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N W DO NOT INSTALL, OPERATE OR REPAIR TH PRECAUTIO ... a And, m This This des O S R Howeve Ia e To in g f H d P w R d e nr O - E e tt o sD U lt h D d y p sE roh T e ,- te - u D r y c D A iR m g o i- isR fh A E A iu N p e r c td r A R c o fa S p u e o r t D C m lit sAT v o C e a S o Iie g N n welder is built n O p n rn s p tG a ee lN e yd lb rle d , a T T y sr s t tc A H aO a h iL oi f n IiI- n iec n N o S n d B t k c E y o n M a bR o b n D u c u le Y n A a ’ y ii fT l s n t N o o l E o H t’ t
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN bE hAzARDOuS. PROTECT YOuRSELF AND OThERS FROM POSSIbLE SERIOuS INJuRY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAuTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting one of our QuALITY products. We want you to take pride in operating this product ••• as much pride as we have in Thank You bringing this product to you! CuSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We respond to our customers based
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vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Welding Process, Physical Dimensions ..........................................................A-2 Safety Precautions ..........................................................................................A-3 Select Suitable
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A-1 A-1 INSTALLATION TEChNICAL SPECIFICATIONS - FX450 POWER SOuRCE-INPuT VOLTAGE AND CuRRENT Input Voltage ± 10% Input Amperes Model Duty Cycle Power Factor @ Idle Power Rated Output 60% rating 72 Watts 37 / 27 / 22 K3073-1 Max. 95% 380 / 460 / 575 / 3 / 50 / 60 100% rating 29 / 21 / 17 (fan on) RATED OuTPuT Process Duty Cycle Volts at Rated Amperes Amperes 60% 36.5V 450 GMAW (CV) 100% 34V 400 60% 28V 450 GTAW (CC) 100% 26V 400 60% 38V 450 SMAW (CC) 100% 36V 400 60% 36.5V 450 FCAW-GS (CV) 1
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A-2 A-2 INSTALLATION WELDING PROCESS PROCESS OuTPuT RANGE (AMPERES) OCV (u o) GMAW (CV) 40-500 60 GTAW (CC) 10-500 24 SMAW (CC) 15-500 60 FCAW-GS (CV) 40-500 60 FCAW-SS (CV) 40-500 60 PhYSICAL DIMENSIONS MODEL hEIGhT WIDTh DEPTh WEIGhT K3073-1 26.66in (677mm) 125lbs (56.6kg)* 18.80in (478mm) 14.14in (359mm) TEMPERATuRE RANGES OPERATING TEMPERATuRE RANGE STORAGE TEMPERATuRE RANGE ** Environmentally Hardened: -40°F to 185°F (-40°C to 85°C) Environmentally Hardened: 14°F to 131°F (-10°C to 5
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A-3 A-3 INSTALLATION SAFETY PRECAuTIONS CAuTION Do not mount the FX450 over combustible sur- WARNING faces. Where there is a combustible surface ELECTRIC ShOCK can kill. directly under stationary or fixed electrical equip- ment, that surface shall be covered with a steel ONLY QuALIFIED PERSONNEL plate at least .060” (1.6mm) thick, which shall ShOuLD PERFORM ThIS INSTALLA- extend not less than 5.90” (150mm) beyond the TION. equipment on all sides. • TuRN OFF INPuT POWER TO ThE POWER ----------
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A-4 A-4 INSTALLATION INPuT FuSE AND SuPPLY WIRE WARNING CONSIDERATIONS ELECTRIC ShOCK can kill. Refer to Specification in this Installation Section for ONLY A QuALIFIED ELECTRICIAN recommended fuse, wire sizes and type of the copper ShOuLD CONNECT ThE INPuT wires. Fuse the input circuit with the recommended LEADS TO ThE FX450. CONNEC- super lag fuse or delay type breakers (also called TIONS ShOuLD bE MADE IN ACCORDANCE "inverse time" or "thermal/magnetic" circuit breakers). WITh ALL L
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A-5 A-5 INSTALLATION CAbLE CONNECTIONS See FIGuRE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FX450. D EC F BA 6-PIN REMOTE CONTROL CONNECTOR Function Pin Wiring F E 6-pin remote A 77 Remote potentiometer, 5K A control con- B 76 Remote potentiometer, wiper D nector for C 75 Remote potentiometer, common B remote or D Trigger, common C hand/foot E Trigger, input amptrol. F Ground 14-PIN CONNECTOR FOR WIRE FEEDER Function Pin Wiring E DM L N CKB A J F G H I 14 pin con- A n
