Red-D-Arc Welderentals FX500XL User manual

RED-D-ARC
FX500XL
IM10499
May-2019
Red-D-Arc Spec-Built Welding Equipment
This
RED-D-ARC
welder is built to
RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder 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.
For use with machines having Code Numbers: 12810
North America’s Largest Fleet of Welding Equipment
1-800-245-3660
OPERATOR’S MANUAL

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

2
TABLE OF CONTENTS
FLEXTEC®FX500XL
Page
Product Description................................................................................................................................................4
Recommended Processes and Equipment ............................................................................................................5
Recommended Processes ........................................................................................................................5
Process Limitations..................................................................................................................................5
Equipment Limitations..............................................................................................................................5
Common Equipment Packages.................................................................................................................5
Common Optional Kits & Accessories .......................................................................................................6
Compatible Wire Feeders .........................................................................................................................6
Design........................................................................................................................................................Section A
Specifications ...............................................................................................................................................A-1
Agency Approvals .........................................................................................................................................A-2
Design Features............................................................................................................................................A-2
Case Front Controls.......................................................................................................................................A-3
Case Back Controls.......................................................................................................................................A-4
Internal Controls............................................................................................................................................A-5
Installation ................................................................................................................................................Section B
Input and Ground Connections ......................................................................................................................B-1
Input Fuse and Supply Wire Considerations...................................................................................................B-2
Input Voltage Selection..................................................................................................................................B-3
Location........................................................................................................................................................B-3
Location and Ventilation for Cooling......................................................................................................B-3
Lifting...................................................................................................................................................B-3
Stacking...............................................................................................................................................B-3
Environmental Limitations ....................................................................................................................B-3
High Frequency Protection ............................................................................................................................B-3
Connection Diagrams, Control Cables....................................................................................................B-4, B-5
Analog Wire Feeder Connectivity...........................................................................................................B-4
ArcLink Wire Feeder & Digital Accessory Connectivity...........................................................................B-5
Recommended Electrode and Work Cable Sizes for Arc Welding ...................................................................B-6
Output Cable Guidelines .......................................................................................................................B-6
Control Cable and Voltage Sensing Connections............................................................................................B-7
Paralleling Machines.....................................................................................................................................B-8
Operation ..................................................................................................................................................Section C
Graphic Symbols that Appear in this Machine or in this Manual.....................................................................C-1
Power Up Sequence......................................................................................................................................C-2
Safety Warnings............................................................................................................................................C-2
Duty Cycle ....................................................................................................................................................C-3
Common Welding Procedures .......................................................................................................................C-3
Making a Weld .....................................................................................................................................C-3
Definition of Welding Modes..........................................................................................................................C-3
Non-Synergic Welding Modes...............................................................................................................C-3
Synergic Welding Modes ......................................................................................................................C-3
Weld Controls and Displays...........................................................................................................................C-3
Weld Processor Selector Switch............................................................................................................C-3
Hot Start Dial........................................................................................................................................C-3
Arc Control Dial ....................................................................................................................................C-3
Output Control Dial ...............................................................................................................................C-4
Volt Display Meter.................................................................................................................................C-4
Amperage Display Meter.......................................................................................................................C-4
Weld Terminals On/Remote Toggle Switch............................................................................................C-4
Control - Local/Remote Toggle Switch..................................................................................................C-4

TABLE OF CONTENTS
FLEXTEC®FX500XL
Page
Wire Feeder Voltmeter Polarity Switch ..................................................................................................C-4
Thermal Light.......................................................................................................................................C-4
VRD Lights............................................................................................................................................C-4
Basic Modes of Operation .............................................................................................................................C-5
SMAW ..................................................................................................................................................C-5
GTAW ...................................................................................................................................................C-6
CV-GAS ................................................................................................................................................C-6
CV-Innershield......................................................................................................................................C-7
ArcLink.................................................................................................................................................C-7
Accessories .............................................................................................................................Section D
General Options...........................................................................................................................D-1
Fume Extracting Systems ............................................................................................................D-1
Stick Options ...............................................................................................................................D-1
TIG Options..................................................................................................................................D-1
Maintenance ............................................................................................................................Section E
Safety Precautions .......................................................................................................................E-1
Visual Inspection..........................................................................................................................E-1
Routine Maintenance ...................................................................................................................E-1
Periodic Maintenance...................................................................................................................E-1
Troubleshooting.......................................................................................................................Section F
Safety Precautions .......................................................................................................................F-1
How to Use Troubleshooting Guide...............................................................................................F-1
Troubleshooting Guide .................................................................................................................F-2
Wiring Diagrams .....................................................................................................................Section G
Parts List ........................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.

