Advertisement

Quick Links

IM982-E
RED-D-ARC
November 2018
DX500e (CE)
(
11531, 11594, 11964, 12197, 12365, 12692
For use with machines having Code Numbers:
OPERATOR'S MANUAL
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.
The Global Leader in Welder Rentals

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Airgas RED-D-ARC DX500e and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Lincoln Electric Airgas RED-D-ARC DX500e

  • Page 1 OPERATOR’S MANUAL 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 ...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 SAFETy PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 7 SAFETy                !" #$ % & '& ( & &&  " % & '& (  ') -./0 %       *+,  & 0 $ 1...
  • Page 8 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: 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.
  • Page 9 SAFETy 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.
  • Page 10: Table Of Contents

    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..........................
  • Page 11 TABLE OF CONTENTS Maintenance......................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.........................
  • Page 12: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - DX500e (CE) (K2754-1) INPUT - DIESEL ENGINE 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.
  • Page 13: Machine Specification

    INSTALLATION MACHINE SPECIFICATIONS MODEL NUMBERS K2754-1 Receptacles 400V (3 Ph) x 1 230V (1 Ph) x 1 115V x 1 14 Pin Connector 6 Pin Connector Residual Current Device (RCD) 4-pole, 25Amp (30mA trip current) Circuit Breakers (Thermal/Magnetic) 3 Phase,25 Amp x 1 1 phase, 15 Amp x 3 10A for Engine Battery Charging Circuit Other Circuit Breakers...
  • Page 14: Safety Precautions

    INSTALLATION SAFETy PRECAUTIONS FIGURE A.1 WARNING Do not attempt to use this equipment until you (VRD)-VOLTAGE REDUCTION DEVICE SWITCH IS LOCATED IN THIS AREA. 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.
  • Page 15: High Altitude Operation

    INSTALLATION TOWING WARNING Use a recommended trailer for use with this equipment for road, • Lift only with equipment of in-plant and yard towing by a vehicle . If the user adapts a non- • adequate lifting capacity. Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard or •...
  • Page 16: Oil

    INSTALLATION MUFFLER OUTLET PIPE Using the clamp provided secure the outlet pipe to the outlet tube The DX500e (CE) is shipped with the engine crankcase filled with with the pipe positioned such that it will direct the exhaust in the high quality SAE 10W-30 Oil that meets classification CG-4 or CH-4 desired direction.
  • Page 17: Electrical Connections

    INSTALLATION ELECTRICAL CONNECTIONS WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs. The welding process dic- MACHINE GROUNDING tates the polarity of the electrode cable. These con- Because this portable engine driven welder creates its nections should be checked periodically and tightened own power, it is not necessary to connect its frame to with a 3/4"(19mm) wrench.
  • Page 18: Standby Power Connections

    INSTALLATION AUXILIARy POWER The auxiliary power capacity is 16,500 watts Peak, 14,500 Watts Continuous of 50 Hz, three phase power. 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.
  • Page 19: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION FIGURE A.2 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Weld Set to Local Terminals On Set Mode to CONNECTION OF ACROSS THE ARC WIRE FEEDERS CV Wire TO THE DX500e These connections instructions apply to both the LN-25 Pro and Activ8 models.
  • Page 20: Operation

    OPERATION SAFETy PRECAUTIONS • Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door. WARNING • Check radiator for proper coolant level. (Fill if nec- essary). • See Engine Owner’s Manual for specific oil and Do not attempt to use this equipment until you coolant recommendations.
  • Page 21 OPERATION FIGURE B.1 (CODES 11531, 11594,11964) FIGURE B.1a (CODE 12197) WELDING CONTROLS (Figure B.1) When in the TOUCH START TIG mode and when an Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of 1.
  • Page 22 OPERATION 4. ARC CONTROL 11. VRD (Voltage Reduction Device) INDICATOR - The ARC CONTROL dial is active in the CV- LIGHTS- WIRE, CC-STICK and DOWNHILL PIPE modes, and has different On the front panel of the DX500e (CE) are two indicator functions in these modes.
  • Page 23: Engine Controls

