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ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:
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- nections 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.
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
•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
Cable Length
Cable Size for
400Amps
60% Duty Cycle
2/ 0 AWG
2 / 0 AWG
3 / 0 AWG
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 DX450 is equipped with a toggle switch for select- ing "hot" welding terminal when in the "WELD TERMI- NALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.
TABLE A.1
CABLE INSTALLATION
Install the welding cables to your DX450 as follows.
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.
CAUTION
•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.
