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G-3
SCHEMATIC - COMPLETE MACHINE - SHEET 1
ENGINEERING CONTROLLED
MANUFACTURER:
POSITIVE
OUTPUT
TERMINAL
206B
BY-PASS
PC BOARD
Located on back of
208
output panel
between terminals
Ferrite on Lead 208A
2 turns
NEGATIVE
OUTPUT
TERMINAL
VRD "OFF"
Open Circuit Volts:
Max
Min
CC
58
58
58
CV
58
Pipe
26
58
12
Tig
12
Gouge
42
58
VRD "ON"
Open Circuit Volts:
Max
Min
CC
12
12
CV
58
58
*
Pipe
---
---
Tig
12
12
*
Gouge
---
---
*
NOTE: Pipe and Gouge Modes are not
active with VRD On
(TO AMPHENOL)
TOROID: Senses auxiliary power load to activate idler.
Generator leads 3 and 6 pass through torroid 3 times in
opposite directions.
Control board circuits associated with J2 are part
of engine electrical system and are common to
frame ground (negative battery terminal).
12 volt ground stud on rear of upper control panel.
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for
approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
REMOTE
CONTROL
CONNECTOR
CHANGE DETAIL:
New
No
Shunt on back of positive
output terminal
SHUNT
50MV=400 AMPS
Chopper module is located on right side of
CURRENT LEVEL
interior panel behind upper control panel.
204S
IGBT'S, FLYBACK DIODES AND
FEED BACK SIGNAL
206S
FILTER CAPACITORS ARE INTEGRAL
CHOPPPPER PC BOARD
206A
TO CHOPPER MODULES AND NOT
INDIVIDUALLY REPLACEABLE.
WIREFEEDER
VOLTMETER
+COM
21
13A
SWITCH
B2
208A
B5
R4 is located above
CONTACTS
rectifier on upper left
(SHOWN IN
interior panel behind
" + " POSITION)
R4
upper control panel.
FILTER
208C
50 OHM
CAPACITORS (6)
208B
100 W
FLYBACK
206B
Choke mounted behind
DIODES (12)
output terminal panel.
B3
IGBT (16)
15
C
B6
CHOKE
PWM Signal to Chopper
15 volt @ 20 kHz
B7
B8
GATE SIGNAL
296
RED
299 (J61-4)
Ferrite onTwisted Pair
4 turns
Power Supply
to Control
296A
GRN
297 (J61-9)
Board
14 13
298 (J61-10)
TWISTED
TWISTED
TWISTED
PAIR
PAIR
PAIR
204S (J6-1)
206S (J6-2)
Located under VRD Control PCBd on the back of the control panel
ARC VOLTAGE
FEEDBACK SIGNAL
208C
208C (J3-15)
Control board common is
(J2-1) 200N
at welder positive output
10 V
(J2-5) 405
77 (J7-1)
and shunt
LOW IDLE COMMAND (0V @ LOW IDLE)
OUTPUT
0-10 V
R1
76 (J7-4)
0 V
Swich closed for high idle.
CONTROL 10K
VRD WELD CONTROL
(J3-14) 257
IDLER SWITCH
0 V
75 (J7-5)
PC BOARD
(J3-7) 256
15 V
2A
10 V
P/N G5507-2
(TO AMPHENOL)
77A (J1-11)
15 V
(J1-4) 2
REMOTE
-15 V (W/O POT.)
WELD TERM. SW.
Located on back of
76A (J1-14)
CONTROL 10K
(J1-3) 4
control panel.
0 V
(TO AMPHENOL)
0 V
4A
75A (J1-10)
CV
(J7-9) 214
(SEE SHEET 2 FOR
GOUGE
(J7-11) 217
MODE
277 (J7-8)
SIMPLIFIED
PIPE
(J7-14) 218
SWITCH
ARC
CONTROL BOARD
R2
278 (J7-7)
CC
CONTROL 10K
SCHEMATIC)
TIG
(J7-15) 220
279 (J7-6)
(J7-16) 222
(J7-2) 215
260 (J3-4)
(J7-10) 216
261 (J3-3)
(J2-9) 262A
Located on wiring behind
(J2-11) 244
250 (J3-5)
receptacles.
(J2-2) 243
250 (J3-1)
Located on front
Jumper required for output.
(J1-8)
control panel.
232 (J2-7)
(J1-12)
(J1-6)
(J1-7)
5G (J2-3)
(J4-1 to 10)
(J5-1 to 10)
(J1-13)
DX450 I.D. JUMPER
(Part of round plug and lead assembly.)
Ferrite on meter leads
WELD AMMETER
WELD VOLTMETER
J
31
A
32
I
41A
42VAC
K
42A
H
21
WORK
A
75B
E
77A
TO CONNECTOR J1
B
76B
REMOTE
77B
CONTROL
F
76A
76B
C
77B
75A
G
CONTACTOR
75B
D
4A
C
2A
B
Ferrite on Leads 75A & 76A
GROUND
GND-A
3 turns
CONNECTOR
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS
Rectifier is located on left side of interior
panel behind upper control panel.
THREE PHASE
60 TO 65 VAC PHASE TO PHASE
RECTIFIER
13C
AT HIGH IDLE
13
W1
W6
W1 W6
7,200uF x6
+
W2
STATOR
W2
DC BUS VOLTAGE
WELD
W3
WINDINGS
90+/-10VDC @ HI IDLE
W3
B1
B4
E
W4
W5
W4
W5
14
14C
FOUR POLE 1500 RPM ALTERNATOR
41
ROTOR FIELD
42 VOLT AC
SLIP RINGS
WIRE FEEDER
POWER
42
3
Auxiliary power to front
-
panel receptacles via circuit
(J61-1) 208B
breakers on front panel.