4
PRODUCT DESCRIPTION
PRODUCT DESCRIPTION
The Flextec®FX500XL is a multi-process CC/CV DC inverter power
source rated for 450 Amps, 38 Volts at 100% duty cycle. The
Flextec®FX500XL comes in a rugged case and is intended for
either indoor or outdoor operation and comes with an IP23
environmental rating. Transporting the Flextec®FX500XL is made
simple through lifting handles. The user interface of the Flextec®
FX500XL is simple and intuitive. Weld modes are selected via a 5
position selector switch. Volts and Amps are displayed on an easy
to view LED display, and the amps and volts are set via a large
output control knob. A hot start and an arc control knob allow for
finer tuning of the welding arc for the application. The Flextec®
FX500XL is designed for the North America and Export markets
and operates on 380V, 460V, or 575V 50hz or 60hz three phase
power. Switching between voltages is made simple via a
reconnect panel located on the case back.
The Flextec®FX500XL is designed to be compatible with the
current range of semi-automatic ArcLink wire feeders in addition
to analog and across-the-arc wire feeders. The Flextec®FX500XL
comes with a 5-pin amphenol, a 12-pin amphenol, and a 14-pin
amphenol standard. Voltage sensing is either done at the studs or
via a 67 lead when operating with an ArcLink wire feeder.
The Flextec®FX500XL machine is factory pre-programmed with
multiple welding procedures, typically including GMAW, FCAW,
SMAW, CAG, and GTAW for a variety of materials, including mild
steel, stainless steel and aluminum. The Flextec®FX500XL
comes standard with the 4 basic process modes which are
accessible via the machine case front controls. The ArcLink mode
position and ArcLink feeders unlock synergic mode capabilities.
All models of the Flextec®FX500XL come with the CrossLinc™
interface for remote voltage setting with CrossLinc™ compatible
feeders or remore controls.

5
PRODUCT DESCRIPTION
FLEXTEC®FX500XL
PROCESS LImITaTIONS
The Flextec®FX500XL is suitable only for the processes listed.
EqUIPmENT LImITaTIONS
Operating Temperature Range is -10° C to + 55° C.
Output is de-rated for temperatures in excess of 40° C.
COmmON EqUIPmENT PaCKaGES
OUTPUT RATINGS AT 40° C
AMPS DUTY CYCLE VOLTS TEMPERATURE
450 100% 38V 40° C
500 60% 40V
OUTPUT RATINGS AT 55° C ELEVATED TEMPERATURES
AMPS DUTY CYCLE VOLTS TEMPERATURE
375 100% 35V 55° C
400 60% 36V
FLEX FEED 84 READY-PAK
K3607-5 FLEXTEC
®
FX500XL
K3056-2 LOCKING FOOT KIT
K3883-13 FLEX FEED 74 HT
K2952-2-10-45 MAGNUM
®
PRO CURVE 400
K1842-10 3/0 WELDING CABLE KIT
K2149-1 WORK LEAD PACKAGE
3100211 HARRIS FLOWMETER
K3059-2 UNDERCARRIAGE
FLEX FEED 74HT READY-PAK
K3607-5 FLEXTEC
®
FX500XL
K3056-2 LOCKING FOOT KIT
K3883-12 FLEX FEED 74HT BENCH MODEL
K2952-2-10-45 MAGNUM
®
PRO CURVE 400
K1842-10 3/0 WELDING CABLE KIT
K2149-1 WORK LEAD PACKAGE
3100211 HARRIS FLOWMETER
K3059-2 UNDERCARRIAGE
LF-74 READY-PAK
K3607-5 FLEXTEC
®
FX500XL
K3056-2 LOCKING FOOT KIT
K2426-5 LF-74 BENCH MODEL
K2952-2-10-45 MAGNUM®PRO CURVE 400
K1842-10 3/0 WELDING CABLE KIT
K2149-1 WORK LEAD PACKAGE
3100211 HARRIS FLOWMETER
K3059-2 UNDERCARRIAGE
RECOmmENDED PROCESSES
The Flextec®FX500XL 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.
WELD MODE PROCESS COMMON
MATERIALS
COMMON
ELECTRODES
GTAW LIFT TIG (CC) STAINLESS, STEEL
SMAW STICK-CC STAINLESS, STEEL 6010, 6011, 7018
CV MIG (GMAW)
FCAW-GS ALUMINUM, STAINLESS, STEEL L-50; L-56
CV-INNERSHIELD FCAW-SS ALUMINUM, STAINLESS,
STEEL NR-203; NR-211, NR-440NI2

