User manual | DIGITAL INVERTER DP400

MANUAL NO:P10355
OWNER'S
MANUAL
FOR
CO2/MAG/MIG
DIGITAL INVERTER
DP400
MODEL: DP-400
P10355
INVERTER CONTROLLED WELDING POWER SOURCE
DO
NOT
DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
DAIHEN Corporation
WELDING PRODUCTS DIVISION
June 1, 2004
Upon contact, advise MODEL and MANUAL NO.
Notice
:
Machine export to Europe
This product does not meet the requirements specified in the EC Directives which are the EU safety
ordinance that was enforced starting on January 1, 1995. Please make sure that this product is not
allowed to bring into the EU after January 1, 1995 as it is.
The same restriction is also applied to any country which has signed the EEA accord.
Please ask us before attempting to relocate or resell this product to or in any EU member country or
any other country which has signed the EEA accord.
No. P10355
TABLE OF CONTENTS
1. SAFETY INFORMATION…………………………………………………………… 2
2. ARC WELDING SAFETY PRECAUTIONS………………………………………
2
3. GENERAL NOTICE OF OPERATION…………………………………………….. 8
4. STANDARD COMPOSITION AND ACCESSORIES……………………………
9
5. FUNCTION OF EQUIPMENT……………………………………………………… 11
6. NECESSARY POWER SOURCE EQUIPMENT………………………………… 12
7. TRANSPORT AND INSTALLATION……………………………………………… 13
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE………….. 15
9. WELDING PREPARATION………………………………………………………… 18
10. OPERATION…………………………………………………………………………. 29
11. APPLIED FUNCTION……………………………………………………………….. 56
12. MAINTENANCE AND TROUBLESHOOTING…………………………………… 65
13. PARTS LIST…………………………………………………………………………. 72
14. SPECIFICATIONS…………………………………………………………………... 74
15. SERVICE AND SUPPORT………………………………………………………… 78
−1−
No. P10355
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.
WARNING
WARNING gives information regarding possible personal injury
or loss of life.
CAUTION
CAUTION refers to minor personal injury or possible equipment
damage.
2. ARC WELDING SAFETY PRECAUTIONS
‹
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
‹
Read and understand the summarized safety information given below and the original
principal information that will be found in the PRINCIPAL SAFETY STANDARDS.
‹
Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
‹
Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
−2−
No. P10355
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output is on. The power line and internal circuits of
this equipment are also live when the line disconnect switch is on. When arc welding all metal
components in the torch and work circuits are electrically live.
1. Do not touch live electrical parts.
2. Wear dry insulating gloves and other body protection that are free of holes.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Be sure to disconnect the line disconnect switch before installing, changing torch parts
or maintaining this equipment.
5. Properly install and ground this equipment according to its Owner’s Manual and national,
state, and local codes.
6. Keep all panels and covers of this equipment securely in place.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not touch electrode and any metal object if POWER switch is ON.
9. Do not wrap cables around your body.
10. Turn off POWER switch when not in use.
ARC RAYS can burn eyes and skin: FLYING SPARKS AND HOT METAL can
cause injury. NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can
burn eyes and skin.
Noise from some arc welding can damage hearing.
1. Wear face shield with a proper shade of filter (See ANSI Z 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a welder
work.
2. Wear approved safety goggles. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare: warn others not
to look at the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs if noise level is high.
Chipping and grinding can cause flying metal. As welds cool, they can throw off slag.
6. Wear approved face shield or safety goggles. Side shields recommended.
7. Wear proper body protection to protect skin.
−3−
No. P10355
2. ARC WELDING SAFETY PRECAUTIONS (continued)
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, spatter, hot
base metal, and hot equipment can cause fire and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 10m (33ft) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easily pass through cracks
and openings into adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
7. Do not weld on closed containers such as tanks or drums.
8. Connect base metal side cable as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire
hazards.
9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
10. Does not use the welding power source for other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connection can cause sparks and excessive heating.
13. Tighten all cable connections.
14. When there is an electrical connection between a work piece and the frame of wire feeder or
the wire reel stand, are may be generated and cause damage by a fire if the wire contacts
the frame or the work piece.
FUMES AND GASES can be hazardous to your health.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. Ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturer’s instructions on
metals, consumables, coatings, and cleaners.
5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
6. Work in a confined space only if it is well ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can displace air causing injury or death.
Be sure the breathing air is safe.
−4−
No. P10355
2. ARC WELDING SAFETY PRECAUTIONS (continued)
CYLINDER can explode if damaged.
A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
1. Use only correct shielding gas cylinders, pressure regulators for gas cylinders, hoses, and
fittings designed for the specific application; maintain them in good condition.
2. Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent
falling or tipping.
4. Keep cylinders away from any welding or other electrical circuit.
5. Never touch cylinder with welding electrode.
6. Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when gas cylinder is in use or connected for
use.
9. Do not disassemble or repair the pressure regulators for gas cylinders except for the
person authorized by the manufacturer of them.
Rotating parts may cause injuries. Be sure to observe the following.
If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s feed roll,
injuries may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
−5−
No. P10355
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
‹ When hanging the welding power source by a crane, do not use the carrying handle.
‹ Put the welding power source and wire feeder solidly on a flat surface.
‹ Do not pull the welding power source across a floor laid with cables and hoses.
‹ Do not put wire feeder on the welding power source.
‹ Do not put the welding power source and wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
‹ Do not press gun trigger until instructed to do so.
‹ Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.
−6−
No. P10355
PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electro technical Commission
Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro
technical Commission
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2,
from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American
Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.
NOTE: The codes listed above may be improved or eliminated. Always refer to the updated codes.
M040414
−7−
No. P10355
3. GENERAL NOTICE OF OPERATION
3.1
Rated Duty Cycle
CAUTION
● Use this welding power source at or under the rated duty cycle. Exceeding the rated duty
cycle limitation may result in damage to the welding machine.
• The rated duty cycle of the welding power source is the following:
400A 50% (for pulse mode)
400A 60% (for DC mode)
• The
duty cycle of 60% means the way the machine is rested for 4 minutes after 6
minutes of continuous welding at the rated current.
OFF
ON
4 min.
6 min.
10 min.
Operation cycle of 60% duty cycle
• Failure to observe duty cycle limitations may cause an excess of the tolerance of the
• The
figure shown right indicates the relation
between welding current and duty cycle. Use
the welding machine within its usable range,
following the duty cycle for the welding current.
• The duty cycle of the welding power source is
100
50
0
100%(270A or less)
82%
60%
DP-400
50%
(Rated)
Usable range
100
200
300 350 400
WELDING CURRENT (A)
(PULSE MODE)
DUTY CYCLE (% )
also limited by the duty cycles of accessories
combined with such as welding torches. Use
the welding machine within the lowest rated
duty cycle of the accessories.
DUTY CYCLE (% )
temperature inside the welding machine. This may contribute to premature welding
machine failure or product damage.
100% (310A or less)
100
60%
50
0
DP-400
Usable range
100
200
(Rated)
300
400
WELDING CURRENT (A)
(DC MODE)
3.2 Applicable Welding Process and Wire Diameter
Refer to Section 10.1.1, “Setting of Welding Mode” for details of applicable welding method and
wire diameter.
3.3 Limitation of use
● Do not use this welding power source for pipe thawing.
−8−
No. P10355
4. STANDARD COMPOSITION AND ACCESSORIES
4.1 Standard Composition
•
•
The parts names indicated in the boxes are standard parts. They are not supplied with this
welding machine. Preparation of the standard parts except the welding power source is
required to use the welding power source.
Input cable and grounding cable
For a switch box, the 2m input and grounding cables are from the back panel of welding power
source.
Input cable
AWG9 10mm2 with 10mmφ terminal x 3
Grounding cable
AWG9 10mm2 with 10mmφ terminal x 1
For air cooling torch
Pressure regulators for gas cylinders
Input cable 6ft (2m)
Digital remote control
（Optionally available）
Gas hose 10ft (3m)
Shield
gas
Shield
gas
(Wire feeder accessory)
Control cable with wire feeder 6ft (2m)
Power cable for wire feeder 6ft (2m)
Welding torch
Wire feeder
Welding power source
Base
Power cable for base metal 6ft (2m)
Grounding cable
Analog remote control with 10ft (3m) control cable
（Optionally available）
For water cooling torch
Pressure regulators for gas cylinders
Water cooler
Gas hose 10ft (3m)
Input cable 6ft (2m)
(Wire feeder accessory)
Control cable with wire feeder 6ft (2m)
Shield gas
Power cable for wire feeder 6ft (2m)
Wire feeder
Welding power source
Welding torch
Power cable for base metal 6ft (2m)
Analog remote control with 10ft (3m) control cable
（Optionally available）
Grounding cable Digital remote control
（Optionally available）
Other length of cable/hose are available. Refer to section 11.4.2 “Cable/Hose”
Note; Use power cable size as follows
Up to 33ft (10m): AWG 2/0 (60mm) Up to 66ft (20m): AWG 3/0 (80mm)
Power cable connectors are attached in power source and wire feeder.
−9−
Base metal
No. P10355
4. STANDARD COMPOSITION AND ACCESSORIES (continued)
4.2 Accessory
Make sure you have the item below before you start using the welding power source.
Description
Specification
Q’ty
Part number
Remarks
For the power cable to welding
power source
For the fan on the rear panel of
welding power source
Power cable connector
DIX SKK 70
2
4734-025
Dust filter
109-1000M3
2
4519-031
NOTE:
•
When using the dust filter, perform 40% (pulse), 50% (DC) or less duty-cycle operation
(without clogging). Otherwise, the welding machine may be damaged. Refer to Section 3.1,
“Rated Duty Cycle”.
4.3 Preparation of consumables for welding
（１） Shield Gas
Use a suitable gas for welding method.
• Carbon dioxide gas (CO2 gas)
For welding (purity: 99.9% or more, moisture content: 0.002% or less)
• MAG gas
80% argon (Ar) + 20% carbon dioxide gas (CO2 gas)
• MIG gas for stainless steel without pulse
90% helium (He) + 7.5% argon (Ar) + 2.5% oxygen (O2)
• MIG gas for stainless steel with pulse
66% argon (Ar) + 33% helium (He) + 1% carbon dioxide gas (CO2 gas)
• MIG gas for Aluminum
Pure argon (Ar)
（２） Welding Wire
−10−
−11−
Output term inal(- )
Cap
Socket for
analog rem ote control
Socket for wire feeder
SPOT TIME
INCHING
GAS
CHECK
ENTER
SAVE
LOAD
J O B
MEMORY
ON
CRATER-FILL
CONDITION
1.2
C ONS TAN T
PENETRATION
WELDING
METHOD
O
|
（2%O 2 ）
MIG
M AG
CO 2
ARC
CONTROL
ＤＰ４００
STAINLESS STEEL
OP2
OP1
T2
±
JO B N O .
ON
STAINLESS CORED
Rubber feet
（m m ）
ＯＰ
1.6
1.4
V
MILD STEEL CORED
MILD STEEL
VOLT. CONTROL
INDIV.
SYNERG.
SYNERG.
MILD STEEL
1.0
FILL
−
MAIN
0. 8
DISPLAY
CHANGE
CONDITION
V
±
m /m in
Sec
A
0. 9
INITIAL
CURR.
INITIAL
CONDITION
WIRE DIA
SPOT
REPEAT
ON
OFF
Ｆ
T1
m/m in
CRATER
A
WARNING
Output term inal(+)
Cap
Power switch
Main power lamp
Parameter adjusting knob
Rubber feet
Carrying handle
Grommets with film
（For pulling out external connection cables ）
Input cable
No. P10355
5. FUNCTION OF EQUIPMENT
5.1 Welding Power Source
No. P10355
6. NECESSARY POWER SOURCE EQUIPMENT
6.1 Welding Power Source Equipment (for commercial use)
WARNING
● When the welding machine is used in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
CAUTION
● Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
welding machine.
Capacity of Necessary Power Source Utility
MODEL
Power supply voltage
Tolerance range of fluctuation of power supply voltage
Installed capacity
Capacity of switch/circuit breaker
DIGITAL INVERTER
DP-400
208/230/460V, Three phase
The welding power source links the
primary voltage automatically.
208/230/460V±10%
24kVA or more
70 A for 208/230V, 50A for 460V
6.2 Precautions for Use of the Engine Generator
CAUTION
● Use the auxiliary power of engine welder whose voltage waveform has been improved. Some
of the engine welders have poor electricity, which may cause product damage. Contact an
engine welder manufacturer for improvement of waveform.
To prevent the engine generator or auxiliary power from being damaged, follow the instructions
below.
•
•
•
Set the output voltage of the engine generator to the voltage range between 230 and 240V at
no-load welding operation. Setting to extremely high output voltage may result in product damage.
Use the engine generator with a damper winding of which capacity is more than twice as much as
the rated input of the welding machine. Generally, the recovery time of the engine generator’s
voltage for load change is slower than that of the commercial input power source, and if the engine
generator does not have sufficient capacity, sudden current change such as arc start will occur.
This may result in abnormal decrease in output current or arc loss. Ask an engine generator
manufacturer for a damper winding.
Do not combine more than two welding machines with an engine generator. The affect of each
welding machine may cause easy loss of arc.
−12−
No. P10355
7. TRANSPORT AND INSTALLATION
7.1 Transport
WARNING
Follow the instructions below to avoid trouble and product damage when carrying the welding
machine.
● Do not touch the charging parts inside or outside the welding machine.
● Be sure to disconnect the line disconnect switch when carrying the welding
machine.
● When hanging the welding power source by a crane, do not use the carrying
handle.
7.2 Installation
WARNING
When installing the welding machine, follow the instructions below to avoid a fire caused by
welding and physical damages by fume gas.
● Do not place the welding machine near combustible materials and flammable
gas.
● Remove combustible materials to prevent dross coming into contact with
combustible objects. If that not possible, cover them with noncombustible
covers.
● To avoid gas poisoning and danger of suffocation, wear a gas mask or
adequately ventilate when the welding machine is used in the place regulated
by a local law.
● To prevent disorder or poisoning caused by fume, wear a gas mask or weld at
a partial exhaust facility approved by the local regulation.
● Adequately ventilate or wear a gas mask when using the welding machine in a
tank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide or
argon gases are drifting there.
● When using the welding machine at a narrow space, comply with a trained
supervisor’s directions. And be sure to wear a gas mask.
● Do not operate the welding machine near the place where degreasing,
cleansing, and spraying are performed. Otherwise, poisonous gas may be
generated.
● Be sure to wear a gas mask or adequately ventilate when welding a coating
steel plate. (Poisonous gas and fume may be generated.)
−13−
No. P10355
7. TRANSPORT AND INSTALLATION (continued)
CAUTION
To prevent electromagnetic troubles, read the following. Also, if electromagnetic
troubles occur, check the following again.
Since large current abruptly flows inside the welding machine during welding, other machines
near the welding power source may be troubled due to electromagnetic noise
● Do not ground the welding power source commonly with other machines.
● Close and fix all doors and covers of the welding machine.
● Do not use an unnecessarily long cable.
● Place a base metal cable and a torch side cable as closely as possible.
In the event of electromagnetic trouble, follow the instructions below.
● Change the installation place of the welding machine.
● Keep the machines which may be affected away as far from the welding machine, cables and
welding site as possible.
● Add a noise filter to the input cables.
● Mount an input cable in the grounded metallic conduit.
● Shield the whole welding places from electromagnetic trouble. If electromagnetic troubles are
still not solved after following the above instructions, consult your nearest DAIHEN dealer.
CAUTION
Follow the instructions below when selecting an installation place of the welding power source.
● Do not install the welding power source in the place subject to direct sunlight and rain.
● Place the welding machine on a strong and stable surface.
● Install the welding machine in the place where the ambient temperature is between -10 ˚C and
+40 ˚C (+14 ˚F and +104 ˚F).
● Do not install the welding machine in the place where metal material such as spatter enters the
welding power source.
● Keep the install distance of 1ft (30 cm) between the welding power source and the wall or other
welding power.
● Install a wind shield to protect arc from wind.
● Fix the gas cylinder to the stand only for gas cylinder.
−14−
No. P10355
8.
CONNECTION PROCEDURE AND GROUND FOR SAFETY USE
WARNING
Follow the instructions below to avoid electric shock.
∗
Do not touch the charging parts, as this will result in fatal shock and severe burn.
● Do not touch the charging parts of the welding machine.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected, following a local low.
● With the line disconnect switch inside the switch box all turned off, ground and connect the
welding machine.
● Do not use a cable with lack of capacity or a cable seriously damaged.
● Tighten and insulate the connections of cables.
● Surely attach the cover of the welding machine after connection of the cables.
8.1 Connecting of the Welding Power Source
When using the air-cooled torch
Gas flow regulator
Power cable for wire feeder
②
Control cable for wire feeder ③
Shield
gas
Gas
cylinder
Gas hose ④
Welding torch
Wire
feeder
Welding power source
⑤
Base metal
Power cable for base metal
①
Analog remote control
Control cable for remote control
（Optionally available ）
M10 terminal
When using the water-cooled torch
Gas flow rate regulator
Water hose ⑦
(for condensed water)
Water cooler
Gas cylinder
For feeding water
Surely insert the connector plugs
into the sockets for wire feeder
and for analog remote control up
to the stop by turning them
Gas hose ⑤
Control cable for wire feeder ④
Power cable for wire feeder ②
Wire feeder
Welding torch ⑥
Welding power source
Power cable for base metal ①
Control cable for remote control
Analog remote control
（Optionally available)
Base metal
M10 terminal
NOTE: In case of putting the “Abnormal water pressure” signal into the welding power source, see
11.2.
−15−
No. P10355
8.
CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
Follow the steps below to attach the cables to the output connectors of the welding power source
referring to the illustrations of “Connection of the Welding Power Source“ on the previous page.
1. Connect between the “base metal ○
- “ terminal and the base metal using the power cable for
base metal.
2. Attach the power cable for wire feeder to the “torch ○
+ “ output terminal and connect to the torch
cable.
