MANUAL NO:P30051

OWNER'S MANUAL

MAG

FOR

DIGITAL INVERTER

DP270C

MODEL: DP-270C P30051

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

July 8, 2008

Upon contact, advise MODEL and MANUAL NO.

12-2-095-1

No. P30051

TABLE OF CONTENTS

2. ARC WELDING SAFETY PRECAUTIONS……………………………………… 2

3. GENERAL NOTICE OF OPERATION…………………………………………….. 8

4. STANDARD COMPOSITION AND ACCESSORIES…………………………… 9

5. FUNCTION OF EQUIPMENT……………………………………………………… 11

6. NECESSARY POWER SOURCE EQUIPMENT………………………………… 13

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE………….. 16

10. OPERATION…………………………………………………………………………. 32

11. APPLIED FUNCTION……………………………………………………………….. 60

12. MAINTENANCE AND TROUBLESHOOTING…………………………………… 67

13. PARTS LIST…………………………………………………………………………. 76

14. SPECIFICATIONS…………………………………………………………………... 80

15. SERVICE AND SUPPORT………………………………………………………… 84

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No. P30051

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.

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No. P30051

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 electrodes or 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 face shields or 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 proper body protection to protect skin.

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No. P30051

2. ARC WELDING SAFETY PRECAUTIONS (continued)

WELDING can cause fire and explosion.

Sparks and spatter fly off from the welding arc. The flying sparks, 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 power cable for base metal 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. Do not use the welding power source for anything 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, arc 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 arc rays 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.

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No. P30051

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 handle 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 the valve outlet when opening cylinder valve.

8. Keep protective cap in place over valve except when a gas cylinder is in use or connected for use.

9. Do not disassemble or repair the gas regulator except if you are authorized by the manufacturer.

WARNING

Be sure to observe the followings for preventing physical injuries, a fire and electric shock.

Handling of plastic parts

Front panel and the likes on this power source are made of polycarbonate.

Make sure to observe the following notice.

1. Do not apply external force and a shock to front panel and the likes. Otherwise it maybe broken and in trouble.

2. Polycarbonate can endure wiping off with water and alcohol in general but using at a sticking place with an organic solvent, chemicals, cutting oil and atmosphere such as composition oil, it gives bad influence to polycarbonate and it causes a crack

(breaking) and a strength down.

If abnormality was discovered such as crack on the front panel, stop operating immediately and ask to repair and change.

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. P30051

2. ARC WELDING SAFETY PRECAUTIONS (continued)

ARC WELDING work areas are potentially hazardous.

FALLING or MOVING machines 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 or wire feeder where they will pit or fall.

WELDING WIRE can cause puncture wounds.

1. Do not press the gun trigger until instructed to do so.

2. Do not point the gun toward any part of the body, other people, or any metal when threading welding wire.

HF

To prevent electromagnetic troubles, read the following. Also, if electromagnetic troubles occur, check the following again.

Before installing arc welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

1. other supply cables, control cables, signalling and telephone cables, above, below and adjacent to the arc welding equipment;

2. radio and television transmitters and receivers;

3. computer and other control equipment;

4. safety critical equipment, for example guarding of industrial equipment;

5. the health of the people around, for example the use of pacemakers and hearing aids;

6. equipment used for calibration or measurement;

7. The user shall ensure that other equipment being used in the environment is compatible;

8. the time of day that welding or other activities are to be carried out;

Methods of reducing EMC:

Public supply system

Add a noise filter to the input cables.

Maintenance of the arc welding equipment

Close and fix all doors and covers of the welding machine.

Welding cables

Do not use an unnecessarily long cable.

Place a base metal cable and a torch side cable as closely as possible.

Equipotential bonding

Bonding of all metallic objects in the surrounding area should be considered.

Earthing of the workpiece

The connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and shielding

It is selective screening and shielding of other cables and equipment in the surrounding area.

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No. P30051

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

Arc welding equipment Part 10: Electromagnetic compatibility (EMC) requirements IEC 60974-10, 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.

M080709

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No. P30051

3. GENERAL NOTICE OF OPERATION

3.1

Rated Duty Cycle

CAUTION

٨

Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle limitation may result in damage to the welding machine.

•

The rated duty cycle of the welding power source is the following:

270A 40

㧑

•

The duty cycle of 40% means the machine must be rested for 4 minutes after 6 minutes of

(170A or less) continuous welding at the rated current.

ON

OFF

4 min.

6 min.

10 min.

Operation cycle of 40% duty cycle

•

Failure to observe duty cycle limitations may cause the temperature inside the welding

Welding current (A) machine to exceed tolerance levels. This may contribute to premature welding machine failure or product damage.

•

The figure shown right indicates the relation between welding current and duty cycle.

Use the welding machine within its usable range, based on the appropriate 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 it, such as welding torches. Use the welding machine within the lowest rated duty cycle of the accessories.

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No. P30051

4. STANDARD COMPOSITION AND ACCESSORIES

4.1 Standard Composition

•

Preparation of the standard parts except the welding power source is required to use the welding power source.

Gas hose *

400V

㨮

3

Ǿ

Grounding cable

Gas regulator

Analog remote control *

Input cables

Shield gas

Welding torch

Welding Power source

* Refer to Section 11.4 “Optional Accessories”.

Power cable for base metal *

4.2 Wire feeding unit

•

The following parts are set. Refer to the optional parts of Section 13 “PART LIST” for the part except these.

Remarks

Pressure roll K5439C00 2 for steel

Feed roll (0.9-1.0/1.2)

Center guide

K5439B12

U5185B05

2 for steel, set in

㱢

1.2 side

1 for steel

Outlet guide U5260J02 1 for steel

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No. P30051

4. STANDARD COMPOSITION AND ACCESSORIES (continued)

4.3 Accessory

Make sure you have the items below before you start using the welding power source.

•

Accessory of welding power source

Remarks

Dust filter P30051J05 1

㧙

For the fan on the rear side of welding power source

4.4 Preparation of consumables for welding

(1) Shield Gas

Use a suitable gas for welding method.

٨

Carbon dioxide gas (CO

2

gas)

For welding (purity: 99.9% or more, moisture content: 0.002% or less)

٨

MAG gas

80% argon (Ar) + 20% carbon dioxide gas (CO

2

٨

MIG gas for mild steel

gas)

90% argon (Ar) + 10% carbon dioxide gas (CO

2

٨

MIG gas for stainless steel

gas)

97.5% argon (Ar) + 2.5% carbon dioxide gas (CO

2

98% argon (Ar) + 2% oxygen (O

2

)

gas)

100% argon (Ar)

٨

MIG gas for aluminum

100% argon (Ar)

(2) Welding wire

٨

Use the welding wire which fitted a purpose.

(3) STICK Welding

٨

Use the proper stick welding electrode for purpose of welding position, shape of joint, etc.

٨

Use the electrode holder electrically insulated.

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No. P30051

5. FUNCTION OF EQUIPMENT

5.1 Welding Power Source(Front side , back side)

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No. P30051

5. FUNCTION OF EQUIPMENT (continued)

5.2 Welding Power Source (Left side)

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No. P30051

6. NECESSARY POWER SOURCE EQUIPMENT

6.1 Welding Power Source Equipment (for commercial use)

WARNING

٨

When the welding machine is used in a humid environment such as a construction site, on a steel plate, or on a steel structure, install a leakage breaker.

CAUTION

٨

Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each welding machine.

Capacity of Necessary Power Source Utility

Power supply voltage

Tolerance range of fluctuation of power supply voltage

Installed capacity

Capacity of switch/circuit breaker

6.2 Precautions for Use of the Engine Generator

400V, Three phase

400V±15%

13.6kVA or more

50A

CAUTION

٨

Use the auxiliary power of an engine welder with an improved voltage waveform. Some engine welders have poor electricity, which may cause product damage. Contact an engine welder manufacturer for improvement of voltage 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 from 400 to 420V at no-load welding operation. Setting to extremely high output voltage may result in product damage.

•

Use an 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 an 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 a single engine generator. The effect of each welding machine may cause easy loss of arc.

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No. P30051

7. TRANSPORT AND INSTALLATION

7.1 Transport

WARNING

Follow the instructions below to avoid trouble and product damage when carrying the welding machine.

٨

Do not touch the live electrical parts inside or outside the welding machine.

٨

Be sure to disconnect the line disconnect switch when carrying the welding machine.

٨

When carrying the welding power source by a crane, do not use the handle and hang the welding power source with the eyebolt surely.

٨

Do not hang welding power source without eyebolt by a crane.

7.2 Installation

WARNING

When installing the welding machine, follow the instructions below to avoid a fire caused by welding or physical injury from gas fumes.

٨

Do not place the welding machine near combustible materials or flammable gas.

٨

Remove combustible materials to prevent dross coming into contact with combustible objects. If that not possible, cover them with noncombustible covers.

٨

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.

٨

To prevent injury or poisoning caused by fume, wear a gas mask or weld at a partial exhaust facility approved by the local regulation.

٨

Adequately ventilate or wear a gas mask when using the welding machine in a tank, boiler, or the hold of a ship. Heavier gases such as carbon dioxide or argon gases tend to collect there.

٨

When using the welding machine at a narrow space, comply with a trained supervisor’s directions. And be sure to wear a gas mask.

٨

Do not operate the welding machine near the place where degreasing, cleansing, or spraying is performed. Otherwise, poisonous gas may be generated.

٨

Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate. (Poisonous gas and fume may be generated.)

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No. P30051

7. TRANSPORT AND INSTALLATION (continued)

CAUTION

HF

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

٨

Do not ground the welding power source commonly with other machines.

٨

Close and fix all doors and covers of the welding machine.

٨

Do not use an unnecessarily long cable.

٨

Place a base metal cable and a torch side cable as closely as possible.

In the event of electromagnetic trouble, follow the instructions below.

٨

Change the installation place of the welding machine.

٨

Keep the machines which may be affected away as far from the welding machine, cables and welding site as possible.

٨

Add a noise filter to the input cables.

٨

Mount an input cable in the grounded metallic conduit.

٨

Shield the whole welding places from electromagnetic trouble. If electromagnetic troubles are still not solved after following the above instructions, consult your nearest DAIHEN dealer.

CAUTION

Follow the instructions below when selecting an installation place of the welding power source.

٨

Do not install the welding power source in the place subject to direct sunlight and rain.

٨

Place the welding machine on a strong and stable surface.

٨

Install the welding machine in the place where the ambient temperature is between -10 ˚C and

+40 ˚C (+14 ˚F and +104 ˚F).

٨

Do not install the welding machine in the place where metal material such as spatter enters the welding power source.

٨

Keep an installation distance of 30 cm between the welding power source and the wall or other welding power.

٨

Install a wind shield to protect arc from wind.

٨

Fix the gas cylinder to the stand only for gas cylinder.

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No. P30051

8.

CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

WARNING

Follow the instructions below to avoid electric shock.