6
PRODUCT DESCRIPTION
FLEXTEC®FX500XL
COMMON OPTIONAL KITS & ACCESSORIES
K3059-2 INVERTER CART
K3056-2 BASE MOUNTING KIT
K3091-1 MULTI-PROCESS SWITCH
K2909-1 12-PIN TO 6-PIN ADAPTER
K4217-1 WIRELESS FOOT PEDAL
K857-2 REMOTE OUTPUT CONTROL WITH 12-PIN UNIVERSAL CONNECTOR (25 FEET)
K857-3 REMOTE OUTPUT CONTROL WITH 12-PIN UNIVERSAL CONNECTOR (100 FEET)
K870-2 FOOT AMPTROL
K963-3 HAND AMPTROL
K3975-1 FLEXTEC
®
CE FILTER KIT (380-575 VAC)
COMPATIBLE WIRE FEEDERS – ANALOG & ARCLINK FEEDERS
NORTH AMERICAN SEMI-AUTOMATIC WIRE FEEDERS
PF10M, PF25M, PF84 POWER FEED SERIES (40VDC INPUT)
LF-72, LF-74 LF SERIES (42VAC INPUT)
ALL MODELS FLEX FEED SERIES (42VAC INPUT)
ALL MODELS LN-10, DH-10 (42VAC INPUT)
ALL MODELS LN-25 PRO SERIES, ACTIVE8
EUROPEAN SEMI-AUTOMATIC WIRE FEEDERS
PF-44, PF-46 POWER FEED SERIES (EXCLUDING PF42 & PF 40 FOR FLUX CORED)
LF-33S, LF-33, LF-34,
LF-35, LF-37, LF-38,
LN-15
LINC FEED SERIES (42VAC INPUTS ONLY)
LF-45, LF-45S LINC FEED SERIES (40VDC INPUTS)
LF-22M, LF-24M,
LF-24 PRO
LINC FEED SERIES (ACROSS THE ARC INPUT)

A-1
DESIGNFLEXTEC®FX500XL
POWER SOURCES - INPUT VOLTAGE AND CURRENT
MODEL DUTY CYCLE INPUT VOLTAGE ± 10% INPUT AMPERES IDLE POWER (W) POWER FACTOR
K3607-5 60% RATING
100% RATING
380 / 460 / 575 / 3 / 50 / 60 39 / 32 / 32 150W FAN ON
70W FAN OFF
91%
33 / 27 / 27
POWER SOURCES - RECOMMENDED INPUT WIRE AND FUSE SIZES1
VOLTAGE INPUT AMPERES
(100% RATING)
TIME DELAY FUSE
OR BREAKER SIZE TYPE 75C COPPER WIRE IN CONDUIT
AWG (IEC) SIZES 40C
(104°F) AMBIENT
TYPE 75C COPPER
GROUND WIRE IN
CONDUIT AWG (IEC)
SIZES
CORD SIZE
AWG SIZES
380/3/50 33 A 60 8 (10) 10 (6) 8
460/3/60 27 A 50 10 (6) 10 (6) 8
575/3/60 27 A 50 10 (6) 10 (6) 8
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT
K3607-5 18.8 IN (477 MM) 14 IN (356 MM) 26.5 IN (673 MM) 120 LBS. (54.43 KG)
TEMPERATURE RANGES
OPERATING TEMPERATURE 14° F TO 131° F (-10° C TO 55° C)*
STORAGE TEMPERATURE -40° F TO 185° F (-40° C TO 85° C)
INSULATION CLASS CLASS H (18O° C)
*Output is derated for temperatures in excess of 40° C (104° F).
RATED OUTPUT
PROCESS DUTY CYCLE VOLTSAT RATED
AMPERES
AMPERESEFFICIENCY
GMAW (CV) 60% 39V 500A
89%
100% 36.5 V 450A
GTAW (CC)60% 30 V 500A
100% 28 V 450A
SMAW (CC)60% 40 V 500A
100% 38 V 450A
FCAW-GS (CV) 60% 39V 500A
100% 36.5 V 450A
FCAW-SS (CV) 60% 39V 500A
100% 36.5 V 450A
(AT RATED OUTPUT)
TECHNICaL SPECIFICaTIONS

