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Red-D-Arc Welderentals D502DX 5+4 Owner's Manual

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OM-224 690H
2009−01
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
File: Engine Drive

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Summary of Contents for Red-D-Arc Welderentals D502DX 5+4

  • Page 1 OM-224 690H 2009−01 Processes Stick (SMAW) Welding TIG (GTAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator File: Engine Drive...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING ......... . . 8-1.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2008−08 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.

  • Page 7: Engine Hazards

    1-3. Engine Hazards HOT PARTS can cause severe burns. BATTERY EXPLOSION can BLIND. D Do not touch hot parts bare handed. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Allow cooling period before working on equip- ment.

  • Page 8: Compressed Air Hazards

    D Keep hands, hair, loose clothing, and tools away from moving HYDRAULIC FLUID can injure or kill. parts. D Before working on hydraulic system, turn off and lockout/tagout D Before working on hydraulic system, turn off and unit, release pressure, and be sure hydraulic pressure cannot be lockout/tagout unit, release pressure, and be sure accidentally applied.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can injure. HOT PARTS can cause severe burns. D Do not touch hot compressor or air system D Keep away from fans, belts and rotors. parts. D Keep all doors, panels, covers, and guards D Let system cool down before touching or ser- closed and securely in place.

  • Page 10: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as micro- communications equipment. processors, computers, and computer-driven equipment such as robots.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION rom_2008−08fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 12 D Porter un casque de soudage approuvé muni de verres filtrants DES PIÈCES CHAUDES peuvent approprié pour protéger visage et yeux pendant le soudage provoquer des brûlures graves. (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux même sous D Ne pas toucher à...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Placer les bouteilles debout en les fixant dans un support station- LES CHAMPS MAGNETIQUES peuvent naire ou dans un porte-bouteilles pour les empêcher de tomber ou affecter des implants médicaux. de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres D Porteur de simulateur cardiaque ou autre im- circuits électriques.

  • Page 14: Dangers Liés À L'hydraulique

    L’utilisation d’un groupe autonome L’ACIDE DE LA BATTERIE peut pro- à l’intérieur PEUT VOUS TUER EN voquer des brûlures dans les YEUX et QUELQUES MINUTES. sur la PEAU. D Ne pas renverser la batterie. D Les fumées d’un groupe autonome contient du D Remplacer une batterie endommagée.

  • Page 15: Dangers Liés À L'air Comprimé

    LIRE LES INSTRUCTIONS. D Lire le manuel d’utilisation avant d’installer, d’utiliser ou d’intervenir sur l’appareil. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. 2-5.

  • Page 16: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    MÉTAL CHAUD provenant LIRE LES INSTRUCTIONS. découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion. D Lire le manuel d’utilisation avant d’installer, d’utiliser ou d’intervenir sur l’appareil. D Ne pas découper ou gouger à proximité D N’utiliser que les pièces de rechange de produits inflammables.

  • Page 17: Proposition Californienne 65 Avertissements

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provo- quer des interférences pour l’équipement élec- D Le rayonnement haute fréquence (H.F.) peut tronique sensible tel que les ordinateurs et provoquer des interférences avec les équipe- l’équipement commandé...

  • Page 18: Information Emf

    2-9. Information EMF Considérations sur le soudage et les effets de basse fréquence et des 1. Garder les câbles ensemble, les torsader, les scotcher, ou les champs magnétiques et électriques. recouvrir d’une housse. Le courant de soudage, pendant son passage dans les câbles de sou- 2.

  • Page 19: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) Remove unit from shipping S-177 571 crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Read Owner’s Manual. Read labels on unit. Use Diesel Fuel only, and fill fuel tank.

  • Page 20: Symbols And Definitions

    3-2. Symbols And Definitions Some symbols are found only on CE products. Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Engine Oil Starting Aid Battery (Engine) Engine Oil Pressure Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive...

  • Page 21: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Welding Weld Output Rated Welding Open- Generator Power Fuel Engine Mode Range Output Circuit Rating Capacity Voltage 500 A, 30 Volts DC 40% Duty Cycle Single-Phase, 25 gal IEC Rating 4 kVA/kW, 34/17 A, DEUTZ CC/DC...

  • Page 22: Volt-Ampere Curves

    4-3. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. Ranges: 230 − Max 170 − 365 110 − 225 70 −...

  • Page 23: Duty Cycle And Overheating

    4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 100% Duty Cycle At 400 Amperes utes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. Continuous Welding 215 084-A 4-6.

  • Page 24: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Do not move or operate unit where it could tip. Always securely fasten weld- Movement ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. NOTICE −...

  • Page 25: Mounting Welding Generator

    5-2. Mounting Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.

  • Page 26: Rating Label Location

    5-3. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

  • Page 27: Using Lifting Eye

    5-5. Using Lifting Eye Lifting Eye Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. To lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket and secure with nut (bolt and nut not supplied).

  • Page 28: Activating The Dry Charge Battery (If Applicable)

    5-7. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a battery. Remove battery from unit. Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 29: Engine Prestart Checks

    5-9. Engine Prestart Checks Full Diesel Full 804 169 Fuel Check all engine fluids daily. To improve cold weather starting: NOTICE − Do not use gasoline. Gasoline Engine must be cold and on a level surface. Keep battery in good condition. Store will damage engine.