∗

Do not touch the live electrical parts, as this will result in fatal shock and severe burn.

٨

Do not touch the live electrical parts of the welding machine.

٨

Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected, following a local low.

٨

With the line disconnect switch inside the switch box all turned off, ground and connect the welding machine.

٨

Do not use a cable with lack of capacity or a seriously damaged cable.

٨

Tighten and insulate the connections of cables.

٨

Securely attach the cover of the welding machine after connection of the cables.

8.1 Connecting of the Welding Power Source

8.1.1 CO

2

/MAG/MIG welding

Gas hose

Welding Power source

Shield gas

Gas regulator

Analog remote control

Welding torch

(Optionally available)

Base metal

Power cable for base metal

8.1.2 Stick welding

Analog remote control

(Optionally available)

Welding Power source

Power cable

(38mm

2

or more)

Holder

Base metal

Power cable for base metal

―16―

No. P30051

8.

CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

8.1.3 TIG welding

Gas regulator

Gas hose

Analog remote control

(Optionally available)

Shield gas

Welding torch

Welding Power source

8.2 Connecting of the Gas Hose

Power cable for base metal

Base metal

WARNING

٨

There is a danger of suffocation caused by lack of oxygen when shield gas is left flowing 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

٨

Be sure to connect the gas hose after fixing to the stand, as physical injuries may result from the gas cylinder toppling over.

٨

Attach a proper gas flow regulator to a gas cylinder. Failure to do so 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 Welding power source with a monkey wrench, etc.

2. Fix the nut for attaching the 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

Pressure gauge

Gas cylinder ԙ

Ԛ

Gas outlet

Welding Power source *

Ԙ

* In the case of TIG welding, connect the gas hose to a welding torch.

―17―

No. P30051

8.

CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

8.3 Connecting of the input cable

WARNING

Follow the instructions below to avoid electric shock.

∗

Touching the live electrical parts may result in a fatal electric shock and severe burn.

٨

Do not touch the live electrical parts of the welding machine.

٨

Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected in accordance with a local law.

٨

With the line disconnect switch in the switch box all touched off, ground and connect the welding machine.

CAUTION

٨

Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each welding machine.

Mount a switch with fuse or a circuit breaker on each welding machine.

Green/Yellow cable

For Grounding cable

Base metal

Input cables

Surely connect the input and grounding cables

AWG 12 (4mm

2

) to the circuit breaker.

CAUTION

Be sure to ground the case of the welding power source.

Use a grounding cable 4mm

2 or more in thickness.

٨

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.

―18―

No. P30051

9.

WELDING PREPERATION

9.1 Preparing the Protective Equipment

To protect you from gas generated from welding, fumes, and lack of oxygen, wear protective equipment.

٨

To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately ventilate when the welding machine is used in a place regulated by a local law.

٨

To prevent injury or poisoning caused by fume, wear a gas mask or weld at a partial exhaust facility approved by local regulations.

٨

Adequately ventilate or wear a gas mask when using the welding machine in a tank, boiler or the hold of a ship. Heavier gases such as carbon dioxide or argon gases tend to collect.

٨

When using the welding machine at a narrow space, comply with a trained supervisor’s directions. Make sure to wear a gas mask.

٨

Do not operate the welding machine near the places where degreasing, cleansing, or spraying is performed. Otherwise, poisonous gas may be generated.

٨

Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate.

(Poisonous gas and fume may be generated.)

NOTE: Install a windshield to protect arc from wind when using an electric fan for ventilation or when welding outdoors. Failure to observe the demand may result in poor welding.

CAUTION

Use protective equipment to protect you and other workers from arc rays, spattering dross, and noise from welding operation.

٨

When performing or monitoring welding operation, wear an eye protector with a good light blocking effect or face shield.

٨

Wear protective glasses to protect your eyes from the spattering dross.

٨

Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, and leather apron.

٨

Install protective screens or barriers to protect the eyes of others in the work area from arc ray.

٨

Wear an ear protector when noise level is high.

―19―

No. P30051

9.

WELDING PREPARATION (continued)

9.2 Operating the Switches and Controlling the Gas Flow Rate Regulator

CAUTION

٨

Keep your face away from the outlet when turning on gas at the gas cylinder main, as burst of high-pressure gas may result in physical injuries.

NOTE: Gas checking automatically stops in two minutes.

Ԙ

Turn on the line disconnect switch. (400V)

Gas flow rate adjusting knob

Ԛ

Press the GAS CHECK key. (The GAS CHECK lamp lights up.) ԝ

Press the GAS CHECK button again. (The GAS

CHECK lamp goes out.) ԛ

Set the gas flow rate regulator to

“SHUT” , then turn on gas at the main.

Ԝ to “OPEN” to adjust the gas flow rate.

ԙ

Set the gas flow rate adjusting knob

Place the power switch in the “I” (ON) position. (There is the power switch on the back side of the welding power source.)

9.3 Inching Operation

WARNING

٨

Do not look into the tip hole to check for the rate of wire feeding while inching.

CAUTION

٨

Keep your hands, fingers, hair or clothes away 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.

INCHING key

Parameter adjusting knob

―20―

No. P30051

9.

WELDING PREPARATION (continued)

9.4 Fitting of Wire

1. Open the feeder cover on the left side of welding power source.

2. Loosen the screw to clamp the cap knob.

3. Detach the cap knob from the wire reel shaft.

4. Mount the wire reel on the wire reel shaft.

Open the cover by pulling up the locks on both sides.

NOTE: Check the positions of the wire reel stop pin and the wire reel stop hole to insert and fully seat the pin into the hole.

NOTE: For holding standard welding wire spools weighting up to 16 kg and with a max. diameter of 300 mm.

―21―

No. P30051

9.

WELDING PREPARATION (continued)

5. Firmly tighten the cap knob.

6. Align the hole in the cap knob with the wire reel stop hole, then cap the wire reel hole with the clamp screw to prevent the cap knob from dropping.

CAUTION

٨

When hanging the wire feeder, firmly fix the cap knob and clamp screw in position to prevent the device from dropping.

7. Bring down the pressure handle, and then raise the pressure roll holder.

8. After pulling out the wire, thread it from the pilot to outlet guide through the center guide.

9. Return the pressure reel holder first, the pressure handle.

9.5 Mounting of the Feed Roll

Confirming of the wire size marked on the feed roll

Use the proper feed roll for the wire size.

Factory setting for proper wire size:

Ǿ

1.2

Groove for

Ǿ

1.2 wire size

Wire size mark

―22―

No. P30051

9.

WELDING PREPARATION (continued)

Replacing of the feed roll

1. Remove the hexagon socket cap screws fixing the feed roll.

2. Bring down the pressure handle, and then lift the pressure roll holder.

3. Separate the feed roll from the wire feeder by pulling out the feed roll toward you.

4. Mount the feed roll, with the wire size marked on the wire feeder facing out.

Feed roll

Hexagon socket cap screws

Adjusting of the wire pressure and straightener

•

Set to the proper wire pressure for the wire type by turning the pressure handle.

•

The numeral on the pressure scale set with the right pressure handle should be corresponded to the one set with the left pressure handle.

Recommended wire pressure adjustment

Mild steel Solid

SUS Solid

Brazing

Mild steel Cored

SUS Cored

AL/Soft

AL/Hard

Ǿ

0.8 1

䌾

2

Ǿ

0.9

Ǿ

1.0

Ǿ

1.2

Ǿ

0.9

2

2

3

1

䌾

䌾

䌾

䌾

3

3

4

2

Ǿ

1.0

Ǿ

1.2

1

䌾

2

2

䌾

3

Ǿ

1.0 1

䌾

2

Ǿ

1.2

1

䌾

2

Ǿ

1.6

2

䌾

3

―23―

No. P30051

9.

WELDING PREPARATION (continued)

9.6 Adjusting of the wire reel hub

After performing inching operation, take care to adjust the brake of the wire reel hub to prevent the wire from slackening. The brake has been properly adjusted before shipment. Therefore, readjustment of the brake is not required for welding in standard welding conditions.

How to adjust the wire reel hub

1. Detach the cap knob from the wire reel shaft.

2. Adjustment of the brake can be achieved by turning the hexagon bolt (M10).

̪

NOTE: Close the feeder cover on the left side, the welding power source and lock both sides after loading the wire.

―24―

No. P30051

9.

WELDING PREPARATION (continued)

9.7 Welding Conditions

When setting to the improper welding conditions, the following troubles will occur.

Cause Trouble

Wire extension is too long.

Wire extension is too short.

Welding voltage is too high.

Welding voltage is too low.

Welding current is too high.

Travel speed is too fast.

㨯

Long Arc length

㨯

Wide bead width

㨯

Poor shield

㨯

Short arc length

㨯

Easy generation of spatter

㨯

Long arc length

㨯

Wide bead width

㨯

Shallow penetration and flat bead

㨯

Stick to base metal and easy generation of spatter

㨯

Narrow bead width

㨯

Deep penetration and low excess metal

㨯

Wide bead width

㨯

Deep penetration and high excess metal

㨯

Narrow bead width

㨯

Shallow penetration and low excess metal

―25―

No. P30051

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.

9.7.1 Example CO

2

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

Leg

Wire

Welding Welding length diameter current voltage

l(mm)

(mm

Ǿ

)

(A) (V)

2.5

㧙

3.0 0.9

㧙

1.0

70

㧙

100 18

㧙

19

2.5

㧙

3.0 0.9

㧙

1.2

90

㧙

120 18

㧙

20

3.0

㧙

3.5 0.9

㧙

1.2

100

㧙

130 19

㧙

20

3.0

㧙

3.5 0.9

㧙

1.2

120

㧙

140 19

㧙

21

3.0

㧙

4.0 0.9

㧙

1.2

130

㧙

170 19

㧙

21

4.0

㧙

4.5

5.0

㧙

6.0

1.2

1.2

190

250

㧙

㧙

230

280

22

26

㧙

㧙

24

29

6.0

㧙

7.0

1.2

280

㧙

300 29

㧙

32

Travel speed

CO2 gas flow rate

(cm/min)

(ℓ/min)

50

㧙

60 10

㧙

15

50

㧙

60 10

㧙

15

50

㧙

60 15

㧙

20

50

㧙

60 15

㧙

20

45

㧙

55 15

㧙

20

45

㧙

55 15

㧙

20

40

㧙

50 15

㧙

20

35

㧙

40 15

㧙

20

(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

Leg

Wire

Welding Welding length

l(mm) diameter

(mm

Ǿ

) current

(A) voltage

(V)

2.5

㧙

3.0

0.9, 1.0

70

㧙

100 18

㧙

19

2.5

㧙

3.0 0.9

㧙

1.2

90

㧙

120 18

㧙

20

3.0

㧙

3.5 1.0

㧙

1.2

100

㧙

130 19

㧙

20

3.0

㧙

3.5 1.0

㧙

1.2

120

㧙

140 19

㧙

21

3.0

㧙

4.0 1.0

㧙

1.2

130

㧙

170 20

㧙

22

4.0

㧙

4.5

1.2

200

㧙

250 23

㧙

26

5.0

㧙

6.0

1.2

280

㧙

300 29

㧙

32

Travel speed

(cm/min)

