null User manual

null  User manual
MANUAL NO:P10499
OWNER'S
MANUAL
FOR
CO2/MAG/MIG
DIGITAL INVERTER
DP500
MODEL: DP-500
P10499
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
March 9, 2005
Upon contact, advise MODEL and MANUAL NO.
No. P10499
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. REQUIREMENT OF INPUT POWER……………………………………………
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…………………………………………………………………... 75
15. SERVICE AND SUPPORT………………………………………………………… 78
㧙1㧙
No. P10499
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.
1. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
Keep children away.
Keep pacemaker wearers away until consulting a doctor.
࡮
࡮
2. Read and understand the summarized safety information given below and the original
principal information that will be found in the PRINCIPAL SAFETY STANDARDS.
3. Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
4. Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
㧙2㧙
No. P10499
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.
㧙3㧙
No. P10499
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.
㧙4㧙
No. P10499
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, gas regulator, 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 gas regulator 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.
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No. P10499
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
1. When hanging the welding power source by a crane, do not use the carrying handle.
2. Put the welding power source and wire feeder solidly on a flat surface.
3. Do not pull the welding power source across a floor laid with cables and hoses.
4. Do not put wire feeder on the welding power source.
5. Do not put the welding power source and wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
1. Do not press gun trigger until instructed to do so.
2. Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.
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No. P10499
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.
M050114
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No. P10499
3. GENERAL NOTICE OF OPERATION
3.1 Rated Duty Cycle
CAUTION
٨Use 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:
350A 100% (for pulse mode)
500A 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.
ON
OFF
6 min.
4 min.
10 min.
Operation cycle of 60% duty cycle
• Failure to observe duty cycle limitations may cause an excess of the tolerance of the
temperature inside the welding machine. This may contribute to premature welding
machine failure or product damage.
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
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 (%)
• The
100
50
0
Duty cycle (%)
100
100% (350A or lower)
DP-500
Usable range
100
200
300 350400
Welding current (A)
(PULSE MODE)
100% (387A or lower)
60%
50
0
DP-500
Usable range
100 200 300 400 500
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.
Do not expose the welding machine to direct sunlight or rain.
٨
٨
㧙8㧙
68%
(420A)
No. P10499
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
Grounding cable
AWG10 (5.3mm2) with 10mm
AWG10 (5.3mm2) with 10mm
Ǿ terminal
Ǿ terminal
x3
x1
For air cooling torch
Gas regulator
Input cable 2m
㧔
Digital remote control
Optionally available
㧕
Gas hose 3m
Control cable with wire feeder 2m
Shield gas
Power cable for wire feeder 2m
Welding torch
Wire feeder
Base metal
Welding power source
Power cable for base metal 2m
㧔
㧕
Analog remote control with 3m control cable
Optionally available
Grounding cable
* Ground a work piece if a
local law requires.
For water cooling torch
Gas regulator
Water cooler
Gas hose 3m
Control cable with wire feeder 2m
Input cable 2m
Shield gas
Power cable for wire feeder 2m
Welding torch
Wire feeder
Welding power source
Power cable for base metal 2m
㧔
㧕
Analog remote control with 3m control cable
Optionally available
Grounding cable Digital remote control
Optionally available
㧔
㧕
*Extension cables / hoses (5m, 10m, 15m and 20m) are available.
㧙9㧙
Base metal
No. P10499
4. STANDARD COMPOSITION AND ACCESSORIES (continued)
4.2 Accessory
Make sure you have the item below before you start using the welding power source.
Part number
Description
4519-031
Dust filter
Specification
109-1000M13
Q’ty
Remarks
2
For the fan on the rear panel of
welding power source
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”.
Part number
None
None
None
None
K5439B01
Description
Cup square neck bolt
Washer
Spring washer
Nut
Feed roll (1.4/1.6)
Specification
M10-30
M10
M10
M10
K5439B01
Q’ty
2
2
2
2
2
None
Square bush
SB-4025
1
Remarks
For output terminal connection
For output terminal connection
For output terminal connection
For output terminal connection
For wire feeder
For connection with water
cooler, use this for base plate.
4.3 Preparation of consumables for welding
㧔㧝㧕 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
98% argon (Ar) + 2% oxygen (O2)
• MIG gas for Aluminum
Pure argon (Ar)
㧔㧞㧕 Welding Wire
㧙10㧙
㧙11㧙
Output terminal (-)
Receptacle socket for
analog remote control
Output terminal (+)
Receptacle socket
for wire feeder
Power switch
Fan guard
Main power lamp
Parameter
adjusting knob
Carrying handle
Caster
Input terminal
Grommets with film (For pulling
out external connection cable)
No. P10499
5. FUNCTION OF EQUIPMENT
5.1 Welding Power Source
No. P10499
6. REQUIREMENT OF INPUT POWER
6.1 Commercial input power
WARNING
٨When 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
٨Be 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-500
400V, Three phase
400V±15%
23.8kVA or more
40 A
6.2 Precautions for Use of the Engine Generator
CAUTION
٨Use 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 400 and 420V 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.
㧙12㧙
No. P10499
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.
٨
٨
٨When 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.)
٨
٨
٨
٨
٨
٨
٨
٨
㧙13㧙
No. P10499
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.
٨
٨
٨
٨
In the event of electromagnetic trouble, follow the instructions below.
٨Change the installation place of the welding machine.
٨Keep the machines which may be affected away as far from the welding machine, cables and
welding site as possible.
٨Add a noise filter to the input cables.
٨Mount an input cable in the grounded metallic conduit.
٨Shield 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 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.
٨
٨
٨
٨
٨
٨
٨
㧙14㧙
No. P10499
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.
٨Do not touch the charging parts of the welding machine.
٨Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected, following a local low.
٨With the line disconnect switch inside the switch box all turned off, ground and connect the
welding machine.
٨Do not use a cable with lack of capacity or a cable seriously damaged.
٨Tighten and insulate the connections of cables.
٨Surely 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 regulator
Power cable for wire feeder
Control cable for wire feeder
Gas hose
Gas cylinder
ԛ
Welding torch
Wire
feeder
Welding power source
ԙ
Ԛ
Power cable for base metal
Analog remote control
㧔Optionally available㧕
Control cable for remote control
Ԝ
Base metal
Ԙ
* Ground a work piece
if a local law requires.
M10 terminal
When using the water-cooled torch
Ԟ
Gas flow rate regulator
Water hose
for condensed water)
Water cooler
Shield gas
Surely insert the connector plugs
into the sockets for wire feeder
and for analog remote control up
to the stop by turning them
clockwise.
Gas hose
Ԝ
ԛ
Power cable for wire feeder ԙ
Control cable for wire feeder
For feeding water
Welding torch
ԝ
Welding power source
Wire feeder
Power cable for base metal
Control cable for remote control
Analog remote control
Optionally available)
㧔
Ԙ
Base metal
M10 terminal
NOTE: In case of putting the “Abnormal water pressure” signal into the welding power source, see
11.2.
㧙15㧙
No. P10499
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.