aGENCY aPPROVaLS
DESIGN FEaTURES
• The Future is Now – You no longer have to pay a price premium
to gain the advantages of inverter technology over conventional
welders.
• Faster arc response means smoother arc action and more
consistent bead appearance
• Low power consumption results in daily operational cost
savings
• Enhanced portability – typically 50% less weight, size and
footprint
• Simple and Easy to Use
• Flexible Multi-Process Capability – Including stick, TIG, MIG,
Flux-cored and CAG.
• Bright Digital Amp and Volt Meters – Easy to monitor, even in
sunlight, and presettable for precise procedure control, display
error codes for troubleshooting
• Compact, Durable Case – Tough IP23 enclosure rating ensures
the ability to withstand extreme field environments.
• Variable Hot Start – Get the extra starting amperage you need
for thick, rusty or dirty material.
• Variable Arc Control – In stick mode, vary the arc force to obtain
the “soft” or “crisp” arc you want as conditions require. In CV
modes vary the pinch or inductance to control spatter, fluidity
and bead appearance.
• Procedure Control – Utilize ArcLink Feeder capabilities such as
user memories, preference options, and procedure lockouts
• Full-Featured Remote Control Capability – Use a foot pedal or
hand control to remotely vary output up to 100 ft. (30.5 mm)
away. Master / Slave functionality for precise arc control.
• 380 – 575 VAC, 50/60Hz Voltage Input – Offers the ability to be
connected anywhere in the world.
• Voltage Compensation and Reliable Input Voltage Connection –
Provides consistent operation over ±10% input voltage variation.
• Easy to Parallel Machines or Run Multiple Arcs in CC mode.
• Severe Duty – Can be stored outdoors. IP23 Rated.
• Desert Duty Rated – Welding outputs are rated for extreme
temperature operation up to 55° C
• ArcLink
®
Wire Feeder Compatible – unlock synergic modes to
increase productivity and control
• Synergic Modes – for easy, repeatable welds
• VRD – reduces OCV when not welding for added safety.
• Low Operating Cost – Operates at a high efficiency
• Transport - Reversible handles for ease of lifting.
A-2
DESIGNFLEXTEC®FX500XL
MODEL MARKET CONFORMITY MARK NOTES
K3607-5 US AND CANADA CSAC/US
AUSTRALIA C-TICK / RCM
REQUIRES K3129-2
CE FILTER KIT
EUROPE CE

A-3
DESIGNFLEXTEC®FX500XL
1. Power Switch:
Controls input power to the Flextec®FX500XL.
2. Voltage LCD Display
3. Amperage LCD Display
4. Thermal LED:
A yellow light that comes on when an over temperature
situation occurs.
Output is disabled until the machine cools down.
When cool, the light goes out and output is enabled.
5. Weld Process Selector Switch:
A rotary switch that toggles through the 5 available weld
modes for the Flextec®FX500XL – CC-SMAW; CC-GTAW; CV;
CV-Innershield; ArcLink.
6. Hot Start Control Dial:
Full range selection of hot start from 0 to 10.
7. Output Control Dial:
Sets the Output Current or Voltage for the selected Weld
Process.
8. Local/Remote Selector Toggle Switch:
Sets the control of the output to local (output control knob) or
remote (K857 hand amptrol or K870 foot amptrol through the
12-pin or 14-pin circular connectors).
9. Arc Force Control Dial:
Full range selection of arc force from -10 to +10.
10. Weld Terminals On/Remote selector switch.
11. 14-pin wire feeder circular connector.
12. Circuit breaker reset button for the 14-pin wire feeder
connector.
13. 12-pin remote circular connector.
14. 5-pin ArcLink wire feeder circular connector.
15. Circuit breaker reset button for the 5-pin wire feeder
connector.
16. Positive and negative welding output studs.
17. Wire Feeder Voltmeter polarity selection switch.
18. VRD LED indicators.
19. CrossLinc Communication Indicator.
1
9
10
12
13
11
16
14
17
15
8
5
7
4
318
2
6
19
CaSE FRONT CONTROLS