CO2 gas flow rate

(ℓ/min)

50

㧙

60 10

㧙

15

50

㧙

60 10

㧙

15

50

㧙

60 15

㧙

20

50

㧙

60 15

㧙

20

45

㧙

55 15

㧙

20

45

㧙

55 15

㧙

20

40

㧙

50 15

㧙

20

―26―

No. P30051

9. WELDING PREPARATION (continued)

(3) Example Welding Conditions of I Shape Butt without Backing Plate

Plate thickness t(mm)

2.0

2.3

3.2

4.5

6.0

Root gap g(mm)

Wire diameter

(mm

Ǿ

)

Welding current

(A)

Welding voltage

(V)

Travel speed

(cm/min)

CO2 gas flow rate

(ℓ/min)

Number of layers

0.9,

㧙

80 17

㧙

18 45

㧙

55

10 1

0.9,

㧙

100 18

㧙

19 45

㧙

55 10

㧙

15

1

0

㧙

0.5

0.9, 1.0

100

㧙

110 19

㧙

20 50

㧙

55 10

㧙

15

0.5

㧙

1.0 0.9

㧙

1.2 110

㧙

130 19

㧙

20 50

㧙

55 10

㧙

15

1.0

㧙

1.2 0.9

㧙

1.2 130

㧙

150 19

㧙

21 40

㧙

50 10

㧙

15

1.2

㧙

1.5

1.2

150

㧙

170 21

㧙

23 40

㧙

50 10

㧙

15

1

1

1

1

1.2

㧙

1.5

1.2

220

㧙

260 24

㧙

26 40

㧙

50 15

㧙

20

Front 1

Back 1

2

(4) Example Welding Conditions of Lap Fillet

㧭

㧮

Plate

Wire

Welding Welding Travel thickness t(mm) diameter

(mm

Ǿ

) current

(A) voltage

(V) speed

(cm/min)

1.2

1.6

2.0

2.3

3.2

0.9

㧙

1.0 80

㧙

100 18

㧙

19 45

㧙

55

0.9

㧙

1.2 100

㧙

120

1.0

㧙

1.2 100

㧙

130

1.0

㧙

1.2 120

㧙

140

1.0

㧙

1.2 130

㧙

160

4.5 1.2

㧙

200

18

18

19

19

21

㧙

㧙

㧙

㧙

㧙

20 45

20 45

21 45

22 45

24 40

㧙

㧙

㧙

㧙

㧙

55

55

50

50

45

9.7.2 Example Welding Conditions of Wire CO

2

with Flux

(1) Example Welding Conditions of Horizontal Fillet

Mark position

A

A

A or B

B

B

B

CO2 gas flow rate

(ℓ/min)

10

㧙

15

10

㧙

15

15

㧙

20

15

㧙

20

15

㧙

20

15

㧙

20

Leg length l(mm)

Wire diameter

(mm

Ǿ

)

Welding current

(A)

Welding voltage

(V)

Travel speed

(cm/min)

4 1.2 250 27 50

5 1.2 270 29 50

6 1.2 270 29 45

7 1.2 280 30 40

8 1.2 300 31 30

―27―

No. P30051

9. WELDING PREPARATION (continued)

9.7.3 Example Welding Conditions of MAG Short Arc

Material: Soft steel, Gas: Mixture gas of Ar + CO

2

(10

㧙

15 ℓ/min)

Joint

Geometry

Plate thickness t(mm)

Wire diameter

(mm

Ǿ

)

Gap

(mm)

Welding current

(A)

1.0

1.2

0.8

㧙

1.0

0.8

㧙

1.0

0

0

50

60

㧙

㧙

Welding voltage

55 13

70 14

(V)

㧙

㧙

Travel speed

(cm/min)

15 40

16 30

㧙

㧙

55

50

Butt

1.6

2.3

3.2

4.0

0.8

㧙

1.0

0

1.0

㧙

1.2 0

㧙

1.0

1.0

㧙

1.2 1.0

㧙

1.5

1.0

㧙

1.2 1.5

㧙

2.0

100

㧙

110 16

㧙

17 40

㧙

60

110-120

120-140

150-170

17

㧙

18 30

㧙

40

17

㧙

19 25

㧙

30

18

㧙

21 25

㧙

40

9.7.4 Example Welding Conditions of Pulse MAG

(1) Example Welding Conditions of Horizontal Fillet Welding

Plate thickness t(mm)

Leg length l(mm)

Aim angle and position

Number of layers

Welding current

(A)

Welding voltage

(V)

Travel speed

(cm/min)

3.2 3.2

4.5 5.2

30-40 q

6.0 6.0

Focus here.

Angle of advance: 10 q

1

1

150

170

8.0 8.0

1 mm 㧔 2 - 3 mm 㧕

30-40 q

12.0 10.0

3

1 2

16.0 12.0

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

(2) Example Welding Conditions of Downward Welding

Plate thickness t (mm)

Shape of joint weld

Welding current

(A)

Welding voltage

(V)

Travel speed

(cm/min)

2.3 butt 100

Remarks

22-23 70 Back bead appearance is good.

21-22 70

Leg length: 4 - 5mm,

Throat depth: 2.5mm

―28―

No. P30051

9. WELDING PREPARATION (continued)

(3) Example Welding Conditions of Upward Welding

Plate thickness t(mm)

12

Shape of joint weld

Stop at both ends

Welding current

(A)

100-110

Welding voltage

(V)

20-21

Remarks

Weaving

Leg length: 10.0mm

(4) Both Side Welding Conditions

Plate thickness t(mm)

Groove shape

6.0

9.0

12.0

Number of layers

Welding current

(A)

Welding voltage

(V)

1

2

170

180

25-26

26-27

Travel speed

(cm/min)

30

30

1

2

270

290

29-30

30-31

30

30

1

2

280

330

30-31

33-34

40

40

―29―

No. P30051

9. WELDING PREPARATION (continued)

(5) Single Bevel Groove Penetration Welding Conditions

Groove shape

Number of layers

Welding current

(A)

Welding voltage

(V)

Flat position

ࠑ ԝ ԛ

Ԙ

Ԛ ԙ

Ԝ

Ԟ

Unit: mm

Remark

26-27

Oscillation

Vertical position

ࠑ ԛ ԙ

Ԙ

Ԝ

Ԛ ԝ

21-22

Oscillation

Unit: mm ԣ ԟ

Ԣ

Ԛ

Ԙ ԙ

Ԝ ԛ

Ԟ ԡ ԝ

Ԡ

ࠑ

Unit: mm

10 180 24-25

11 180 24-25

12 180 24-25

Wire diameter: 1.2 mm

Ǿ㧘

Gas: 20% CO

2

+ Ar

―30―

No. P30051

9.

WELDING PREPARATION (continued)

9.7.5 Example Welding Conditions of Aluminum Pulse MIG

(1) Example Welding Conditions of I Shape Butt

Plate

Wire

Welding Welding thickness diameter current voltage t(mm)

(mm

Ǿ

)

(A) (V)

Travel speed

(cm/min)

Wire extension

(mm)

Gas flow rate

(ℓ/min)

(2) Example Welding Conditions of Horizontal Fillet

Plate thickness t(mm)

Wire diameter

(mm

Ǿ

)

Welding current

(A)

Welding voltage

(V)

Travel speed

(cm/min)

Wire extension

(mm)

Gas flow rate

(ℓ/min)

9.7.6 Example Short Welding Conditions of Aluminum MIG

(1) Example Short Welding Conditions of I Shape Butt

Plate

Wire

Welding Welding thickness diameter current voltage t(mm)

(mm

Ǿ

)

(A) (V)

Travel speed

(cm/min)

Wire extension

(mm)

Gas flow rate

(ℓ/min)

(2) Example Short Welding Conditions of Horizontal Fillet

Plate thickness t(mm)

Wire diameter

(mm

Ǿ

)

Welding current

(A)

Welding voltage

(V)

Travel speed

(cm/min)

Wire extension

(mm)

Gas flow rate

(ℓ/min)

―31―

10. Front Panel

[21] [20] [19] [4] [13]

No. P30051

10. OPERATION

[8] [15] [5] [6] [9] [10]

J O B

MEMORY

WARNING

LOAD

A m/min

Sec

Hz

SAVE

A m/min

MAIN

CONDITION

ENTER

GAS

CHECK

INCHING

SPOT TIME

ON

ON

SPOT

CRATER

㧙

FILL.

T1

INITIAL

CONDITION

㧲

OFF

DISPLAY

CHANGE

ON

INITIAL

COND.

SYNERG.

SYNERG.

INDIV.

VOLT. CONTROL

᳉᳊

CO

MILDSTEEL

MAG

㧔 80Ar/20CO

2

㧕

MI G

㧔 90Ar/10CO

2

㧕

MILDSTEEL

MILDSTEEL

BRAZING CuSi

MI G

㧔 100Ar 㧕

BRAZING

CuAl

AL/PURE

AL/MG

WIRE DIA.

㧔 mm

㧕

Refer to manual for recommended shielding gases

CRATER-FILL.

CONDITION

ON

V

V d

%

JOB NO.

A R C

CONTROL d

T2 f

WATER

WAVE FREQ.

Ტ 126+ 10Უ

CONSTANT

PENETRATION

TORCH

STAINLESSSTEEL

STAINLESSSTEEL

MI G

㧔 97.5Ar/2.5CO

2

㧕

MI G

㧔 98Ar/2O

2

㧕

STAINLESSSTEEL

MI G

㧔

100Ar

㧕

INCONEL

OPTION

㧕

TITANIUM

㧔

OPTION

㧕

᳉᳊Ძ

MI G

㧔 100Ar 㧕

᳉᳊Წ

WELDING

METHOD

DC PULSE

DC WAVE PULSE

㧔

OPTION

㧕

DC

DC-TIG

DC-STICK

OP

[17] [18]

[11] [7]

[12] [3] [14] [2] [16] [1]

[1] WELDING METHOD key [9] ARC CONTROL key

[2] WIRE/GAS selector keys [10] WAVE PULSE key (optional)

[17] GAS CHECK key

[18] INCHING key

[3] WIRE DIA (mm) key [11] SPOT TIME key

[4] A/m/min selector key

[5] V/

±

selector key

[12] F (FUNCTION) key

[13] INITIAL CURR. key

[6] Parameter adjusting knob [14] VOLT. CONTROL key

[7] CRATER-FILL key

[8] DISPLAY CHANGE key

[15] CONSTANT PENETRATION key

[16] TORCH key

[19] LOAD key

[20] SAVE key

[21] ENTER key

―32―

No. P30051

10. OPERATION (continued)

CAUTION

٨

This welding machine should be operated by persons only after reading and understanding contents of this owner’s manual and having knowledge and skills for handling the welding machine safely.