3. Insert the control cable for wire feeder into the socket for wire feeder.
4. Attach the gas hose to the gas inlet on the wire feeder.
5. Connect the welding torch to the wire feeder.
6. Connect the hoses for water supply and for condensed water to the water cooler. (When using a
water-cooled torch.)
8.2 Connecting of the Gas Hose
WARNING
● You may suffer from danger of suffocation caused by lack of oxygen when
shield gas keeps drifting in a closed place. Be sure to turn off the shield gas
at the main when the welding power source is not in use.
CAUTION
● Be sure to connect the gas hose after fixing to the stand, as physical injuries may result
from falling down of gas cylinder.
● Attach a proper gas flow regulator to a gas cylinder. Failure to observe the demand may
result in physical injuries. The gas flow regulator for high pressure gas must be used.
1. Securely attach the gas hose to the gas inlet located on the rear side of the wire feeder with a
monkey wrench, etc.
2. Fix the nut for attaching gas cylinder to the gas cylinder with a monkey wrench, etc.
3. Securely attach the gas hose to the gas outlet with a monkey wrench, etc.
Nut for attaching gas cylinder
Gas flow rate regulator
②
③
Gas outlet
Wire feeder
①
Gas hose fitting size: 9/16-18UNF
−16−
Gas cylinder
No. P10355
8.
CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
WARNING
Follow the instructions below to avoid electric shock.
∗ Touching the charging parts may result in fatal electric shock and severe burn.
● Do not touch the charging parts of the welding machine.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected in accordance with a local low.
● With the line disconnect switch in the switch box all touched off, ground and connect the
welding machine.
CAUTION
● Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
welding machine.
Mount a switch with fuse or a circuit breaker
on each welding machine.
GREEN cable
for Grouding cable
Base metal/JIG
Input cable
Surely connect the input and grounding cables
AWG9 (10mm2) to the circuit breaker .
CAUTION
Be sure to ground the case of the welding power source.
Use a grounding cable of which thickness is more than AWG9 (10mm2).
● If the welding power source which is not grounded is used, voltage will be generated in the
case through the capacitor between the welding power source input circuit and the case or
floating capacity (electrostatic capacity naturally generated between the input conductor and
the case metal). If you touch the case or the base metal, you may suffer from electric shock.
Be sure to ground the case of the welding power source.
−17−
No. P10355
9.
WELDING PREPERATION
9.1 Preparing the Protective Equipment
To protect you from gas generated from welding, fume, and lack of oxygen,
wear protective equipment.
● To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately ventilate
when the welding machine is used in the place regulated by a local law.
● To prevent disorder or poisoning caused by fume, wear a gas mask or weld at a partial
exhaust facility approved by the local regulation.
● Adequately ventilate or wear a gas mask when using the welding machine in a tank, a boiler,
a hold of a ship, because heavier gas such as carbon dioxide or argon gases are drifting
● When using the welding machine at a narrow space, comply with a trained supervisor’s
directions. And be sure to wear a gas mask.
● Do not operate the welding machine near the places where degreasing, cleansing, and
spraying are performed. Otherwise, poisonous gas may be generated.
● Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate.
(Poisonous gas and fume may be generated.)
NOTE: Install a windshield to protect arc from wind when using an electric fan for
ventilation or when welding outdoors. Failure to observe the demand may result in poor
welding.
CAUTION
Use the protective equipment to protect you and other workers from arc rays,
spattering dross, and noise from welding operation.
● When performing or monitoring welding operation, wear an eye protector with a good light
blocking effect or face shield.
● Wear protective glasses to protect your eyes from the spattering dross.
● Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, and
leather apron.
● Install protective screens or barriers to protect the eyes of others in the work area from arc
ray.
● Wear an ear protector when noise level is high.
−18−
No. P10355
9. WELDING PREPARATION (continued)
9.2 Operating the Switches and Controlling the Pressure regulators for gas cylinders
CAUTION
● Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as
burst of high-pressure gas may result in physical injuries.
NOTE: Gas checking automatically stops in two minutes.
① Turn on the line disconnect
switch.
④ Set the pressure regulators for gas
cylinders to “SHUT” , then turn on gas at
⑤ Set the gas flow rate adjusting knob
to “OPEN” to adjust the gas flow rate.
③
Press the GAS CHECK
key. (The GAS CHECK
lamp lights up.)
② Place the power switch in the “I” (ON)
position.
⑥ Press the GAS CHECK
button again. (The GAS
CHECK lamp goes out.)
9.3 Inching Operation
WARNING
● Do not look into the tip hole to check for the rate of wire feeding while inching.
CAUTION
● Keep away your hands, fingers, hair or clothes from the rotating parts of the feed
roll, etc. to prevent you from being caught into the rotating parts while inching.
After straightening the welding torch, feed the wire while pressing the
inching button. (“INCHING” lamp lights up). When the wire appears
from the end of the torch, release the INCHING key. Cut the wire at
about 10 mm from the end of the torch. When adjusting wire feed rate,
use the parameter adjusting knob. Inching operation can be controlled
by using the INCHING button on the analog remote control (optional
accessory). When controlling inching operation with the remote control,
the INCHING key on the front panel does not function.
Parameter adjusting knob
インチング
INCHING key
−19−
No. P10355
9.
WELDING PREPARATION (continued)
9.4 Welding Conditions
When setting to the improper welding conditions, the following troubles will occur.
Cause
Wire extension is too long.
Wire extension is too short.
Arc voltage is too high.
Arc voltage is too low.
Welding current is too high.
Welding speed is too fast.
Trouble
･Long Arc length
･Wide bead width
･Poor shield
･Short arc length
･Easy generation of spatter
･Long arc length
･Wide bead width
･Shallow penetration and flat bead
･Stick to base metal and easy generation of spatter
･Narrow bead width
･Deep penetration and high excess metal
･Wide bead width
･Deep penetration and high excess metal
･Narrow bead width
･Shallow penetration and low excess metal
The data in the tables below is only for reference. Please find the optimum welding conditions for
weldment shape and welding position.
9.4.1
Example CO2 Welding Conditions
(1) Example Welding Conditions of Horizontal Fillet
Plate
Leg length
thickness
l (in [mm])
t (in [mm])
0.047 [1.2] 0.098-0.118
(2.5−3.0)
0.063 [1.6] 0.098-0.118
(2.5−3.0)
0.079 [2.0] 0.118-0.138
(3.0−3.5)
0.091 [2.3] 0.118-0.138
(3.0−3.5)
0.126 [3.2] 0.118-0.157
(3.0−4.0)
0.177 [4.5] 0.157-0.177
(4.0−4.5)
0.236 [6.0] 0.197-0.236
(5.0−6.0)
0.354 [9.0] 0.236-0.276
(6.0−7.0)
0.472 [12.0] 0.276-0.315
(7.0−8.0)
Wire
diameter
(in [mm]φ)
0.035
[0.9−1.0]
0.035-0.045
[0.9−1.2]
0.035-0.045
[0.9−1.2]
0.035-0.045
[0.9−1.2]
0.035-0.045
[0.9−1.2]
0.045 [1.2]
190−230
0.045 [1.2]
250−280
0.045 [1.2]
280−300
0.045 [1.2]
300−340
Welding
current
(A)
70−100
90−120
100−130
120−140
130−170
−20−
CO2 gas
Arc
Welding
voltage
speed
flow rate
(V)
(ft [cm]/min) (gal [ℓ]/min)
1.6-2.0
2.6-4.0
18−19
[50−60]
[10−15]
1.6-2.0
2.6-4.0
18−20
[50−60]
[10−15]
1.6-2.0
4.0-5.3
19−20
[15−20]
[50−60]
1.6-2.0
4.0-5.3
19−21
[50−60]
[15−20]
1.5-1.8
4.0-5.3
19−21
[45−55]
[15−20]
1.5-1.8
4.0-5.3
22−24
[45−55]
[15−20]
1.3-1.6
4.0-5.3
26−29
[40−50]
[15−20]
1.1-1.3
4.0-5.3
29−32
[35−40]
[15−20]
1.0-1.1
5.3-6.6
32−34
[30−35]
[20−25]
No. P10355
9. WELDING PREPARATION (continued)
(2) Example Welding Conditions of Down Fillet
Plate
thickness
t (in [mm])
0.047 [1.2]
Leg
length
l (in [mm])
0.098-0.118
[2.5−3.0]
0.063 [1.6] 0.098-0.118
[2.5−3.0]
0.079 [2.0] 0.118-0.138
[3.0−3.5]
0.091 [2.3] 0.118-0.138
[3.0−3.5]
0.126 [3.2] 0.118-0.157
[3.0−4.0]
0.177 [4.5] 0.157-0.177
[4.0−4.5]
0.236 [6.0] 0.197-0.236
[5.0−6.0]
0.354 [9.0] 0.236-0.315
[6.0−8.0]
12.0 [0.472] 0.394-0.472
[10.0−12.0]
Wire
diameter
(in [mm]φ)
0.035
[0.9, 1.0]
0.035-0.045
[0.9−1.2]
0.035-0.045
[1.0−1.2]
0.035-0.045
[1.0−1.2]
0.035-0.045
[1.0−1.2]
0.045 [1.2]
200−250
0.045 [1.2]
280−300
0.045 [1.2]
300−350
0.045 [1.2]
320−350
Welding
current
(A)
70−100
90−120
100−130
120−140
130−170
Arc
Welding
voltage
speed
(V)
(ft [cm]/min)
1.6-2.0
18−19
[50−60]
1.6-2.0
18−20
[50−60]
1.6-2.0
19−20
[50−60]
1.6-2.0
19−21
[50−60]
1.5-1.8
20−22
[45−55]
1.5-1.8
23−26
[45−55]
1.3-1.6
29−32
[40−50]
1.3-1.5
32−34
[40−45]
0.8-1.1
33−36
[25−35]
CO2 gas
flow rate
(gal [ℓ]/min)
2.6-4.0
[10−15]
2.6-4.0
[10−15]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
5.3-6.6
[20−25]
(3) Example Welding Conditions of I Shape Butt without Backing Plate
Plate
thickness
t (in [mm])
0.047 [1.2]
0.063 [1.6]
0.079 [2.0]
0.091 [2.3]
0.126 [3.2]
0.177 [4.5]
0.236 [6.0]
0.354 [9.0]
Wire
Root
diameter
gap
g (in [mm]) (in [mm]φ)
0
0.035
[0.9, 1.0]
0
0.035
[0.9, 1.0]
0-0.02
0.035
[0.9, 1.0]
[0−0.5]
0.02-0.039 0.035-0.045
[0.5−1.0]
[0.9−1.2]
0.039-0.047 0.035-0.045
[1.0−1.2]
[0.9−1.2]
0.047-0.059 0.045[1.2]
[1.2−1.5]
0.047-0.059 0.045[1.2]
[1.2−1.5]
0.047-0.059 0.045[1.2]
[1.2−1.5]
Welding
current
(A)
Arc
voltage
(V)
70−80
17−18
80−100
18−19
100−110
19−20
110−130
19−20
130−150
19−21
150−170
21−23
220−260
24−26
320−340
32−34
−21−
Welding
speed
(ft [cm]/min)
1.5-1.8
[45−55]
1.5-1.8
[45−55]
1.6-1.8
[50−55]
1.6-1.8
[50−55]
1.3-1.6
[40−50]
1.3-1.6
[40−50]
1.3-1.6
[40−50]
1.5-1.8
[45−55]
CO2 gas
Number
of
flow rate
layers
(gal [ℓ]/min)
2.6
1
[10]
2.6-4.0
1
[10−15]
2.6-4.0
1
[10−15]
2.6-4.0
1
[10−15]
2.6-4.0
1
[10−15]
2.6-4.0
1
[10−15]
Front 1
4.0-5.3
2
[15−20] Back 1
Front 1
4.0-5.3
2
[15−20] Back 1
No. P10355
9. WELDING PREPARATION (continued)
(4) Example Welding Conditions of Single and Double Grooves
Plate
thickness
t
(in [mm])
Bevel
shape
Wire
Root
Root
diameter
gap
face
g (in [mm]) h (in [mm]) (in [mm]φ)
0.472 [12]
0-0.02
[0−0.5]
0.157
-0.236
[4−6]
0.045
[1.2]
1/16
[1.6]
g
0.630 [16]
0-0.02
[0−0.5]
0.630 [16]
0.748 [19]
0.157
-0.236
[4−6]
0.157
-0.236
[4−6]
0.45
[1.2]
1/16
[1.6]
0.45
[1.2]
Welding
current
(A)
CO2 gas Number
Arc
Welding
voltage
speed
of
flow rate
(V)
(ft [cm]/min) (gal [ℓ]/min) layers
300−350
32−35
300−350
32−35
380−420
32−35
380−420
32−35
300−350
32−35
300−350
32−35
380−420
32−35
380−420
32−35
300−350
32−35
300−350
32−35
380−420
36−39
380−420
36−39
400−450
36−42
400−450
36−42
400−420
36−39
400−420
39−42
400−420
36−39
400−450
39−42
0
0.197
-0.276
[5−7]
1/16
[1.6]
0.984 [25]
−22−
1.0-1.3
[30−40]
1.5-1.6
[45−50]
1.1-1.6
[35−50]
1.5-1.6
[45−50]
1.0-1.3
[30−40]
1.5-1.6
[45−50]
1.1-1.6
[35−50]
1.5-1.6
[45−50]
1.0-1.1
[30−35]
1.0-1.1
[30−35]
1.1-1.3
[35−40]
1.1-1.3
[35−40]
0.8-1.0
[25−30]
0.8-1.0
[25−30]
1.3-1.5
[40−45]
1.0-1.1
[30−35]
1.3-1.5
[40−45]
1.0-1.1
[30−35]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
5.3-6.6
[20−25]
Front
Back
Front
Back
Front
Back
Front
2
Back
Front
Back
Front
Back
Front
Back
1 F
2 B
1 F
2 B
4
No. P10355
9. WELDING PREPARATION (continued)
-
Example Welding Conditions of Lap Fillet
Ａ
Plate
Thickness
t (in [mm])
0.047
[1.2]
0.063
[1.6]
0.079
[2.0]
0.091
[2.3]
0.126
[3.2]
0.177
[4.5]
Wire
diameter
(in [mm]φ)
0.035
[0.9−1.0]
0.035-0.045
[0.9−1.2]
0.035-0.045
[1.0−1.2]
0.035-0.045
[1.0−1.2]
0.035-0.045
[1.0−1.2]
0.045
[1.2]
Welding
current
(A)
80−100
Welding
voltage
(V)
18−19
100−120
18−20
100−130
18−20
120−140
19−21
130−160
19−22
150−200
21−24
Welding
speed
(ft [cm]/min)
1.5-1.8
[45−55]
1.5-1.8
[45−55]
1.5-1.8
[45−55]
1.5-1.6
[45−50]
1.5-1.6
[45−50]
1.3-1.5
[40−45]
Ｂ
Mark
position
A
A
A or B
B
B
B
CO2 gas
flow rate
(gal [ℓ]/min)
2.6-4.0
[10−15]
2.6-4.0
[10−15]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
4.0-5.3
[15−20]
9.4.2 Example Welding Conditions of Wire CO2 with Flux
(1)Example Welding Conditions of Horizontal Fillet
Leg
length
ℓ (in [mm])
0.16
[4]
0.20
[5]
0.24
[6]
0.28
[7]
0.32
[8]
0.35
[9]
Wire diameter
(in [mm]φ)
Welding current
(A)
Arc voltage
(V)
Welding speed
0.045 [1.2]
0.052 [1.4]
1/16 [1.6]
0.045 [1.2]
0.052 [1.4]
1/16 [1.6]
0.045 [1.2]
0.052 [1.4]
1/16 [1.6]
0.045 [1.2]
0.052 [1.4]
1/16 [1.6]
0.045 [1.2]
0.052 [1.4]
1/16 [1.6]
0.045 [1.2]
0.052 [1.4]
1/16 [1.6]
250
330
350
270
330
370
270
330
380
280
350
380
300
350
380
320
350
380
27
29
31
29
30
33
29
31
34
30
32
34
31
33
34
32
34
34
1.6 [50]
3.3 [100]
3.4 [105]
1.6 [50]
3.0 [90]
3.0 [90]
1.5 [45]
2.6 [80]
2.6 [80]
1.3 [40]
1.6 [50]
2.1 [65]
1.0 [30]
1.5 [45]
1.7 [52]
1.0 [30]
1.3 [40]
1.3 [40]
−23−
(ft [cm]/min)
No. P10355
9. WELDING PREPARATION (continued)
9.4.2
Example Welding Conditions of MAG Short Arc
Material: Soft steel, Gas: Mixture gas of Ar + CO2 (10−15 ℓ/min)
Plate
Wire
Gap
Welding
Joint
thickness
diameter
(in [mm])
current
Geometry
(A)
t(in [mm]φ)
(in [mm]φ)
0.039
0.030-0.035
0
50−55
[1.0]
[0.8−1.0]
0.047
0.030-0.035
0
60−70
[1.2]
[0.8−1.0]
0.063
0.030-0.035
0
100−110
[1.6]
[0.8−1.0]
Butt
0.091
0.035-0.045
0-0.039
110-120
[2.3]
[1.0−1.2]
[0−1.0]
0.126
0.035-0.045 0.039-0.059
120-140
[3.2]
[1.0−1.2]
[1.0−1.5]
0.157
0.035-0.045 0.059-0.079
150-170
[4.0]
[1.0−1.2]
[1.5−2.0]
Arc voltage
(V)
Welding
speed
(ft [cm]/min)
13−15
14−16
16−17
17−18
17−19
18−21
1.3-1.8
[40−55]
1.0-1.6
[30−50]
1.3-2.0
[40−60]
1.0-1.3
[30−40]
0.8-1.0
[25−30]
0.8-1.3
[25−40]
9.4.4 Example Welding Conditions of Pulse MAG
(1) Example Welding Conditions of Horizontal Fillet Welding
Aim angle
Plate
Leg
Number
and
thickness
length
of
position
(in [mm]) (in [mm])
layers
0.126
[3.2]
0.177
[4.5]
0.236
[6.0]
0.12∼0.16
[3∼4]
0.20
[5.0]
0.24
[6.0]
0.315
[8.0]
0.32
[8.0]
30-40°
Focus here.
