Lincoln Electric Red-D-Arc DX500e Mode d'emploi
- Catégorie
- Système de soudage
- Taper
- Mode d'emploi
RED-D-ARC
DX500e (CE)
IM982-E
November 2018
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:
11531, 11594, 11964, 12197, 12365, 12692
The Global Leader in Welder Rentals
OPERATOR’S MANUAL
(
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
U
se 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 de velop 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 - 06/15/2016
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
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
t
heir 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 - 06/15/2016
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
o
f 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 It ems 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 - 06/15/2016
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
f
rom 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,
e
tc. 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 - 06/15/2016
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SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
e pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
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SAFETY
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SAFETY
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i
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
s
tandard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
v
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SAFETY
v
ii
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special
applications
1.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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x
ix
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Machine Specification................................................................................................... A-2
Safety Precautions........................................................................................................ A-3
VRD (Voltage Reduction Device)..................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking........................................................................................................................ A-3
Angle of Operation........................................................................................................ A-3
Lifting.............................................................................................................................A-3
High Altitude Operation................................................................................................. A-4
High Temperature Operation........................................................................................ A-4
Cold Weather Operation...................................................................................................... A-4
Towing..................................................................................................................................A-4
Vehicle Mounting..................................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-5
Fuel............................................................................................................................... A-5
Engine Coolant..............................................................................................................A-5
Battery Connections......................................................................................................A-5
Muffler Outlet Pipe........................................................................................................ A-5
Spark Arrester............................................................................................................... A-5
Remote Control............................................................................................................. A-5
Electrical Connections..........................................................................................................A-6
Machine Grounding.............................................................................................................. A-6
Welding Terminals................................................................................................................A-6
Welding Output Cables........................................................................................................ A-6
Cable Installation..................................................................................................................A-6
Auxiliary Power Receptacles and Plugs...............................................................................A-7
Standby Power Connections................................................................................................ A-7
Connection of Lincoln Electric Wire Feeders.................................................................A-7,A-8
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions .............................................................................................................. B-1
General Description..............................................................................................................B-1
For Auxiliary Power.............................................................................................................. B-1
Engine Operation..................................................................................................................B-1
Add Fuel............................................................................................................................... B-1
Break in Period.....................................................................................................................B-1
Welder Controls............................................................................................................. B-2,B-3
Engine Controls....................................................................................................................B-4
Fuel Consumption......................................................................................................... B-4
Starting and Stopping the Engine...........................................................................B-4,B-5
Welding Operation................................................................................................................B-5
Duty Cycle and Electrode Information...........................................................................B-5
Constant Current (Stick) Welding.........................................................................................B-5
Downhill Pipe (Stick) Welding....................................................................................... B-5
Tig Welding................................................................................................................... B-6
Typical Current Ranges for Tungsten Electrodes......................................................... B-6
Wire Welding-CV...........................................................................................................B-7
Arc Gouging.................................................................................................................. B-7
Auxiliary Power.....................................................................................................................B-7
Simultaneous Welding and Power Loads..................................................................... B-7
Extension Cord Recommendations...............................................................................B-7
________________________________________________________________________________
Accessories.....................................................................................................Section C
Field Installed
Options / Accessories ...............................................................................C-1
________________________________________________________________________________
x
x
TABLE OF CONTENTS
M
aintenance......................................................................................................Section D
Safety Precautions................................................................................................ D-1
Routine Maintenance............................................................................................ D-1
Engine Service Items.............................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Filter Change.................................................................................D-2
Air Cleaner ..................................................................................................... D-2
Service Instructions And Installation Tips for Engine Air Filter....................... D-3
Cooling System..................................................................................................... D-4
Fan Belt...........................................................................................................D-4
Fuel................................................................................................................. D-4
Bleeding the Fuel System............................................................................... D-4
Fuel Filter........................................................................................................ D-5
Engine Adjustment.......................................................................................... D-5
Battery Maintenance....................................................................................... D-5
Servicing Optional Spark Arrestor................................................................... D-5
Welder / Generator Maintenance........................................................................ D-6
Storage........................................................................................................... D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement.................................................................. D-6
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide............................................................................ E-2 thru E-6
________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F
________________________________________________________________________
Parts List.................................................................................................................P-585
________________________________________________________________________
DX500e (CE) (RED-D-ARC)
Lift Bail weight rating 2300 lbs. (1043 kg.) Maximum.
(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.