٨

Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle limitation may result in damage to the welding machine .

When reading the operating instructions described below, unfold Page 82 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, when selecting “WAVE PULSE” while setting "DC HARD SOLID CO

2

φ

1.0 " with the WELDING METHOD key [1], the "MILD STEEL SOLID CO

2

" 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

AL/MG (HARD)

A5183 䇮 A5356 etc.

䋩

AL/PURE(SOFT)

䋨 A4043 etc.

䋩

㪮㫀㫉㪼㩷㪻㫀㪸㪅 㪤㫆㪻㪼

㱢㪈㪅㪇

㪧㪬㪣㪪㪜

㪛㪚

㱢㪈㪅㪉

㪧㪬㪣㪪㪜

㪛㪚

㱢㪈㪅㪍

㪧㪬㪣㪪㪜

㪛㪚

㱢㪈㪅㪉

㱢㪈㪅㪍

㪧㪬㪣㪪㪜

㪛㪚

㪧㪬㪣㪪㪜

㪛㪚

㪮㪼㫃㪻㫀㫅㪾㩷㪺㫌㫉㫉㪼㫅㫋㩷䋨䌁䋩

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

㪌㪇 㪈㪇㪇 㪉㪇㪇 㪊㪇㪇

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 the wire feeding unit.

―33―

No. P30051

10. OPERATION (continued)

Table of the Welding Mode

Contents

Status

Gas / Wire 0.8

0.9

1.0 1.2 1.6

DC CO

DC CO

DC CO

2

2

2

Mild Steel Solid

Mild Steel Cored(*1)

SUS Cored(*1)

DC 80/20 CO

2

Mild Steel Solid

DC 80/20 CO2 Mild Steel Cored(*1)

DC 80/20 CO

DC 90/10 CO

2

2

SUS Cored(*1)

Mild Steel Solid

㩷

㩷

O

㩷

O

㩷

O O

O O

㩷

㩷

㩷

O

O

O

㩷

O

㩷

O O

㩷

O

㩷

㩷

㩷 㩷

O

㩷

㩷

O

㩷

O O

㩷

DC 97.5/2.5 CO

2

SUS

㩷

O O

㩷

DC 98/2 O

2

SUS Solid

DC Ar Brazing CuSi

DC Ar Brazing CuAl

DC Ar AL/PURE(Soft)

DC Ar AL/MG(Hard)

O

O

O

㩷

㩷

O

O

㩷

㩷

㩷

O

O

O

O

㩷

㩷

O O

㩷

㩷

O O

O O O

DC Stick Welding - - - Standard

Option

DC TIG Welding

DC Pulse 80/20 CO

DC Pulse 80/20 CO

DC Pulse 80/20 CO

DC Pulse 90/10 CO

DC Pulse 97.5/2.5 CO2 SUS Solid

DC Pulse 98/2 O

2

2

2

2

2

SUS Solid

DC Pulse Ar SUS Solid Normal

DC Pulse Ar SUS Solid Soft(*2)

DC Pulse Ar Br CuSi

DC Pulse Ar Br CuAl

DC Pulse Ar AL/PURE(Soft)

DC Pulse Ar AL/MG(Hard)

DC Wave Pulse Ar AL/PURE(Soft)

DC Wave Pulse Ar AL/MG(Hard)

DC Pulse Ar Inconel

Mild Steel Solid

Mild Steel Cored

SUS Cored

Mild Steel Solid

DC Pulse Ar Titanium

- - -

㩷

㩷

㩷

㩷

㩷

O

O

㩷

㩷

㩷

㩷

㩷

㩷

㩷

㩷

O O O

㩷

㩷 㩷

O

㩷

㩷

O

O O

㩷

㩷

O

㩷

㩷

㩷

O O

㩷

O O O

O O O

㩷

O

O O O

㩷

O O O

㩷

㩷

㩷

㩷

㩷

㩷

O O

㩷

㩷

O O

O O O

㩷

O O

O O O

O

㩷

O

㩷

O O

㩷

*1 Required to changeover the function for selection. (Refer to 10.4.1(12))

*2 Required to changeover the function for selection. (Refer to 10.4.1(13))

―34―

No. P30051

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/ the upper left of the V/

±

±

lamp (located at

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.

A

m/min

T1

INITIAL

CONDITION

MAIN

CONDITION

DISPLAY

CHANGE

CRATER-FILL

CONDITION

V d

T2

[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

᲻

O OK P

5GE

Hz

᳐ d

%

,1$ 0Q

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.

―35―

No. P30051

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.

―36―

No. P30051

10. OPERATION (continued)

10.1.3 Setting of the CRATER-FILL Functions

Crater

Bead

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.

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( ) " .

Depressing the CRATER-FILL key [7] changes the crater-fill mode in the following order.

"OFF"

→

"ON (-)"

→

"ON ( )"

→

"SPOT"

Crater

Initial

Current

Timing Chart

OFF

Torch Switch

Gas Flow

Welding Voltage

Wire Feed Speed

Welding Current

Pre-flow time

10

No-load voltage

Anti-stick (burnback) time

Slow-down speed

MAIN WELDING

Keep the torch switch pressed and held during welding.

1((

Post-flow

time

―37―

Crater

ON or

ON

No. P30051

ON

Initial

Current

OFF

10. OPERATION (continued)

Timing Chart

Torch Switch

Gas Flow

Voltage Between

Output Terminals

Wire feedpeed

Welding current

Torch Switch

ON

Pre-flow time

No-load voltage

OFF

Slow-down speed

Welding Current

MAIN WELDING

ON

OFF

Pre-flow time

No-load voltage

Gas Flow

ON

OFF

Anti-stick (Burnback) time

Post-flow time

Crater Current

CRATER

ON

OFF

Anti-stick (Burnback) time

Post-flow time

Voltage Between

Output Terminals

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.

―38―

No. P30051

10. OPERATION (continued)

10.1.4 Setting of Arc Spot Time

㧔 㧕

When performing arc spot treatment, set to "SPOT" using the CRATER-FILL key [7].

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 voltagerelated parameter using the V/

±

selector key [5].

The SPOT TIME key functions only during Arc Spot time.

Torch Switch

ON

OFF

Output Current

ARC SPOT time

Welding 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 CRATER-FILL function to “SPOT” while the

CONSTANT PENETRATION function is “ON”, the setting of the CONSTANT

PENETRATION function is automatically changed to “OFF”.

―39―

No. P30051

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 ALMINUM (AL/PERE or AL/MG), 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 .

10.1.6 CONSTANT PENETRATION Function

For conventional CO

2

/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).

―40―

No. P30051

10. OPERATION (continued)

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 voltage-related 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.

10.1.8

WAVE PULSE Function (optional)

In wave pulse welding, the ripple bead appearance is changed by applying two separate pulses cyclically at low frequency. This feature will also assist in welding joints that have some poor fit up or gaps. Although, the wave mode is usually most applicable for fully automatic welding, benefits are also achieved even in semi-automatic applications. Good bead appearances are obtained by setting the wave frequency to 5Hz or more even for semi-automatic.

When setting wave pulse frequency, select “DC WAVE PULSE” with the WELDING

METHOD key [1]. Normally, the WELDING METHOD key does not work 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.

―41―

No. P30051

10. OPERATION (continued)

CHECK Function (with gas save function)

GAS 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.

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.

―42―

No. P30051

10. OPERATION (continued)

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 12.6, "Troubleshooting".

NOTE: The average output values shown in the displays are processed by software and are not guaranteed as control data of measuring instruments.

Display accuracy: Class 2.5 or equivalent).

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.

―43―

No. P30051

10. OPERATION (continued)

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.

WELDING CURRENT knob

100

50

150

200

250

#

᳑Ჿ᳆Ჾ᳃᳈᳁ Ჽ᳏᳌᳌Ჿ᳈᳎

300

. 11

5'

350

᳀᳉᳌ Ჽ1 /#) /+ )

᳎᳃

᳁᳂

᳎

16

14

18

20

22 24

᳃᳈Ჽ᳂᳃᳈᳁

26

28

30

32

34

36

8

᳆᳉᳑ ᳂᳃᳁᳂

᳍᳓᳈Ჿ᳌᳁Შ᳀᳃᳈Ჿ ᲻Ჾ᳄Შ

To set welding current.

VOLTAGE knob

INCHING button

< INDIVIDUAL adjustment>

Pressing this switch feeds wire only. The wire feed rate changes by turning the

WELDING CURRENT knob on the left

.

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.

•

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.

―44―

No. P30051

10. OPERATION (continued)

CAUTION

For electrode stick, follow the instruction below.

٨

Keep the electrode stick in a place with low humidity.

٨

Dry the electrode stick sufficiently before using.

٨

When the gas burner is used for pre-heating or removing moisture of the base metal, be sure to heat to 100˚C or above.

٨

Slag and fume generated when tack welding will cause wetting the part of base metal to be welded. Remove slag and fume immediately after tack welding.

٨

When welding is performed outdoors and wind velocity exceeds 10ft/sec, use a wind shield.

10.2 TIG welding

10.2.1

TIG welding

Set the welding process to DC TIG with the WELDING METHOD key[1].

Welding current is selected automatically. The setting value is displayed in the left digital meter with the unit indicator LED for amperage “A” lighted.

When changing the setting to DC TIG or turning on the welding power source as TIG welding setting, the touch sensing voltage is not outputted for 5 seconds. After 5 seconds have passed, the touch sensing voltage is outputted automatically.

10.2.2

Welding current setting

Welding current can be set with the Parameter adjusting knob[6]. The setting range is

10A-300A.

10.2.3

START /STOP setting of Welding

1.Welding START(Lift start

㧕

This is a method to start an arc generation by supplying current to a circuit formed with an electrode and a base metal contacted and then separating the electrode from the base metal.

1 2 3

Switch the welding process to DC TIG in the state that electrode is not contacted with a base metal.

2) Bring the electrode in touch with the base metal in the state that the touch sensing voltage is outputted.

) Draw the electrode apart from the base metal to generate arc.

2.Welding STOP

When stopping welding, draw up the electrode from the base metal. Current is stopped to supply automatically and return to the touch sensing voltage output.

―45―

No. P30051

10. OPERATION (continued)

10.3 DC STICK welding

10.3.1

DC STICK welding

Set the welding process to DC-STICK welding with the WELDING METHOD key [1].

The welding current setting mode is automatically selected and setting value is indicated on the left digital display with the unit indicator LED for amperage “A” turned ON.

When switched to DC STICK welding, or when turn on the switch with DC STICK welding is selected, no-load voltage is not provided for approx. 5 seconds for safety. 5 seconds later, the voltage is automatically provided.

10.3.2

Welding current setting

The welding current may be set with the parameter adjusting knob [4] in the range specified in the table shown below:

Current range is 20A-300A.