Angle of advance: 10°
30-40°
Welding
current
(A)
Welding
voltage
(V)
(ft [cm]/min)
1
150
26-27
2.0 [60]
1
170
26-27
1.3 [40]
1
200
27-28
1.3 [40]
1
250
29-30
1.1 [35]
1
2
3
180-200
180-200
180-200
25-27
25-28
25-28
1.5 [45]
1.5 [45]
1.5 [45]
1
2
3
220-230
220-230
210-230
25-28
25-28
25-28
1.5 [45]
1.5 [45]
1.5 [45]
Welding
speed
1 mm（2 - 3 mm）
0.472
[12.0]
0.630
[16.0]
0.39
[10.0]
0.47
[12.0]
3
1
2
−24−
No. P10355
9. WELDING PREPARATION (continued)
(2) Example Welding Conditions of Downward Welding
Plate
Shape of Welding Welding
Welding
thickness joint weld current
voltage
speed
(ft [cm]/min)
t(in [mm])
(A)
(V)
0.091 [2.3]
butt
100
22-23
2.3 [70]
0.126 [3.2]
fillet
100
21-22
2.3 [70]
(3) Example Welding Conditions of Upward Welding
Plate
Welding
thickness
Shape of joint weld
current
t (in [mm])
(A)
0.472
[12]
Stop at both ends
100-110
(4) Both Side Welding Conditions of (Semi-automatic)
Plate
Number of
Groove shape
thickness
layers
(in [mm])
Back bead appearance is good.
Leg length: 0.157-0.197in
[4 - 5mm],
Throat depth: 0.098in [2.5mm]
Welding
voltage
(V)
20-21
Remarks
Weaving
Leg length: 0.394in
[10.0mm]
Welding
current
(A)
Welding
voltage
(V)
(ft [cm]/min)
1
170
25-26
1.0 [30]
2
180
26-27
1.0 [30]
1
270
29-30
1.0 [30]
2
290
30-31
1.0 [30]
1
280
30-31
1.3 [40]
2
330
33-34
1.3 [40]
Front 1
Front 2
Rear 1
Rear 2
300
300
340
280
31-32
31-32
32-33
30-31
1.5 [45]
1.5 [45]
1.5 [45]
1.5 [45]
Front 1
Front 2
Front 3
Rear 1
Rear 2
Rear 3
300
320
320
340
320
320
31-32
32-33
32-33
32-33
32-33
32-33
0.236
[6.0]
0.354
[9.0]
0.472
[12.0]
0.748
[19.0]
0.984
[25.0]
Remarks
−25−
Welding
speed
1.5 [45]
1.5 [45]
1.5 [45]
1.5 [45]
1.5 [45]
1.5 [45]
No. P10355
9. WELDING PREPARATION (continued)
(5) Example Welding Conditions of Single Side Welding Conditions (Automatic)
Plate
Number of
Welding
thickness
Groove shape
layers
current
T (in [mm])
(A)
0.126
[3.2]
Welding
voltage
(V)
Welding
speed
(ft [cm]/min)
1
140
24-25
1.64 [50]
1
130
23-24
0.82 [25]
2
150
25-26
0.82 [25]
1
180
24-25
0.82 [25]
2
290
30-32
0.82 [25]
0.472
[12.0]
1
2
3
180-190
200
200
24-25
25-26
26-27
0.82 [25]
0.82 [25]
0.82 [25]
0.748
[19.0]
1
2
3
180
300
300
24-25
29-30
29-30
0.82 [25]
0.82 [25]
0.82 [25]
0.236
[6.0]
0.472
[12.0]
Oscillation width: 0.047in [2 mm]
Oscillation times: 120 times/min.
−26−
No. P10355
9. WELDING PREPARATION (continued)
32
32
(6) Single Bevel Groove Penetration Welding Conditions (Semi-automatic)
Number of
Welding
Groove shape
layers
current
(A)
Flat position
1
100
45゜
2
280
3
280
⑥
⑦
4
280
④
⑤
③
5
280
②
6
280
①
Unit: mm
3.2
7
280
Vertical position
1
100
45゜
2
130
⑥
3
130
⑤
4
130
④
③
5
130
②
①
6
120
⑫
32
Oscillation
Oscillation
④ ⑥⑨
1
100-200
20-22
2
200
24-25
3
200
24-25
4
200
24-25
5
200
24-25
No
6
200
24-25
oscillation
7
200
24-25
8
200
24-25
9
180
24-25
10
180
24-25
11
180
24-25
Unit: mm
12
180
24-25
Wire diameter: 0.045in (1.2 mm)φ，Gas: 20% CO2 + Ar
45゜
⑧ ⑪
⑤ ⑦
⑩
③
3.2
Remark
Unit: mm
3.2
① ②
Welding
voltage
(V)
20-21
26-27
26-27
26-27
26-27
26-27
26-27
20-21
21-22
21-22
21-22
21-22
19-20
−27−
No. P10355
9.
WELDING PREPARATION (continued)
9.4.5 Example Welding Conditions of Aluminum Pulse MIG
(1) Example Welding Conditions of I Shape Butt
Plate
Wire dia.
Welding
Welding
thickness
(in [mm])
current
voltage
(in [mm])
(A)
(V)
0.059 [1.5]
3/64 [1.2]
60-80
16-18
0.079 [2.0]
3/64 [1.2]
70-80
17-18
0.118 [3.0]
3/64 [1.2]
80-100
17-18
0.157 [4.0]
3/64 [1.2]
90-120
18-21
0.236 [6.0]
3/64, 1/16
[1.2, .1.6]
150-180
20-23
(2) Example Welding Conditions of Horizontal Fillet
Plate thickness
Wire dia.
Welding Welding
(in [mm])
(in [mm])
current
voltage
(A)
(V)
0.059 [1.5]
60-80
16-18
3/64 [1.2]
Welding
speed
(ft [cm]/min)
2.0-2.6
[60-80]
1.3-1.6
[40-50]
1.3-1.6
[40-50]
1.3-1.6
[40-50]
1.3-1.6
[40-50]
Welding
speed
Wire
extension
(in [mm])
0.472-0.591
[12-15]
0.591
[15]
0.591
[15]
0.591
[15]
0.591-0.709
[15-18]
2.0 [60]
Wire
extension
(in [mm])
0.591 [15]
(ft [cm]/min)
0.118 [3.0]
3/64 [1.2]
100-120
19-21
2.0 [60]
0.591 [15]
0.236 [6.0]
3/64, 1/16
[1.2, .1.6]
150-180
20-23
1.6-2.0
[50-60]
0.591 [15]
Gas flow
rate
(gal [ℓ]/min)
5.3
[20]
5.3
[20]
5.3
[20]
5.3
[20]
5.3
[20]
Gas flow
rate
(gal [ℓ]/min)
4-5.3
[15-20]
4-5.3
[15-20]
5.3 [20]
9.4.6 Example Short Welding Conditions of Aluminum MIG
(1) Example Short Welding Conditions of I Shape Butt
Plate thickness
Wire dia.
Welding Welding
(in [mm])
(in [mm])
current
voltage
(A)
(V)
0.118 [3.0]
120-140
20-22
3/64 [1.2]
0.157 [4.0]
3/64 [1.2]
150-170
22-24
0.236 [6.0]
1/16 [1.6]
180-210
23-25
Welding
speed
(ft [cm]/min)
2.0-2.6
[60-80]
2.0-2.6
[60-80]
1.3-2.0
[40-60]
(2) Example Short Welding Conditions of Horizontal Fillet
Welding Welding Welding
Plate
Wire dia
thickness
(in [mm])
current
voltage
speed
(ft [cm]/min)
(in [mm])
(A)
(V)
0.118 [3.0]
140-160
21-22
2.0-2.3
3/64 [1.2]
[60-70]
0.157 [4.0]
150-170
22-24
1.6-2.0
3/64 [1.2]
[50-60]
0.236 [6.0]
1/16 [1.6]
200-230
23-25
1.6-2.1
[50-65]
−28−
Wire
extension
(in [mm])
0.591 [15]
0.591-0.709
[15-18]
0.669-0.787
[17-20]
Wire
extension
(in [mm])
0.591
[15]
0.591-0.709
[15-18]
0.669-0.787
[17-20]
Gas flow
rate
(gal [ℓ]/min)
5.3 [20]
5.3 [20]
5.3-6.6
[20-25]
Gas flow
rate
(gal [ℓ]/min)
4.0-5.3
[15-20]
4.0-5.3
[15-20]
5.3-6.6
[20-25]
No. P10355
10. OPERATION
10. Front Panel
[21] [20]
[19]
[4]
[13]
[8]
J OB
WARNING
MEMORY
[6]
A
IPM
±
[9] [10]
V
Sec
%
Hz
JOB NO.
A
IPM
MAIN
CONDITION
T1
DISPLAY
CHANGE
ENTER
[5]
DIGITAL INVERTER
LOAD
SAVE
[15]
INITIAL
CONDITION
V
CRATER-FILL
CONDITION
ARC
CONTROL
±
f
T2
WAVE PULSE
SYNERG.
ON
INITIAL
CURR.
Ｆ
OFF
ON
( )
INCHING
ON
( )
SPOT
SPOT TIME
CONSTANT
PENETRATION
TORCH
（ OP T I ON）
INDIV.
.030
CO2
.035
MAG
MILDSTEEL
ＯＰ１
DC PULSE
MILDSTEEL
ＯＰ２
DC
MILDSTEELCORED
ＯＰ３
ＯＰ
STAINLESSCORED
ＯＰ４
STAINLESS
ＯＰ５
DC WAVE PULSE
（ OP T I ON）
SOFT ALUMINUM
ＯＰ６
.040
.0453/64
.052
MI G
1/16
MI G
HARD ALUMINUM
ＯＰ７
ＯＰ
CRATER
− FILL
WATER
SYNERG.
VOLT. CONTROL
GAS
CHECK
ON
WIREDIA
WELDING
METHOD
(inch)
Refer to manual for
recommended shielding gases
[17][18] [11]
[7]
[12] [3]
[1] WELDING METHOD key
[2] WIRE/GAS selector keys
[3] WIRE DIA (inch) key
[4] IPM selector key
[5] V/± selector key
[6] Parameter adjusting knob
[7] CRATER-FILL key
[8] DISPLAY CHANGE key
[14]
[2]
[9] ARC CONTROL key
[10] WAVE PULSE key (optional)
[11] SPOT TIME key
[12] F (FUNCTION) key
[13] INITIAL CURR. key
[14] VOLT. CONTROL key
[15] CONSTANT PENETRATION key
[16] TORCH key
−29−
[16]
[1]
[17] GAS CHECK key
[18] INCHING key
[19] LOAD key
[20] SAVE key
[21] ENTER key
No. P10355
10. OPERATION (continued)
CAUTION
● This welding machine should be operated by persons only after reading and
understanding contents of this owner’s manual and having knowledge and skills for
handling the welding machine safely.
● Use this welding power source at or under the rated duty cycle. Exceeding the rated duty
cycle limitation may result in damage to the welding machine.
When reading the operating instructions described below, unfold Page 76 so that you can read them
confirming the location of the keys on the front panel.
10.1 Basic Settings
10.1.1 Setting of Welding Mode
Choose the welding mode using the WELDING METHOD key [1], the WIRE/GAS selector
keys [2], the WIRE DIA (inch) key [3] the in accord with the welding method and wire diameter
used. The selectable welding modes are shown on the next page.
When setting the welding mode, select the welding method using the WELDING METHOD
key [1] first. Once the welding method is set, the available wire diameters are automatically
decided according to the welding method. Then, select wire/gas using the WIRE/GAS
selector keys [2]. Finally, set the wire diameter with the WIRE DIA (inch) key [3].
For example, for DP-400, when selecting “WAVE PULSE” while setting "DC HARD SOLID
CO2 φ0.035in [1.0mm] " with the WELDING METHOD key [1], the "MILD STEEL SOLID CO2"
lamp blinks, which means the preset combination is incorrect. In that case, select material
and gas again using the WIRE/GAS selector keys [2] or reset the welding method using the
WELDING METHOD key [1]. Selecting the proper combination of material and gas can
cancel the error and activate the welding power source.
Wrong combination of welding mode and wire diameter will cause “---”and “---“ in the displays
to blink, the LED lamps to light, and the welding power source to stop.
The following table shows the selections of wire diameter for setting current at aluminum
welding. Refer to the table for selecting a wire.
Material
Wire dia.
Mode
φ.035
PULSE
(φ1.0mm)
φ3/64
AL/MG (HARD)
(A5183、A5356 etc.） (φ1.2mm)
φ1/16
DC
PULSE
DC
PULSE
(φ1.6mm)
DC
φ3/64
PULSE
AL/PURE(SOFT) (φ1.2mm)
（A4043 etc.）
DC
φ1/16
PULSE
(φ1.6mm)
DC
Welding current （Ａ）
Standard range of stable welding current
50
100
200
300
400
NOTE:
• The data shown above differ depending on actual welding conditions such as
welding rate and welding position, etc.
• Observe the maximum current and the rated duty cycle. Optional accessories are
necessary for some combinations of a torch and a wire feeder.
−30−
No. P10355
10. OPERATION (continued)
Table of the Welding Mode
Welding mode
Welding
Type of wire
method
Gas
DC
MILD STEEL
SOLID
CO2
DC
MILD STEEL
SOLID
MAG
（80%Ar+20%CO2）
DC
PULSE
MILD STEEL
SOLID
MAG
（80%Ar+20%CO2）
DC
STAINLESS
STEEL SOLID
MIG
（90%He+7.5%Ar+2.5%O2）
DC pulse
STAINLESS
STEEL SOLID
MIG
(66%Ar+33%He+1%CO2)
DC
MILD STEEL
CORED
STAINLESS
STEEL CORED
MAG
（80%Ar+20%CO2）
MAG
（80%Ar+20%CO2）
DC
DC
PULSE
DC
WAVE
PULSE
AL/PURE
(SOFT
ALMINUM)
MIG
（Ar）
DC
DC
PULSE
DC
WAVE
PULSE
AL/MG
(HARD
ALUMINUM)
MIG
（Ar）
“O” ; Standard mode
−31−
WIRE DIA.
Inch.(mm)
DP-400
.030 (0.8)
.035 (0.9)
.040 (1.0)
.045 (1.2)
.030 (0.8)
.035 (0.9)
.040 (1.0)
.045 (1.2)
.052 (1.4)
.035 (0.9)
.040 (1.0)
.045 (1.2)
.052 (1.4)
.030 (0.8)
.035 (0.9)
.040 (1.0)
.045 (1.2)
.035 (0.9)
.040 (1.0)
.045 (1.2)
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
.045 (1.2)
O
.045 (1.2)
O
3/64 (1.2)
1/16 (1.6)
3/64 (1.2)
1/16 (1.6)
3/64 (1.2)
O
O
O
O
Option
1/16 (1.6)
Option
3/64 (1.2)
1/16 (1.6)
3/64 (1.2)
1/16 (1.6)
3/64 (1.2)
O
O
O
O
Option
1/16 (1.6)
Option
No. P10355
10. OPERATION (continued)
10.1.2 Setting the Parameter
Pressing the key while the A/m/min lamp (located
at the upper left of the A/m/min selector key) is lit
changes over displays of current setting and wire
feed rate. Pressing the A/m/min selector key
while the A/m/min lamp is not lit causes the
A/m/min lamp to light. While the A/m/min lamp is
lit, current can be adjusted using the parameter
adjusting knob [6].
Pressing the key while the V/± lamp (located at the
upper left of the V/± selector key) is lit changes over
displays of current setting and wire feed rate. Pressing
the V/± selector key while the V/± lamp is not lit causes
the V/± lamp to light. While the V/± lamp is lit, current
can be adjusted using the parameter adjusting knob [6].
Select a parameter using this key.
MAIN
CONDITION
A
V
IPM
T1
DISPLAY
CHANGE
INITIAL
CONDITION
±
T2
CRATER-FILL
CONDITION
[Parameter selector]
Choose a desired parameter using the DISPLAY CHANGE key [8]. Display in the
displays are changed according to the parameters you select and the UNIT lamp of
the parameter lights up.
UNIT lamps
WARNING
Ａ
Ｖ
I PM
±
Sec
%
Hz
JOB No.
Digital Meter
[Parameter displays]
z
When the wire feed speed is displayed, you can not set to the maximum feed speed
using the parameter adjusting knob [6] depending on the welding mode settings
(especially for large diameter). You are only allowed to set the wire feed rate to the
value that can achieve the current setting determined by the rated output current.
z
The values shown in the displays are not the actual data but the setting values of
voltage, current, and wire feed speed. Use the values in the displays as
approximates.
−32−
No. P10355
10. OPERATION (continued)
10.1.2 Setting the Parameter (continued)
(1) Pre-flow Time Setting
Once the pre-flow time is chosen, the setting value is displayed in the left display and the
"sec." lamp lights. At this condition, you can set pre-flow time while turning the parameter
adjusting knob [6]. The setting range of pre-flow time covers 0 second to 10 seconds.
(2) Setting of the Initial Conditions
The initial conditions can be chosen only when initial current is set to ON. Once the initial
conditions are chosen, the setting values of initial conditions are displayed in the displays.
(3) Setting of the Main Conditions
Once the main conditions are chosen, the setting values of the main conditions are
displayed in the displays.
(4) Setting of the Crater Conditions
Only for ON (-) or ON (
), the crater conditions can be selected. Once crater conditions
are chosen, the setting values of the crater conditions are displayed in the display.
(5) Setting of the Post-flow Time
Once the post-flow time is selected, the setting value is displayed in the right display and
the "sec." lamp lights up. At this conditions, the post-flow time can be set while turning the
parameter adjusting knob [6]. The setting range of post-flow time covers 0 second to 10
seconds.
−33−
No. P10355
10. OPERATION (continued)
10.1.3 Setting of the CRATER-FILL Functions
Crater
Crater is a depression left at the
termination of the weld. As it may cause
cracks and poor welding, a crater
treatment called crater-filler is used to fill in
the depression.