    OPERATION 18. ENGINE PROTECTION LIGHT- ENGINE CONTROLS: A warning indi- cator light for Low Oil Pressure and/or Coolant Over 12. RUN/STOP SWITCH - RUN position energizes the Temperature.The light is off when the systems are func- engine prior to starting. STOP position stops the tioning properly.
  • Page 24: Constant Current (Stick) Welding

    OPERATION NOTE: If the unit fails to start turn Run/Stop switch The ARC CONTROL dial sets the short circuit current to off and repeat step 3 through step 7 after (arc-force) during stick welding to adjust for a soft or waiting 30 seconds.
  • Page 25: Tig Welding

    OPERATION When in the TOUCH START TIG mode and when a The OUTPUT CONTROL dial adjusts the full output Amptrol is connected to the 6-Pin connector the OUT- range for pipe welding. PUT CONTROL dial is used to set the maximum cur- rent range of the current control of the Amptrol.
  • Page 26: Wire Welding-Cv

    OPERATION This will keep the "Solid State" contactor open and provide a Set the OUTPUT CONTROL knob to adjust output "cold" electrode until the Amptrol or Arc Start Switch is pressed. current to the desired level for the gouging electrode being used according to the ratings in the following When using the TIG Module, the OUTPUT CONTROL on the Table B.4.
  • Page 27: Accessories

    ACCESSORIES FIELD INSTALLED OPTIONS / TIG OPTIONS ACCESSORIES K1783-9 Pro -Torch® PTA-26V TIG Torch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. K903-1 SPARK ARRESTOR - Includes a heavy gage steel, approved spark arrestor, clamp and adapter for mounting to KP509 Magnum Parts Kit for PTA-26V TIG Torch...
  • Page 28: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS Read the Safety Precautions in the front of this manual and in the Engine Owner’s Manual before WARNING working on this machine. • Have qualified personnel do all maintenance Keep all equipment safety guards, covers, and and troubleshooting work. devices in position and in good repair.
  • Page 29: Engine Oil Change

    MAINTENANCE ENGINE OIL CHANGE OIL FILTER CHANGE Drain the engine oil while the engine is warm to assure • Drain the oil. rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as •...
  • Page 30 MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.
  • Page 31: Cooling System

    MAINTENANCE FUEL COOLING SySTEM WARNING At the end of each day’s use, refill the fuel tank to min- imize moisture condensation and dirt contamination in HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to expand.
  • Page 32: Fuel Filter

    MAINTENANCE CLEANING THE BATTERy FUEL FILTER Keep the battery clean by wiping it with a damp cloth 1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon- accumulation or sediment. nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 2.
  • Page 33: Welder / Generator Maintenance

    MAINTENANCE WELDER / GENERATOR MAINTENANCE STORAGE: Store in clean, dry protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal for the brushes and slip rings to wear and darken slightly.
  • Page 34: Troubleshooting

    TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SyMPTOMS) CAUSE COURSE OF ACTION 1. Contact your local Authorized Major Physical or Electrical Damage Field Service Facility. is Evident. 1. Battery is low, Charge Battery. Engine will not "crank". 2.
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SyMPTOMS) CAUSE COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant tempera- load. ture. Reduce load if it is exceed- ing machine rating. Add coolant to system if low.
  • Page 37 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SyMPTOMS) CAUSE COURSE OF ACTION Engine will not go to high idle when 1. Auxiliary power load is less than using auxiliary power. 100 watts. Idler may not respond with less than a 100 watt load.
  • Page 38 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SyMPTOMS) CAUSE COURSE OF ACTION No welding power output. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal. 2. "Weld Terminals" switch in wrong position.
  • Page 39 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SyMPTOMS) CAUSE COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory.
  • Page 40 DIAGRAMS DX500e (CE) (RED-D-ARC)
  • Page 41 DIAGRAMS DX500e (CE) (RED-D-ARC)
  • Page 42 WIRING DIAGRAM DX500e (CE) (RED-D-ARC)
  • Page 43 DIAGRAMS DX500E (CE) (RED-D-ARC)
  • Page 44 DIMENSION PRINT DX500e (CE) (RED-D-ARC)
  • Page 45 NOTES DX500E (CE) (RED-D-ARC)
  • Page 46 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAUCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 47 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAUCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 48 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

Table of Contents