10.3.3

Hazard reducing

This is a safety function that reduces risks of an electric shock by limiting no-load voltage of welder to lower level at any time except welding period.

―46―

No. P30051

10. OPERATION (continued)

10.4 Applied Settings

10.4.1 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].

WARNNING

᲻

᳧

/min

UGE

Hz

᳐ d

%

,1$ 0Q

The number of function blinks.

The conditions of function lights.

↓

A function number can be preset with the parameter adjusting knob [6]

The above example indicates that F19 is set to “on”.

When pressing the F key [12] again after presetting the desired function number, the function number lights and the function conditions blinks. Under this condition, functions can be preset by using the parameter adjusting knob

[6].

WARNNING

᲻

᳧

/min

UGE

Hz

᳐ d

%

,1$ 0Q

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.

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 [6], 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.

―47―

No. P30051

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) When the setting value of anti-stick (burnback) time is 25 seconds, add 0.25 second to the standard anti-stick (burnback) time.

Ex. 2) When the setting value of anti-stick (burnback) time is -10, subtract

0.1 second from the standard anti-stick (burnback) time.

(2) Fine Adjustment of Anti-stick (Burnback) Voltage: F2*

Anti-stick (Burnback) voltage means the voltage which is output when processing is carried out to prevent electrode wire from fusing to base metal at the end of welding. Anti-stick (Burnback) voltage is preset to proper conditions according to welding methods and wire diameters at shipment, but it can be finely adjusted by activating F2. The standard anti-stick (burnback) voltage is preset to “0”. When the voltage is set in the negative direction, it decreases.

When the voltage is set in the positive direction, it increases. The fine adjustment range is 0 V to ±9.9V.

(3) Fine Adjustment of Slow-down Speed: F3*

Slowdown speed means the speed to feed wire that is slower than the feed rate at normal welding during the period from startup to arc start. The slowdown speed is preset to proper conditions according to welding methods and wire diameters at shipment, but it can be finely adjusted by activating F3.

The standard slow-down speed is preset to “0”. When the slowdown speed is set in the negative direction, it decreases. When the slowdown speed is set in the positive direction, it increases. The fine adjustment range is 0 m/min to

±

1.0 m/min. When poor arc start occurred, lower the slowdown speed. Even when arc start is good, the slow-down speed can be increased to shorten tact time.

NOTE: The minimum slow-down speed is 0.4 m/min.

―48―

No. P30051

10. OPERATION (continued)

(4) 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.

(5) 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.

(6) 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.

(7) 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.

―49―

No. P30051

10. OPERATION (continued)

(8) 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.

100

50

150

200

250

#

᳑Ჿ᳆Ჾ᳃᳈᳁ Ჽ᳏᳌᳌Ჿ᳈᳎

300

.11

5'

350

᳀᳉᳌ Ჽ1 /#) /+ )

᳎᳃

᳁᳂

᳎

16

18

20

22 24

14

᳃᳈Ჽ᳂᳃᳈᳁

26

28

30

32

34

36

8

᳆᳉᳑ ᳂᳃᳁᳂

᳍᳓᳈Ჿ᳌᳁Შ᳀᳃᳈Ჿ ᲻Ჾ᳄Შ

―50―

No. P30051

10. OPERATION (continued)

(9)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 subtracted 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.

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.

―51―

No. P30051

10. OPERATION (continued)

(9-1) 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 subtracted 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.

(9-2) 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 subtracted 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.

(9-3) 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 subtracted or added the fine adjusting value from the standard value of the base current is output.

(9-4) 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 subtracted or added the fine adjusting value from the standard value of the L pulse peak current is output as L pulse peak current.

(9-5) 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 subtracted or added the fine adjusting value from the standard value of the L pulse peak time is output as L pulse peak time.

(9-6) 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 subtracted or added the fine adjusting value from the standard value of the L pulse peak current is output as L pulse peak current.

High pulse condition

Low pulse condition

High pulse condition

Example of current wave at wave pulse welding

(10) 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.

―52―

No. P30051

10. OPERATION (continued)

(11) Conditions calling using external signals: F21

By ON-OFF combination of 3 external signals (3) to (5) on the 12P terminal block built-in the welding power source, to change over 8 welding conditions is possible; that is, Conditions No. 1 to 8. (While this function is in use, the “external gas control function” of terminal block (3) cannot be used.)

The relation between the ON/OFF combinations and welding condition number is as shown in the table below.

Relation between Condition No. and ON-OFF Pattern

Condition No.

1

(5): EXT2

OFF (Open)

(4): EXT1

OFF (Open)

(3): GAS

OFF (Open)

5

6

7

8

ON (Closed)

ON (Closed)

ON (Closed)

ON (Closed)

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

ON (Closed)

OFF (Open)

ON (Closed)

OFF (Open)

ON (Closed)

OFF (Open)

ON (Closed)

When the three signals described above are changed during welding operations, welding conditions will be changed.

(12) Changeover to cored wire: F22

Setting F22 to ON can be selected cored wire with the WIRE/GAS selector keys[2]. Gas and wire which is switched by ON/OFF of F22 is as shown below.

Changeover of Gas / Wire

OFF ON

DC CO

2

Mild Steel Solid DC CO

2

Mild Steel Cored

DC 80/20 CO

2

Mild Steel Solid DC 80/20 CO2 Mild Steel Cored

DC 97.5/2.5 CO

2

SUS Solid DC CO

2

SUS Cored

DC 98/2 O

2

SUS Solid DC 80/20 CO

2

SUS Cored

(13) Changeover to Normal/Soft modes of DC Pulse 100 Ar SUS Solid: F23

Setting F23 to ON can changeover to Soft mode from Normal in DC Pulse

100 Ar SUS Solid mode. Setting F23 to OFF returns to Normal mode from

Soft.

―53―

No. P30051

10. OPERATION (continued)

10.4.2

Key Lock

Key lock is for keeping the welding conditions in order not to operate keys and knobs on the front panel accidentally. 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].

Holding down both the F [12] key and ENTER key

ENTER

T1

[21] simultaneously

GAS

㧲

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 released by holding both the F key and

ENTER key simultaneously for a while again. Key lock cannot be released by starting the machine up again.

While keys are locked, the F lamp blinks

Even when the keys are locked, GAS CHECK, INCHING, and JOB MEMORY functions can be activated.

10.4.3

JOB MEMORY Function

The JOB MEMORY function enables welding conditions to be retrieved 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

٨

The welding conditions (electronic data) stored by this function are susceptible to occurrence of static electricity, impact, repair, etc., and there is a possibility that the stored contents may be changed or lost. BE SURE TO MAKE A COPY FOR IMPORTANT

DATA.

٨

Please note that we shall not assume any responsibility for any change or loss of electronic data resulting from repair.

Once the machine enters the memory mode and read-out mode, only the SAVE, LOAD, and ENTER keys can be operated. 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 you want to copy.

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.

―54―

No. P30051

10. OPERATION (continued)

Ԙ

SAVE

Welding conditions being currently in use are stored in the memory inside the welding power source.

•

Storing 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 [6].

WARNNING

᲻

O OK P

5' %

Hz

᳐ d

%

, 1$ 0Q

Welding current setting value stored in memory Condition number blinks

In the event that any memory data is already preset to the condition number you selected, the CRATER lamp, the WELDING METHOD lamp, etc. also light up. If no memory data is preset to the condition number you selected, “- - -” blinks in the left-side display. In this case, the system skips the parameter check condition of Step (2) and jumps to Step (3).

WARNNING

᲻

᳧

/min

5'%

Hz

᳐ d

%

, 1$ 0Q

(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 stores the data in memory and enables you to exit from the memory mode.

―55―

No. P30051

10. OPERATION (continued) ԙ

LOAD

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. On the left-side display, the setting of welding current preset to condition number "1" lights up. Under this condition, a condition number can be set while turning the parameter adjusting knob [6].

WARNNING

᲻ m/min

5' %

Hz

᳐ d

%

, 1$ 0Q

Welding Current stored 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.

WARNNING

᲻ m/min

5'%

Hz

᳐ d

%

,1$ 0Q

(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 able to change condition number or select a welding method, etc. To reset the condition number, press the LOAD key [19], 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 ENTER key [21] again, you can read out the preset welding conditions and exit from the readout mode.

―56―

No. P30051

10. OPERATION (continued)

•

Memory mode operation

Press the MEMORY key.

Discontinue

Set the welding condition number while turning the parameter adjusting knob.

Press the ENTER key.

Press the MEMORY key.

Discontinue

Press the DISPLAY CHANGE key to check the parameter value.

Reset the welding condition number.

The welding conditions are preset to the number you selected.

Press the LOAD key.

Press the ENTER key.

The memory mode quits

.

•

Readout mode operation

Press the LOAD key.

Discontinue

Set the welding condition number while turning the parameter adjusting knob.

Press the ENTER key.

Press the LOAD key.

Discontinue

Press the DISPLAY CHANGE key to check the parameter value.

Reset the welding condition number.

The welding conditions are preset to the number you selected.

Press the SAVE key.

Press the ENTER key.

The readout mode quits

.

―57―

No. P30051

10. OPERATION (continued)

Ԛ

Erasing the Welding Conditions

You can select either erasing all or erasing one when erasing the welding conditions stored in memory.

•

Erasing the welding conditions

(1) Turn off the power switch and turn on the power switch with both the LOAD key [19] and SAVE key [20] pressed. Release the keys after tuning on the power switch, and then "dEL" appear in the left-side display. See the picture below.

WARNNING

᲻ m/min

5' %

Hz

᳐ d

%

, 1$ 0Q

" 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 right-side display as illustrated below and you can erase all the welding conditions.

WARNNING

᲻ m/min

5' %

Hz

"

dEL" is displayed "ALL" blinks

᳐ d

%

, 1$ 0Q

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.

―58―

No. P30051

10. OPERATION (continued)

10.4.4

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 [17] held down. When "End"s appear in the displays after turning on the power switch, release the keys, turn off the power switch, then turn it on again. See the picture below.

WARNNING

᲻ m/min

5' %

Hz

᳐ d

%

, 1$ 0Q

See “SPECIFICATIONS” for initial values of each parameter and function.

10.4.5

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 : "P30051"

←

Software number (P30051) 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"

↓ Press the F key [12].

←

Combination is displayed.

The welding power source starts up as usual and gets ready to perform welding.

10.4.6

Automatic Stop of Fan

The cooling fan automatically stops in 10 minutes after welding is finished and automatically starts moving when welding is started. When powering the welding power source, the cooling fan is also moving 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.

10.4.7 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 150 A or less output current.

―59―

No. P30051

11. APPLIED FUNCTION

11.1 How to Solve an Error

WARNING

Observe the following to prevent electrical shock.

When touching the live electrical parts, critical electric shock and burn may occur.

٨

Do not touch the live electrical parts inside or outside the welding machine.

٨

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.

٨

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.