Bead
Pool
NOTE: When “DC” welding method is selected, you can not set to ON(-).
When treating a crater, set to “ON(-)” or “ON(
)”.
In the event that crater fill is carried out, set the CRATER-FILL key to "ON(-)" or "ON(
)".
Each press of the CRATER-FILL key [7] changes the crater-fill mode in order.
"OFF" → "ON (-)" → "ON (
Crater
Initial
Current
)" → "SPOT"
Timing Chart
ON
Torch Switch
Pre-flow time
No-load voltage
Anti-stick (burnback) time
Gas Flow
Post-flow time
OFF
Welding Voltage
Wire Feed Speed
Slow-down speed
Welding Current
MAIN WELDING
z
OFF
Keep the torch switch pressed and held during welding.
−34−
No. P10355
10. OPERATION (continued)
Crater
Initial
Current
Timing Chart
ON
ON
Torch Switch
Gas Flow
OFF
OFF
Pre-flow time
Anti-stick (Burnback) time
No-load voltage
Post-flow time
Voltage Between
OFF
Output Terminals
Slow-down speed
ON
Welding Current
Wire feedpeed
Crater Current
Welding current
or
MAIN WELDING
CRATER
ON
ON
Torch Switch
ON
OFF
OFF
Pre-flow time
No-load voltage
Anti-stick (Burnback) time
Gas Flow
Post-flow time
Voltage Between
Slow-down speed
Output Terminals
ON
Wire feed speed
Initial current
Welding current
Crater Current
Welding Voltage
INITIAL
•
•
•
•
•
MAIN WELDING
CRATER
Even if the torch switch is switched off during welding, start signal will be self-hold.
The torch switch should be kept pressed and held during the INITIAL and CRATER
times.
Even if the CONSTANT PENETRATION switch is set to "ON" during the CRATER
time, constant penetration will not be carried out.
Setting the CRATER-FILL key [7] to “ON(
)” or “ON(-)” after selecting “DC PUSLE”
or “DC WAVE PULSE”, pulse welding is performed during the CRATER time.
When selecting “ON(-)”, no-pulse welding is performed during the CRATER time
regardless of the settings of the welding method.
Welding method at the INITIAL time is the same as that at the MAIN WELDING.
−35−
No. P10355
10. OPERATION (continued)
10.1.4 Setting of Arc Spot Time（
）
When arc spot treatment is carried out using the CRATER-FILL key [7], set to "SPOT". Then,
when pressing the SPOT TIME key [11], the SPOT TIME lamp (located at the upper left of
the CRATER-FILL key) lights up, the setting value is displayed in the right display, then the
"sec." lamp lights up. At that condition, the ARC SPOT time can be set while turning the
parameter adjusting knob [6]. The ARC SPOT time between 0.1 second and 10 seconds can
be set. Press the SPOT TIME key again or press the DISPLAY CHANGE key [8] to return to
the last parameter item . It is also possible to change the display to a current-related
parameter using the A/m/min selector key [4] and to a voltage-related parameter using the
V/± selector key [5].
The SPOT TIME key functions only during Arc Spot time.
ON
Torch Switch
OFF
ARC SPOT time
Welding Current
Output Current
•
Keep the torch switch pressed and held during the Arc Spot time.
NOTE: When the welding machine is in the ARC SPOT mode, the penetration control
does not function. When setting the CATER-FILL function to “SPOT” while the
CONSTANT PENETRATION function is “ON”, the setting of the CONSTANT
PENETRATION function is automatically changed to “OFF”.
−36−
No. P10355
10. OPERATION (continued)
10.1.5 Adjusting Welding Voltage
Using the VOLT. CONTROL key [14] allows you to select one of the following voltage
adjustment methods.
(1)Making the INDIVIDUAL Adjustment
The INDIVIDUAL adjustment can be achieved when the VOLT.CONTROL lamp (located at
the upper left of the VOLT. CONTROL key [14]) is off. In the case of the INDIVIDUAL
adjustment, welding current and welding voltage must be adjusted individually. When you
want to set welding voltage, make sure that the VOLT. CONTROL lamp is lit, then adjust the
welding voltage while turning the parameter adjusting knob [6]. When you want to set welding
voltage, make sure that the VOLT. CONTROL lamp is lit, then set welding voltage while
turning the parameter adjusting knob [6].
NOTE: When selecting HARD ALMINUM or SOFT ALUMINUM, the INDIVIDUAL
adjustment can not be achieved. The SYNERGIG adjustment function is automatically
activated.
(2)Making the SYNERGIC Adjustment
The SYNERGIC adjustment can be achieved when the VOLT. CONTROL lamp (located at
the upper left of VOLT. CONTROL key [14]) is on. For the SYNERGIC adjustment, the proper
welding current for the current setting is automatically set. When the VOLT. CONTROL lamp
is lit, welding voltage can be finely adjusted using the parameter adjusting knob [6]. In
addition, it is also possible to change over the display setting in the right display using the V/±
selector key [5]. The selectable display settings are the INDIVIDUAL mode (V) and the
SYNERGIC mode (± adjustment) . In the SYNERGIC display mode, the standard value is 0.
The setting range of welding voltage is 0 to ±30 .
NOTE: Use of mixture gas other than the mixture ratio of the following gas may not
properly adjust welding voltage at Synergic control, etc.
• Carbon dioxide gas (CO2 gas)
For welding (purity: 99.9% or more, moisture content: 0.002% or less)
• MAG gas
80% argon (Ar) + 20% carbon dioxide gas (CO2 gas)
• MIG gas for stainless steel without pulse
90% helium (He) + 7.5% argon (Ar) + 2.5% oxygen (O2)
• MIG gas for stainless steel with pulse
66% argon (Ar) + 33% helium (He) + 1% carbon dioxide gas (CO2 gas)
• MIG gas for Aluminum
Pure argon (Ar)
−37−
No. P10355
10. OPERATION (continued)
10.1.6
CONSTANT PENETRATION Function
For conventional CO2/MAG welding, as the wire extension changes, welding current
changes and base metal penetration depth and bead width change. By setting the
constant penetration function to “ON”, wire feed speed is automatically adjusted so that
constant current can be always obtained even when wire extension varies. As a result,
effects of reducing change in penetration depth and in bead width of the base metal are
able to be obtained. When penetration depth is particularly held constant, set the
CONSTANT PENETRATION function to “ON” using the CONSTANT PENETRATION key
[15].
Penetration control ON/OFF selection can be done by using the CONSTANT
PENETRATION key [15]. When setting the CONSTANT PENETRATION function to ON,
the CONSTANT PENETRATION lamp (located at the upper left of the CONSTANT
PENETRATION key) lights up. When setting the CONSTANT PENETRATION function to
OFF, the CONSTANT PENETRATION lamp goes out. Set the CONSTANT
PENETRATION function to ON to hold constant penetration depth by using the
CONSTANT PENETRATION key [15]. The CONSTANT PENETRATION function is
activated only during the INITIAL and MAIN welding times. It does not function during the
CRATER time.
NOTE: The CONSTANT PENETRATION function is not available in the combination
of the following welding conditions, and the CONSTANT PENETRATION function is
automatically set to “OFF”.
• SPOT TIME “ON” setting
• Selection of AL/PURE (SOFT) or AL/MG (HARD).
10.1.7 Arc Characteristics Function
When pressing the ARC CONTROL key [9] while the INITIAL CONDITION, MAIN
CONDITION, or CRATER-FILL CONDITION is selected the ARC CONTROL lamp (located
at the upper left of the ARC CONTROL key [9]) lights up, the setting value is displayed in the
right display, and the V/± lamp lights up. At that condition, it is possible to set arc
characteristics by using the parameter adjusting knob [6]. The setting range is 0 to ±10.
Pressing the ARC CONTROL key [9] again or pressing the DISPLAY CHANGE key [8]
returns to the previous parameter setting. In addition, it is also possible to change over the
display to a current-related parameter by using the A/m/min selector key [3] and to a voltagerelated parameter by using the V/± selector key [4].
The standard setting value of arc characteristic is 0. As the setting value of the arc
characteristic is set in the negative direction (up to -10), arc condition becomes harder. As
the setting value of the arc characteristic is set in the positive direction, arc condition
becomes softer (up to 10). When you use the welding power source in the low current range,
set the setting value of the arc characteristic in the positive direction to obtain good welding
results. When you use the welding machine in the high current range, set the setting value of
the arc characteristic in the positive direction to obtain good welding results. If you can not
obtain optimum arc condition due to use of the extension cables, set the setting value of the
arc characteristic in the negative direction.
−38−
No. P10355
10. OPERATION (continued)
10.1.8
WAVE PULSE Function (optional)
In wave pulse welding, the ripple bead appearance is changed by applying two separate
pulses cyclically at low frequency. This feature will also assist in welding joints that have
some poor fit up or gaps. Although, the wave mode is usually most applicable for fully
automatic welding, benefits are also achieved even in semi-automatic applications. Good
bead appearances are obtained by setting the wave frequency to 5Hz or more even for
semi-automatic.
When setting wave pulse frequency, select “DC WAVE PULSE” with the WELDING
METHOD key [1]. Normally, the WELDING METHOD key does not function during pulse
welding or no-pulse welding. When the WAVE PULSE key is pressed while “INITIAL
CONDITION”/ “MAIN CONDITION”/ “CRATER-FILL. CONDITION” is selected, the WAVE
PULSE lamp (located at the upper left of the WAVE PULSE key) lights up, the setting value
appears in the left display, the “Hz” LED lamp lights up. Under these conditions, wave pulse
frequency can be adjusted while turning the parameter adjusting knob. The setting range of
wave pulse frequency is 0.5 Hz to 32 Hz. Adjust wave pulse frequency until you can obtain
the desired bead appearance.
When pressing the WAVE PULSE key or DISPLAY CHANGE key again, return to the last
parameter that you have set. When changing the display to a current-related parameter,
press the A/m/min selector key [4]. When changing the display to a volt-related parameter,
press the V/± selector key [5].
low frequency
high frequency
NOTE:
• Wave pattern of the welding bead varies depending on the heat input during
welding.
• When using annealed wire, bead surface may blacken somewhat if shorting occurs
frequently during the welding operation.
10.1.9 GAS CHECK
Function (with gas save function)
S
This function isGAused
when opening the discharge valve of the shield gas and when adjusting
the gas flow rate. When pressing the GAS CHECK key [17] once, the GAS CHECK lamp
(located at the upper left of the GAS CHECK key) lights up and allows gas to flow. Pressing
the GAS CHECK key again turns off the GAS CHECK lamp and stops discharging gas. In
more than two minutes after the GAS CHECK key is pressed, gas discharge automatically
stops and the GAS CHECK lamp goes out. In the event that the machine is started while
gas is being checked, gas stops flowing after welding is completed (upon completion of postflow) and gas does not continue to flow during down period.
10.1.10 INCHING
Function
When pressing the INCHING key [18], the INCHING lamp (located at the upper left of the
INCHING key) lights up and begins feeding wire. Releasing the key stops wire feeding and
causes the INCHING lamp to go out. When changing the wire feed rate by turning the
parameter adjusting knob [6], make sure that the INCHING lamp lights up. When connecting
to the analog remote control (optionally available), the INCHING key on the front panel can
not be used for inching operation. When connecting to the analog remote control, use the
inching switch on the remote control to activate the INCHING function.
−39−
No. P10355
10. OPERATION (continued)
10.1.11 TORCH WATER/AIR Selection
Select WATER/AIR according to your torch by using the TORCH key [16]. When using a
water-cooled torch, select “WATER” by pressing the TORCH key once. When “WATER” is
selected, the TORCH lamp (located at the upper left of the TORCH key) lights up. When
using an air-cooling torch, make sure that the TOCH lamp goes out. When lack of water
pressure and no water flow occur while “WATER” is selected, the WARNING lamp lights up.
10.1.12 Verifying the Parameters in the Displays
The displays on the front panel provides the following functions:
1. Display of Parameter Setting Value
When setting to “parameter setting values display” mode during down period (excluding
the result display period right after the completion of welding) and during welding, values
of parameters under adjustment are displayed.
2. Display of Output Current During Welding
The parameters shown in the displays automatically change to average values of output
current and output voltage according to the output conditions every about 0.5 second.
The display accuracy is Class 2.5 or equivalent and is the same as that of a general
needle type meter. When you want to change the parameters during welding, switch to
the “parameter setting values display” mode by using the DISPLAY CHANGE key [8].
When no welding operation is not carried out for about 5 seconds or the DISPLAY
CHANGE key [8] is held down, the display mode automatically returns to the “average
parameter setting values display” mode. When the TORCH key is pressed, the LED
lamps of the sequence parameters go on sequentially according to the welding
operations. When the display setting is switched to the "parameter setting values
display" mode, each LED lamps (located at the sequence parameter setting section) of
the sequence that is currently outputting begin blinking. Refer to Section 10.1.13, “Using
the Parameter Adjusting Knob” for the parameters that can be adjusted using the
parameter adjusting knob [6] during welding.
3. Display of Welding Results after Completion of Welding
Upon completion of welding, the average output current and voltage for last one second
blink for about 20 seconds (however, the output conditions of crater fill are ignored).
Therefore, the operators can verify the welding conditions right after the completion of
welding and can use them as approximates when adjusting the welding conditions. This
display is cancelled by starting the next welding or by pressing any key on the front
panel without waiting 20 seconds after the completion of welding. The result display
time can be preset to F8 by using the F key [12]. The setting value is displayed in the
left digital and the "sec" lamp lights up. The setting range of the result display time is 5
seconds to 60 seconds.
NOTE: In the case where the less than one-second welding such as tack welding,
etc. is performed, the correct results of the welding are not displayed.
4. Display of Error Message
If an error is detected in the power source of electric welding, an error number indicating
error messages blinks. See Section 11.1, "Troubleshooting".
NOTE: The average output values shown in the displays are processed by
software and are not guaranteed as control data of measuring instruments.
Display accuracy: Class 2.5 or equivalent).
−40−
No. P10355
10. OPERATION (continued)
10.1.13
Using the Parameter Adjusting Knob
When adjusting parameters using the parameter adjusting knob [6] during welding, change
over the display mode to the “parameter setting value display” mode by pressing the
DISPLAY CHANGE key [8]. The initial conditions, the main conditions, and the fill crater
conditions can be changed during the INITIAL welding, MAIN welding, and CRATER
welding respectively. Pressing the ARC CONTROL key [9] after changing to the
“parameter setting value display” mode adjusts the pulse arc characteristics. Pressing the
WAVE PULSE key adjusts the wave frequency. In the “average parameter value display”
mode, you can not adjust the parameter.
10.1.14
Using the Analog Remote Control K5416H (optional accessory)
The welding machine automatically recognizes the analog remote control when the power
switch is turned on. When the analog remote control is connected to the welding power
source, the analog remote control is recognized first. Therefore, even when selecting
welding current/voltage, the welding current/voltage can not be adjusted by using the
parameter adjusting knob [6] on the front panel. When the analog remote control is
connected, adjust the parameter while turning the WELDING CURRENT/VOLTAGE knobs
on the analog remote control. It is possible to verify the parameter setting values which are
preset with the analog remote control, in the displays of the front panel. Once the analog
remote control is disconnected, the setting values preset with the remote control are
erased.
NOTE: With the power switch turned off, connect or disconnect the analog remote
control.
350
150
200
ＦＯＲ ＣO2/ MAG/ MI G
250
LO
OS
E
100
300
350
50
20
18
ＨＴ
Ｇ
ＴＩ
30
32
16
34
14
36
V
A
ＷＥＬＤＩＮＧ ＣＵＲＲＥＮＴ
22 24 26 28
ＩＮＣＨＩＮＧ
ＬＯＷ
ＨＩＧＨ
ＳＹＮＥＲＧ．
Ｆ
ＩＮＥ ＡＤＪ．
WELDING CURRENT knob
To set welding current.
VOLTAGE knob
INCHING button
Pressing this switch feeds wire only. The
wire feed rate changes by turning the
WELDING CURRENT knob on the left.
< INDIVIDUAL adjustment>
Set welding voltage.
< SYNERGIC adjustment >
Aligning to mark “ ● ” achieves the standard
setting. Turn the knob in the "HIGH" direction to
increase voltage and in the "LOW" direction to
decrease voltage.
−41−
No. P10355
10. OPERATION (continued)
10.1.14
Using the Analog Remote Control K5416H (optional accessory) (continued)
• When making the INDIVIDUAL adjustment:
Selecting the "INDIVIDUAL" adjustment allows you to set welding current and welding
voltage individually.
NOTE: INDIVIDUAL adjustment is activated when selecting AL/PURE (SOFT
ALUMINUM) or AL/MG (HARD ALUMINUM). In pulse welding, even when the
INDIVIDUAL adjustment is selected, the scales on the analog remote control may
not correspond with the actual welding current/voltage.
• When making the SYNERGIC adjustment:
When selecting the "SYNERGIC" adjustment, welding voltage is automatically adjusted
only by turning the WELDING CURRENT knob [6]. To finely adjust welding voltage, use
the VOLTAGE. knob.
NOTE: It is possible to adjust low-current region, where a small-diameter wire is
used for weld, and to finely adjust welding current by replacing with the full-scale
200A plate (supplied). To replace the scale plate, press the F key [12] and change
the initial value of F9 to 200. Refer to Section 10.2.1(9), “Selection of scale plate of
analog remote control”.
−42−
No. P10355
10. OPERATION (continued)
10.2
10.2.1
Applied Settings
Using Internal Function
• How To Use Internal Functions
①
When holding down the F key [12] for a few seconds, the function number in
the left-side display blinks, and the status of function assigned to the function
number lights up and is displayed in the right-side display. Under this condition,
a function number can be preset by using the parameter adjusting knob [6].
WARNNING
Ａ
ｍ/min
Ｖ
sec
%
Hz
±
JOB No.
The number of function blinks.
The conditions of function lights.
↓
A function number can be preset with the parameter adjusting knob [6]
The above example indicates that F19 is set to “on”.
When pressing the F key [12] again after presetting the desired function
number, the function number lights and the function conditions blinks. Under
this condition, functions can be preset by using the parameter adjusting knob
[6].