(2) Reduced to less than 30V in the CC-stick Mode when
VRD (VOLTAGE REDUCTION DEVICE) is on.
(3) Maximum per circuit breaker rating.
(4) To Top of enclosure. Add 7.35 (186.7mm) to top of exhaust. Add 3.87”(98.3mm) to top of Lift Bail.
A-1
INSTALLATION
A
-1
TECHNICAL SPECIFICATIONS - DX500e (CE) (K2754-1)
Make/Model Description Speed (RPM) Displacement Starting Capacities
cu. in. (ltrs.) System
4 cylinder
Bore x Stroke inch (mm)
12VDC Battery & Oil:
Perkins 37.2 HP High Idle 1575 starter
8.45Qts. (8L) Fuel: 20 gal.
404D-22T 1500 RPM Full Load 1575
3.43 X 3.64
(Group 34; 650
(75.7 L)
Turbo Charged Low Idle 1200 cold crank amps)
Radiator
water cooled (87.1 x 92.5mm) 65 Amp Alternator
Coolant:
INPUT - DIESEL ENGINE
RATED OUTPUT @ 104° F (40° C) - WELDER
LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR
Full Pressure
EPA Tier IV Interim Compliant
Mechanical Fuel Pump, Auto air bleed Electronic
with Full Flow Filter system, Electric shutoff solenoid, Indirect fuel injector.
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Low noise Muffler: Shutdown on low oil
Single Element Automatic Idler Top outlet can be rotated. pressure & high engine
Made from long life, aluminized steel. coolant temperature
ENGINE WARRANTY:
2 years / 2000 hours, all non-electric components, 3 years major non-electric components.
Welding Process
DC Constant Current
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
Output Range
30 TO 500 AMPS
40 TO 300 AMPS
20 TO 250 AMPS
14 TO 40 VOLTS
Max. Weld OCV
@Rated Load RPM
60 Volts
(2)
60 Volts
Welding Output
Current/Voltage/Duty Cycle
400A / 36V / 100%
450A / 38V / 60%
300A / 32V / 100%
250A / 30V / 100%
400A / 36V / 100%
450A / 38V / 60%
450A / 38V / 60%
Auxiliary Power
(1)
16,500 Watts Peak / 14,500 Watts Continuous, 50 Hz 400 Volts 3-Phase
3,400 Watts Peak
(3)
/ 3,400 Watts Continuous, 50 Hz 230 Volts 1-Phase
3,400 Watts Peak
(3)
/ 3,400 Watts Continuous, 50 Hz 115 Volts 1-Phase
Sound Levels (Sound power: 96 dB Lwa)
ENGINE
RATED OUTPUT @ 40° C (104° F)
.
- GENERATOR
HEIGHT WIDTH DEPTH WEIGHT
35.94
(4)
in. 27.05 in. 62.59 in.
913 mm 687 mm 1590 mm
PHYSICAL DIMENSIONS
1290 lbs. (586kg.)
A-2
INSTALLATION
DX500e (CE) (RED-D-ARC)
A-2
MODEL NUMBERS K2754-1
MACHINE SPECIFICATIONS
Receptacles
Residual Current Device (RCD)
Circuit Breakers (Thermal/Magnetic)
Other Circuit Breakers
400V (3 Ph) x 1
230V (1 Ph) x 1
115V x 1
(5)
14 Pin Connector
6 Pin Connector
4
-pole, 25Amp
(30mA trip current)
3 Phase,25 Amp x 1
1 phase, 15 Amp x 3
10A for Engine Battery Charging Circuit
10A for Wire Feeder Power
(5) Center-Tapped to ground.
A-3
INSTALLATION
DX500e (CE) (RED-D-ARC)
A-3
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
m
anual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINEEXHAUSTcan kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTScan injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
WARNING
VRD (VOLTAGE REDUCTION DEVICE)
The VRD feature provides additional safety in the CC-Stick
mode especially in an environment with a higher risk of
electric shock such as wet areas and hot humid sweaty
conditions.
The VRD reduces the OCV (Open Circuit Voltage) at the
welding output terminals while not welding to less than
30V
DC when the resistance of the output circuit is above
200Ω (ohms).
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 con-
nections also limits the possibility of other safety issues
such as heat-generated damage, burns and fires.
The machine is shipped with the VRD switch in the “Off”
position. To turn it “On” or “Off”:
• Turn the engine “Off”.
• Disconnect the negative battery cable.
• Lower the control panel by removing 4 front
panel screws.
(See Figure A.1)
• Place the VRD switch in the “On or “Off” position.