3. Remove the right-side plate of the wire feeder, and then attach the power cable for wire feeder to
the M10 terminal. Surely fix the power cable in position not to contact with the bottom of the
frame and the terminal board. Put around the terminals with insulating tape.
4. Insert the control cable for wire feeder into the socket for wire feeder.
5. Attach the gas hose to the gas inlet on the wire feeder.
6. Connect the welding torch to the wire feeder.
7. 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 regulator
ԙ
Gas cylinder
Ԛ
Gas outlet
Wire feeder
Ԙ
16
No. P10499
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.
٨Do not touch the charging parts of the welding machine.
٨Have 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.
٨With the line disconnect switch in the switch box all touched off, ground and connect the
welding machine.
CAUTION
٨Be 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.
Input cable.
Green cable for grounding cable.
Surely connect the input cable AWG10 (5.3mm2) and
2
grounding cables AGW10 (5.3mm ) 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 AWG10 (5.3mm2).
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.
٨
㧙17㧙
No. P10499
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.
٨To 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.
٨To prevent disorder or poisoning caused by fume, wear a gas mask or weld at a partial
exhaust facility approved by the local regulation.
٨Adequately 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
٨When using the welding machine at a narrow space, comply with a trained supervisor’s
directions. And be sure to wear a gas mask.
٨Do not operate the welding machine near the places where degreasing, cleansing, and
spraying are performed. Otherwise, poisonous gas may be generated.
٨Be 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.
٨When performing or monitoring welding operation, wear an eye protector with a good light
blocking effect or face shield.
٨Wear protective glasses to protect your eyes from the spattering dross.
٨Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, and
leather apron.
٨Install protective screens or barriers to protect the eyes of others in the work area from arc
ray.
٨Wear an ear protector when noise level is high.
㧙18㧙
No. P10499
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.
Turn on the line disconnect
switch.
Set the pressure regulators for gas
cylinders to “SHUT” , then turn on gas at
the main.
Set the gas flow rate adjusting knob
to “OPEN” to adjust the gas flow rate.
Press the GAS CHECK
key. (The GAS CHECK
lamp lights up.)
Press the GAS CHECK
button again. (The GAS
CHECK lamp goes out.)
Place the power switch in the “I” (ON)
position.
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.
19
Parameter adjusting knob
INCHING key
No. P10499
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
20
No. P10499
9. WELDING PREPARATION (continued)
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
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
6.0
9.0
12.0
Leg
length
l (mm)
㧙3.0
㧙3.0
㧙3.5
㧙3.5
㧙4.0
㧙4.5
㧙6.0
㧙7.0
㧙8.0
2.5
2.5
3.0
3.0
3.0
4.0
5.0
6.0
7.0
Wire
diameter
(mm )
0.9 1.0
0.9 1.2
0.9 1.2
0.9 1.2
0.9 1.2
1.2
1.2
1.2
1.2
Welding
current
(A)
Ǿ
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
70 100
90 120
100 130
120 140
130 170
190 230
250 280
280 300
300 340
Arc
voltage
(V)
㧙19
㧙20
㧙20
㧙21
㧙21
㧙24
㧙29
㧙32
㧙34
18
18
19
19
19
22
26
29
32
Welding
speed
(cm/min)
㧙60
㧙60
㧙60
㧙60
㧙55
㧙55
㧙50
㧙40
㧙35
50
50
50
50
45
45
40
35
30
CO2 gas
flow rate
(ℓ/min)
10 15
10 15
15 20
15 20
15 20
15 20
15 20
15 20
20 25
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
(2) Example Welding Conditions of Down Fillet
Plate
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
6.0
9.0
12.0
Leg
length
l (mm)
㧙3.0
㧙3.0
㧙3.5
㧙3.5
㧙4.0
㧙4.5
㧙6.0
㧙8.0
㧙12.0
2.5
2.5
3.0
3.0
3.0
4.0
5.0
6.0
10.0
Wire
diameter
(mm )
0.9, 1.0
Ǿ
0.9㧙1.2
1.0㧙1.2
1.0㧙1.2
1.0㧙1.2
1.2
1.2
1.2
1.2
Welding
current
(A)
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
70 100
90 120
100 130
120 140
130 170
200 250
280 300
300 350
320 350
㧙21㧙
Arc
voltage
(V)
㧙19
㧙20
㧙20
㧙21
㧙22
㧙26
㧙32
㧙34
㧙36
18
18
19
19
20
23
29
32
33
Welding
speed
(cm/min)
㧙60
㧙60
㧙60
㧙60
㧙55
㧙55
㧙50
㧙45
㧙35
50
50
50
50
45
45
40
40
25
CO2 gas
flow rate
(ℓ/min)
10 15
10 15
15 20
15 20
15 20
15 20
15 20
15 20
20 25
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
㧙
No. P10499
9. WELDING PREPARATION (continued)
(3) Example Welding Conditions of I Shape Butt without Backing Plate
Plate
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
6.0
9.0
Wire
diameter
(mm )
0.9, 1.0
0.9, 1.0
0.9, 1.0
Root
gap
g (mm)
0
0
Ǿ
㧙
㧙
㧙
㧙
1.2㧙1.5
1.2㧙1.5
0 0.5
0.5 1.0
1.0 1.2
1.2 1.5
㧙
㧙
0.9 1.2
0.9 1.2
1.2
1.2
1.2
Welding
current
(A)
㧙
㧙
㧙
㧙
㧙
㧙
220㧙260
320㧙340
70 80
80 100
100 110
110 130
130 150
150 170
Arc
voltage
(V)
㧙18
㧙19
㧙20
㧙20
㧙21
㧙23
24㧙26
32㧙34
17
18
19
19
19
21
Welding
speed
(cm/min)
㧙55
㧙55
㧙55
㧙55
㧙50
㧙50
40㧙50
45㧙55
45
45
50
50
40
40
CO2 gas
flow rate
(ℓ/min)
10
㧙15
㧙15
㧙15
㧙15
㧙15
15㧙20
15㧙20
10
10
10
10
10
Number
of
layers
1
1
1
1
1
1
Front 1
2
Back 1
Front 1
2
Back 1
(4) Example Welding Conditions of Single and Double Grooves
Plate
thickness
t
(mm)
Bevel
shape
Root
gap
g (mm)
Root
face
h(mm)
Wire
diameter
(mm )
Ǿ
1.2
12
㧙
0 0.5
㧙
1.6
4 6
1.2
16
g
1.6
㧙
16
1.2
4 6
0
19
㧙
1.6
5 7
25
㧙22㧙
Welding
current
(A)
㧙350
300㧙350
380㧙420
380㧙420
300㧙350
300㧙350
380㧙420
380㧙420
300㧙350
300㧙350
380㧙420
380㧙420
400㧙450
400㧙450
400㧙420
400㧙420
400㧙420
400㧙450
300
Arc
voltage
(V)
㧙35
32㧙35
32㧙35
32㧙35
32㧙35
32㧙35
32㧙35
32㧙35
32㧙35
32㧙35
36㧙39
36㧙39
36㧙42
36㧙42
36㧙39
39㧙42
36㧙39
39㧙42
32
Welding
speed