  • Page 30: Connecting To Weld Output Terminals

    5-10. Connecting To Weld Output Terminals Stop engine. Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output...

  • Page 31: Selecting Weld Cable Sizes

    5-11. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m)

  • Page 32: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 236 984-A/ Ref. 804 168 OM-224 690 Page 28...

  • Page 33: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Engine Oil Pressure Gauge Stick/TIG Selection Switch Engine Control Switch Use switch to disable the max OCV circuit Normal pressure is 30 − 60 psi (207 − 414 kPa).

  • Page 34: Remote Amperage Control (Optional)

    6-3. Remote Amperage Control (Optional) Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-12). In Example: Example: Combination Remote Amperage Control (Stick) Range = 110 to 225 A DC Percentage Of Range = 50% Max = About 168 A DC (50% of 110 to 225) Max (168 A DC) Min (90 A DC) Set Switches...

  • Page 35: Fuel/Hour Gauge Descriptions

    6-5. Fuel/Hour Gauge Descriptions OM-224 690 Page 31...

  • Page 36: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Receptacles 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC Receptacle Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops...

  • Page 37: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label OM-224 690 Page 33...

  • Page 38: Routine Maintenance

    8-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent...

  • Page 39: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.

  • Page 40: Inspecting And Cleaning Optional Spark Arrestor Muffler

    8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material.

  • Page 41: Adjusting Engine Speed

    8-6. Adjusting Engine Speed Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load speeds).

  • Page 42: Servicing Fuel And Lubrication Systems

    8-7. Servicing Fuel And Lubrication Systems Tools Needed: 804 169 / Ref. 800 159 in base. See engine manual and engine To replace secondary fuel filter: Stop engine and let cool. maintenance label for oil/filter change in- See engine manual. After servicing, start engine and formation.

  • Page 43: Overload Protection

    8-8. Overload Protection Stop engine. When a circuit breaker, supplementa- ry protector, or fuse opens, it usually indicates a more serious problem ex- ists. Contact Factory Authorized Ser- vice Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload.

  • Page 44: Troubleshooting

    8-9. Troubleshooting A. Welding − CC Models Trouble Remedy No weld output; generator power output Check position of Ampere Range switch. okay at ac receptacles. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-12 and 6-1).
  • Page 45 B. Standard Generator Power Trouble Remedy No generator power output at ac recep- Reset receptacle supplementary protectors. tacles; weld output okay. Reset GFCI receptacle. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuses F1 and F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, and the rotor.
  • Page 46 Trouble Remedy Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1. weld speed (models with idle option only).
  • Page 47 Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm...

  • Page 48: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For CC Welding Generator OM-224 690 Page 44...
  • Page 49 237 428-A OM-224 690 Page 45...

  • Page 50: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE run_in1 2007−04 10-1. Wetstacking NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 51: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

  • Page 52: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

  • Page 53: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 54 11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device GND/PE Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 55 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 56 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 57 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 58 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na- Fused tional, state, and local codes. Welding Utility Disconnect...
  • Page 59 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68) 137 (42)

  • Page 60: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 102 (Fig. 12-5) (Fig. 12-2) 106 (Fig. 12-3) Figure 12-1. Main Assembly OM-224 690 Page 56...
  • Page 61 28 (Fig. 12-4) 804 172-C OM-224 690 Page 57...
  • Page 62 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ....189 824 PANEL, gen LH ..........
  • Page 63 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....190 207 CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng .
  • Page 64 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....+200 999 BASE ............
  • Page 65 804 175-D Figure 12-2. Control Box Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-2. Control Box Assembly (Figure 12-1 Item 98) ..F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V ........
  • Page 66 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Control Box Assembly (Continued) ....236606 HARNESS, control box, weld control (consisting of) .
  • Page 67 Hardware is common and not available unless listed. 804 171-B Figure 12-3. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-3. Panel, Front w/Components (Figure 12-1 Item 106) ....019 602 KNOB, pointer .
  • Page 68 Item Dia. Part Mkgs. Description Quantity Figure 12-3. Panel, Front w/Components (Continued) ....192 558 HARNESS, range (consisting of) ........
  • Page 69 802 552-B Figure 12-4. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator (Figure 12-1 Item 28) ....132 053 SCREW, .375−16x1.50 hex hd−pln gr5 pld .
  • Page 70 Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator (Continued) ....049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln ......
  • Page 71 Hardware is common and not available unless listed. 802 279-A Figure 12-5. Main Rectifier Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-5. Main Rectifier Assembly (Figure 12-1 Item 102) ...
  • Page 72 Notes OM-224 690 Page 68...
  • Page 73 Notes OM-224 690 Page 69...
  • Page 74 Notes OM-224 690 Page 70...

  • Page 75: Warranty

    Warranty Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) Induction Heating Coils and Blankets, Cables, and This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or Non-Electronic Controls warranties expressed or implied.
  • Page 76 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Contact the Delivering Carrier for: File a claim for loss or damage during shipment.

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