(See Figure A.1)
With the VRD switch in the “On” position, the VRD lights
are enabled.
LOCATION AND VENTILATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate
the welder so that the engine exhaust fumes are prop-
erly vented to an outside area.
STACKING
DX500e (CE) machines cannot be stacked.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 25
degrees in all directions, 35 degrees Intermittent (less
than 10 minutes continuous) in all directions. If the
engine is to be operated at an angle, provisions must
be made for checking and maintaining the oil level at
the normal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the amount
specified.
LIFTING
The DX500e (CE) weighs approximately
1440lbs.(653kg) with a full tank of fuel, 1290lbs.
(586kg) less fuel. A lift bail is mounted to the machine
and should always be used when lifting the machine.
(
VRD)-VOLTAGE REDUCTION DEVICE
S
WITCH IS LOCATED IN THIS AREA.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(
VRD) SWITCH
FIGURE A.1
A-4
INSTALLATION
DX500e (CE) (RED-D-ARC)
A-4
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 engine for
high altitude are restricted within the United States. If
required contact an authorized Perkins engine field service
shop to determine if any adjustments can be made for oper-
ation in higher elevations.
HIGH TEMPERATURE OPERATION
At temperatures above 104°F(40°C), Welder output derating
is necessary. For maximum output ratings, derate the
welder output 2 volts for every 18°F(10°C) above
104°F(40°C).
Cold weather starting:
With a fully charged battery and the proper oil, the
engine should start satisfactorily down to -15°F(-
26C°). If the engine must be frequently started at or
below 0°F (-18°C), it may be desirable to install cold-
starting aides. The use of No. 1D diesel fuel is recom-
mended in place of No. 2D at temperatures below
23°F (-5°C). Allow the engine to warm up before
applying a load or switching to high idle.
Note: Extreme cold weather starting may require
longer glow plug operation.
Under no conditions should ether or other starting
fluids be used with this engine!
------------------------------------------------------------------------
TOWING
Use a recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle
(1)
. If the user adapts a non-
L
incoln trailer, he must assume responsibility that the method of
attachment and usage does not result in a safety hazard or
damage the welding equipment. Some of the factors to be con-
sidered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment and
l
ikely additional attachments.
2. Proper support of, and attachment to, the base of the welding
equipment so there will be no undue stress to the framework.
3. Proper placement of the equipment on the trailer to insure
stability side to side and front to back when being moved and
when standing by itself while being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of sur-
face on which the trailer will be operated; environmental con-
ditions; like maintenance.
5. Conformance with federal, state and local laws.
(1)
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public
highways.
WARNING
•• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
l
ift bail if it is equipped with a
gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
• DO NOT EXCEED MAXIMUM LIFT BAIL WEIGHT
RATING.
( SEE TECHNICAL SPECIFICATIONS PAGE)
------------------------------------------------------------------------
VEHICLE MOUNTING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
WARNING
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
• Stop engine and allow to cool before fueling.
• Do not smoke when fueling.
• Fill fuel tank at a moderate rate and do not over-
fill.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
WARNING
WARNING
OIL
The DX500e (CE) is shipped with the engine crankcase filled with
high quality SAE 10W-30 Oil that meets classification CG-4 or CH-4
f
or diesel engines. Check the oil level before starting the engine. If
it is not up to the full mark on the dip stick, add oil as required.
Check the oil level every four hours of running time during the first
5
0 running hours. Refer to the engine Operator’s Manual for specif-
ic oil recommendations and break-in information. The oil change
interval is dependent on the quality of the oil and the operating envi-
ronment. Refer to the Engine Operator’s Manual for more details on
the proper service and maintenance intervals.
FUEL
DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur
fuel in U.S.A. and Canada.
• Fill the fuel tank with clean, fresh fuel. The capacity of the
tank is 20 gals. (75.7L). When the fuel gauge reads empty the
tank contains approximately 2 gals. (7.6ltrs.) of reserve fuel.
NOTE: A fuel shut off valve is located on the pre-filter/sedi-
ment filter. Which should be in the closed position
when the welder is not used for extended periods of
time.
------------------------------------------------------------------------
ENGINE COOLING SYSTEM
Air to cool the engine is drawn in the side and exhausted
through radiator & case back. It is important that the intake and
exhaust air is not restricted. Allow a minimum clearance of 1ft.
(0.6m) from the case back and 16 in. (406mm) from either side
of the base to a vertical surface.