When using this product with a robot of our company, refer to “Application (arc welding)” in owner’s manual of the robot.

No.

Displays on the front panel

Classification of errors

Left Right

1

2

3 d A I

E -

E -

H E n

0 0 0

1 0 0

4

5

6

7

8

9

E -

E -

E -

E -

E -

E -

2 0 0

2 1 0

3 0 0

5 1 0

6 0 0

7 0 0

Torch switch off state waiting

Operation Stop

Control power supply error

Primary / secondary current detection error

Error in the voltage detection

Thermal overload

Lack of water pressure*

Battery low(warning)

Output over current

10

11

12

13

14

15

E - 7 1 0 Lack of phase

E -

E -

E -

8 0 0

8 1 0

8 2 0

Encoder in the wire feeder error

Thermal overload in the governor circuit

Motor over current (warning)

E - 8 3 0 Motor over current (error)

E - 9 X X Microcomputer error

*When input relay signal to 12P terminal block (TM12P)

Ԣ

ԣ

only.

―60―

No. P30051

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 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.

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 P30051T are surely connected.

5) E-210 Display

If “E-“ and “210” in the displays blink, it indicates the “Error in the voltage detection”.

If there is an error in the voltage detection line, the warning lamp will light up, then the welding power source will stop automatically. In this case, check the no-load voltage at output terminal of welding power source.

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.

―61―

No. P30051

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 “Lack of water pressure”.

Then the welding machine will automatically stop. In this case, check to make sure that the water-cooled 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

Ԙ

ԙ

, contact between CON

Ԙ

ԙ

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).

8) E-600 Display

If “E-” and “600” in the displays blink, it indicates the “Battery low (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 battery” 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 error”.

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, the motor cable, and the printed circuit board P10533Q.

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 P10533Q) is detected, the

WARNING lamp will light up, and then the welding machine will stop automatically. In this case, check for defective printed circuit board P10533Q, short circuit on the motor power supply lines, rough feeding of wire, and error in the torch or the wire feeding unit.

―62―

No. P30051

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 10.3.1(7) “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 (error)”.

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 feeding unit.

15) E-9XX Display

If “E-” and “9XX” 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.

―63―

No. P30051

11. APPLIED FUNCTION (continued)

WARNING

Observe the following to prevent electrical shock.

٨

Do not touch the live electrical parts inside or outside the welding machine.

٨

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.

٨

When touching the parts inside the welding power source, wait three minutes have passed after powering off all input power supply by turning off the line disconnect switch in the switch box.

CAUTION

٨

Try to move the control cable which is pulled out from the automatic connection terminal on the chassis further 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.

٨

Pull out only the wiring on the printed circuit board to outside.

11.2 External Connection of Inside Terminal Block of Automatic Machine

When taking off the left side cover of the welding power source, you will find there is a 12P terminal block (TM12P) on the chassis. Use the 12p terminal block to connect with an automatic machine. Refer to Section 12.8 “Parts layout” for the locations of the terminal blocks.

NOTE: Wait three minutes have passed after turning off the line disconnect switch or no-fuse 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.

Ĭ ĭ

Ქ

4'#&;

Į

Ქ

᳁᲻᳍ į

Ქ

':6Ძ

İ

Ქ

':6Წ ı IJ

Ქ

[12P terminal block] ij

᳍᳎᳉᳊

Ĵ

᳑Ჽ᳌ ĵ Ķ ķ

―64―

No. P30051

11. APPLIED FUNCTION (continued)

12P terminal block (TM 12P)

Ԙ

+

Pin No.

㧙 ԙ

-

Signal name

READY

(OUTPUT)

Ready Power

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.

Ԛ

+

㧙 ԝ

-

Solenoid Valve ԛ

+

㧙 ԝ

Control

-

EXT1 (INPUT) external signals. (If the terminals are short-circuited, the gas valve will open.)

The terminals used for special specifications. These terminals

*1

*2

*2

Ԝ

+

㧙 ԝ

-

Signal 1

EXT2 (INPUT) The terminals used for special specifications. These terminals *2

Ԟ

Ԡ

+

+

㧙

㧙 ԟ ԡ

-

-

Signal 2

STOP (INPUT)

Operation Stop

WCR(OUTPUT)

Current

Detection

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.

Precaution for connection with terminals on the terminal block

The wires from the terminal blocks should be twisted for each signals to avoid accidental

*2

*3 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.

64

2%

8

Figure 1

Figure 2

―65―

No. P30051

11.3 Optional Accessories

11. APPLIED FUNCTION (continued)

11.3.1 Other Optional Accessories

Analog remote control

Digital remote control

Remarks

K5416H00

E-2454A

With a 3-meter cable

A CAN communication module and cable are needed.

K5422C00 CAN communication

module

CAN communication

cable

Wheel kit

BKCAN-0405

BKCAN-0410

K5416L00

11.3.2 Cable/Hose (Extension of Work Space)

BKCAN-0405 (for 5 m)

BKCAN-0410 (for 10 m)

DP-270C Type

CAUTION

٨

Do not connect an overlong extension cable.

٨

When using an extension cable, roll it out. Failure to do so may result in unstable arc.

Choose a proper cable (separately sold) for work space. When extending the work space, use other extension cables/hoses (separately sold ) that match the work space.

1. Power Cable (for base metal)

2m 7m 12m

Model BKPDT-6002 BKPDT-6007 BKPDT-6012

2. Gas Hose

Model BKGG-0605 BKGG-0610 BKGG-0615 BKGG-0620

3. Control Cable for Analog Remote Control (6P)

5m

Model BKCPJ-0605 BKCPJ-0610

―66―

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING

WARNING

To avoid electric shock, follow the below instructions.

٨

Do not touch the live electrical parts inside or outside the welding machine.

٨

Turn off all of the line disconnect switches before touching the parts inside the welding machine.

٨

Perform maintenance checks periodically. If any damaged parts are found, only use the welding machine after troubleshooting or repairing.

٨

Only certified operators should maintain, inspect, or repair the welding machine.

٨

When carrying out maintenance, wait three minutes have passed 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.

٨

This welding power source uses a high-frequency inverter system, be careful of accidental connection of the line disconnect switch at input side.

٨

Have qualified operators or the persons familiar with this welding power source test withstand voltage. And install a protective wall around the welding machine to keep away others from the welding machine.

CAUTION

Rotating parts may cause injuries. Be sure to observe the following.

٨

Only certified operators should maintain, inspect, or repair the welding machine.

٨

Install a fence around the welding machine to keep others away from it.

٨

Do not put your hands, fingers, hair and clothes near the fans and wire feed roll rotating.

CAUTION

٨

Do not touch the parts for the main circuit which are located inside the power source, such as single-phase transformer, DC inductor, heat sink, etc. immediately after welding is performed, as the parts are extremely hot. Wait until the parts cool down, when touching. Failure to observe the demand may result in burn.

CAUTION

٨

The welding conditions (electronic data) 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.

٨

We shall not assume any responsibility for any change or loss of the electronic data resulting from repair.

―67―

No. P30051

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.)

-

There is no trouble in crack and the like on front panel.

•

Checking the followings each three to six months:

-

There is no damage inside the torch.

-

There are no loose connections or no poor contacts caused from rust, on input side of the welding power source and output side of the cables.

-

There is no trouble with insulation.

-

The welding power source is properly grounded.

-

Built-up dust on the transistor or the cold plate on the rectifier may affect the equipments.

Take off the cover of the welding power source once a half year, then remove dust by blowing moisture-free compressed air on each part.

-

The dust protective filter located on the inlet of the fan does not clog, which may result in damage to the welding power source. Be sure to inspect it periodically.

12.2 Precaution for Replacement of the Printed Circuit Board

•

Make sure that the connector number inscribed on the printed circuit board matches the number marked on the

㧝 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

%0 inside the welding power source discharge.

•

This welding power source uses a highfrequency inverter system, be careful of accidental connection of the line disconnect

NOTE: Match the number on the printed circuit board with that on the connector. 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 from the adherence of the organic solvent.

―68―

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.3 Insulation Resistance Test

WARNING

Observe the following to prevent an electrical shock.

When touching the live electrical parts, a critical electric shock and burn may occur.

٨

Have qualified operators or the persons familiar with this welding power source measure insulation resistance and test withstand voltage . And install a protective wall around the welding machine to keep away others from the welding machine. Check to make sure that charging voltage does not exist before carrying out the maintenance before carrying out measurement of insulation resistance and withstand voltage test.

When measuring insulation resistance and testing withstand voltage, follow the steps below.

And, refer to the schematic diagram, parts layout, and parts list for maintenance.

1. Disconnect the grounding cable (wiring number: 80) from the earth.

2. Short-circuit on AC side and commutation side of DR1.

3. Short-circuit between TR1 (C1) and (E1), TR2(C2) and (E2), TR3(C2) and (E2) ,

TR4(C2) and (E2).

Be sure to reconnect the cables after carrying out measurement of insulation resistance and withstand voltage test.

12.4 Replacement of battery

WARNING

Be sure to observe the followings for preventing a fire and the explosion.

٨

Do not connect (+)(-) of the batteries with wire. Do not disassemble, heat and deform the batteries. Do not solder anything directly to the batteries. Do not throw batteries into fire.

٨

Do not inset the connector in opposite polarity.

٨

The batteries should be replaced only by an experienced repairman or engineer.

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 three minutes have passed, remove the 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.P10533R to replace the printed circuit board.

Refer to the position for “Rear side of the front panel” in Section 13. “ Parts List”.

4. Insert the disconnected connectors into the P.C.B.P10533R.

5. Screw the front panel into position.

―69―

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.5

Replacing of the Outlet Guide

Pressure handle

Follow the procedures below when replacing the outlet guide.

Torch socket

Flathead screwdriver

Snap ring

1. Bring down the pressure handle first, and then lift the pressure roll holder.

2. Forcibly insert a flathead screwdriver, etc. into the space between the outlet guide and the snap ring to remove the snap ring while holding the snap ring with long-nose pliers.

3. Remove the outlet guide by pushing it toward the torch socket.

4. Insert a new outlet guide from the direction of the torch socket, and then place the snap ring under the new outlet guide.

5. Return the pressure roll holder first, the pressure handle.

Long-nose

pliers

Outlet guide

CAUTION

٨

Do not attempt to disassemble the feed motor. This may result in damage to the wire feeder.

٨

Do not check the amount of brushing friction or replace the brush.

Service life of the brush varies depending on ambient temperature, etc., but normally the service life is about 4,000 hours. (If the machine is operated for six hours a day, the service life of the brush will be about two years). Periodical replacement of the feed motor is recommended.

―70―

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.6 Troubleshooting

٨

When an error code is displayed, refer to Section 11.1, “How To Solve an Error”.

Check the troubleshooting information listed below before contacting your dealer for service.

No. Trouble Cause Solution

1

2

3

The power switch on the front panel is tripped.

Never turn it on again. Contact your dealer.