WARNNING
Ａ
ｍ/min
sec
Hz
Ｖ
±
%
JOB No.
The number of function lights.
The condition of function blinks.
↓
Conditions can be set while turning the parameter adjusting knob.
The above example indicates that F4 is set to “off”.
②
Pressing the F key [12] again causes the function number to light up and
returns
① to the step . To cancel the function mode, hold down the F key [12] for
a few seconds.
NOTE: In the function mode, no confirmation of the function is carried out
when it is changed. Upon change of the setting by using the parameter
adjusting knob [5], the change becomes valid. Therefore, before changing a
function setting, carefully check to make sure that the correct function number
is selected and that the proper setting value for the function number is set.
−43−
No. P10355
10. OPERATION (continued)
The following welding conditions can be adjusted by using the F key [12] and the
parameter adjusting knob [6], but only the welding conditions with* next to the
function numbers can be preset to the welding condition numbers.
(1) Fine Adjustment of Anti-Stick (Burnback) Time: F1*
Anti-stick (Burnback) time means the processing time to prevent electrode wire
from fusing to base metal when welding is completed. Anti-stick (burnback) time
is preset to proper conditions according to welding methods and wire diameters
at shipment, but it can be finely adjusted by activating F1. The standard anti-stick
(burnback) time is preset to "0", time decreases in the negative direction and
increases in the positive direction. The fine adjustment range is 0 to ±50 and the
unit is 0.01 seconds.
Ex. 1)
Ex. 2)
When the setting value of anti-stick (burnback) time is 25 seconds, add
0.25 second to the standard anti-stick (burnback) time.
When the setting value of anti-stick (burnback) time is -10, subtract 0.1
second from the standard anti-stick (burnback) time.
(2) Fine Adjustment of Anti-stick (Burnback) Voltage: F2*
Anti-stick (Burnback) voltage means the voltage which is output when processing
is carried out to prevent electrode wire from fusing to base metal at the end of
welding. Anti-stick (Burnback) voltage is preset to proper conditions according to
welding methods and wire diameters at shipment, but it can be finely adjusted by
activating F2. The standard anti-stick (burnback) voltage is preset to “0”. When
the voltage is set in the negative direction, it decreases. When the voltage is set
in the positive direction, it increases. The fine adjustment range is 0 V to ±9.9V.
(3) Fine Adjustment of Slow-down Speed: F3*
Slowdown speed means the speed to feed wire that is slower than the feed rate
at normal welding during the period from startup to arc start. The slowdown
speed is preset to proper conditions according to welding methods and wire
diameters at shipment, but it can be finely adjusted by activating F3. The
standard slow-down speed is preset to “0”. When the slowdown speed is set in
the negative direction, it decreases. When the slowdown speed is set in the
positive direction, it increases. The fine adjustment range is 0 m/min to ±1.0
m/min. When poor arc start occurred, lower the slowdown speed. Even when arc
start is good, the slow-down speed can be increased to shorten tact time.
NOTE: The minimum slow-down speed is 1.3ft[0.4 m]/min.
−44−
No. P10355
10. OPERATION (continued)
(4) Selection of Auto/Semi-automatic: F4
Use this function when combining with a robot or an automatic machine.
Selection of Auto allow the welding power source to do the following operation.
• Operation Stop can be cancelled by short-circuiting Operation Stop terminals.
• Initial setting of this function is semi-automatic. To quit Operation Stop, start up
the machine up again.
• After anti-stick (burnback) voltage time, the voltage to cancel deposition is
applied for approximately 0.2 second.
When using the welding power source by combining a robot, etc. and inputting
welding current and welding voltage by utilizing external voltage, set to the Auto
mode.
To activate “Auto” mode, set F4 to “on”.
NOTE: Even when supplying external setting voltage to a remote control
receptacle in the "semi-auto" mode, the values preset at the front panel are
valid. Regardless of auto/semi-auto mode, when the analog remote control
is connected, the values preset with the analog remote control are
recognized first.
• When welding current and welding voltage are input utilizing external setting
voltage, make the connections as illustrated below.
Remote control receptacle
４
MAX 0.5mA
MAX 0.5mA
３
0V∼15V
１
Ｅ１
Ｅ２
CON2 （Welding Voltage） （Welding Current）
Acceptable plug
Spec.
Part No.
DPC25-6A
4730-009
CAUTION
● Supply 0 - +15 voltage to E1 and E2. Exceeding +15V may result in damage to the
control circuit of the welding power source.
● Be sure to finish setting of and inputting to E1 and E2 within 100 milliseconds before
starting signals are input. Inputting after 100 milliseconds or at start signals may result
in affecting start.
−45−
No. P10355
10. OPERATION (continued)
(5) For external setting voltage ranges between 0 and 10V: F5
When the welding machine is used by combining with a robot or an automatic
machine and when the maximum command voltage from the robot is output up
to 10V, set F5 using the F key [12]. This function is preset to “OFF” at shipment.
Set F5 and F4 to "on" to activate the function using the F key [12].
• The relationship between current/voltage command voltage from outside and
welding current and welding voltage is shown as follows. The welding current
and welding voltage corresponding to welding conditions setting voltage may
differ from the indications in the graphs due to wire extension length and
dragging of output cable. These graphs are only for reference.
45
400
40
Welding voltage(V)
Welding current（Ａ）
350
300
250
200
150
100
Setting signal 1
Setting signal 2
35
30
25
20
15
Setting signal 1
10
Setting signal 2
5
50
0
0
0
0
5
10
15
Currentsignal
command
voltage (V)
Setting
for voltage（V)
5
10
Setting
for voltage
current（V)
Voltagesignal
command
voltage(V)
(V)
Setting Signal 1: When command voltage is externally supplied in the range
from 0V to 15V under the standard se-+ttings.
Setting Signal 2: When command voltage is externally supplied in the range
from 0V to 10V with F 5 set to "on"
NOTE: The current and voltage indicated in the graphs above are not
measured after fine adjustment of unit pulse conditions. You may not
obtain such the results as the graphs show depending on finely
adjustable range of pulse unit conditions.
(6) Setting of Upslope Time: F6*
Upslope time means the time for increasing welding conditions stepwise when
initial current is changed to final current. The upslope time at shipment is set to 0
second, but can be adjusted by using F6. The setting range is 0 second to 10
second. This function is used when wire burns up while conditions are changed
over due to the great difference of setting between initial current and main
current.
(7) Setting of Down-slope Time: F7*
Down-slope time means the time for decreasing welding conditions stepwise
when main current is changed to crater current. The down-slope time at the time
of product shipment is set to 0 second, but can be adjusted by using F7. The
setting range covers 0 second to 10 second. This function is used when wire
crashes into the base metal while the conditions are changed over due to the
great difference of setting between main current and crater current.
−46−
15
No. P10355
10. OPERATION (continued)
(8) Setting of Result Display Holding Time: F8
After completion of welding, the average value of output current and output
voltage for last one second blinks for about 20 seconds, but the result display
holding time can be set by F8 using F key [12]. The setting range of result
display holding time is 5 seconds to 60 seconds.
(9) Selection of Scale Plate of Analog Remote Control: F9
When the analog remote control (optional accessory) is used, it is possible to
finely adjust a low-current region where a small-diameter wire is used for weld
by replacing the full-scale 350A scale plate with the full-scale 200A scale plate
(supplied). The analog remote control scale plate is changed over by using the
F selector key [12]. Set to "200" by using F9.
(10) Setting of Feed Motor Load Current Error Detection Level: F10
In the event that contact resistance is applied to the wire feed line section due
to worn liners, defective tips, etc., the current supplied to the motor increases
(when feed roll lacks smooth movement). Monitoring current of this motor can
detect defective feed. The motor load current detection level at shipment is 70%
(2.0A) of the rated motor current 2.8A (continuous), and if the current exceeds
the setting value, "E-" and "820" in the displays are displayed after welding
operation is stopped. But, in this case, the welding machine stops operation
automatically, then it self-restores by re-welding. This detection level can be
changed by changing the setting of F10 using F selector key [12]. The setting
range of motor load current trouble detection level is 20% to 150%.
NOTE: Adjust the detection level optionally and use it in the best detection
level, because the application environment and judgment criteria vary
depending on wires and torches and customers respectively.
(11) Setting of Job Memory Fine Adjustment: F11
Under the welding conditions already stored in JOB MEMORY, current can be
finely adjusted with the WELDING CURRNET knob located on the optional
analog remote control and voltage with the VOLTAGE knob. The initial setting
of F11 is “oFF”. When activating the function, set F11 to “on”. Setting both
CURRENT and VOLTAGE knobs to the center of the scales allows the machine
to work under the conditions already stored in the welding conditions memories.
To increase welding current slightly, turn the knob clockwise and to decrease
slightly, turn it counter-clockwise. Welding voltage can be adjusted in the same
manner. The fine adjustment range is ±20%.
NOTE:
•
When no data is stored in the JOB MEMORY, the function cannot be
activated.
•
For the conditions stored in memory in synergic mode, adjust them in
individual mode.
Place these knobs in the center positions.
350
150
200
ＦＯＲ ＣO2/ MAG/ MI G
250
LO
OS
E
100
300
Ｔ
Ｈ
Ｇ
ＴＩ
350
50
20
18
30
32
16
34
14
36
V
A
ＷＥＬＤＩＮＧ ＣＵＲＲＥＮＴ
22 24 26 28
ＩＮＣＨＩＮＧ
−47−
ＬＯＷ
ＨＩＧＨ
ＳＹＮＥＲＧ．Ｆ
ＩＮＥ ＡＤＪ．
No. P10355
10. OPERATION (continued)
(12) Arc voltage direct detection ON/OFF selection: F12
When using an extension cable results in abnormal generation of spatter or
when unstable welding is caused from malfunction of pulse weld, use a
voltage detection cable (optional accessory K5416G00) for directly detecting
arc voltage(-). When using an extension cable that is more than 30 m long,
use an arc voltage direct detection cable. Connect between base metal and
wire feeder or the direct voltage detection (-) terminal inside the welding power
source. (Voltage detection cable K5416G00 is a 30 m single core cab tyre
cable. Cut it as necessary.)
After connecting the voltage detection cable, activate the function of voltage
direct detection by setting F12 to “on”. The function is preset to “oFF” (invalid)
at factory.
NOTE: When using the equipment with such as brush for feeding parts
like a turn table, connecting the voltage detection cable to the terminal
for the base metal power cable after setting F12 to “on” is recommended.
(13)Fine Adjustment of Pulse Peak Current
The unit pulse conditions (pulse peak current/time and base current) at pulse
welding is set properly according to welding method and wire diameter, but
you can make the fine adjustment to obtain the optimum conditions of unit
pulse according to the wire brand or welding position.
• The finely adjustable range of pulse peak current is 0 A to ±150 A. The peak
current is set by 1A.
• The finely adjustable range of pulse peak time is 0 ms to ±1.5 ms. The pulse
peak time is set by 0.1 ms.
• The fine adjustable range of
base current is 0 A to ±60A. The base current
is set by 1 A.
In function mode, when pressing the DISPLAY CHANGE key [8] during the
fine adjustment of pulse width, the DISPLAY CHANGE lamp lights up (located
at the upper left of the DISPLAY CHANGE key). Under this condition, you can
switch the fine adjustment value shown in the right display to the modulus (the
value which is substrusted or added the fine adjustment value from the
standard value). When pressing the DISPLAY CHANGE key, you can return to
the fine adjustment value display mode.
[Example of Fine Adjustment of the Unit Pulse Conditions]
When making a fine adjustment of the unit pulse conditions, adjust the pulse
peak time first. Take longer fine adjustment time when large droplet and
unstable arc (droplet transfer) occurs. Take shorter fine adjustment time when
sharp tip of wire and extremely strong arc occurs. Adjust the pulse peak
current following the same steps as pulse peak time adjustment.
[Precaution for the Fine Adjustment of the Unit Pulse Conditions]
Maximum pulse peak current which can be output varies depending on the
type (capability) of welding machine or arc load. When the pulse peak current
finely adjusted exceeds the maximum pulse peak current, the preset pulse
peak current is not output.
−48−
No. P10355
10. OPERATION (continued)
NOTE: When the unit pulse conditions change significantly, there may be
a possibility of difference between the preset current value and the
output current and an impossibility of appropriate synergic fine
adjustment.
(13-1) Fine adjustment of Pulse Peak Current : F13*
The fine adjustment of pulse peak current can be achieved by activating F13
using the F key [8]. The value which is substrusted or added the fine adjusting
value from the standard value of the pulse peak current is output. At the wave
pulse welding, the high pulse condition (H. pulse) is adjusted.
(13-2) Fine Adjustment of the Pulse Peak Time: F14*
The fine adjustment of pulse peak time can be achieved by activating F14 using
the F key [8]. The value which is substructed or added the fine adjusting value
form the standard value of the pulse peak time is output. At the wave pulse
welding, the high pulse condition (H pulse) is adjusted.
(13-3) Fine Adjustment of the Base Current: F15*
Fine adjustment of base current can be achieved by activating F15 using the F
key [8]. The value which is substrusted or added the fine adjusting value from
the standard value of the base current is output.
(13-4) Fine Adjustment of L Pulse Peak Current: F16*
(available in optional wave
pulse mode only)
The fine adjustment of low pulse condition (L pulse) peak current at wave pulse
welding can be achieved by activating F16 using the F key [8]. The value which
is substrusted or added the fine adjusting value from the standard value of the L
pulse peak current is output as L pulse peak current.
(13-5) Fine Adjustment of L Pulse Peak Time: F17*
(available in optional wave pulse
mode only)
The fine adjustment of L pulse peak time of the second pulse condition at wave
pulse welding can be achieved by activating F17 using the F key [8]. The value
which is substrusted or added the fine adjusting value from the standard value
of the L pulse peak time is output as L pulse peak time.
(13-6) Fine Adjustment of L Pulse Base Current: F18*
(available in optional wave
pulse mode only)
The fine adjustment of the pulse base current of the second pulse condition at
wave pulse welding can be achieved by activating F18 using the F key [8]. The
value which is substrusted or added the fine adjusting value from the standard
value of the L pulse peak current is output as L pulse peak current.
High pulse condition
Low pulse condition
High pulse condition
Example of current wave at wave pulse welding
−49−
No. P10355
10. OPERATION (continued)
(14) Turbo Start ON/OFF Selection: F19
The welding power source has Turbo Start function by capacitor discharge,
which enable you to obtain good welding start. At poor welding start with
burnback, setting F19 to “oFF” deactivates the Turbo Start function. The
function is preset to “on” (valid) at factory.
(15) Keypad tone ON/OFF Selection: F20
Setting F20 to “oFF” deactivates key pad tone function. The volume of the
key pad tone can not be adjusted.
10.2.2
Key Lock
Key lock is a function to prevent the welding conditions from being changed by accidentally
operating keys and knobs on the front panel. Only the keys and parameter adjusting knobs
which are used for changing each parameters and modes can be protected. However, the
settings can be checked and confirmed by using the DISPLAY CHANGE key [8] and the
SPOT TIME key [11].
ENTER
T1
Ｆ
Holding down both the F [12] key and ENTER key [21]
simultaneously
Holding down both the F key [12] and ENTER key [18]
simultaneously for a while brings the key-lock condition.
While keys are locked, the F lamp (located at the upper
left of the F key) blinks. Key lock can be cancelled by
holding both the F key and ENTER key simultaneously
for a while again. Key lock cannot be cancelled by
starting the machine up again.
GAS
While keys are locked, the F lamp blinks
Even when the keys are locked, GAS CHECK, INCHING, and JOB MEMORY
functions can be activated.
10.2.3
JOB MEMORY Function
The JOB MEMORY function enables welding conditions to be reproducible by storing the
welding conditions in memory inside power source and by reading out the stored data at
any time. The number of welding conditions that can be held in memory is up to100.
CAUTION
● The welding conditions (electronic information) stored by this function are susceptible
to occurrence of static electricity, impact, repair, etc., and there is a possibility that the
storage contents may be changed or lost. BE SURE TO MAKE A COPY FOR
IMPORTANT INFORMATION.
● We shall not assume any responsibility for any change or loss of electronic information
resulting from repair, which you should note in advance.
Once the machine enters the memory mode and read-out mode, all the key operations are
denied except the SAVE, LOAD, and ENTER keys. To exit the mode, press the LOAD key
[19] if it is in the memory mode, and the SAVE key [20] if in the read-out mode. Memory can
be copied to a different condition number after reading the welding conditions to be copied.
NOTE: Even when welding conditions are read out while the analog remote control is
connected to the welding power source, the setting values preset with the analog
remote control are valid.
−50−
No. P10355
10. OPERATION (continued)
① SAVE Function
Welding conditions being currently in use are stored in the memory inside the
welding power source.
• Holding the welding conditions in memory
(1) When pressing the SAVE key [20], the machine enters memory mode, the
SAVE lamp (located at the upper left of the SAVE key) lights up. See the
following picture. In the right display, the condition number “1” blinks and
the LED lamp of the welding condition number lights up. In the left display,
the setting value of welding current preset to the condition number "1"
appears. Under this condition, a condition number can be set while turning
the parameter adjusting knob [5].
WARNNING
Ａ
I PM
SE C
Hz
Ｖ
±
%
J OB No.
Welding Current setting value held in memory Condition number blinks
In the event that any memory data is already preset to the condition
number you selected, the CRATER lamp, the WELDING METHOD lamp,
etc. also light up. If no memory data is preset to the condition number you
selected, “- - -” blinks in the left-side display. In this case, the system
skips the parameter check condition of Step (2) and jumps to Step (3).
WARNNING
Ａ
I PM
SEC.
Hz
Ｖ
±
%
J OB No.
(2) When pressing the ENTER key [21] after setting the condition number, the
ENTER lamp blinks (located at the upper left of the key). Under this
condition, you are allowed to confirm the setting value of the parameter
preset to the condition number by using the DISPLAY CHANGE key [8].
The setting value of the parameter you selected blinks.
NOTE: In the save mode, you can not change the welding condition
number or select any memory/readout mode. To reset the condition
number, press the SAVE key [20], then return to the step (1). To quit
the setting and exit from the memory mode, press the LOAD key [19].