A-4
DESIGNFLEXTEC®FX500XL
CaSE BaCK CONTROLS
1. Input Power Cord Access Hole
2. Access Panel – Allows access for connecting input power and
configuring the machine
3. Input Power Reconnect – Configures the machine for the input
supply voltage
4. Input Power Fuse Protection
5. Input Power Connection Terminal Block
6. OPTION – Base Mounting Kit
1
2
5
3
4
6

A-5
DESIGNFLEXTEC®FX500XL
INTERNaL CONTROLS
Internal Controls Description
The User Interface pc board has one bank of dip switches
(See Figure A.1). As shipped from the factory and under normal
conditions, the dip switches are all in the ‘off’ position (Figure A.2).
There are 2 instances that require a change of the dip switch.
1. Enter VRD Mode (VRD Enabled)
a.Turn switch #5 to the ‘ON’ Position (See Figure A.3).
Dip Switch Location on User Interface PCB

 


  
  
  




Figure A.1
Figure A.2
Figure A.3

B-1
INSTALLATIONFLEXTEC®FX500XL
INSTALLATION
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 FLEXTEC GROUNDING LUG
(LOCATED INSIDE THE RECONNECT INPUT ACCESS
DOOR) TO A PROPER SAFETY (EARTH) GROUND.
• ONLY A QUALIFIED ELECTRICIAN SHOULD
CONNECT THE INPUT LEADS TO THE FLEXTEC™
MACHINE. CONNECTIONS SHOULD BE MADE IN
ACCORDANCE WITH ALL LOCAL AND NATIONAL
ELECTRICAL CODES AND THE CONNECTION
DIAGRAM LOCATED UNDERNEATH THE CASE TOP
OF THE MACHINE. FAILURE TO DO SO MAY RESULT
IN BODILY INJURY OR DEATH.
INPUT AND GROUND 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.
WARNING

B-2
INSTALLATIONFLEXTEC®FX500XL
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. Remove the
reconnect access panel located on the case back and connect L1,
L2, L3 and ground according to the Input Supply Connection Diagram
decal. (See Figure B.1)
Input Fuse and Supply Wire Considerations
Refer to Page A-1 for 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.
Figure B.1
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.
Reconnect Terminal Block
Reconnects auxiliary transformer for
the proper input voltages
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.

B-3
INSTALLATIONFLEXTEC®FX500XL
INPUT VOLTaGE SELECTION
Welders are shipped connected for 460V input voltage. 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 User Interface 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 FAN will run continuously.
• The machine will need to have the misconnect condition
removed before it will recover.
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 and front.
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 Flextec®FX500XL has two handles that can be used to lift the
machine.
Both handles should be used when lifting the machine. When
using a crane or overhead device to lift using the handles, a lifting
strap should be connected to both handles. Do not attempt to lift
the Flextec®FX500XL with accessories attached to it.
STaCKING
The Flextec®FX500XL cannot be stacked.
ENVIRONmENTaL LImITaTIONS
The Flextec®FX500XL is IP23 rated for use in an outdoor
environment. The machine 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®FX500XL 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.
HIGH FREqUENCY PROTECTION
Locate the Flextec®FX500XL away from radio controlled
machinery. The normal operation of the machine may adversely
affect the operation of RF controlled equipment, which may result
in bodily injury or damage to the equipment.

B-4
INSTALLATIONFLEXTEC®FX500XL
CONNECTION DIaGRamS, CONTROL CaBLES
Picture Function Pin Wiring
J
A
H
B
K
I
C
L
N
D
M
E
F
G
A
BGround
CTrigger, Common
DTrigger input
E77 Remote potentiometer, 10V
F76Remote potentiometer, wiper
G75 Remote potentiometer, common
HWork (21)
I42 VAC
J
K42 VAC
L
M
N
14-pin
connector for
wire feeder
connectivity.
Analog Wire Feeder Connectivity

B-5
INSTALLATIONFLEXTEC®FX500XL
Picture Function Pin Wiring
5-pin
connector for
wire feeder
connectivity.
A ArcLinkCAN
B ArcLink CAN
CElectrode Sense Lead
D40Vdc
E40Vdc Common
Picture Function Pin Wiring
12-pin remote
control
connector for
remote or
hand/foot
amptrol and
digital
accessories.
AArcLinkCAN
BArcLink CAN
C
D
E
FALPS connection
GTrigger
H Trigger
J40Vdc Common
K40Vdc
LNot Used
MNot Used
Remote Potentiometer Wiper
Remote Potentiometer Common
Remote Potentiometer +10V
ArcLink Wire Feeder & Digital Accessory Connectivity