Lincoln Electric RED-D-ARC DX450 manual

RED-D-ARC DX450 IM962-B January, 2010 Red-D-Arc Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operat[...]

DX450 (RED-D-ARC) 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. ______________________________[...]

DX450 (RED-D-ARC) ii SAFETY ii ARC R A Y S can bur n. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant materia[...]

iii SAFETY iii DX450 (RED-D-ARC) FOR ELECTRIC ALL Y pow ered 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 accordanc[...]

iv SAFETY iv DX450 (RED-D-ARC) Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse ?[...]

v v T T h h a a n n k k Y Y o o u u for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular a[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...........................[...]

vii vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ........................................................... .....................................D-1 Routine Maintenance ...........................................................[...]

DX450 (RED-D-ARC) A-1 INST ALLA TION A-1 1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. * To Top of enclosure, add 10.68”(271.3mm) to top of exhaust pipe. Add 6.67”(169.4mm) to top of Lift B[...]

A-2 INST ALLA TION DX450 (RED-D-ARC) A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maint[...]

A-3 INST ALLA TION DX450 (RED-D-ARC) A-3 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 1.0% for every 2000 ft. (610m) up to 6000 ft. (1828m) and 2.0% for every 2000 ft. (610m) over 6000 ft. (1828m). Due to new EPA and other local emissions regulations, modifications to the engi[...]

The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the K903-1 must be installed and properly maintained. An incorrect spark arrestor may lead to damage to the engine or adversely affect performance. ----------------------------------------------[...]

A-5 INST ALLA TION A-5 ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.) To prevent dangerous electric shock, other equipment to which this engine driven welder s[...]

ST ANDBY POWER CONNECTIONS The DX450 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule. The DX450 can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 50 amp service. Connections must be made by a licensed electrician who can determine how the [...]

A-7 INST ALLA TION DX450 (RED-D-ARC) A-7 x y z xyz HUBBELL CS6365C WH I T E CONNECTION OF DX450 T O PREMISES WIRING W ARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that: • The installation complies with the National Electrical Code and all other app[...]

A-8 INST ALLA TION DX450 (RED-D-ARC) A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the DX450 1. Shut the welder off. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. 3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required[...]

A-9 INST ALLA TION DX450 (RED-D-ARC) A-9 Spool Gun (K487-25) and Cobramatic to DX450 • Shut the welder off. • Connect per instructions on the appropriate connec- tion diagram in Section F. Connection of the LN-25 to the DX450 Shut off welder before making any electrical con- nections. ------------------------------------------------------------[...]

B-1 OPERA TION B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ---------------------------------------------------------[...]

B-2 OPERA TION B-2 WELDING CONTROLS (Figure B.1) 1 . OUTPUT CONTROL- The OUTPUT dial is used to preset the output voltage or current as dis- played on the digital meters for the five welding modes. When in the CC-STICK, ARC GOUGING or CV-WIRE modes and when a remote control is con- nected to the 3-Pin or 14-Pin Connector, the auto- sensing circuit [...]

B-3 OPERA TION B-3 4. ARC CONTROL - The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, and has different functions in these modes. This control is not active in the TIG and ARC GOUGING mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a[...]

TYPICAL DX450 FUEL CONSUMPTION TABLE B.2 KUBOTA V2403M Gal./Hr (Liters/Hr) .42(1.58) .60(2.28) 1.57(5.93) 1.63(6.16) 1.28 (4.83) Running Time for 20 gallons / hours 48.03 33.18 12.76 12.29 15.67 Low Idle - No Load 1400 R.P.M. High Idle - No Load 1800 R.P.M. DC Weld Output 500 Amps @ 40Volts 20,000 Watts 3 Phase 12,000 Watts 1 Phase NOTE: This data [...]

WELDER OPERA TION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a 60% duty cycle, rep resents 6 minutes of load and 4 minutes of no load in a 10 minute period. ELECTRODE INFORMATION For any electrode the procedures should be kept with- in the rating of the machine. For information on el[...]