------------------------------------------------------------------------
BATTERY CONNECTION
Use caution as the electrolyte is a strong acid that can burn
skin and damage eyes.
------------------------------------------------------------------------
The DX500e (CE) is shipped with the negative battery cable discon-
nected. Make certain that the RUN-STOP switch is in the STOP
position. Remove the two screws from the battery tray using a
screwdriver or a 3/8"(10mm) socket. Attach the negative battery
cable to the negative battery terminal and tighten using a
1/2"(13mm) socket or wrench.
NOTE: This machine is furnished with a wet charged battery; if
unused for several months, the battery may require a booster
charge. Be careful to charge the battery with the correct polarity.
(See Battery in “Maintenance Section”)
A-5
INSTALLATION
DX500e (CE) (RED-D-ARC)
A-5
MUFFLER OUTLET PIPE
U
sing the clamp provided secure the outlet pipe to the outlet tube
with the pipe positioned such that it will direct the exhaust in the
desired direction. Tighten using a 9/16"(14mm) socket or wrench.
SPARK ARRESTER
Some federal, state or local laws may require that gasoline or diesel
engines be equipped with exhaust spark arresters when they are
operated in certain locations where unarrested sparks may present
a fire hazard. 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.
------------------------------------------------------------------------
REMOTE CONTROL
The DX500e (CE) is equipped with a 6-pin and a 14-pin connector.
The 6-pin connector is for connecting the K857 or K857-1 Remote
Control or for TIG welding, the K870 foot Amptrol or the K936-3
hand Amptrol. When in the CC-STICK, ARC GOUGING or CV-
WIRE modes and when a remote control is connected to the 6-pin
Connector, the auto-sensing circuit automatically switches the OUT-
PUT control from control at the welder to remote control.
When in the DOWNHILL PIPE mode and when REMOTE CON-
TROL is connected to the 6-Pin or 14-Pin Connector, the OUTPUT
CONTROL is used to set the maximum current range of the OUT-
PUT CONTROL of the REMOTE.
Example: When the OUTPUT CONTROL on the welder is set to
200 amps the current range on the REMOTE CONTROL will be 40-
200 amps rather than the full 40-300 amps. Any current range that
is less than the full range provides finer current resolution for more
fine tuning of the output.
When in TOUCH START TIG mode and when a Amptrol is connect-
ed to the 6-Pin Connector, the OUTPUT dial is used to set the max-
imum current range of the CURRENT CONTROL of the Amptrol.
The 14-pin connector is used to directly connect a wire feeder con-
trol cable. In the CV-WIRE mode, when the control cable is con-
nected to the 14-pin connector, the auto-sensing circuit automatical-
ly makes the Output Control inactive and the wire feeder voltage
control active.
NOTE: When a wire feeder with a built in welding voltage con-
trol is connected to the 14-pin connector, do not connect any-
thing to the 6-pin connector.
------------------------------------------------------------------------
WARNING
CAUTION
WARNING
WARNING
WARNING
A-6
INSTALLATION
DX500e (CE) (RED-D-ARC)
A-6
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Because this portable engine driven welder creates its
o
wn power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
p
remises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
• Be grounded to the frame of the welder using a
grounded type plug or be double insulated.
• Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect-
ed between the machine grounding stud and the
frame of the vehicle. When this engine driven welder
is connected to premises wiring such as that in a
home or shop, its frame must be connected to the
system earth ground. See further connection instruc-
tions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat-
ed joints, or to the metal framework of a building
which has been effectively grounded.
The National Electrical Code lists a number of alter-
nate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
WELDING TERMINALS
The DX500e (CE) is equipped with a toggle switch for
selecting "hot" welding terminal when in the "WELD
TERMINALS ON" position or "cold" welding terminal
when in the "REMOTELY CONTROLLED" position.
WARNING
WELDING OUTPUT CABLES
With the engine off connect the electrode and work
cables to the output studs. The welding process dic-
tates the polarity of the electrode cable. These con-
n
ections should be checked periodically and tightened
with a 3/4"(19mm) wrench.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
TABLE A.1
CABLE INSTALLATION
Install the welding cables to your DX500e (CE) as fol-
lows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals
.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identi-
fied on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
• Do not cross the welding cables at the output ter-
minal connection. Keep the cables isolated and
separate from one another.