The main power lamp

PL1 does not light.

When turning on the power switch, the Trouble with PL1. displays light.

When turning on the power switch, nothing appears in the display.

The line disconnect switch in the switch box is not turned on.

The input cables are not surely attached.

When turning on the power switch, nothing appears in the display.

The main power lamp PL1 does not light.

PL1 lights.

Refer to No.2 in this list.

Shortage of the input voltage

Trouble with the power circuit.

Inspect PL1.

Inspect the power

box.

Inspect the input

cables.

Check for proper

input voltage.

After inspecting

PCB P10532Q, replace them if necessary.

4

When turning on the power switch, the

WARNING and TEMPERATURE lamps light up and an error code appears in the display,

Refer to Section 11.1, “How To

Solve an Error”.

The discharge valve of the gas cylinder is closed.

Open the valve.

5

Shield gas is not generated when the torch switch is pressed.

Gas is not generated when the GAS

CHECK key is pressed.

Lack of gas pressure of the gas cylinder.

Trouble with the gas electromagnetic valve SOL.

Check for proper gas pressure.

Inspect the gas

electromagnetic valve SOL.

Gas is generated when the GAS

CHECK key is pressed.

Disconnection of the torch switch cable or incomplete insertion to receptacle.

Check the wiring

number 222 and

223.

6

7

Shield gas does not stop.

The GAS CHECK lamp lights up.

Trouble with the gas solenoid

valve SOL

When the torch switch is pressed, noload voltage is not output but shield gas is generated.

Trouble with the inverter main

circuit

Trouble with the control circuit

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

PCBP10265P or

P30051T replace it if necessary.

―71―

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

No. Trouble Cause Solution

Trouble with the control circuit

After inspecting PCB P10265P or

P30051T and replace it if necessary.

8

Current and voltage can not be set.

Trouble with the filter circuit

Trouble with the remote

control

Error in wire voltage detection

After inspecting PCB P30051Z, replace it if necessary.

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 P30051T or CN1 on PCB

P10533X.

9

10

WCR keeps operating.

Wire is not fed.

Trouble with the hole current detector CT2

Trouble with the WCR circuit

Trouble with the motor control circuit

Trouble with the filter circuit

Poor contact or breakdown in the encoder cable

Trouble with the motor

Inspect the hole current detector CT2.

After inspecting PCB P10265P, replace

it if necessary.

After inspecting PCB P10533Q, replace it if necessary.

After inspecting PCB P30051Z, replace it if necessary.

Check the socket.

Check the cables and replace them, if necessary.

Replace the motor, if necessary.

11

12

13

Wire gets deformed.

Wire pressure is too weak.

Refer to “Recommended wire pressure adjustment” in Section 9.5

Dust or chip is accumulated on the outlet guide and on the feed roll.

Remove the dust and chip.

Wire pressure is too strong.

Feed roll of wrong wire size is used.

Feed roll and pressure roll are worn.

Pressure roll does not rotate smoothly.

Failure of the pressure roll holder.

Wire is not fed Adjustment of the brake is smoothly through the wire reel.

either too strong or too

weak.

Refer to “Recommended wire pressure adjustment” in

Section 9.5

Replace it with the feed roll of proper

wire size.

Replace the feed roll and the pressure roll, if necessary.

Replace it, if necessary.

Refer to “Adjustment of the wire reel hub” in Section 9.6

―72―

12.7 Schematic Diagram

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

―73―

12.8 Parts layout (electric parts)

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

―74―

No. P30051

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.9 Parts layout (wire feeding unit parts)

㪉㪋

㪈㪏

㪈㪎

㪉

㪊

㪈㪍

㪌

㪈㪈

㪈㪇 㪈㪐

㪍

㪋

㪉㪇

㪐

㪏

㪎

㪈㪌

㪈

㶎

㪈㪊

㪈㪋

㪈㪉

㪉㪉

㪉㪌

㶎

㪉㪎

13. PARTS LIST

―75―

No. P30051

13. PARTS LIST

•

Please contact your dealer to order parts. (See the back cover for telephone numbers, fax numbers and mailing addresses.)

Parts list for electric parts

Description Specifications Q’ty Remarks

FN3025HP-20-71 1

N46010A7KW-01 1

DIODE DF75AC160

DR2a

㨪 d 4531-308 MODULE DBA200UA60

D1N60-5060

TR1,2,3,4

4534-407 IGBT 2MBI150TA-060-50

1

4

1

4

W-W03029A 1

1

1

1

1

1

E04RA400270150 2

RI-17.5-28.5-10.7 1

E04RA400270150 1

RI-17.5-28.5-10.7 1

E04RA400270150 1

ZCAT3035-1330 1

RI-17.5-28.5-10.7 2

1

R4a

㨪 h 100-0234

W-31156D 1

1

RS2B ǡ

3

RD20S J 8

40SHN JA 2

20SH JA 1

R10a

㨪 c 100-0175 ABSOBER ENE911D-14A 3

1

US20X472JAASA 2

CS17-F2GA103MYAS 2

―76―

No. P30051

13. PARTS LIST (continued)

Parts list for electric parts(continued)

Description Specifications Q’ty Remarks

0235003P

03455LS1H

1

1

1

1 VLP-03V

ELP-06V 1

1

P30051T00 1

P10265P00

1

P10532Q00

P10538V00

1

1

P30051Z00

P30051M00

P10533Q00

P10533R00

P10541R00

P10533X00

K5439K00

1

1

1

1

1

1

1

*NOTE: When ordering a printed circuit board P10265P00, provide the software version on a label below a nameplate attached to the rear side of the welding power source.

P30051 Ver. ###.###.000

Replace the ###.### with software version.

―77―

No. P30051

13. PARTS LIST (continued)

Parts list for wire feeding unit parts

Standard parts

Ref.

No.

Part number Description Q’ty Remarks

1-1

3

4

5

9

9-1

9-2 none

U5185B02

U5185S00

U5185T00

U5439B12

3361-880

3361-884

Cap screw

Pressure roll holder pin

Pressure roll holder (R)

Pressure roll holder (L)

Feed roll (0.9-1.0/1.2)

Cap screw

Bolt

1

2 M6 x 30

1

2

1

1

2

2

2

2

4 M4 x 16

4 M4 x 10

1

1

14-1

16

21-1

27-1

3361-895

U5185B09

3361-897

AM6000

1

1

3

3 M6 x 20 Flat head screw

Pressure spring holder

1

2

Compression 2

2

Hexagon bolt

Euro central adapter

27-4 None Bolt

2

1

2

2 M8 x 30

1

2

1

1

1

1

(1)

(1)

(1)

(1)

(1)

―78―

No. P30051

13. PARTS LIST (continued)

Optional parts

Ref.

No.

Part number

Steel Aluminum

9

6 K5439C00* - Pressure

#

Feed roll (1.0/1.2)

- Feed

2

2

2

8 U5185P00* - Gear

#

2

Gear 4

K5439B01

K5439B04

K5439B05

K5439B06

-

-

-

-

Feed roll (1.4/1.6)

Feed roll (1.2/1.4)

Feed roll (1.2/1.2)

Feed roll (1.4/1.4)

2

2

2

2

K5439B07 - Feed roll (1.6/1.6)

K5439B11 K5463R03 Feed roll (1.2/1.6)

K5439B12* - Feed roll (0.9-1.0/1.2)

2

2

2

K5439B13 -

#

Feed roll (0.8/0.9-1.0)

Feed roll (1.0/1.2)

2

2

9-1 3361-880* -

3361-880

#

Cap screw

#

Cap screw

Center guide

K5644P01

U5311J01

#

#

Outlet guide

4

8

1

1

M4 x 16

M4 x 16

Pilot 1

*: Standard parts

#: Aluminum kit K5644P00

Aluminum kit K5644P00 (for dia. 1.0 or 1.2)

Ref.

No.

Part number Description

9-1 3361-880 Cap screw

Q’ty Remarks

4

2

4 M4 x 16

1

1

1

―79―

No. P30051

14. SPECIFICATIONS

14.1 Specifications

㧔

1

㧕

Welding power source

㩷 㩷 㩷 㩷 㩷 㩷 㩷 㩷

Model

Specificaitons

Digital Inverter

㩷

DP270C

Model DP-270C

Number of phase 3

Rated frequency 50 / 60 Hz

Rated input voltage

Input voltage range

Rated input power

Rated input current

Rated output current

Rated load voltage

Rated output current range

Rated output voltage range

400 V

400 V ± 15%

13.6kVA,

㩷

12.1kW

㩷

20A

270 A

27.5 V

30 - 300 A

12 – 30 V

Maximum no-load voltage

Rated duty cycle

Number of welding condition

Temperature rise

Usable temperature range

Usable moisture range

Storage temperature range

Storage moisture range

External dimensions(W x D x H)

81 V

40%

100

+160 ˚C (+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 664 mm

The welding power source complies with the requirements of IEC60974-1.

―80―

14.2 External View

No. P30051

14. SPECIFICATIONS (continued)

―81―

Pre-flow time

14. SPECIFICATIONS (continued)

●

Initial Values and Setting Range of Parameter

No. P30051

Initial value

0.1 second

Setting range

0 – 10 seconds

●

Front Panel

[21] [20] [19] [4] [13]

࡮

Initial condition

࡮

Main condition

Current

Voltage

࡮

Crater filler condition

Fine adjustment of voltage

Post-flow time

Arc spot time

Arc characteristic

Wave frequency

JOB MEMORY numbers

●Function

20 A

12 V

0

0.4 second

3 seconds

0

3 Hz

1

Initial value

20 – 300 A

12 – 30 V

-30 – 30

0 – 10 seconds

0.1 – 10 seconds

-10 – 10

0.5 – 32 Hz

1 – 100

Setting item

J O B

MEMORY

LOAD

SAVE

WARNING

A m/min

A m/min

Sec

Hz

[8]

MAIN

CONDITION

Welding method

Wire/Gas

DC pulse

MILD

STEEL

MAG

DC PULSE / DC / DC-TIG

DC-STICK / DC WAVE PULSE(OPTION)

MILD STEEL CO

2

/ MAG / MIG

BRAZING CuSi MIG / BRAZING CuAl MIG

AL/PURE MIG / AL/MG MIG

SUS MIG(2.5CO

2)

/ MIG(2O

2

) / MIG(100Ar)

Wire diameter

Initial current

1.2

OFF

0.8 / 0.9 / 1.0 / 1.2 / 1.6

ON / OFF

Adjustment of welding voltage

Penetration control

SYNERGIC

OFF

SYNERGIC / INDIVIDUAL

ON / OFF

●Internal Functions (Function

㧕

<Refer to Section 10.4.1, “Using of internal functions >

F1

Fine adjustment of anti-stick (burnback) time*

Initial value

0

Setting range

-50(0.50 second down) – 50(0.50 second up)

F2

Fine adjustment of anti-stick (burnback) voltage*

0.0 -9.9 – 9.9 V

F3

F6

F7

F8

Fine adjustment of slow-down speed*

Setting of up-slope time*

Setting of down-slope time*

Result display holding time

F10

Feed motor load current error detection level

F11 Fine adjustment of Job Memory Fine Adjustment

F13

Fine adjustment of pulse peak current*

F14

Fine adjustment of pulse peak time*

F15

Fine adjustment of base current*

0.0

0.0

0.0

20

-1.0 – 1.0 m/min.