(3) Pressing the ENTER key [21] again holds the data in memory and allow
you to exit from the memory mode.
−51−
No. P10355
10. OPERATION (continued)
② LOAD Function
The welding conditions stored in memory are read out from the memory inside
welding power source.
NOTE: The welding conditions currently used can be overwritten with the
welding conditions read out. When you wan to save the welding conditions
that have been used until now, preset the welding conditions to any
condition number, then carry out readout.
• Reading out the preset welding conditions
(1) When pressing the LOAD key [19], the machine enters the readout mode,
LOAD lamp (located at the upper left of the LOAD key) lights up. See the
figure below. The condition number "1" in the right-side display blinks and the
JOB No. LED lamp lights up. In the left-side display, the setting of welding
current preset to condition number "1" lights up. Under this condition, a
condition number can be set while turning the parameter adjusting knob [6].
WARNNING
Ａ
IP M
SE C
Hz
Welding Current held in memory
Ｖ
±
%
J OB No.
Condition blinks
In the event that any memory data is preset to the condition number you
selected, the CRATER lamp, the WELDING METHOD lamp, etc. also
light up. When no memory data is preset to the condition number, "- - -"
in the left-side display blinks. See the figure below.
WARNNING
Ａ
I PM
SEC
Hz
Ｖ
±
%
JOB No.
(2) When pressing the ENTER key [21] after setting the condition number, the
ENTER lamp (located at the upper left of the key) blinks. Under this condition,
you are allowed to confirm the setting of each parameter you want to read
out by using the DISPLAY CHANGE key [8]. The setting of the parameter
you selected blinks.
NOTE: You are not allowed to change condition number or select a
welding method, etc. To reset the condition number, press the SAVE
key [20], then return to the step (1). To quit the setting and exit from the
readout mode, press the SAVE key [20].
(3) When pressing the SAVE key [20] again, you can read out the preset welding
conditions and exit from the readout mode.
−52−
No. P10355
10. OPERATION (continued)
• Operation flow in the memory mode
Press the MEMORY key.
Discontinue
Set the welding condition number while
turning the parameter adjusting knob.
Press the ENTER key.
Discontinue
Press the MEMORY key.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
The welding conditions are preset to the number you selected.
Press the LOAD key.
Press the ENTER key.
The memory mode quits.
• Operation flow in the readout mode
Press the LOAD key.
Discontinue
Set the welding condition number while
turning the parameter adjusting knob.
Press the ENTER key.
Discontinue
Press the LOAD key.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
The welding conditions are preset to the number you selected.
Press the SAVE key.
Press the ENTER key.
The readout mode quits.
−53−
No. P10355
10. OPERATION (continued)
③ Erasing the Welding Conditions
When you erase the welding conditions stored in memory, you can select either
erasing all or erasing one.
• Erasing the welding conditions
(1) Turn off the power switch and turn on the power switch with both the LOAD
key [19] and SAVE key [20] pressed. Release the keys after tuning on the
power switch, and then "dEL" appear in the left-side display. See the picture
below.
WARNNING
Ｖ
Ａ
IPM
SE C
±
%
Hz
"dEL" is displayed, which indicates
the machine is in deletion mode
J OB No.
Condition number to be deleted blinks
(2) Set the condition number to be deleted while turning the parameter adjusting
knob [6]. When turning the knob counterclockwise, "ALL" appears in the rightside display as illustrated below and you can erase all the welding conditions.
WARNNING
Ｖ
Ａ
I PM
SE C
±
%
Hz
"dEL" is displayed
J OB No.
"ALL" blinks
NOTE: When the welding conditions are deleted by selecting "ALL",
welding conditions currently in use are also deleted. Consequently, all
the parameters return to the initial settings.
(3) Pressing the ENTER key [21] blinks "dEL". Confirm the condition number
again and if you want to cancel erasing of the condition number, press any
key other than the ENTER key [21] to return to step (2). To quit the delete
mode, turn off the welding power source.
(4) Pressing the ENTER key [21] again delete the welding condition preset to the
condition number. When "End" is displayed after end of data deletion, turn off
the power switch, then start up the welding machine.
NOTE: If you press the ENTER key twice in the deletion mode, you can
not recover the erased welding conditions. When you attempt to delete a
welding condition held in memory, make sure that the condition number
you want to erase is surely selected.
−54−
No. P10355
10. OPERATION (continued)
10.2.4
Resetting to Initial Values
The welding conditions that are currently used (including the welding condition currently
used) are all reset to initial values. To reset to initial values, turn off the power switch and
then turn on the power switch with both the F key [12] and GAS CHECK key [14] held down.
When "End"s appear in the displays after turning on the power switch, release the keys,
turn off the power switch, then turn it on again. See the picture below.
WARNNING
Ａ
I PM
SE C
Hz
Ｖ
±
%
J OB No.
See “SPECIFICATIONS” for initial values of each parameter and function.
10.2.5
Confirming software version
The version of software incorporated in the welding power source can be verified following
these steps. Turn on the power switch with only the F key [12] held down. After powering
the welding power source, the version number appears in the display.
(Example)
Right and left displays : "P10355"
← Software number (P10355) is displayed.
↓ Press the F key [12].
Left display : "001"
← Main software version (Ver. 001) is
displayed.
Right display : "000"
← Sub software version is displayed.
↓ Press the F key [12].
Left display : "- - -"
Right display : "002"
← Combination is displayed.
↓ Press the F key [12].
The welding power source starts up as usual and gets ready to perform welding.
10.2.6 Automatic Stop of Fan
The cooling fan automatically stops in 10 minutes after welding is finished and automatically
starts turning when welding is started. When powering the welding power source, the cooling
fan is also turning but automatically stops in 10 minutes when no operation is carried out.
10.2.7 Reduction of Fan Noise
When the welding power source is not temporarily in use, the rate of fan rotation decreases
so that fan noise can reduce. This function works only for 250 A or less output current.
−55−
No. P10355
11. APPLIED FUNCTION
11.1 How to Solve an Error
WARNING
Observe the following to prevent electrical shock.
When touching charging parts, critical electric shock and burn may occur.
● Do not touch charging parts inside or outside the welding machine.
● Grounding to the case of the welding power source should be performed by persons qualified
electric work and according to the laws and regulations in your area.
● When touching the parts inside the welding power source, wait more than three minutes after
powering off all input power supply by turning off the line disconnect switch in the switch
box.
If an error occurs during use, an error code shown in the displays on the front panel blinks, then the
welding power source stops automatically. In this case, check the errors in the following table.
No.
Displays on the front panel
Classification of errors
Left
Right
1
dAI
HEn
Torch switch off state waiting
2
E-
000
Operation Stop
3
E-
100
4
E-
200
5
E-
210
Control power supply error
Primary / secondary current detection
error
Error in the voltage detection wire
6
E-
300
Thermal overload
7
E-
510
Abnormal water pressure*
8
E-
600
Replacement of batteries (warning)
9
E-
700
Output over current
10
E-
710
Lack of phase
11
E-
800
Encoder in the wire feeder
12
E-
810
Thermal overload in the governor
circuit
13
E-
820
Motor over current warning
14
E-
830
Motor over current error
15
E-
900
Microcomputer error
*When input the relay signal to the 12P terminal block (TM12P) ⑪-⑫ only.
−56−
No. P10355
11. APPLIED FUNCTION (continued)
1) dAIHEn Display
If “dAI” and “HEn” in the displays blink, it indicates the “Torch switch off state waiting“.
When turning on the power switch, the displays on the front panel shows “dAI” and “Hen” for one
second, then the welding power source becomes operable. But, if the torch switch remains on,
the safety circuit will function, the welding power source will hold a halt condition, then the
WARNING lamp and "dAI” and “HEn" shown in the displays will blink. In this case, turn off the
torch switch to reset the safety circuit and make the welding power source operable.
2) E-000 Display
If “ E-“ and “000” in the displays blink, it indicates the “Operation Stop “.
When disconnecting the wiring of the STOP terminals (Operation Stop terminals: wiring number
143) on the 12P external connection terminal block, “E-“ and “000” in the displays blink and the
welding power source stops. In this case, after turning off the power switch and eliminating the
possible causes of the stoppage of the welding power source, short-circuit the STOP terminals
and turn on the power switch to cancel the error.
NOTE: When canceling Operation Stop, it is also possible to solve the error only by shortcircuiting the Operation Stop terminals again without start the welding power source up
again. Refer to Section 10.2.1 (4), “Selecting Auto/Semi-auto”.
3) E-100 Display
If “E-“ and “ 100” the displays blink in, it indicates the " Control power supply error ".
If there is an error in the control power source, the warning lamp will light up and “E-“ and “100” in
the displays will blink, then the welding power source will automatically stop. To cancel the error,
start the machine up again.
4) E-200 Display
If “E-“ and “200” in the displays blink, it indicates the " Primary/Secondary current detection error ".
If an error is detected in the current detecting area, “E-“ and “200” in the displays will blink and the
welding power source will stop automatically. In this case, turn off the power switch, then turn it on
again after making sure that CN8 and CN9 on the printed circuit board P10264U are surely
connected.
5) E-210 Display
If “E-“ and “210” in the displays blink, it indicates the " Error in the voltage detection wire ".
If there is an error in the plus voltage detection line (+), the warning lamp will light up, “E-“ and
“210” in the displays will blink, then the welding power source will stop automatically. In this case,
after checking to make sure that the wire feeder control cable (10P) is not damaged and that CN6
and CN10 on the printed circuit board P10264T, CN23 and CN 24 on the printed circuit board
P10264U, and CN 1 on the printed circuit board P10264X are surely connected, start the machine
up again.
6) E-300 Display
If “E-“ and “300” in the displays blink, it indicates the "Thermal overload"
If the actual duty cycle exceeds the rated duty cycle of or temperature inside the welding power
source increases, "E-“ and “300" will blink and the welding power source will stop automatically.
At this time, the temperature lamp also will be lit. In this case, wait more than 10 minutes with the
power switch pressed and the fan turned. When restart welding, turn off the power switch and
restore the system after lowering the duty cycle and the welding current. Such action will cancel
the error. Repetitious welding without more than ten-minute rest may lead to damage to the
welding machine. Refer to Section 3.1, “Rated Duty Cycle” for the rated duty cycle of the welding
power source.
−57−
No. P10355
11. APPLIED FUNCTION (continued)
7) E-510 Display
−In the case of connecting the water pressure switch−
If “E-“ and “510” in the displays blink, it indicates the “Abnormal water pressure”.
Then the welding machine will automatically stop. In this case, check to make sure that the watercooled hose does not leak water and that adequate cooling water is going through the hose.
When set the switch of the front panel “Water” and connected the relay contact of water pressure
between ⑪ and ⑫ on the 12P terminal block (TM12P), contact between ⑪ and ⑫ is “Open”
makes E-510 light up.
When using an air-cooled torch, make sure that the TORCH lamp on the front panel is OFF (AIR).
Refer to section 11.2.
8) E-600 Display
−Refer to section 11.2−
If "E-“ and “600" in the displays blink, it indicates the "Replacement of batteries (warning)".
This welding power source uses batteries so that it can hold the welding conditions in memory
even when no operation is carried out for long time. “E-“ and “600” in the displays blink when the
batteries get low. “E-“ and “600” are displayed only when the front panel and the welding power
source are temporarily not in use. To cancel the display of the error , press any key. Even when
“E-“ and “600” appear in the displays, welding can continued to be performed, but when the
batteries run down, the preset welding condition functions and the settings of functions
are all erased. The last welding conditions before power is applied to the welding machine
can not be stored. Each time power is applied to the equipment, all the parameters are
reset to initial values. Refer to Section 12.4, “ Replacement of batteries” for details.
9) E-700 Display
If “E-“ and “700” in the displays blink, it indicates the “Output overcurrent”.
If an overcurrent or short circuit on the secondary output continues for more than one second
during welding, the WARNING lamp lights up, “E-“ and “700” in the display blinks, then the
welding power source stops automatically. In this case, turn off the control power switch and
check to make sure that the welding current does not exceed the rated output value, or that there
is no short circuit on the output side such as a contact between the tip and the base metal, or a
short circuit of the output cables.
10) E-710 Display
If “E-“ and “710” in the displays blink, it indicates the “Lack of phase”.
If a lack of phase is detected at the primary input, the warning lamp will light up, “E-“ and “710” in
the displays will blink, and then the welding power source will stop automatically. In this case,
make sure that there is no lack of phase in primary input voltage.
11) E-800 Display
If “E-“ and “800” in the displays blink, it indicates the “Encoder in the wire feeder “.
If there is an error in an encoder feedback signal for detecting the feeding rate of wire feeder, the
warning lamp will light up, “E-“ and “800” in the displays will blink, and then the welding machine
will stop automatically. In this case, make sure that there is no damage in the encoder connector
(4P) on the top of the motor inside the wire feeder, the control cable for the wire feeder (10P),
and the printed circuit board P10261Q.
12) E-810 Display
If “E-“ and “810” in the displays blink, it indicates the “Thermal overload in the governor circuit “.
If thermal overload in governor circuit (printed circuit board P10261Q) is detected, the WARNING
lamp will light up, “E-“ and “810” in the displays will blink, and then the welding machine will stop
automatically. In this case, check for defective printed circuit board P10261Q, short circuit on the
motor power supply lines, rough feeding of wire, and error in the torch or the wire feeder.
−58−
No. P10355
11. APPLIED FUNCTION (continued)
13) E-820 Display
If “E-“ and “820” blink in the displays, it indicates the “Motor overcurrent warning”.
Contact resistance to the feeding parts causes motor current to increase. If the motor current
exceeds 70% of the rated duty cycle, “E-“ and “820” in the displays will blink only while no
operation at the front panel is carried out. When pressing any key or starting welding again, “E”
and “820” in the displays will disappear (, but welding power source does not stop automatically).
In this case, check for short circuit in the motor power
transmission line, rough feeding of wire, and an error in the torch or the wire feeder. Refer to
Section 10.2.1(10) “Setting of Feed Motor Load Current Error Detection Level”.
14) E-830 Display
If “E-“ and “830” in the displays blink, it indicates the “Motor overcurrent”.
If short circuit in the power line to the motor or motor overload happens, “E-“ and “830” in the
displays will blink and the welding machine will automatically stop. In this case, check for short
circuit in the power supply line, rough feeding of the wire, and an error in the torch or the wire
feeder.
15) E-900 Display
If “E-“ and “900” in the displays blink, it indicated the “Microcomputer error”.
There could be an error in the built-in microcomputer, Please contact your dealer immediately.
When contacting your dealer, you are required to provide the details of the problem you are
facing.
−59−
No. P10355
11. APPLIED FUNCTION (continued)
WARNING
Observe the following to prevent electrical shock.
● Do not touch charging parts inside or outside the welding machine.
● Grounding to the case of the welding power source should be performed by persons
qualified electric work and according to the laws and regulations in your area.
● When touching the parts inside the welding power source, wait more than three minutes
after powering off all input power supply by turning off the line disconnect switch in the
switch box.
CAUTION
● Try to move the control cable which is pulled out from the automatic connection terminal
on the chassis father away from the welding power cable or the torch cable when making
an external connection. Otherwise, equipment failure may be caused by noise, etc., during
welding operation.
● Pull out only the wiring on the printed circuit board to outside.
11.2 External Connection of Inside Terminal Block of Automatic Machine
When taking off the upper cover of the welding power source, you will find there is a 12P
terminal block (TM12P) and a 6P terminal block (TM6P) on the chassis. Use the 12p terminal
block to connect with an automatic machine. Refer to Section 12, “Parts layout” for the
locations of the terminal blocks.
NOTE: Wait more than three minutes after turning off the line disconnect switch or nofuse breaker and the power switch on the front panel to remove the cover.
NOTE: Break the grommet with filter located on the rear side of the welding machine to
lead in the external connecting wires. When leading in the external connection wires, do
not touch the parts on the printed circuit board and the edges of the steel plate.
①
＋
②
-
READY
③＋
④＋
ＧＡＳ
⑤＋
EXT１
⑥-
⑦＋
⑧-
⑨
ＳＴＯＰ
ＷＣＲ
[12P terminal block]
①
②
③
＋
-
＋
Ａ
⑩
EXT２
④
Ｖ
⑥
-
[6P terminal block]
−60−
⑤
DIRECT
⑪
⑫
No. P10355
11. APPLIED FUNCTION (continued)
12P terminal block (TM 12P)
Pin No.
Signal name
+
READY
① − ②
(OUTPUT)
Ready Power
+
③− ⑥
+
④ − ⑥
+
⑤ − ⑥
+
⑦ −⑧
+
⑨ − ⑩
+
⑪ − ⑫
GAS
(INPUT)
Solenoid Valve
Control
EXT1 (INPUT)
Extra
Input
Signal 1
EXT2 (INPUT)
Extra
Input
Signal 2
STOP (INPUT)
Operation Stop
WCR(OUTPUT)
Current
Detection
Abnormal water
pressure
detection
(INPUT)
6P terminal block (TM 6P)
Pin No.
Signal name
+
AMMETER
−
①
②
+
③ −④
VOLTMETER
⑤
⑥
Unused
Negative
Terminal
Direct
Detection
Voltage
for
of
Function
The terminals used for ready power for prep. relay. When
there is not any error such as open phase, Operation Stop,
output over current, and thermal overload, the terminals work,
etc. while the power switch is on, the terminals function.
The terminals used for controlling the gas solenoid valve by
external signals. (If the terminals are short-circuited, the gas
valve will open.)
The terminals used for special specifications. These terminals
should not be used for normal use.
*1
*2
*2
The terminals used for special specifications. These terminals
should not be used for normal use.
*2
To stop welding externally. Release the wiring between two
terminals to run Operation Stop. Welding machine is stopped
by running Operation Stop. Close the terminals after turning
off the torch switch to restart welding. To avoid accidental
restart, use of a Push lock Turn reset switch is suggested.
Contact Output of welding current relay used for detection of
welding current. The contacts close while welding current is
flowing.