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A-6 A-6 INSTALLATION • Route all cables directly to the work and wire RECOMMENDED ELECTRODE AND feeder, avoid excessive lengths and do not coil WORK CAbLE SIzES FOR ARC WELDING excess cable. Route the electrode and work cables in close proximity to one another to minimize the General Guidelines loop area and therefore the inductance of the weld Connect the electrode and work cables between the circuit. appropriate output studs of the FX450 per the follow- ing guidelines: • Always weld in a d
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b-1 b-1 OPERATION SAFETY PRECAuTIONS GRAPhIC SYMbOLS ThAT Read this entire section of operating instructions APPEAR ON ThIS MAChINE before operating the machine. OR IN ThIS MANuAL WARNING INPuT POWER ELECTRIC ShOCK can kill. • unless using cold feed feature, when ON feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several OFF seconds after the welding ceases. • Do not touch electrically live parts or electrodes with your ski
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b-2 b-2 OPERATION GRAPhIC SYMbOLS ThAT PRODuCT DESCRIPTION APPEAR ON ThIS MAChINE The FX450 is a multi-process CC/CV DC inverter and OR IN ThIS MANuAL is rated for 450 amps, 38 volts at a 60% duty cycle. This machine is intended for both factory and field operation. It comes in a compact, rugged case that is OPEN CIRCuIT u designed for portability and outdoor use with an IP23 0 VOLTAGE environmental rating. The user interface of the FX450 is simple and intuitive. Weld modes are selected by a 4
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b-3 b-3 OPERATION RECOMMENDED PROCESSES AND EQuIPMENT RECOMMENDED PROCESSES The FX450 is designed for CC-SMAW, CC-GTAW (lift tig), CV-GMAW, CV-FCAW-SS and CV-FCAW-GS welding processes. CAG (arc gouging) is also supported. PROCESS LIMITATIONS The FX450 is suitable only for the processes listed. EQuIPMENT LIMITATIONS Operating Temperature Range is -10° C to + 55° C. Output De-rated at Temperatures above 40°C. COMMON EQuIPMENT PACKAGES basic Package K3073-1 FX450 K2327-5 LF-72 Bench Model K2
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b-4 b-4 OPERATION CASE FRONT CONTROL DESCRIPTIONS (See Figure B.1) 11. Wire feeder voltmeter polarity selection toggle switch 1. Power Switch 12. Circuit breaker reset button for the 14-pin wire 2. Voltage Display Meter feeder connector 3. Amperage Display Meter 13. 14-pin wire feeder circular connector 4. Thermal LED 14. 6-pin remote circular connector 5. Output Control Dial 15. Positive and negative welding output studs 6. Weld Process Selector Switch 7. hot Start Toggle Switch 8. Output Contr
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b-5 b-5 OPERATION 3. CV – This is CV (constant voltage) weld mode used CASE bACK CONTROL for welding the GMAW MIG welding process and (See Figure B.2) the FCAW-GS, flux cored gas shielded welding process. 1. Input Power Cord Access hole. FIGuRE b.2 4. CV-Innershield – This is a CV (constant voltage) 1 weld mode used for welding the FCAW-SS, flux 1 cored self shielded welding process The FX450 is also capable of gouging. Gouging can be done in either the SMAW mode or the CV and CV- Innershield m
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b-6 b-6 OPERATION Amperage Display Meter Arc Control - The Arc Control regulates the Arc Force • Prior to STICK or TIG operation (current flow), the to adjust the short circuit current. The minimum setting meter displays preset current value. (-10) will produce a "soft" arc and will produce minimal • Prior to CV operation, the meter displays four dash- spatter. The maximum setting (+10) will produce a es indicating non-presettable AMPS. "crisp" arc and will minimize electrode sticking. • Durin
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b-7 b-7 OPERATION GTAW CV-GAS This weld mode is a constant current (CC) mode featuring con- This weld mode is a constant voltage (CV) mode featuring con- tinuous control from 10 – 500 amps. It is intended for the GTAW tinuous control from 10 to 45 volts. TIG welding processes. It is intended for the GMAW, FCAW-GS, MCAW welding processes and arc gouging. hot Start - The Hot Start control regulates the starting current at arc initiation. Hot Start can be set to “Off” and no additional hot Start –
