INVERTER
INPUT POWER
T REE P ASE
DIRECT CURRENT
OPEN CIRCUIT
VOLTAGE
REDUCED OPEN
CIRCUIT VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE
GROUND
WARNING or CAUTION
Explosion
Dangerous Voltage
Shock azard
Read & Understand
Manual
U0
Ur
U1
U2
I1
I2