(cm/min)
㧙40
45㧙50
35㧙50
45㧙50
30㧙40
45㧙50
35㧙50
45㧙50
30㧙35
30㧙35
35㧙40
35㧙40
25㧙30
25㧙30
40㧙45
30㧙35
40㧙45
30㧙35
30
CO2 gas Number
of
flow rate
layers
(ℓ/min)
㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20㧙25
20
Front
Back
Front
Back
Front
Back
Front 2
Back
Front
Back
Front
Back
Front
Back
1 F
2 B
1 F 4
2 B
No. P10499
9. WELDING PREPARATION (continued)
-
Example Welding Conditions of Lap Fillet
Plate
Thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
Wire
diameter
(mm )
0.9 1.0
0.9 1.2
1.0 1.2
1.0 1.2
1.0 1.2
1.2
Ǿ
㧙
㧙
㧙
㧙
㧙
Welding
current
(A)
㧙
㧙
㧙
㧙
㧙
㧙
Welding
voltage
(V)
80 100
100 120
100 130
120 140
130 160
150 200
18
18
18
19
19
21
㧙19
㧙20
㧙20
㧙21
㧙22
㧙24
㧭
Welding
speed
(cm/min)
Mark
position
㧙55
㧙55
㧙55
㧙50
㧙50
㧙45
A
A
A or B
B
B
B
45
45
45
45
45
40
㧮
CO2 gas
flow rate
(ℓ/min)
10 15
10 15
15 20
15 20
15 20
15 20
㧙
㧙
㧙
㧙
㧙
㧙
9.4.2 Example Welding Conditions of Wire CO2 with Flux
(1)Example Welding Conditions of Horizontal Fillet
Leg
length
ℓ(mm)
4
5
6
7
8
9
Wire diameter
(mm)
Welding current
(A)
Arc voltage
(V)
Welding speed
(cm/min)
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
1.6
1.2
1.4
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
50
100
105
50
90
90
45
80
80
40
50
65
30
45
52
30
40
40
㧙23㧙
No. P10499
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 diameter
Gap
Welding
Joint
thickne
(mm)
current (A)
(mm )
Geometry
ss
t (mm)
1.0
0
0.8 1.0
50 55
0
1.2
60 70
0.8 1.0
0
1.6
100 110
0.8 1.0
Butt
110-120
2.3
0 1.0
1.0 1.2
3.2
120-140
1.0 1.2
1.0 1.5
150-170
4.0
1.0 1.2
1.5 2.0
Arc voltage
(V)
15
16
17
18
19
21
13
14
16
17
17
18
Welding
speed
(cm/min)
55
50
60
40
30
40
40
30
40
30
25
25
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
(mm)
(mm)
layers
3.2
3 4
4.5
5.0
6.0
6.0
q
30-40
Focus here.
q
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/min)
1
150
26-27
60
1
170
26-27
40
1
200
27-28
40
1
250
29-30
35
1
2
3
180-200
180-200
180-200
25-27
25-28
25-28
45
45
45
1
2
3
220-230
220-230
210-230
25-28
25-28
25-28
45
45
45
Angle of advance: 10
8.0
8.0
q
30-40
㧔
㧕
1 mm 2 - 3 mm
12.0
10.0
3
1
16.0
2
12.0
(2) Example Welding Conditions of Downward Welding
Plate
Shape of Welding Welding
Welding
thickness joint weld current
voltage
speed
t (mm)
(A)
(V)
(cm/min)
2.3
butt
100
22-23
70
3.2
fillet
100
21-22
24
70
Remarks
Back bead appearance is good.
Leg length: 4 - 5mm,
Throat depth: 2.5mm
No. P10499
9. WELDING PREPARATION (continued)
(3) Example Welding Conditions of Upward Welding
Plate
Welding
thickness
Shape of joint weld
current
t (mm)
(A)
12
Stop at both ends
100-110
(4) Both Side Welding Conditions of (Semi-automatic)
Plate
Number of
thickness
Groove shape
layers
(mm)
Welding
voltage
(V)
20-21
Remarks
Weaving
Leg length: 10.0mm
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(mm/min)
1
170
25-26
30
2
180
26-27
30
1
270
29-30
30
2
290
30-31
30
1
280
30-31
40
2
330
33-34
40
Front 1
Front 2
Rear 1
Rear 2
300
300
340
280
31-32
31-32
32-33
30-31
45
45
45
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
45
45
45
45
45
45
6.0
9.0
12.0
19.0
25.0
㧙25㧙
No. P10499
9. WELDING PREPARATION (continued)
(5) Example Welding Conditions of Single Side Welding Conditions (Automatic)
Plate
Number of
Welding
thickness
Groove shape
layers
current
T (mm)
(A)
3.2
Welding
voltage
(V)
Welding
speed
(cm/min)
1
140
24-25
50
1
130
23-24
25
2
150
25-26
25
1
180
24-25
25
2
290
30-32
25
12.0
1
2
3
180-190
200
200
24-25
25-26
26-27
25
25
25
19.0
1
2
3
180
300
300
24-25
29-30
29-30
25
25
25
6.0
12.0
Oscillation width: 2 mm
Oscillation times: 120 times/min.
㧙26㧙
No. P10499
9. WELDING PREPARATION (continued)
(6) Single Bevel Groove Penetration Welding Conditions (Semi-automatic)
Number of
Welding
Groove shape
layers
current
(A)
Flat position
1
100
ࠑ
2
280
3
280
ԝ
Ԟ
4
280
ԛ Ԝ
Ԛ
5
280
ԙ
6
280
Ԙ
Unit: mm
7
280
Vertical position
1
100
ࠑ
2
130
ԝ
3
130
Ԝ
4
130
ԛ Ԛ
5
130
ԙ
Ԙ
6
120
ԣ
ԟԢ
Ԝ
Ԛ Ԟԡ
Ԙ ԙ ԛ ԝԠ
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
Remark
Oscillation
Oscillation
Unit: mm
ࠑ
Unit: mm
1
100-200
2
200
3
200
4
200
5
200
6
200
7
200
8
200
9
180
10
180
11
180
12
180
Wire diameter: 1.2 mm
27
20-22
24-25
24-25
24-25
24-25
No
24-25
oscillation
24-25
24-25
24-25
24-25
24-25
24-25
Gas: 20% CO2 + Ar
No. P10499
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
(mm)
current
voltage
(mm)
(A)
(V)
1.5
1.2
60-80
16-18
2.0
1.2
70-80
17-18
3.0
1.2
80-100
17-18
4.0
1.2
90-120
18-21
6.0
1.2, .1.6
150-180
20-23
Welding
speed
(cm/min)
60-80
40-50
40-50
40-50
40-50
Wire
extension
(mm)
12-15
15
15
15
15-18
Gas
flow
rate
(ℓ/min)
20
20
20
20
20
(2) Example Welding Conditions of Horizontal Fillet
Plate
Wire dia. Welding Welding
thickness
(mm)
current
voltage
(mm)
(A)
(V)
1.5
1.2
60-80
16-18
3.0
1.2
100-120
19-21
6.0
1.2, 1.6
150-180
20-23
Welding
speed
(cm/min)
60
60
50-60
Wire
extension
(mm)
15
15
15
Gas
flow
rate
(ℓ/min)
15-20
15-20
20
Welding
speed
(cm/min)
60-80
60-80
40-60
Wire
extension
(mm)
15
15-18
17-20
Gas
flow
rate
(ℓ/min)
20
20
20-25
(2) Example Short Welding Conditions of Horizontal Fillet
Plate
Wire dia. Welding Welding
Welding
thickness
(mm)
current
voltage
speed
(mm)
(A)
(V)
(cm/min)
3.0
1.2
140-160
21-22
60-70
4.0
1.2
150-170
22-24
50-60
6.0
1.6
200-230
23-25
50-65
Wire
extension
(mm)
15
15-18
17-20
Gas
flow
rate
(ℓ/min)
15-20
15-20
20-25
9.4.6 Example Short Welding Conditions of Aluminum MIG
(1) Example Short Welding Conditions of I Shape Butt
Plate
Wire dia. Welding Welding
thickness
(mm)
current
voltage
(mm)
(A)
(V)
3.0
1.2
120-140
20-22
4.0
1.2
150-170
22-24
6.0
1.6
180-210
23-25
㧙28㧙
No. P10499
10. OPERATION
10. Front Panel
[21] [20] [19]
[4]
[13]
[8]
[15]
[5]
[6]
[9] [10]
J OB
WARNING
MEMORY
A
m/min
LOAD
SAVE
V
r
Sec
%
Hz
JOB NO.