0 – 10.0 seconds

0 – 10.0 seconds

5 – 60 seconds

70 20 – 150 %

OFF ON

䋨

VALID

䋩

/ OFF

䋨

INVALID

䋩

0 -150 A – 150 A

0 -1.5 (ms) – 1.5 (ms)

0 -60 A – 60 A

F16

Fine adjustment of L pulse peak current*

F17

Fine adjustment of L pulse peak time*

0

0

-150 A – 150 A

-1.5 (ms) – 1.5 (ms)

F18 Fine adjustment of L pulse base current*

F20

Keypad tone ON/OFF selection

F21

Conditions calling using external signals

F22 Changeover to Cored

F23

Changeover to Normal/Soft modes of DC Pulse

100 Ar SUS Solid

0 -60 A – 60 A

ON ON

䋨

VALID

䋩

/ OFF

䋨

INVALID

䋩

OFF

ON

䋨

VALID

䋩

/ OFF

䋨

INVALID

䋩

OFF

ON

䋨

Cored

䋩

/ OFF

䋨

Solid

䋩

OFF

ON

䋨

Soft

䋩

/ OFF

䋨

Normal

䋩

*

Welding conditions which can be preset to a JOB MEMORY number.

There is not the function of F4, F5, F9, F12 and F19. These functions set it in “OFF”.

ENTER

GAS

CHECK

INCHING

SPOT TIME

[17] [18] [11]

ON

ON

SPOT

CRATER

㧙

FILL.

[7]

T1

INITIAL

CONDITION

㧲

OFF

[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

[12]

DISPLAY

CHANGE

ON

INITIAL

COND.

SYNERG.

SYNERG.

INDIV.

VOLT. CONTROL

᳉᳊

CO

MILDSTEEL

MAG

㧔 80Ar/20CO

2

㧕

MI G

㧔

90Ar/10CO

2

㧕

MILDSTEEL

MILDSTEEL

BRAZING CuSi

㧔

MI G

100Ar

㧕

BRAZING

CuAl

AL/PURE

AL/MG

WIRE DIA.

㧔 mm 㧕

Refer to manual for recommended shielding gases

[3] [14] [2]

[15]

CRATER-FILL.

CONDITION

ON

[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

[5]

V

V d

%

JOB NO.

d

T2

WATER

[6]

A R C

CONTROL f

WAVE FREQ.

Ტ 126+ 10Უ

CONSTANT

PENETRATION

TORCH

STAINLESSSTEEL

STAINLESSSTEEL

MI G

㧔

97.5Ar/2.5CO

2

㧕

MI G

㧔

98Ar/2O

2

㧕

STAINLESSSTEEL

MI G

㧔 100Ar 㧕

INCONEL

㧔 OPTION 㧕

TITANIUM

㧔 OPTION 㧕

᳉᳊Ძ

MI G

㧔 100Ar 㧕

᳉᳊Წ

WELDING

METHOD

DC PULSE

DC WAVE PULSE

㧔

OPTION

㧕

DC

DC-TIG

DC-STICK

OP

[16] [1]

[9] [10]

[17] GAS CHECK key

[18] INCHING key

[19] LOAD key

[20] SAVE key

[21] ENTER key

―82―

No. P30051

14. SPECIFICATIONS (continued)

QUICK MANUAL

Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”.

Ԙ

Before Using the Welding Power Source

1. Settings of Welding Method

᳉᳊

CO

MILDSTEEL

MAG

㧔 80Ar/20CO

㧔

MI G

㧕

㧕

MILDSTEEL

MILDSTEEL

BRAZING CuSi

MI G

㧔 100Ar 㧕

BRAZING CuAl

AL/PURE

AL/MG

WIRE DIA.

㧔 mm

㧕

Refer to manual for recommended shielding gases

STAINLESS STEEL

STAINLESS STEEL

STAINLESS STEEL

MI G

2

㧕

MI G

2

㧕

MI G

㧔 100Ar 㧕

MI G

㧔

100Ar

㧕 TITANIUM

᳉᳊Ძ

㧕

᳉᳊Წ

WELDING

METHOD

DC PULSE

DC WAVE PULSE

㧔 OPTION 㧕

DC

DC-TIG

DC-STICK

OP

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.

2. Settings of Crater/Arc Spot

OFF

SPOT TIME

SPOT

CRATER

㧙 FILL

ON

ON

Use the CRATER-FILL key to select

OFF/ON(-)/ON( )/ SPOT.

3. Settings of Functions

ON

INITIAL

CURR.

SYNERG.

SYNERG.

INDIV.

VOLT. CONTROL

•

•

•

•

[SYNERGIC]: VOLT. CONTROL lamp is on.

[INDIVIDUAL]: VOLT. CONTROL lamp is off. set the function to “ON”.

[WATER]: TORCH lamp is on.

[AIR]: TORCH lamp is off.

ON

For using INITIAL CURRENT, press the INITIAL

CURR. key to set the function to “ON”.

[ON]: INITIAL CURR. lamp is on.

[OFF]: INITIAL CURR. lamp is off.

WATER

TORCH

For controlling voltage in the SYNERG. way, select

“SYNERG.” by pressing the VOLT.CONTROL key.

For activating a CONSTANT PENETRATION function,

[ON]: CONTANT PENETRATION lamp is on.

[OFF]: CONSTANT PENETRATION lamp is off.

For using a water-cooled torch, select “WATER” by pressing the TORCH key, then run cooling water.

4. Settings of Parameter

Parameter adjusting knob

6. Inching the Wire ԛ

Loading the Welding Conditions

WARNING

A m/min

T1

INITIAL

CONDITION

A m/min

Sec

Hz

MAIN

CONDITION

DISPLAY

CHANGE

V d

%

JOB NO.

CRATER-FILL

CONDITION

V d

T2

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

INCHING key. When pressing the INCHING key again, the wire feeding stops.

Now you have completed the preparations that are required to start welding. Press the torch switch to start welding.

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 or selector key. m/min

V d

INCHING

When adjusting SPOT TIME, press the SPOT

TIME key, then set SPOT TIME while turning the parameter adjusting knob.

SPOT TIME

[ON]: SPOT TIME lamp is on.

[OFF]: SPOT TIME lamp is off.

Ԛ

Presetting the Welding Conditions

A R C

CONTROL f

WAVE PULSE

Ტ 12 6+ 10Უ

NOTE:

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]: ARC CONTROL lamp is on.

[OFF]: ARC CONTROL lamp is off.

When the welding method is wave pulse, to obtain the desired bead appearance after turning on the WAVE PULSE lamp by pressing the WAVE PULSE key, set the wave pulse while turning the parameter adjusting knob.

[ON]: WAVE PULSE lamp is on.

[OFF]: WAVE PULSE lamp is off.

•

Turning the parameter adjusting knob clockwise increases the parameter. To decrease the parameter, turn the parameter adjusting knob counter-clockwise.

•

There may be unavailable parameters in some crater settings and function settings. Refer to

Section 10, “OPERATION” for details .

ENTER

㧲

J O B

MEMORY

LOAD

SAVE

ENTER

•

Protecting of the keys

Hold down the ENTER key + the F key at a time for a few seconds. The F lamp starts blinking. Blinking of the F lamp means the welding machine is in the key protection mode.

•

Releasing the key protection

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.

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.

1) 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.

2) 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.

3) Press the ENTER key to check for the parameter preset to the number.

4) When pressing the ENTER key again, the welding conditions preset to the welding condition number are retrieved.

Press the LOAD key.

Discontinue

Set the welding condition number while turning the parameter adjusting knob.

Press the ENTER key.

Press the SAVE key.

Press the ENTER key.

The readout mode quits

.

Press the LOAD key.

Discontinue

Press the DISPLAY CHANGE key to check the parameter value.

Reset the welding condition number.

The welding conditions are preset to the number you selected.

Ԝ

Settings of the (Internal) Functions

1) 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.

2) Set the function number while turning the parameter adjusting knob.

3) When pressing the F key, the function number lights up, then the function status blinks.

4) Set the function status while turning the parameter adjusting knob.

5) To cancel the function mode, hold down the F key for a few minutes.

5. Checking the Rate of Gas Flow

5 1 0 Lack of water pressure

Battery low (warning)

GAS

CHECK

Open the discharge valve of the gas cylinder, press the GAS CHECK key to check the rate of gas flow. After performing GAS CHECK, stop the gas flow by pressing the GAS

CHECK key.

9 ˜˜

When using this product with a robot of our company, refer to

“Application (arc welg)” in ow’al of the robot.

㧙

83

㧙

No. P30051

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-270C

㨯

DATE: 20XX

㨯

SERIAL NO.: P30051YXXXXXXXXXXX

P30051 Ver ###.###.000

㧙

84

㧙

DAIHEN Corporation

4-1, Koyocho-nishi,Higashinada-ku,

Kobe, Hyogo 658-0033

Phone: +81-78-275-2006, Fax: +81-78-845-8159

DAIHEN, INC. DAYTON OFFICE

1400 Blauser Drive

Tipp City, Ohio 45371, USA

Phone: +1-937-667-0800, Fax: +1-937-667-0885

OTC DAIHEN EUROPE GmbH.

Krefelder Strasse 675-677,

D-41066 Mönchengladbach, GERMANY

Phone: +49-2161-6949710, Fax: +49-2161-6949711

OTC Industrial (Shanghai) Co.,Ltd.

17F Majesty Building, 138 Pu Dong Da Dao Shanghai

The People's Republic of China

Post Code: 200120

Phone: +86-21-5882-8633, Fax: +86-21-5882-8846

OTC (Taiwan) Co.,Ltd.

2F No. 153, Huanbei Rd., Chung Li City,

Taoyuan Hsien, Taiwan R.O.C.

Phone: +886-3-461-3962, Fax: +886-3-434-2394

OTC DAIHEN Asia Co.,Ltd.

23/43, 16th F1.Sorachai Building,

23 Soi 63 Sukhumvit Road,

Klongtonnua, Wattana, Bangkok 10110, Thailand

Phone: +66-2-714-3201, Fax: +66-2-714-3204

OTC DAIHEN Korea Co.,Ltd

11B/L Hyeongok Industrial Complex, 463-1 Hyeongok-ri,

Cheongbuk-myeon, Pyeongtaek, Gyeonggi-do, 451-831, Republic of Korea

Phone: +82-31-686-7459, Fax: +82-31-686-7465

Upon contact, advise MODEL and MANUAL NO.