When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin connector the OUT- PUT CONTROL dial is used to set the maximum cur- rent range of the current control of the Amptrol. The ARC CONTROL is not active in the TIG mode. To STOP a weld, simply pull the TIG torch away from the work. When the arc voltage reaches approximately 30[...]

Carbon Diameter Current Range (DC, electrode positive) 1/8"(3.2mm) 60-90 Amps 5/32"(4.0mm) 90-150 Amps 3/16"9(4.8mm) 200-250 Amps 1/4"(6.4mm) 300-400 Amps 5/16"(8.0mm) 400-Max.Amps AUXILIAR Y POWER: Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the wel[...]

C-1 ACCESSORIES C-1 DX450 (RED-D-ARC) FIELD INST ALLED OPTIONS / ACCESSORIES K903-1 SPARK ARRESTOR - Includes a heavy gage steel, approved spark arrestor, clamp and adapter for mounting to the muffler exhaust pipe. K704 ACCESSORY SET - Includes 35 ft. (10m) of elec- trode cable and 30 ft. (9.1m) of work cable, headshield, work clamp electrode holde[...]

D-1 MAINTENANCE D-1 DX450 (RED-D-ARC) SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Tu rn t he eng in e of f bef or e wo rk in g in si de the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal i[...]

D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Locate oil drain hose and valve in bottom of base[...]

D-3 MAINTENANCE D-3 DX450 (RED-D-ARC) Unfasten or unlatch the s ervice cover . Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking the seal on a jar . Gently move the end of the filter back and forth to break the seal then rotate while pulling straight out. Avo[...]

D-4 MAINTENANCE D-4 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in the radiator and recovery bottle. Add 50/50 antifreeze / water solution if the level is close to or below the "LOW&quo[...]

D-5 MAINTENANCE D-5 FUEL FIL TER 1 . Check the fuel filter and fuel pre-filter for water accumulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre-fil- ter. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Service Center or an authorized Field Service Shop. [...]

D-6 MAINTENANCE D-6 DX450 (RED-D-ARC) GFCI MODULE TESTING AND RESETTING PROCEDURE The GFCI module should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI module: • If the module has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down, [...]

E-1 TROUBLESHOOTING E-1 DX450 (RED-D-ARC) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Gu ide is provided to help you locate and repair possi[...]

E-2 TROUBLESHOOTING E-2 DX450 (RED-D-ARC) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYM[...]

E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

E-4 TROUBLESHOOTING E-4 DX450 (RED-D-ARC) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYM[...]

E-5 TROUBLESHOOTING E-5 DX450 (RED-D-ARC) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYM[...]

E-6 TROUBLESHOOTING E-6 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

F-1 DIAGRAMS F-1 DX450 (RED-D-ARC)[...]

F-2 DIAGRAMS F-2 DX450 (RED-D-ARC)[...]

F-3 DIAGRAMS F-3 DX450 (RED-D-ARC)[...]

F-4 DIAGRAMS F-4 DX450 (RED-D-ARC)[...]

F-5 DIAGRAMS F-5 DX450 (RED-D-ARC) 2 9/03[...]

F-6 DIAGRAMS F-6 DX450 (RED-D-ARC)[...]

F-7 WIRING DIAGRAM F-7 DX450 (RED-D-ARC) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. CB6 10A 42A 42 REC[...]

F-8 DIMENSION PRINT F-8 DX450 (RED-D-ARC) L1 38 5 7 A.0 1 25.82 655.8 27.00 685.8 55.50 1409.7 2.25 57.2 5.75 146.0 35.94 913.0 24.00 609.6 39.81 20.60 523.3 28.95 735.3 37.05 941 60.00 1524.0 N.A. N.A. CENTER OF GRAVITY W ITH OIL IN ENGINE, COOLANT IN RADIATOR, AND EMP TY FUEL TANK. 1.27 32.3 46.62 1184.15 12.50 317.5 29.38 746.3[...]

NOTES DX450 (RED-D-ARC)[...]

NOTES DX450 (RED-D-ARC)[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fume s. ● Use venti lation or ex haust to remo ve fu m[...]

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