MAIN
CONDITION
A
m/min
ENTER
T1
ARC
CONTROL
V
r
DISPLAY
CHANGE
INITIAL
CONDITION
CRATER-FILL
CONDITION
f
T2
WAVE PULSE
SYNERG.
ON
OFF
INCHING
ON
SPOT
SPOT TIME
[17][18] [11]
CRATER
㧙 FILL
[7]
[1] WELDING METHOD key
[2] WIRE/GAS selector keys
[3] WIRE DIA (mm) key
[4] A/m/min selector key
[5] V/± selector key
[6] Parameter adjusting knob
[7] CRATER-FILL key
[8] DISPLAY CHANGE key
TORCH
㧻㧼㧝
㧻㧼㧞
㧻㧼㧟
㧻㧼㧠
㧻㧼㧡
㧻㧼㧢
㧻㧼㧣
MILDSTEEL
ON
CONSTANT
PENETRATION
CO
MILDSTEELCORED
STAINLESSCORED
MAG
MI G
MILDSTEEL
㧔2%O2㧕STAINLESSSTEEL
AL/PURE
MI G
AL/MG
㧻㧼
DC PULSE
DC
㧻㧼
DC WAVE PULSE
㧔126+10㧕
WIRE DIA
WELDING
METHOD
㧔mm㧕
[12] [3]
㧔126+10㧕
INDIV.
VOLT. CONTROL
GAS
CHECK
WATER
SYNERG.
INITIAL
CURR.
㧲
ON
[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
㧙29㧙
[16]
[1]
[17] GAS CHECK key
[18] INCHING key
[19] LOAD key
[20] SAVE key
[21] ENTER key
No. P10499
10. OPERATION (continued)
CAUTION
٨This 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.
٨
When reading the operating instructions described below, unfold Page 77 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 (mm) 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 (mm) key [3].
For example, for DP-500, when selecting “WAVE PULSE” while setting "DC HARD SOLID
CO2 φ1.0 " 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.
㪤㪸㫋㪼㫉㫀㪸㫃
㪮㫀㫉㪼㩷㪻㫀㪸㪅
㱢㪈㪅㪇
AL/MG (HARD)
(A5183䇮A5356 etc.䋩
㱢㪈㪅㪉
㱢㪈㪅㪍
㱢㪈㪅㪉
AL/PURE(SOFT)
䋨A4043 etc.䋩
㱢㪈㪅㪍
㪮㪼㫃㪻㫀㫅㪾㩷㪺㫌㫉㫉㪼㫅㫋㩷䋨䌁䋩
㪤㫆㪻㪼
㪧㪬㪣㪪㪜
㪛㪚
㪧㪬㪣㪪㪜
㪛㪚
㪧㪬㪣㪪㪜
㪛㪚
㪧㪬㪣㪪㪜
㪛㪚
㪧㪬㪣㪪㪜
㪛㪚
㪪㫋㪸㫅㪻㪸㫉㪻㩷㫉㪸㫅㪾㪼㩷㫆㪽㩷㫊㫋㪸㪹㫃㪼㩷㫎㪼㫃㪻㫀㫅㪾㩷㪺㫌㫉㫉㪼㫅㫋
䇭䇭䇭㩷㪌㪇㩷㩷㩷㩷㩷㩷㪈㪇㪇㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪉㪇㪇㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪊㪇㪇㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪋㪇㪇
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.
㧙30㧙
No. P10499
10. OPERATION (continued)
Table of the Welding Mode
Welding method
DC
DC
DC PULSE
DC
DC PULSE
DC
DC
DC PULSE
DC
WAVE PULSE
DC
DC PULSE
DC
WAVE PULSE
Welding mode
Type of wire
Gas
㱢
WIRE
DIA.( )
DP-500
0.8
0.9
1.0
MILD STEEL
CO2
SOLID
1.2
1.4
1.6
0.8
0.9
1.0
MAG
MILD STEEL
1.2
SOLID
䋨80%Ar+20%CO2䋩
1.4
1.6
0.8
0.9
1.0
MAG
MILD STEEL
1.2
SOLID
䋨80%Ar+20%CO2䋩
1.4
1.6
0.8
0.9
STAINLESS
MIG
1.0
STEEL
䋨98%Ar+2%O2䋩
SOLID
1.2
1.6
0.8
0.9
STAINLESS
MIG
1.0
STEEL
䋨98%Ar+2%O2䋩
SOLID
1.2
1.6
1.0
1.2
MILD STEEL
CO2
CORED
1.4
1.6
0.9
STAINLESS
1.2
STEEL
CO2
CORED
1.6
1.2
1.6
AL/PURE
MIG
1.2
(SOFT
䋨Ar䋩
1.6
ALMINUM)
•
1.2
•
1.6
1.0
1.2
1.6
1.0
AL/MG
MIG
(HARD
1.2
䋨Ar䋩
ALUMINUM)
1.6
1.0
•
1.2
•
1.6
ο Supported • : Optionally supported - : Not supported
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
ο
㧦
㧙31㧙
No. P10499
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
m/min
T1
r
COINITIAL
NDITION DISPLAY
CHANGE
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
㧭
O O KP
5GE
Hz
㨂
r
%
, 1 $ 0 Q
Digital Meter
[Parameter displays]
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.
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.
㧙32㧙
No. P10499
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.
㧙33㧙
No. P10499
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
10
Torch Switch
Pre-flow time
1((
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
Keep the torch switch pressed and held during welding.