In case of there is the abnormal water pressure detection
relay in the cooling unit, which is like a pressure switch,
remove the jumper wire on the terminal and connect the relay
contact. (Close: normal Open: abnormal) Then torch key in
the front panel is set “Water“ and contact is “Open” make E510 light up.
*2
Function
Terminals for connecting an ammeter.
Use the ammeter (400A/60mV, part number: 4403-057).
Terminals for connecting a voltmeter.
Use the voltmeter (full scale 100V, part number: 4401-016).
*3
*3
*4
When using a power cable that is more than 30 m long, direct
connection of a direct detection wire of the base metal (-) to the
wire feeder is recommended, but it is impossible to connect to the
wire feeder due to jig, use the terminal block inside this welding
power source. Refer to Section 10.2.1 (12) “Arc Voltage Direct
Detection ON/OFF Selection” for details of direct detection.
Precaution for connection with terminals on the terminal block
The wires from the terminal blocks should be twisted for each signals to avoid accidental operation.
Take care that the wires form the terminal blocks do not cross other signal wires from other welding
power source.
*1 Equivalent circuit is as the figure shown right. Maximum capacity of TR is 80V, 100mA. When
connecting such as relay to two terminals, do not exceed 80% of the maximum capacity of TR.
(Figure 1)
*2 Equivalent circuit is as the figure shown right. Connect allowable contacts (10mA or more) to two
terminals. (Figure 2)
*3 Rating of the provided relay contacts is 125V AC, 0.5A, 30V DC, 1A. Do not exceed 80% of the
rating of the provided relay contacts.
−61−
No. P10355
11. APPLIED FUNCTION (continued)
*4 Be careful that no-load voltage (100V or less) is applied to between the terminals during welding.
24V
TR
PC
+
2.7kΩ
Figure 1
+
-
Figure 2
11. 3 Combining with an Automatic Machine
When combining with an automatic machine, use the 12P/6P terminal block inside the welding
power source, the 10P terminal block inside the wire feeder, and the receptacle for the remote
control or for the wire feeder. Refer to Section 11.2, “External Connection of the Inside
Terminal Block of the Automatic Machine” for the details of the terminal block inside the
welding power source.
(1) Current/Voltage Settings and Inching Signal
When the analog remote control (optionally supplied) is not in use, resistor R23 for current
setting, resistor R24 for voltage setting, and switch PB for inching, which are all listed in
Section 13.1 “Parts List”, should be used. For setting current/voltage on external voltage, refer
to Section 10.2.1(4), “Selection of Auto/Semi-automatic”.
Analog remote control
93
1
94
2
95
3
96
4
97
5
98
6
Current setting
94
R23
Voltage setting
94
R24
96
95
93
93
PB
98
97
Inching
(2) Start Signal
When removing the right-side plate of the wire feeder, you will find a 10P terminal block. See
the figure below. Welding is carried out by the start signal when wiring numbers 306 and 307
are contact input and when the terminals are closed. Welding stops when the terminals are
open.
−62−
No. P10355
11. APPLIED FUNCTION (continued)
(3) Direct Detection Signal
When using a power cable that is more than 30 m long, connect the base metal (-) and the
connector for voltage detection of wire feeder (wiring number: 310) with voltage detection
cable K5416G00. When using the equipment which employs a brush, etc., as the feeding
parts like a positioner or a turn table, attachment of the voltage detection cable to the terminal
for the base metal power cable is recommended.
Refer to Section 10.2.1(12), ” Arc voltage detection ON/OFF selection” for details of direct
detection.
*Outgoing lines of start signal and direct detection signal are located next to the 10P control
cable. Break the grommet with film.
Terminals for
start signal
Terminals
for voltage
detection
11.4 Optional Accessories
11.4.1 Other Optional Accessories
Description
Analog remote control
Digital remote control
CAN communication module
CAN communication cable
Wheel kit
Voltage detection cable
Part No.
K5416H00
E-2454
K5422B00
BKCAN-04XX
K5416L00
K5416G00
−63−
Remarks
With a 3-meter cable
A CAN communication module and cable are
needed.
XX= 05 (for 5 m), 10 (for 10 m)
30 m, with a crimp-style terminal
No. P10355
11. APPLIED FUNCTION (continued)
11.4.2 Extension Cable/Hose (Extension of Work Space)
CAUTION
● Do not connect an unnecessarily long extension cable.
● When using an extension cable, roll it out. Failure to observe the demand may result
in unstable arc.
Choose a proper torch cable (separately sold) for work space. When extending the work
space, use other extension cables/hoses (separately sold ) that match the work space.
②
*
Gas hose
③ Control cable for wire feeder
①Power cable for wire feeder
Wire feeder
④ Control cable for remote control
Analog remote control
Welding power source
(Optionally available)
* A water cooler and water hoses are necessary for use of a water-cooled torch.
1. Power Cable (for torch and for base metal)
5m
10m
Mode
BKPDT-6007
BKPDT-6012
l
AWG2/0 (60mm2)
15m
20m
BKPDT-8017
BKPDT-8022
AWG3/0 (80mm2)
2. Gas Hose
Mode
l
5m
10m
15m
20m
BKGG-0605
BKGG-0610
BKGG-0615
BKGG-0620
15m
20m
BKCPJ-1015
BKCPJ-1020
3. Control Cable for Wire Feeder (10 P)
5m
10m
Mode
BKCPJ-1005
BKCPJ-1010
l
4. Control Cable for Analog Remote Control (6P)
5m
10m
15m
Model BKCPJ-0605
BKCPJ-0610
BKCPJ-0615
20m
BKCPJ-0620
5. Water Hose (for feeding water and condensed water)
5m
10m
15m
Model
BKWR-0605
BKWR-0610
BKWR-0615
20m
BKWR-0620
−64−
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING
WARNING
To avoid electric shock, follow the below instructions.
● Do not touch live electrical parts inside or outside the welding machine.
● Turn off all of the line disconnect switches before touching the parts inside the welding
machine.
● Perform the maintenance checks periodically. If any damaged parts are found, only use the
welding machine after troubleshooting or repairing.
● Only certified operators should maintain, inspect, or repair the welding machine.
● When carrying out the maintenance, wait more than three minutes after powering off all input
power supply by turning off the line disconnect switch in the switch box. Capacitor may be
discharging even after powering off all input power supply. Check to make sure that charging
voltage does not exist before carrying out the maintenance.
● This welding power source uses a high-frequency inverter system, be careful of accidental
connection of the line disconnect switch at input side.
● Have qualified operators or the persons familiar with this welding power source test withstand
voltage. And install a protective wall around the welding machine to keep away others from the
welding machine.
CAUTION
Rotating parts may cause injuries. Be sure to observe the following.
● Only certified operators should maintain, inspect, or repair the welding machine.
● Install a fence around the welding machine to keep others away from it.
● Do not put your hands, fingers, hair and clothes near the fans and wire feed roll rotating.
CAUTION
● Do not touch the parts for the main circuit which are located inside the power
source, such as single-phase transformer, DC inductor, heat sink, etc.
immediately after welding is performed, as the parts are extremely hot. Wait
until the parts cool down, when touching. Failure to observe the demand may
result in burn.
CAUTION
● The welding conditions (electronic information) stored using the JOB MEMORY keys are likely
to be affected by occurrence of static electricity, and there is a possibility that the preset data
contents may be changed or erased. We recommend taking notes of important data.
● We shall not assume any responsibility for any change or erase of the electronic information
resulting from repair.
−65−
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.1 Carrying out Maintenance on the Welding Power Source
(1) Periodical checking
(2)
Periodically check the welding power source to ensure the safety of the equipment and the
efficiency of work.
• Daily checking the followings:
- No strange vibration, buzzing
noise, and smell are generated from the welding power
source.
-
No excessive heat is generated from the cable connections.
Fan functions properly when the power switch is turned on.
The switches properly function.
Connection and insulation of cables are surely made.
There are no break in cables.
Fluctuation of power source voltage is not large.
Case Earth is surely connected. (Disconnection of the Case Earth may result in failure or
malfunction of the equipment.)
• Checking the followings each three to six months:
- There is no damage inside the torch.
- There are no loose connections or no poor contacts caused from rust, on input side of the
welding power source and output side of the cables.
-
There is no trouble with insulation.
The welding power source is properly grounded.
Built-up dust on the transistor or the cold plate on the rectifier may affect the equipments.
Take off the cover of the welding power source once a half year, then remove dust by
blowing moisture-free compressed air on each part.
- The dust protective filter located on the inlet of the fan does not clog, which may result in
damage to the welding power source. Be sure to inspect it periodically.
12.2 Precaution for Replacement of the Printed Circuit Board
• Make sure that the connector number
inscribed on the printed circuit board matches
the number marked on the connector.
１
• Turn
off the control power switch and line
disconnect
switch
before
carrying
out
maintenance on the welding power source, and
wait three minutes until the capacitors inside the
welding power source discharge.
• This
welding power source uses a highfrequency inverter system, be careful of
accidental connection of the line disconnect
switch at input side.
•
C N1
NOTE: Match the number on the printed
circuit board with that on the connector.
Surely connect the connectors until the connector clicks. Failure to do so may result in
damage to the printed circuit board and the welding .
• With the connectors disconnected, do not turn on the power switch on the front panel.
• Do not use organic solvent such as thinner, trichloroethylene, gasoline, etc., to clean the
plastic cover and carrying handle of the welding machine. Deformation and flaw may result
from the adherence of the organic solvent.
−66−
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.3 Insulation Resistance Test
WARNING
Observe the following to prevent an electrical shock.
When touching charging parts, a critical electric shock and burn may occur.
● Have qualified operators or the persons familiar with this welding power source measure
insulation resistance and test withstand voltage . And install a protective wall around the
welding machine to keep away others from the welding machine. Check to make sure that
charging voltage does not exist before carrying out the maintenance before carrying out
measurement of insulation resistance and withstand voltage test.
When measuring insulation resistance and testing withstand voltage, follow the steps below.
And, refer to the schematic diagram, parts layout, and parts list for maintenance.
1. Disconnect the grounding cable (wiring number: 80) from the earth.
2. Short-circuit on AC side and commutation side of DR1.
3. Short-circuit between TR1 (C1) and (E1), TR2(C2) and (E2), TR3(C2) and (E2).
Be sure to reconnect the cables after carrying out measurement of insulation resistance and
withstand voltage test.
12.4 Replacement of Batteries
This welding power source uses lithium batteries to hold welding conditions in memory. The life
of the batteries differs depending on the environments. “E-“ and “600” shown in the displays on
the front panel blinks when the batteries gets low. Replacement of the batteries every 5 years
or so are recommended even when “E-“ and “600” do not blink. Replace the batteries following
the steps:
1. Turn off the line disconnect switch in the switch box or the no-fuse breaker and the power
switch of the welding power source.
2. After more than three minutes, remove six screws that secure the front panel, and then pull
the front panel out. Do not pull it forcibly. With the wiring inside the equipment
disconnected, do not turn on the power switch. Failure to do so may result in damage to
the welding power source.
3. Remove the connectors on the P.C.B.P10263R to replace the printed circuit board. Refer
to the position for “Rear side of the front panel” in Section 12.7, “ Parts List”.
4. Insert the disconnected connectors into the P.C.B.P10263R.
5. Screw the front panel in position.
−67−
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.5 Troubleshooting
When an error code is displayed, refer to Section 11.1, “How To Solve an Error”.
•
No.
1
2
3
4
5
6
Check the troubleshooting information listed below before contacting your dealer for
service.
Trouble
Cause
Solution
The power
Never turn it on again. Contact your dealer.
switch on the
front panel is
tripped.
When turning on the
Trouble with PL1.
Inspect PL1.
The main
power switch, the
power lamp
displays light.
PL1 will not
light.
The line disconnect switch in Inspect the power
When turning on the
the switch box is not turned
box.
power switch, nothing
appears in the display. on.
The input cables are not
Inspect the input
surely attached.
cables.
When turning
The main power lamp
Refer to No.2 in this list.
on the power
PL1 will not light.
switch,
Shortage of the input voltage Check for proper
nothing
input voltage.
appears in the
Trouble with the power
After inspecting
display.
PL1 lights.
circuit.
PCB P10263Q
and P10322X,
replace them if
necessary.
When turning on the power switch, the
Refer to Section 11.1, “How
WARNING and TEMPERATURE lamps To Solve an Error”.
light up and an error code appears in
the display,
Shield gas is
Gas is not generated
The discharge valve of the
Open the valve.
not generated when the GAS CHECK gas cylinder is closed.
when the torch key is pressed.
Lack of gas pressure of the
Check for proper
switch is
gas cylinder.
gas pressure.
pressed.
Trouble with the gas
Inspect the gas
electromagnetic valve SOL.
electromagnetic
valve SOL.
Gas is generated
Disconnection of the torch
Check the wiring
when the GAS CHECK switch cable or incomplete
number 306 and
key is pressed.
insertion to receptacle.
307.
Shield gas does not stop.
The GAS CHECK lamp lights
up.
Trouble with the gas solenoid
valve SOL
When the torch switch is pressed, noload voltage is not output but shield gas
is generated.
7
Trouble with the inverter
main circuit
Trouble with the control
circuit
−68−
Stop gas checking
by pressing the
GAS CHECK key.
Check for
operation of the
gas solenoid valve
of wire feeder.
Turn off the power
switch, then
contact your
dealer.
After inspecting
PCBP10264P or
P10352 replace it
if necessary.
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING (continued)
No.
Trouble
Current and voltage
can not be set.
8
Cause
Trouble with the control
circuit
Solution
After inspecting PCB P10264P or
P10264U and replace it if necessary.
Trouble with the filter
circuit
After inspecting PCB P10264T, replace
it if necessary.
Trouble with the remote
control
After inspecting the cable/plug for
remote control or the remote control,
replace them if necessary.
Inspect connections of CN23 and CN
24 on PCB P10352U or CN1 on PCB
P10264X.
After inspecting the contacts of the plug
and cable, replace them if necessary.
Error in wire voltage
detection
Wire is not fed.
9
WCR keeps working.
10
Incomplete insertion or
breaking of the control
cable for wire feeder
Trouble with the motor
control circuit
After inspecting PCB P10264Q, replace
it if necessary.
Trouble with the filter
circuit
After inspecting PCB P10264T, replace
it if necessary.
Trouble with the hole
current detector CT2
Inspect the hole current detector CT2.
Trouble with the WCR
circuit
After inspecting PCB P10264P, replace
it if necessary.
−69−
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.6 Schematic Diagram
(P10352M)
(P10264S)
(P10264X)
(P10264V)
(P10322X)
(P10263Q)
(P10264S)
(P10352U)
(P10264P)
(P10264R)
(P10264T)
(P10261Q)
−70−
(P10263R)
No. P10355
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.7 Parts Layout
TR1-4
Front Panel
P10263R
(Battery board)
Under frame
⑦, ⑧
⑩
②, ③
P10264R
P10352U
C14
⑨
P10264P
L4
C12, R30
P10352M
Heat sink
SCR1
R18, C15
T1
CON2
⑥
DR1
DR7
NF
Behind of
Control Panel
R16, DR18
R25
Bottom Chassis
THP2
Heat sink
L1
CON1
⑥
DR2-6
R26
⑪
⑪
P10264V
CT1
L5
R20
R19
Back Side of Front Panel
C8
Heat sink
C9
④
TR5
Rear Panel
T2
R6
P10322X
Top Chassis
TM1
P10264S
Middle Chassis
R27a-d, R28
R19-21
TM2
P10261Q
P10264T
①
FM1
P10263Q
LF1
FM2
P10264X
R32
R31
R1-4
−71−
No. P10355
13. PARTS LIST
•
Please contact your dealer to order parts. (See the back cover for telephone and fax numbers,
and mailing addresses.)
Symbol
Part No.
Description
Specifications
Q’ty
Remarks
NF
4614-104 Circuit protector
LF
4519-037 Line filter
PL1
4600-341 Pilot lamp
DR1
4531-717 Diode module
DR2 – 7
4531-308 High speed diode module
DR8
4531-505 Diode
TR1-4
4534-528 IGBT module
TR5
4534-529 IGBT module
SCR1
4530-412 Thyristor
CT1
4810-030 Current transformer
CT2
4406-009 Hole current detector
T1
P10264B00 Inverter transformer
T2
4810-351 Auxiliary transformer
L1
P10352B00 DC reactor
L2,3,6,7,8
4739-497 Ferrite core
L4
P10322L00 Input reactor
L5
P10352C00A Choke coil
L11,12
4739-543 Ferrite core
THP1
4258-041 Thermostat
119-0637(480V 75A)
FS5681-50-99
NPA10−2H−WS
DFA150AA160
DBA200UA60
S2L60
CM200DY-12NF
SKM300GAL128D
SG25AA20
TMH0.025X5X25X35
HA400S3EH
P10264B00
W-W02921A
P10352B00
E04RA400270150
P10322L00
P10352C00A
E04RA310190100
US-602AXTTL 110℃
1
1
1
1
6
1
4
1
1
1
1
1
1
1
5
1
1
2
1
THP2
4614-057
Thermostat
67L080
1
THP3
FM1,2
SH
TM1
TM2
R1 - 4
R6
R8−13,17
R14,15
R16
R18
R19,20,21
R23,24
R25,26
R27a−d
R28
R29,R30
R31,R32
C2
C4,C5
C7,C12
C8,C9
C10
4258-033
4805-074
4403-116
4739-505
4739-504
4516-119
4509-819
4509-704
4509-121
4509-916
4509-107
4509-128
4501-039
4509-883
4504-321
4504-322
4509-704
4509-922
4518-530
4518-519
4518-402
4511-344
4518-533
Thermostat
Fan
Meter shunt
Terminal block
Terminal block
Surge absorber
Cement resistor
Carbon resistor
Metal film resistor
Cement resistor
Carbon resistor
Metal oxide film resistor
Variable resistor
Cement resistor
Non-inductive resistor
Non-inductive resistor
Carbon resistor
Cement resistor
Film capacitor
Film capacitor
Film capacitor
67L070
4715SL-05W-B60-D00
KY400A 400A/60mV
TB10-01 12P
TB10-01 6P
ENC911D−14A
40SH 200ΩJ
RD1/4W 1kΩJ
RNP−50SC 10ΩF
T20SH 2.2ΩJA
RS2W 15ΩJ
RS2B 200kΩJ
RV24YN20SB 5kΩ
20SH 20kΩJ
NCRF22V 10Ω
NCRF22V 20Ω
RD1/4W 1kΩJ
20SH 10ΩJA
US16X154JAASA
MIC-ST3D182J
0.47µF 50V
400LGSN3300MBD13
US20X473JAASA
1
2
1
1
1
4
1
7
2
1
1
3
2
2
4
1
2
2
1
2
2
2
1
Aluminum electrode capacitor
Film capacitor
−72−
No. P10355
13. PARTS LIST (continued)
Symbol
Part No.