+
(J61-8) 206B
5
4
REVOLVING FIELD
AC AUX. POWER
RESISTANCE APPROX.
5A
3 TO 5 - 120 VAC 1 PHASE
36 OHMS @ 75F
6A TO 5 -120 VAC 1 PHASE
Weld volts >30, RED light on
3 TO 6 - 240 VAC 1 PHASE
120 VOLT AC
Weld volts <30, GREEN light on
+15DC
3, 4 AND 6 - 240 VAC 3 PHASE
POWER FOR
6
ROTOR FIELD CIRCUIT
Switching Power
+
(J60-6) 14C
6A
Supply Voltage
-
(J60-1) 13C
Regulator
5H
Rotor Flashing: +12 volts
@ 0.5 amps
VDR DISPLAY PC BOARD
until generator builds up
then +190 volts @ 0 amps.
R3 10 OHM / 25 WATT
ROTOR FLASHING
OIL
COOLANT
FUEL
PRESSURE
TEMPERATURE
4
1
J51
VRD
SWITCH
Located on VRD control mounting
262
228
232B
232I
232F
232K
241
232C
5K
bracket. Shown in "ON" position
5M
232H
232
5L
229
262A
YELLOW
ALT.
LAMP
Located in top
of fuel tank
229
FUEL
LEVELSENSOR
230 OHMS EMPTY
5J
30 OHMS FULL
262
232F
HOUR
METER
PULLS LOW TO
RUN HOUR METER
Field capacitor located
on lower rear of fan baffle
on right side of machine.
200
200B
+
160 VDC
Diode Bridge
4200uf
located on
300vdc
upper control
6
5H
panel, right rear.
201
RUN/STOP DETECT
Located on rear
of upper control
START BUTTON SENSE
panel
31GV
(PULLS LOW TO
ENERGIZE STARTER
RUN-STOP SWITCH
SHOWN IN RUN POS.
Located on front panel
236B
CB
236C
234A 238C
232C
232K
236D
232B
231A
+
238
B
D+
232I
1G
L
ENGINE
ALTERNATOR
26GV
Battery voltage:
12.6 volts at rest
14 volts engine
running
+
12 VOLT
BATTERY
GENERATOR
FRAME
SUPPORT
GROUND
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
SCALE:
CONTROL:
CLEVELAND
EQUIPMENT TYPE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm)
NONE
DRAWN BY:
Maglietta
ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm)
IF PRINTED
SUBJECT:
ON ALL ANGLES IS ± .5 OF A DEGREE
@ A1 SIZE
MATERIAL TOLERANCE (" ") TO AGREE
t
ENGINEER:
SF
WITH PUBLISHED STANDARDS.
UNITS:
MATERIAL
INCH
DO NOT SCALE THIS DRAWING
APPROVED:
DISPOSITION:
G-3
241
228
Oil Pressure
Switch
10 OHMS @ 0 PSI
closes on low
100 OHMS @ 75PS1
oil pressure.
OIL PRESSURE
27GV
SWITCH
SENDER
TEMPERATURE
28GV
Temperature
SWITCH
SENDER
Switch
500-600 OHMS COLD
closes on high
50-100 OHMS HOT
temperature.
Located in engine
thermostat housing
LEAD NOT USED
9GV
6GV
ACTUATOR
+
34GV
OIL PRESSURE
-
CURRENT
SWITCH INPUT
27GV
18GV
FEED BACK
WATER TEMP
19GV
SWITCH INPUT
28GV
ALT DETECT
12V
26GV
20GV
TACH INPUT
17GV
31GV
SIGNAL
5P
16GV
ECU POWER
15GV
13GV
WATER
TEMP.
SENSOR
+5V
5U
11GV
RPM ADJUSTMENT
ADJUST INPUT
(+5V = 0 ADJUSTMENT)
2GV
( 0V = 150 IPM)
12GV
1GV
STARTER
RELAY DRIVE
7GV
ENGINE CONTROL UNIT
MOTOR)
START RELAY
10A
12GV
2
1
START
BUTTON
4
3
SWITCH
230
232H
231
7GV
238A
238B
GLOW PLUG
Located on front
ENGINE
BUTTON
Located in engine
control panel.
STARTER
GLOW PLUGS
SWITCH
intake manifold
SOLENOID
239
ENGINE
STARTER
238B
238C
LEAD COLOR CODE:
COMPONENT VALUE UNITS:
B-BLACK OR GRAY
CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/WATTS
O-ORANGE
R-RED OR PINK
CONNECTOR PIN NUMBERS
U-BLUE
W-WHITE
EX. 12 PIN CONNECTOR
Y-YELLOW
1
2
6
LABELS:
COMMON
7
12
FRAME GROUND
LATCH
EARTH GROUND
VIEW OF CONNECTOR ON PC BOA
RED-D-ARC DX450
1
2
PAGE ___ OF ___
DOCUMENT
DOCUMENT
MACHINE SCHEMATIC
NUMBER:
REVISION:
G6378
REFERENCE:
A
NA
APPROVAL
PROJECT
8/22/2008
CRM39756-A
DATE:
NUMBER:
G6277
Red-D-Arc DX450
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