㧙34㧙
No. P10499
10. OPERATION (continued)
Crater
Initial
Current
Timing Chart
ON
ON
Torch Switch
OFF
OFF
Pre-flow time
Anti-stick (Burnback) time
No-load voltage
Gas Flow
Post-flow time
OFF
Voltage Between
Output Terminals
Slow-down speed
ON
Welding Current
W ire 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
Output Terminals
ON
Wire feed speed
Slow-down 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.
㧙35㧙
No. P10499
10. OPERATION (continued)
10.1.4 Setting of Arc Spot Time㧔 㧕
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.
Torch Switch
ON
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”.
㧙36㧙
No. P10499
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
98% argon (Ar) + 2% oxygen (O2)
• MIG gas for Aluminum
Pure argon (Ar)
㧙37㧙
No. P10499
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.
㧙38㧙
No. P10499
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 semiautomatic.
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.
Function (with gas save function)
10.1.9 GAS CHECK
AS
This function is Gused
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 post-flow)
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.
㧙39㧙
No. P10499
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.
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.
㧙40㧙
No. P10499
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.
㧲㧻㧾 㧯1 / # )/+)
300 350
250
200
27
400
150
.1
450
15
'
㧴㨀
㨀㧵㧳
39
21
42
45
15
A
㨃㧱㧸㧰㧵㧺㧳 㧯㨁㧾㧾㧱㧺㨀
36
18
500
100
30 33
24
V
㧵㧺㧯㧴㧵㧺㧳
㧸㧻㨃
㧴㧵㧳㧴
㧿㨅㧺㧱㧾㧳㧚㧲㧵㧺㧱 㧭㧰㧶㧚
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.
㧙41㧙
No. P10499
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”.
㧙42㧙
No. P10499
10. OPERATION (continued)
10.2
10.2.1
Applied Settings
Using Internal Function
• How To Use Internal Functions
Ԙ
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].
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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].
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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”.
ԙ
Pressing the F key [12] again causes the function number to light up and returns
to the step . To cancel the function mode, hold down the F key [12] for a few
seconds.
Ԙ
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.
㧙43㧙
No. P10499
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 slowdown speed can be increased to shorten tact time.
NOTE: The minimum slow-down speed is 0.4 m/min.
㧙44㧙
No. P10499
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
㧠
MAX 0.5mA
㧟
MAX 0.5mA
㨪15V
0V
㧝
CON2
㧱㧝
㧱㧞
㧔Welding Voltage㧕 㧔Welding Current㧕
Acceptable plug
Spec.
Part No.
DPC25-6A
4730-009
CAUTION
٨ Supply 0 - +15 voltage to E1 and E2. Exceeding +15V may result in damage to the
control circuit of the welding power source.
٨ 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.
㧙45㧙
No. P10499
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.
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Setting Signal 1: When command voltage is externally supplied in the range
from 0V to 15V under the standard settings.
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.
㧙46㧙
No. P10499
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.
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No. P10499
㧙48㧙
No. P10499
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.
㧙49㧙
No. P10499
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 waveform at wave pulse welding
㧙50㧙
No. P10499
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
㧲
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
٨The 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.
٨
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.
㧙51㧙
No. P10499
10. OPERATION (continued)
Ԙ
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].
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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).
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(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.
㧙52㧙
No. P10499
10. OPERATION (continued)
ԙ
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].
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Welding Current held in memory
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.
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(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.
㧙53㧙
No. P10499
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.
㧙54㧙
No. P10499
10. OPERATION (continued)
Ԛ
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.
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"
dEL" is displayed, which indicates
Condition number to be deleted blinks
the machine is in deletion mode
(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.
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"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.
㧙55㧙
No. P10499
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.
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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 : "P10499"
← Software number (P10499) 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. Low
speed fan rotation will work for 3 minutes every 20 minutes without weld.
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.
㧙56㧙
No. P10499
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-
500
Abnormal water pressure*
8
E-
510
Pump error
9
E-
600
Replacement of batteries (warning)
10
E-
700
Output over current
11
E-
710
Lack of phase
12
E-
800
Encoder in the wire feeder
13
E-
810
Thermal overload in the governor
circuit
14
E-
820
Motor over current warning
15
E-
830
Motor over current error
16
E-
900
Microcomputer error
*When input relay signal to 12P terminal block (TM12P)
57
- only.
No. P10499
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.
㧙58㧙
No. P10499
11. APPLIED FUNCTION (continued)
7) E-510 Display
㧙In the case of connecting connector CON4㧙
If “E-“ and “510” in the displays blink, it indicates the “Pump error”.
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 CON4 - , contact between CON4 - 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).
Ԙԙ
Ԙԙ
8) E-600 Display
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.
㧙59㧙
No. P10499
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.
㧙60㧙
No. P10499
11. APPLIED FUNCTION (continued)
WARNING
Observe the following to prevent electrical shock.
٨Do not touch charging parts inside or outside the welding machine.
٨Grounding 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.
٨When 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
٨Try 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.
٨
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 (TM1) and a 6P terminal block (TM2) 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.
Ԙ
㧗
ԙ
4'# &;
Ԛ㧗
ԛ㧗
㧳㧭㧿
Ԝ㧗
' : 6㧝
ԝ
' : 6㧞
Ԟ㧗
ԟ
Ԡ
㧿㨀㧻㧼
㨃㧯㧾
[12P terminal block]
Ԙ ԙ
㧗㧭 Ԛ
㧗
㨂
ԛ
[6P terminal block]
㧙61㧙
Ԝ
ԡ
ԝ
DIRECT
Ԣ
ԣ
No. P10499
11. APPLIED FUNCTION (continued)
12P terminal block (TM1)
Pin No.
Signal name
+
READY
(OUTPUT)
Ready Power
㽲㧙㽳
㽴 㧙 㽷
㽵 㧙 㽷
㽶㧙 㽷
㽸 㧙㽹
+
-
+
+
-
-
+
-
㽺㧙 㽻
㽼㧙 㽽
+
-
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
(No connection)
6P terminal block (TM2)
Pin No.
Signal name
+
AMMETER
㽲 㧙㽳
㽴 㧙㽵
+
㽶
㽷
-
VOLTMETER
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 Pushlock 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.
*2
Function
Terminals for connecting an ammeter.
Use the ammeter (600A/60mV, part number: 4403-122).
Terminals for connecting a voltmeter.
Use the voltmeter (full scale 100V, part number: 4401-016).
*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.
*4 Be careful that no-load voltage (100V or less) is applied to between the terminals during welding.
8
64
2%
Mǡ
Figure 1
㧙62㧙
Figure 2
No. P10499
11. APPLIED FUNCTION (continued)
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.
(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
㧙63㧙
No. P10499
11. APPLIED FUNCTION (continued)
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
Remarks
With a 3-meter cable
A CAN communication module and cable are
needed.
K5422B00
BKCAN-04XX
XX= 05 (for 5 m), 10 (for 10 m)
K5416B00
K5416G00
30 m, with a crimp-style terminal
11.4.2 Extension Cable/Hose (Extension of Work Space)
CAUTION
٨Do not connect an unnecessarily long extension cable.
٨When 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.
*
Ԛ
Control cable for wire feeder
ԙ
Ԙ
Gas hose
Power cable for wire feeder
Wire feeder
ԛ
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.