------------------------------------------------------------------------
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100 Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for
400 Amps
60% Duty Cycle
2 / 0 AWG
2 / 0 AWG
3 / 0 AWG
CAUTION
A-7
INSTALLATION
DX500e (CE) (RED-D-ARC)
A-7
AUXILIARY POWER
The auxiliary power capacity is 16,500 watts Peak,
14,500 Watts Continuous of 50 Hz, three phase
p
ower. The auxiliary power capacity rating in watts is
equivalent to volt-amperes at unity power factor. The
max permissible current of the 400 VAC output is 22
amps. Output voltage is within ± 10% at all loads up
t
o the rated capacity.
Single phase power is:
• 3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz
230 Volts 1-Phase.
• 3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz
115 Volts 1-Phase.
STANDBY POWER CONNECTIONS
The machine is suitable for temporary, standby or
emergency power using the engine manufacturer’s
recommended maintenance schedule.
The machine can be permanently installed as a
standby power unit for 400 VAC, three phase, 21
amp service.
Connections must be made by a licensed electrician
who can determine how the power can be adapted to
the particular installation and comply with all applica-
ble electrical codes.
• Take necessary steps to assure load is limited to
the capacity of the DX500e (CE).
• Only a licensed, certified, trained electrician
should install the machine to a premises or resi-
dential electrical system. Be certain that:
• The installation complies with the National
Electrical Code and all other applicable electri-
cal codes.
• The premises is isolated and no feedback into
the utility system can occur. Certain laws
require the premises to be isolated before the
generator is linked to the premises. Check your
local requirements.
-----------------------------------------------------------------------
-
WARNING
A-8
INSTALLATION
A-8
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
CONNECTION OF ACROSS THE ARC WIRE FEEDERS
TO THE DX500e
These connections instructions apply to both the LN-25 Pro and
Activ8 models. The feeders have an internal contactor and the
electrode is not energized until the gun trigger is closed. When the
gun trigger is closed the wire will begin to feed and the welding
process is started.
• Shut the welder off.
• For electrode Positive, connect the electrode cable to the "+"
terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "-"
terminal of the welder and work cable to the "+" terminal of the
welder.
• Attach the single lead from the front of the feeder to work using
the spring clip at the end of the lead. This is a control lead to
supply current to the wire feeder motor; it does not carry weld-
ing current (See Figure A.3).
• Set the MODE switch to the "CV-WIRE" position (See Figure A.7).
• Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the “REMOTE/LOCAL” switch to “LOCAL” control.
FIGURE A.2
FIGURE A.3
Set Mode to
C
V Wire
Weld
Terminals On
S
et to Local
B-1
OPERATION
DX500e (CE) (RED-D-ARC)
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
s
tarting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
• Always operate the welder with the hinged door
closed and the side panels in place.
• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.
GENERAL DESCRIPTION
The DX500e (CE) is a diesel engine powered DC
multi-process welding power source and AC power
generator. The engine drives a generator that supplies
three phase power for the DC welding circuit, single
phase and Three Phase power for the AC auxiliary
outlets. The DC welding control system uses state of
the art Chopper Technology for superior welding
performance.
The DX500e (CE) is fitted with a selectable
VRD(Voltage Reduction Device). The VRD operates
in the CC-Stick mode reducing the OCV to <13 volts,
increasing operator safety when welding is performed
in environments with increased hazard of electric
shock such as wet areas and hot, humid sweaty con-
ditions.
FOR AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
ENGINE OPERATION
Before Starting the Engine:
• Be sure the machine is on a level surface.
• Open side engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.
•
Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if nec-
essary).
•
See Engine Owner’s Manual for specific oil and
coolant recommendations.
ADD FUEL
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
DIESEL FUEL ONLY-Low sulphur fuel or ultra low
sulphur fuel in U.S.A. and Canada.
------------------------------------------------------------------------
• Remove the fuel tank cap.
• Fill the tank. DO NOT FILL THE TANK TO THE
POINT OF OVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recom-
mendations.
BREAK-IN PERIOD
The engine will use a small amount of oil during its
“break-in” period. The break-in period is about 50 run-
ning hours.
Check the oil every four hours during break-in.
Change the oil after the first 50 hours of operation and
every 200 hours thereafter. Change the oil filter at
each oil change.
During break-in, subject the Welder to moderate
loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow
the engine to cool several minutes.
------------------------------------------------------------------------
WARNING
WARNING
CAUTION
DIESEL FUEL
can cause fire.
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Lincoln Electric Red-D-Arc DX500e Mode d'emploi
- Catégorie
- Système de soudage
- Taper
- Mode d'emploi
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