C11
C13
C14
CON1
CON2
PCB1
PCB2*
PCB3
PCB4
PCB5
PCB6
PCB7
PCB8
PCB9
PCB10
PCB11
PCB12
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
Plug for ⑪
Plug for ⑪
4518-528
4517-455
4511-510
4730-421
4730-426
P10352U00
P10264P00
P10263Q00
P10264V00
P10264T00
P10352M00
P10261Q00
P10263R00
P10264R00
P10264X00
P10322X00
P10264S00
4739-474
4735-038
4735-039
4739-475
P10355W02
4739-476
P5801G03
P10263G12
P10264J01
P10263J02
4734-007
4734-025
4734-026
Description
Film capacitor
Ceramic capacitor
Aluminum electrode capacitor
Metal receptacle
Metal receptacle
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Grommet with film
Knob
Cap
Rubber foot
Control panel sheet
Cap
Carrying Handle
Bush
Front cover
Control panel cover
Machine socket
Power cable connector
Power cable connector
Specifications
US20X103JAASA
0.01µF 2kV
LWA2N601MSMAZO
HS25R-10
25-6BK
P10352U00
P10264P00
P10263Q00
P10264V00
P10264T00
P10352M00
P10261Q00
P10263R00
P10264R00
P10264X00
P10322X00
P10264S00
W-W02805
K-100 22RSB
K-100 22CSBL
C-30-RK-3220
P10355W02
W-W02814
P5801G03
P10263G12
P10264J01
P10263J02
DIX BE 50/70
DIX SKK 70
DIX SKK 95
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
4
1
2
2
4
1
1
2
1
1
Remarks
Refer to “NOTE” below.
Adjusting knob
Output terminal
For 60mm2 cable
For 80 mm2 cable
*NOTE: When ordering a printed circuit board P10264P00, provide the software
version on a label below a nameplate attached to the rear side of the welding power
source.
P10355 Ver. ###.###.000
Replace the ###.### with software version.
Parts list for analog remote control (optional accessories)
Symbol
Part no.
Description
Specifications
R23,24
4501-039
Variable resistor
RV24YN20SB 5KΩ
PB
4250-077
Push button switch
A2A-4R
4730-009
Metal socket plug
DPC25-6A
4735-007
Knob
K-2195（large）
K5416H02
350/500A scale plate
K5416H02
−73−
Q’ty
2
1
1
2
1
Remarks
No. P10355
14. SPECIFICATIONS
14.1 Specifications
（1）Welding power source
Model
Specificaitons
Digital Inverter DP400
Model
DP-400
Pulse
Number of phase
Rated frequency
Rated input voltage
Input voltage range
Rated input power
Rated input current
Rated output current
Rated load voltage
Rated output current range
Rated output voltage range
Maximum no-load voltage
Rated duty cycle
Number of welding condition
Temperature rise
Usable temperature range
Usable moisture range
Storage temperature range
Storage moisture range
External dimensions(W x D x H)
Mass
DC
Pulse
DC
3
50 / 60 Hz
208 / 230 V
208 / 230 V ± 10%
21.4 kVA,
17.9 kVA,
21.5 kW
17.5 kW
53.7 A
45.0 A
460 V
460 V ± 10%
23.6kVA,
19.8 kVA,
21.5 kW
17.5 kW
29.6 A
24.8 A
400 A
34 V
30 - 400 A
12 – 38 V
84 / 92 V
50%
80 V
60%
50%
100
+160 ˚C (+320 ˚F)
-10 – +40 ˚C (+14 - +104 ˚F)
20 – 80%（without dew condensation）
-10 – +60 ˚C (+14 - +140 ˚F)
20 – 80%（without dew condensation）
9.8 in. x 25.2 in. x 21.4 in.
(250 mm x 640 mm x 544 mm)
（without the carrying handle）
99.2 lb (45 kg)
−74−
60%
No. P10355
14. SPECIFICATIONS (continued)
20.4 (524)
21.4 (544)
22.7 (577)
−75−
25.2 (640)
9.8 (250)
7.5 (190)
19.7 (500)
15.7 (398)
1.97 (50)
In. (mm)
14.2 External View
No. P10355
14. SPECIFICATIONS (continued)
Front Panel
●Initial Values and Setting Range of Parameter
Initial value
Setting range
0.1 second
0 – 10 seconds
Current
20 A
20 – 400 A
Voltage
10 V
10 – 45 V
Pre-flow time
・ Initial condition
・ Main condition
・ Crater filler condition
0
-30 – 30
Post-flow time
0.4 second
0 – 10 seconds
Arc spot time
3 seconds
0.1 – 10 seconds
0
-10 – 10
3 Hz
1
0.5 – 32 Hz
1 – 100
Initial value
OFF
DC pulse
OFF / ON (without pulse) / ON（with pulse）/ SPOT
MILD STEEL
MAG
MILD STEEL CO2/MILD STEEL CORED
CO2/STAINLESS CORED CO2/MILD STEEL
CORED MAG/STAINLESS STEEL MIG/
ALUMINUM PURE MIG/ ALUMINUM MIG
0.045in
(1.2mm)
OFF
0.030/0.035/0.040/0.045(3/64)/[1/16]in
(0.8/0.9/1.0/1.2/1.6mm)
ON/OFF
SYNERGIC
SYNERGIC/INDIVIDUAL
OFF
ON/OFF
Fine adjustment of voltage
Arc characteristic
Wave frequency
JOB MEMORY numbers
[21] [20]
Wire/Gas
Wire diameter
Initial current
Adjustment of welding voltage
Penetration control
F2
F3
F4
F5
F6
F7
F8
F9
F10
Fine adjustment of anti-stick (burnback) time*
Fine adjustment of anti-stick (burnback)
voltage*
Fine adjustment of slow-down speed*
SAVE
Setting item
DC pulse / DC wave pulse (optional )
Initial value
0
Setting range
-50(0.50 second down) – 50(0.50 second up)
0.0
-9.9 – 9.9 V
0.0
-1.0 – 1.0 m/min.
Selection of automatic/semi-automatic
External command 10VMAX
Setting of up-slope time*
Setting of down-slope time*
Result display holding time
Selection of scale plate of analog remote
control
OFF
OFF
0.0
0.0
20
ON(AUTOMATIC)/OFF(SEMI-AUTOMATIC)
ON(VALID)/OFF(INVALID)
0 – 10.0 seconds
0 – 10.0 seconds
5 – 60 seconds
350
200/350
Feed motor load current error detection level
70
20 – 150 %
OFF
ＯＮ（VALID）/ＯＦＦ（INVALID）
OFF
0
0
ＯＮ（DIRECT）/ＯＦＦ（TERMINAL）
-150 A – 150 A
-1.5 (ms) – 1.5 (ms)
F12
F13
F14
Fine adjustment of Job Memory Fine
Adjustment
Arc voltage direct detection ON/OFF selection
Fine adjustment of pulse peak current*
Fine adjustment of pulse peak time*
F15
Fine adjustment of base current*
0
-60 A – 60 A
F16
Fine adjustment of L pulse peak current*
0
-150 A – 150 A
F11
F17
Fine adjustment of L pulse peak time*
0
-1.5 (ms) – 1.5 (ms)
F18
Fine adjustment of L pulse base current*
0
-60 A – 60 A
F19
Turbo Start ON/OFF selection
ON
ＯＮ（VALID）/ＯＦＦ（INVALID）
F20
Keypad tone ON/OFF selection
ON
ＯＮ（VALID）/ＯＦＦ（INVALID）
[13]
[8]
[15]
A
IPM
[6]
[9] [10]
V
±
Sec
%
Hz
JOB NO.
A
IPM
MAIN
CONDITION
T1
DISPLAY
CHANGE
ENTER
[5]
DIGITAL INVERTER
LOAD
INITIAL
CONDITION
V
CRATER-FILL
CONDITION
ARC
CONTROL
±
f
T2
WAVE PULSE
SYNERG.
ON
Ｆ
OFF
ON
( )
INCHING
ON
( )
SPOT
SPOT TIME
INITIAL
CURR.
CRATER
− FILL
ON
WATER
CONSTANT
PENETRATION
TORCH
（ OP T I ON）
SYNERG.
INDIV.
VOLT. CONTROL
GAS
CHECK
●Internal Functions (Function） <Refer to Section 10.2.1, “Using of internal functions >
F1
[4]
J O B WARNING
MEMORY
●Function
Crater
Welding method
[19]
.030
CO2
MILDSTEEL
ＯＰ１
DC PULSE
.035
MAG
MILDSTEEL
ＯＰ２
DC
MILDSTEELCORED
ＯＰ３
ＯＰ
STAINLESSCORED
ＯＰ４
DC WAVE PULSE
（ OP T I ON）
.040
.0453/64
.052
MI G
STAINLESS
ＯＰ５
1/16
MI G
SOFT ALUMINUM
ＯＰ６
HARD ALUMINUM
ＯＰ７
ＯＰ
WIREDIA
WELDING
METHOD
(inch)
Refer to manual for
recommended shielding gases
[17][18] [11]
[7]
[1] WELDING METHOD key
[2] WIRE/GAS selector keys
[3] WIRE DIA (inch) key
[4] IPM selector key
[5] V/± selector key
[6] Parameter adjusting knob
[7] CRATER-FILL key
[8] DISPLAY CHANGE key
*Welding conditions which can be preset to a JOB MEMORY number.
−76−
[12] [3]
[14]
[2]
[9] ARC CONTROL key
[10] WAVE PULSE key (optional)
[11] SPOT TIME key
[12] F (FUNCTION) key
[13] INITIAL CURR. key
[14] VOLT. CONTROL key
[15] CONSTANT PENETRATION key
[16] TORCH key
[16]
[1]
[17] GAS CHECK key
[18] INCHING key
[19] LOAD key
[20] SAVE key
[21] ENTER key
No. P10355
14. SPECIFICATIONS (continued)
QUICK MANUAL
Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”.
① Before Using the Welding Power Source
Parameter adjusting knob
4.
1.
Settings of Welding Method
Set a welding method,
wire/ shield gas, then
wire diameter by using
the WELDING METHOD
key,
the WIR/GAS
selector keys, and the
WIRE DIA. (mm) key
respectively.
MILDSTEEL
ＯＰ１
MILDSTEELCORED
ＯＰ２
DC
. 040
STAINLESSCORED
ＯＰ３
ＯＰ
MILDSTEEL
- AG
. 045M
3/ 64 G
STAINLESSSTEEL
. 052（MI
2%O ）
ＯＰ４
DC WAVE PULSE
（ OP T I ON）
AL/PURE
ＯＰ６
AL/MG
ＯＰ７
CO2
2
1/ 16 MI G
ＯＰ
ＯＰ５
WIRE DIA
WELDING
METHOD
（mm）
2.
DC PULSE
. 030
ON
( )
T1
INITIAL
CONDITION
Use the CRATER-FILL key to select
OFF/ON(-)/ON(( ))/ SPOT.
INCHING
SPOT
SYNERG.
ON
WATER
ARC
CONTROL
SYNERG.
INDIV.
CONSTANT
PENETRATION
TORCH
CRATER-FILL
CONDITION
ENTER
When adjusting SPOT TIME, press the SPOT
TIME key, then set SPOT TIME while turning
the parameter adjusting knob.
J OB
MEMORY
NOTE:
• Turning
the parameter adjusting knob clockwise
increases the parameter. To decrease the parameter,
turn the parameter adjusting knob counterclockwise.
Discontinue
Press the ENTER key.
Open the discharge valve of the gas cylinder,
press the GAS CHECK key to check the rate
of gas flow. After performing GAS CHECK,
stop the gas flow by pressing the GAS
CHECK key.
Discontinue
−77−
The welding conditions are preset to the number you selected.
Press the SAVE key.
Press the ENTER key.
The readout mode quits.
⑤
Settings of the (Internal) Functions
1)
2)
3)
4)
5)
When holding down the F key for a few seconds, the
function mode is activated. The function number blinks
in the left display, the function status is displayed in
the right display.
Set the function number while turning the parameter
adjusting knob.
When pressing the F key, the function number lights
up, then the function status blinks.
Set the function status while turning the parameter
adjusting knob.
To cancel the function mode, hold down the F key for
a few minutes.
Press the MEMORY key.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
The welding conditions are preset to the number you selected.
Press the LOAD key.
Press the ENTER key.
The memory mode quits.
Press the LOAD key.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
Set the welding condition number while
turning the parameter adjusting knob.
Checking the Rate of Gas Flow
GAS
CHECK
Press the ENTER key.
Discontinue
1) Pressing the SAVE key enters the save
mode. The preset welding condition
number is displayed in the right display
and the welding current is displayed in
the left display.
2) Preset the welding conditions to the
desired numbers 0 - 100 while turning
the parameter adjusting knob. When “--“ is displayed in the left display, the
number you selected is available. When
“---” is not displayed in the left display,
the number you selected is unavailable.
In this case, select another number.
Otherwise, the welding conditions preset
to the number are erased and
overwritten with the welding conditions
you newly set.
3) Press the ENTER key to check the
parameter preset to the number.
4) When pressing the ENTER key again,
the welding conditions are set.
Set the welding condition number while
turning the parameter adjusting knob.
Press the MEMORY key.
• There
5.
Discontinue
Hold down the ENTER key + the F key at a
time for a few seconds. When the F lamp turns
off, the key protection function is released.
LOAD
may be unavailable parameters in some
crater settings and function settings. Refer to
Section 10, “OPERATION” for details.
Pressing the LOAD key enter the load mode. The
preset welding condition number is displayed in the
right display and the welding current is displayed in the
left display.
Preset the welding conditions to the desired numbers 0
– 100 while turning the parameter adjusting knob.
When “---“ is displayed in the left display, no welding
conditions are preset to the number you selected.
Press the ENTER key to check for the parameter
preset to the number.
When pressing the ENTER key again, the welding
conditions preset to the welding condition number are
retrieved.
Press the LOAD key.
③ Presetting the Welding Conditions
ENTER
[WATER]: TORCH lamp is on.
[AIR]: TORCH lamp is off.
4)
Hold down the ENTER key + the F key at a
time for a few seconds. The F lamp starts
blinking. Blinking of the F lamp means the
welding machine is in the key protection mode.
• Releasing the key protection
Ｆ
To adjust the desired arc characteristic
(HARD/SOFT), after turning on the ARC
CONTROL lamp by pressing the ARC
CONTROL key, set the level of the arc
characteristic.
3)
• Protecting of the keys
[SYNERGIC]: VOLT. CONTROL lamp is on.
[INDIVIDUAL]: VOLT. CONTROL lamp is off.
For using a water-cooled torch, select “WATER” by
pressing the TORCH key, then run cooling water.
2)
② Protecting the Keys and Releasing the Key Protection
[ON]: WAVE PULSE lamp is on.
[OFF]: WAVE PULSE lamp is off.
For activating a CONSTANT PENETRATION function,
set the function to “ON”.
1)
Now you have completed the preparations that are required to
start welding. Press the torch switch to start welding.
For controlling voltage in the SYNERG. way, select
“SYNERG.” by pressing the VOLT.CONTROL key.
（ OP T I ON）
④ Loading the Welding Conditions
T2
SAVE
f
[ON]: CONTANT PENETRATION lamp is on.
[OFF]: CONSTANT PENETRATION lamp is off.
•
±
When the welding method is wave pulse, to
obtain the desired bead appearance after
turning on the WAVE PULSE lamp by
pressing the WAVE PULSE key, set the wave
pulse while turning the parameter adjusting
knob.
WAVE PULSE
•
V
[ON]: ARC CONTROL lamp is on.
[OFF]: ARC CONTROL lamp is off.
For using INITIAL CURRENT, press the INITIAL
CURR. key to set the function to “ON”.
[ON]: INITIAL CURR. lamp is on.
[OFF]: INITIAL CURR. lamp is off.
•
DISPLAY
CHANGE
After pressurizing the wire mounted on the
wire feeder using the pressure roll, feed the
wire up to the end of the torch while using the
INCHING key. When pressing the INCHING
key again, the wire feeding stops.
INCHING
[ON]: SPOT TIME lamp is on.
[OFF]: SPOT TIME lamp is off.
VOLT. CONTROL
•
JOB NO.
Inching the Wire
SPOT TIME
Settings of Functions
INITIAL
CURR.
%
Hz
m/min
CRATER
− FILL
ON
Sec
Use the DISPLAY CHANGE key to select the parameter
you want to set, then adjust it while turning the parameter
adjusting knob.
When changing the parameter unit in the display, use the
A
or V± selector key.
( )
3.
V
±
IPM/
ON
SPOT TIME
A
IPM
MAIN
CONDITION
A
Settings of Crater/Arc Spot
OFF
6.
WARNING
TORCH
. 035
Settings of Parameter
510
No.P10355
15. SERVICE AND SUPPORT
Please contact your local dealer for service. (See the back cover for telephone numbers, fax
numbers, and mailing addresses.)
NOTE:
1) See Section 12, “MAINTENANCE AND TROUBLESHOOTING” before contacting your
dealer for service.
2) When contacting your dealer for service, you are required to provide the following
information:
• Address
• Name
• Telephone number
• Product model
• Manufacture year
• Serial number
• Software version number
• Details of troubles
･ MODEL: DP-400
･ DATE: 20XX
･ SERIAL NO.: P10355YXXXXXXXXXXX
P10355 Ver ###.###.000
−78−

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