㧙64㧙
No. P10499
11. APPLIED FUNCTION (continued)
1. Power Cable (for torch)
5m
Model BKPJT-6007
10m
BKPJT-6012
2. Power Cable (for base metal)
5m
10m
Model BKPT-6007
BKPT-6012
15m
BKPJT-8017
20m
BKPJT-8022
15m
BKPT-8017
20m
BKPT-8022
15m
BKGG-0615
20m
BKGG-0620
15m
BKCPP-1017
20m
BKCPP-1022
3. Gas Hose
Model
5m
BKGG-0605
10m
BKGG-0610
4. Control Cable for Wire Feeder (10 P)
5m
10m
Model BKCPP-1007
BKCPP-1012
5. Control Cable for Analog Remote Control (6P)
5m
10m
15m
Model
BKCPJ-0605 BKCPJ-0610
BKCPJ-0615
20m
BKCPJ-0620
6. Water Hose (for feeding water and condensed water)
5m
10m
15m
Model
BKWR-0605
BKWR-0610
BKWR-0615
20m
BKWR-0620
㧙65㧙
No. P10499
12. MAINTENANCE AND TROUBLESHOOTING
WARNING
To avoid electric shock, follow the below instructions.
٨Do not touch live electrical parts inside or outside the welding machine.
٨Turn off all of the line disconnect switches before touching the parts inside the welding
machine.
٨Perform the maintenance checks periodically. If any damaged parts are found, only use the
welding machine after troubleshooting or repairing.
٨Only certified operators should maintain, inspect, or repair the welding machine.
٨When 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.
٨
٨
CAUTION
Rotating parts may cause injuries. Be sure to observe the following.
٨Only certified operators should maintain, inspect, or repair the welding machine.
٨Install a fence around the welding machine to keep others away from it.
٨Do not put your hands, fingers, hair and clothes near the fans and wire feed roll rotating.
CAUTION
٨Do 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
٨The 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.
٨
㧙66㧙
No. P10499
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
䯽
inscribed on the printed circuit board matches
the number marked on the connector.
• 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 high-frequency
CN
NOTE: Match the number on the printed
circuit board with that on the connector.
inverter system, be careful of accidental
connection of the line disconnect switch at input
side.
•
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
㧙67㧙
1
No. P10499
from the adherence of the organic solvent.
㧙68㧙
No. P10499
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.
٨
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. Short-circuit between input terminals and short-circuit between output terminals.
2. Disconnect the grounding cable (wiring number: 80) from the earth. (Including CN5 of the
printed board P10264T.)
3. Short-circuit between AC side and rectifier side of DR1.
4. Short-circuit between TR1(C1) and (E1); TR2(C2) and (E2); TR3(C1) and (E1); and
TR4(C2) and (E2).
5. Short-circuit between anode and cathode of DR2, and DR6 as well.
6. Disconnect CN3 of printed board P10264T.
7. Turn ON the NF.
8. Short-circuit heat sink of inverter module to the case.
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.
㧙69㧙
No. P10499
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.
The main
When turning on the Trouble with PL1.
Inspect PL1.
power switch, the
power lamp
PL1 will not
displays light.
light.
When turning on the The line disconnect switch in the
Inspect the power box.
switch box is not turned on.
power switch,
nothing appears in
The input cables are not surely
Inspect the input cables.
the display.
attached.
When turning
The main power
Refer to No.2 in this list.
on the power
lamp PL1 will not
switch, nothing light.
appears in the
Shortage of the input voltage
Check for proper input
display.
voltage.
PL1 lights.
Trouble with the power circuit.
After inspecting PCB
P10263Q, replace them if
necessary.
When turning on the power switch, the Refer to Section 11.1, “How To
WARNING and TEMPERATURE
Solve an Error”.
lamps light up and an error code
appears in the display,
Shield gas is
Gas is not generated The discharge valve of the gas
Open the valve.
not generated when the GAS
cylinder is closed.
when the torch CHECK key is
Lack of gas pressure of the gas
Check for proper gas
pressed.
switch is
cylinder.
pressure.
pressed.
Trouble with the gas
Inspect the gas
electromagnetic valve SOL.
electromagnetic valve
SOL.
Gas is generated
Disconnection of the torch switch
Check the wiring number
when the GAS
cable or incomplete insertion to
306 and 307.
CHECK key is
receptacle.
pressed.
Shield gas does not stop.
The GAS CHECK lamp lights up.
Trouble with the gas solenoid
valve SOL
7
When the torch switch is pressed, noload voltage is not output but shield
gas is generated.
Trouble with the inverter main
circuit
Trouble with the control circuit
㧙70㧙
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
P10499U replace it if
necessary.
No. P10499
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
P10499U 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 P10499U 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 P10261Q, 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.
㧙71㧙
No. P10499
12. MAINTENANCE AND TROUBLESHOOTING (continued)
㧙 㧙
12.6 Schematic Diagram
72
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No. P10499
2
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12. MAINTENANCE AND TROUBLESHOOTING (continued)
6
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*
12.7 Parts layout
73
No. P10499
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.
NF
LF
PL1
DR1
DR2 10
DR11
DR12
TR1 4
SCR1
CT1
CT2
T1
T2
L1
L2
L3,4,6,7,9,
10
L5
4614-101
4519-026
4600-360
4531-717
4531-308
4531-505
4531-710
4534-417
4530-412
4810-030
4406-009
P10265B00
4810-916
P10265C00
P10322L00
Circuit protector
Line filter
Neon lamp
DR and SCR complex module
High speed diode module
Diode
Diode
IGBT module
Thyristor
Current transformer
Hole current detector
Inverter transformer
Auto transformer
DC reactor
Input reactor
CB3-X0-10-072-42D-C
NF3050C-RQ2
N46010A7KW-01
DFA150AA160
DBA200UA60
S2L60
D1N60
CM300DY-12NF
SG25AA20
W-W03029
HA400S3EH
P10265B00
W-W02936B
P10265C00
P10322L00
1
1
1
1
9
1
1
4
1
1
1
1
1
1
1
4739-497
Ferrite core
E04RA400270150
6
4739-497
4739-497
4739-294
4739-579
4614-051
4258-046
4805-074
4403-122
Ferrite core
Ferrite core
Ferrite core
Clamp filter
Thermostat
Thermostat
Fan
Meter shunt
E04RA400270150
E04RA400270150
RN502510M
ZCAT3035-1330
67L090
US-602AXTTL 120˚C
4715SL-05W-B60-D00
KY600A 600A/60mV
2
2
1
1
1
1
2
1
䌾
䌾
L8
L11
THP1
THP2
FM1, 2
SH
Description
㧙72㧙
Specifications
Q’ty
Remarks
No. P10499
13. PARTS LIST (continued)
Symbol
䌾
R1 4
R5
R6
R7
R8 13
R14,15
R16
R17
R18
R19,20
R21,22
R23,24
R25,26
R27,28
R29
R30
C1
C2
C3
C4,5
C6
C7,10
C8,9,11
䌾
Part No.
4536-119
4509-819
4509-825
4509-704
4509-121
4509-916
4509-704
4509-905
4501-039
4508-015
4509-837
4508-015
4518-530
4518-528
4517-401
4518-402
C12
4511-510
CON1
CON2
CON3
CON4
TM1
TM2
PCB1
PCB2
PCB3
PCB4
PCB5
PCB6
PCB7
PCB8
PCB9
PCB10
PCB11
4730-421
4730-010
P10499X02
P10499X04
4739-505
4739-504
P10499U00
P10264P00
P10263Q00
P10330V00
P10264T00
P10488M00
P10261Q00
P10263R00
P10264R00
P10264X00
P10264S00
Description
Specifications
Surge absorber
Missing number
Cement resistor
Cement resistor
Carbon resistor
Metal oxide film resistor
Cement resistor
Carbon resistor
Missing number
Cement resistor
Missing number
Variable resistor
Carbon resistor
Cement resistor
Missing number
Carbon resistor
Missing number
Film capacitor
Missing number
Film capacitor
Ceramic capacitor
Film capacitor
Missing number
Aluminum
electrolysis
capacitor
Metal receptacle socket
Metal receptacle socket
Cable with 3P connector
Cable with 6P connector
Terminal block
Terminal block
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
䋭
Q’ty
ENC911D 14A
4
40SH 200ΩJ
20SH 15KΩJ
RD1 4W 1kΩJ
RNP 50SC 10ΩF
T20SH 2.2ΩJA
RD1/4W 1kΩJ
1
1
6
4
1
1
MHR20A513JI
2
RV24YN20SB 5KΩ
RD1/4W 1kΩJ
20SH 10ΩJA
2
2
RD1/4W 1kΩJ
1
US16X154JAASA
1
US20X103JAASA
0.01µF 2kV
0.47µF 50V
2
1
2
LWA2N601MSMAZO
1
HS25R-10
DPC25-6BP
P10499X02
P10499X04
TB10-01 12P
TB10-01 6P
P10499U00
P10264P00
P10263Q00
P10330V00
P10264T00
P10488M00
P10261Q00
P10263R00
P10264R00
P10264X00
P10264S00
1
1
䋯 㩷
䋭 㩷
㩷
㩷
㧙73㧙
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
No. P10499
13. PARTS LIST (continued)
Symbol
Ԙ
ԙ
Ԛ
ԛ
Ԝ
ԝ
Ԟ
ԟ
Ԡ
ԡ
Ԣ
ԣ
Ԥ
ԥ
Part No.
4739-603
4739-604
4735-038
4735-039
4739-516
P10313W02
P5801G03
P10263G12
P10261J01
P10263J02
K3927B00
P10261G23
4519-030
4519-031
Description
Grommet with film
Grommet with film
Knob
Cap
Fixing caster
Control panel sheet
Carrying Handle
Bush
Front cover
Control panel cover
Output terminal
Bush
Filter kit
Dust filter
Specifications
C-30-SG-14A
C-30-SG-32A
K-100㩷 22RSB
K-100㩷 22CSBL
420SR-RD50
P10313W02
P5801G03
P10263G12
P10261J01
P10263J02
K3927B00
P10261G23
109-1000F13
109-1000M13
Q’ty
1
4
1
1
4
1
2
4
1
1
2
1
1
1
Remarks
for adjusting
knob
With fan guard
Filter only
*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.
P10499 Ver. ###.###.000
Replace the ###.### with software version.
Parts list for analog remote control (optional accessories)
Symbol
Part No.
Description
R23,24
PB
4501-039
4250-077
4730-009
4735-007
Variable resistor
Push button switch
Metal socket plug
Knob
㧙74㧙
Specifications
RV24YN20SB 5kΩ
A2A-4R
DPC25-6A
K-2195 䋨large䋩
Q’ty
2
1
1
2
Remarks
No. P10499
14. SPECIFICATIONS
14.1 Specifications
1 Welding power source
㩷 㩷 㩷 㩷 㩷 㩷 㩷 㩷 Model
Specificaitons
Digital InverterDP-500
Model
DP-500
Pulse
Number of phase
Rated frequency
Rated input voltage
Input voltage range
Rated input power
Rated input current
Rated output current
Rated load voltage
Ooutput current range
Output voltage range
Rated 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
3
50 / 60 Hz
400 V
400 V ± 15%
17.8 kVA, 16.7 kW
23.8kVA, 22.2 kW
25.7 A
350 A
31.5 V
30 - 350 A
12 – 36 V
34.4 A
500 A
39.0 V
30 - 500 A
12 – 45 V
86 V
100%
60%
100
+160 K (+320 ˚F)
-10 – +40 ˚C (+14 - +104 ˚F)
20 – 80%䋨without dew condensation䋩
-10 – +60 ˚C (+14 - +140 ˚F)
20 – 80%䋨without dew condensation䋩
300 mm x 653 mm x 595 mm䋨without the carrying handle䋩
55 kg
The welding power source complies with the requirements of IEC 60974-1 and IEC60974-10
75
No. P10499
14. SPECIFICATIONS (continued)
14.2 External View
㧙76㧙
No. P10499
14. SPECIFICATIONS (continued)
●Initial Values and Setting Range of Parameter
Initial value
Setting range
0.1 second
0 – 10 seconds
Current
20 A
20 – 550 A
Voltage
10 V
10 – 50 V
Fine adjustment of voltage
0
-30 – 30
Pre-flow time
࡮ Initial condition
࡮ Main condition
࡮ Crater filler condition
Post-flow time
0.4 second
0 – 10 seconds
Arc spot time
3 seconds
0.1 – 10 seconds
Arc characteristic
Wave frequency
JOB MEMORY numbers
0
-10 – 10
3 Hz
1
0.5 – 32 Hz
1 – 100
Front Panel
[21] [20] [19]
[4]
[13]
[8]
Crater
Welding method
A
m/min
LOAD
Setting item
DC pulse / DC / wave pulse (optional )
MILD
STEEL
MAG
Wire diameter
1.2
1.2/1.4/1.6
Initial current
OFF
ON/OFF
INDIVIDUAL
SYNERGIC/INDIVIDUAL
OFF
ON/OFF
Adjustment of welding voltage
Penetration control
●Internal Functions (Function
㧕
F1
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*
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
Feed motor load current error detection
level
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*
O
0
O
0.0
-9.9 – 9.9 V
O
0.0
-1.0 – 1.0 m/min.
X
X
O
O
X
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
X
350
200/350/500
X
70
20 – 150 %
X
OFF
OFF
0
0
-150 A – 150 A
-1.5 (ms) – 1.5 (ms)
O
0
-60 A – 60 A
O
0
-150 A – 150 A
O
0
-1.5 (ms) – 1.5 (ms)
O
0
F19
Fine adjustment of base current*
Fine adjustment of L pulse peak
current*
Fine adjustment of L pulse peak time*
Fine adjustment of L pulse base
current*
Turbo Start ON/OFF selection
X
ON
F20
Keypad tone ON/OFF selection
X
ON
F15
F16
F17
F18
%
Hz
JOB NO.
ARC
V
m/min
ENTER
T1
CONTROL
r
DISPLAY
CHANGE
INITIAL
CONDITION
CRATER-FILL
CONDITION
f
T2
WAVE PULSE
ON
SYNERG.
OFF
INCHING
ON
SPOT
SPOT TIME
[17][18] [11]
CRATER
㧙 FILL
[7]
[1] WELDING METHOD key
[2] WIRE/GAS selector keys
[3] WIRE DIA (mm) key
[4] A/m/min selector key
[5] V/± selector key
[6] Parameter adjusting knob
[7] CRATER-FILL key
[8] DISPLAY CHANGE key
-60 A – 60 A
䌏䌎䋨VALID䋩/䌏䌆䌆䋨INVALID䋩
䌏䌎䋨VALID䋩/䌏䌆䌆䋨INVALID䋩
*Welding conditions which can be preset to a JOB MEMORY number.
㧙77㧙
WATER
CONSTANT
PENETRATION
TORCH
㧻㧼㧝
㧻㧼㧞
㧻㧼㧟
㧻㧼㧠
㧻㧼㧡
㧻㧼㧢
㧻㧼㧣
MILDSTEEL
CO
MILDSTEELCORED
STAINLESSCORED
MAG
MILDSTEEL
MI G
㧔2%O 㧕STAINLESSSTEEL
AL/PURE
2
MI G
㧻㧼
AL/MG
DC PULSE
DC
㧻㧼
DC WAVE PULSE
㧔126+10㧕
WIRE DIA
WELDING
METHOD
㧔mm㧕
[12] [3]
㧔126+10㧕
INDIV.
ON
ON
SYNERG.
INITIAL
CURR.
VOLT. CONTROL
GAS
CHECK
-50(0.50 second down) – 50(0.50 second up)
X
F13
F14
V
MAIN
CONDITION
Setting range
O
O
F12
[9] [10]
r
Sec
A
㧲
Initial
value
䌏䌎䋨VALID䋩/䌏䌆䌆䋨INVALID䋩
䌏䌎䋨DIRECT䋩/䌏䌆䌆䋨TERMINAL䋩
F11
SAVE
<Refer to Section 10.2.1, “Using of internal functions >
Memory
[6]
OFF / ON (without pulse) / ON䋨with pulse䋩/ SPOT
MILD STEEL CO2/MILD STEEL CORED CO2/
STAINLESS CORED CO2/MILD STEEL MAG/
STAINLESS STEEL MIG/ALUMINUM PURE MIG/
ALUMINUM MIG
Wire/Gas
[5]
J OB
WARNING
MEMORY
●Function
Initial value
OFF
DC pulse
[15]
[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. P10499
14. SPECIFICATIONS (continued)
QUICK MANUAL
Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”.
㽲 Before Using the Welding Power Source
1.
4.
Settings of Welding Method
MILDSTEEL
㧻㧼㧝
MILDSTEELCORED
㧻㧼㧞
DC
STAINLESSCORED
㧻㧼㧟
㧻㧼
DC WAVE PULSE
㧔126+10㧕
CO
MILDSTEEL
㧻㧼㧠
㧔2%O 㧕STAINLESSSTEEL
AL/PURE
MI G
㧻㧼㧡
㧻㧼
AL/MG
㧻㧼㧣
MAG
MI G
2
INCHING
WIRE DIA
2.
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.
DCPULSE
㧻㧼㧢
WELDING
METHOD
㧔mm㧕
A
Use the CRATER-FILL key to select
OFF/ON(-)/ON(
)/ SPOT.
3.
INCHING
CRATER
㧙 FILL
INITIAL
CURR.
SYNERG.
ON
WATER
ARC
CONTROL
INDIV.
CONSTANT
PENETRATION
TORCH
For using INITIAL CURRENT, press the INITIAL
CURR. key to set the function to “ON”.
f
WAVE PULSE
㧔126+10㧕
For controlling voltage in the SYNERG. way, select
“SYNERG.” by pressing the VOLT.CONTROL key.
[SYNERGIC]: VOLT. CONTROL lamp is on.
[INDIVIDUAL]: VOLT. CONTROL lamp is off.
•
ENTER
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.
4)
Press the LOAD key.
• Releasing the key protection
㧲
When adjusting SPOT TIME, press the SPOT
TIME key, then set SPOT TIME while turning
the parameter adjusting knob.
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.
Discontinue
Set the welding condition number while
turning the parameter adjusting knob.
Press the ENTER key.
㽴 Presetting the Welding Conditions
For activating a CONSTANT PENETRATION function,
set the function to “ON”.
J OB
MEMORY
LOAD
SAVE
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.
ENTER
NOTE:
• Turning
the parameter adjusting knob clockwise
increases the parameter. To decrease the
parameter, turn the parameter adjusting knob
counter-clockwise.
Discontinue
Press the LOAD key.
Press the ENTER key.
6.
Open the discharge valve of the gas cylinder,
press the GAS CHECK key to check the rate
of gas flow. After performing GAS CHECK,
GAS
stop the gas flow by pressing the GAS
CHECK
CHECK key.
Inching the Wire
㧙78㧙
The welding conditions are preset to the number you selected.
Press the SAVE key.
Press the ENTER key.
The readout mode quits.
Settings of the (Internal) Functions
㽶
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.
Discontinue
Checking the Rate of Gas Flow
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.
may be unavailable parameters in some
crater settings and function settings. Refer to
Section 10, “OPERATION” for details.
5.
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.
Press the MEMORY key.
• There
For using a water-cooled torch, select “WATER” by
pressing the TORCH key, then run cooling water.
[WATER]: TORCH lamp is on.
[AIR]: TORCH lamp is off.
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.
[ON]: WAVE PULSE lamp is on.
[OFF]: WAVE PULSE lamp is off.
[ON]: CONTANT PENETRATION lamp is on.
[OFF]: CONSTANT PENETRATION lamp is off.
•
3)
• Protecting of the keys
T2
[ON]: ARC CONTROL lamp is on.
[OFF]: ARC CONTROL lamp is off.
[ON]: INITIAL CURR. lamp is on.
[OFF]: INITIAL CURR. lamp is off.
•
㽳 Protecting the Keys and Releasing the Key Protection
r
[ON]: SPOT TIME lamp is on.
[OFF]: SPOT TIME lamp is off.
SYNERG.
VOLT. CONTROL
•
2)
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.
SPOT TIME
Settings of Functions
ON
CRATER-FILL
CONDITION
m/min
SPOT
SPOT TIME
DISPLAY
CHANGE
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 Vr selector key.
ON
INITIAL
CONDITION
1)
Now you have completed the preparations that are required
to start welding. Press the torch switch to start welding.
JOB NO.
V
m/min
OFF
r
%
MAIN
CONDITION
T1
㽵 Loading the Welding Conditions
V
m/min
Sec
Hz
A
Settings of Crater/Arc Spot
ON
Settings of Parameter
WARNING
TORCH
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.
Parameter adjusting knob
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.
No.P10499
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
㨯 MODEL: DP-500
㨯 DATE: 20XX
㨯 SERIAL NO.: P10499YXXXXXXXXXXX
P10499 Ver ###.###.000
㧙79㧙
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