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MANUAL No.P30190
OWNER'S
MANUAL
FOR
CO2/MAG/MIG
DIGITAL INVERTER
M380S
MODEL: M-380S
P30190
INVERTER CONTROLLED WELDING POWER SOURCE
DO
NOT
DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
DAIHEN Corporation
WELDING PRODUCTS DIVISION
March 14, 2015
Upon contact, advise MODEL and MANUAL No.
P30190-1
No.P30190
TABLE OF CONTENTS
1. SAFETY INFORMATION����������������������� 2
2. ARC WELDING SAFETY PRECAUTIONS���������������
2
3. GENERAL NOTICE OF OPERATION�����������������.. 8
4. STANDARD COMPOSITION AND ACCESSORIES�����������
9
5. FUNCTION OF EQUIPMENT��������������������� 10
6. NECESSARY POWER SOURCE EQUIPMENT������������� 11
7. TRANSPORT AND INSTALLATION������������������ 12
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE����.. 14
9. WELDING PREPARATION���������������������� 17
10. OPERATION����������������������������. 23
11. APPLIED FUNCTION������������������������.. 59
12. MAINTENANCE AND TROUBLESHOOTING�������������� 66
13. PARTS LIST����������������������������. 73
14. SPECIFICATIONS�������������������������... 75
15. SERVICE AND SUPPORT���������������������� 79
-1-
No.P30190
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.
-2-
No.P30190
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.
Leaving accretive dust in the welding machine may cause an insulation deterioration and result in
electrical shock and fire.
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.
11. Remove dust by blowing moisture-free compressed air on each part periodically.
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.
-3-
No.P30190
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.
Leaving piled-up dust in the welding power source may cause insulation deterioration and result
in electrical shock and 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.
15. Remove dust by blowing moisture-free compressed air on each part periodically.
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.
-4-
No.P30190
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 injury, 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 injury. 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,
injury may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
-5-
No.P30190
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.
-6-
No.P30190
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
WARNING: The class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected to a public low voltage
system, it is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the equipment may be connected.
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.
M111025EP
-7-
No.P30190
3. GENERAL NOTICE OF OPERATION
3.1 Rated Duty Cycle
CAUTION
● Use this welding machine 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
ON
following: 380A, 50%
OFF
The
duty cycle of 50% means the machine must be
rested for 5 minutes after 5 minutes of continuous
welding at the rated current.
5 min.
5 min.
10 min.
Operation cycle of 50% duty cycle
Failure
to observe duty cycle limitations may cause
the temperature inside the welding power source to
exceed tolerance levels. This may contribute to
premature welding power source failure or product
damage.
The figure shown right indicates the relation between
welding current and duty cycle. Use the welding
power source within its usable range, based on the
appropriate duty cycle for the welding current.
M-380S
Usable range
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
power source within the lowest rated duty cycle of the
accessories.
3.2 Limitation of use
● This welding power source is not suitable for use in the rain.
● Do not use this welding power source for pipe thawing.
3.3 Applicable Welding Process and Wire Diameter
Applicable wire
G3Si1
(MILD STEEL SOLID)
Wire dia.(mmφ)
0.8
1.0
1.2
Applicable gas
CO2 or MAG(80%Ar, 20% CO2)
G3Si1 (Fill)
1.2
CO2
(MILD STEEL CORED)
NOTE: Use of mixture gas other than the mixture ratio of the gas mentioned above may not
properly adjust welding voltage at SYNERGIC control, etc.
-8-
No.P30190
4. STANDARD COMPOSITION AND ACCESSORIES
4.1 Standard Composition
● This welding power source is not included the accessories indicated in the boxes.
Preparation of the Accessories for welding.
Gas regulator
400V, 3φ
Digital remote control
(Optionally available)
Gas hose (3m)*
Shielding
Input cable
Control cable with wire feeder (2m)*
gas
Power cable for wire feeder (2m)*
Welding torch
Wire feeder
Base metal
Welding power source
Power cable for base metale(2m)*
Analog remote control
Control cable for remote control(3m)*
(Optionally available)
Ground a base metal if a local
law requires.
* Other length of cables/hoses is available. Refer to Section 11.4.2,”Extention Cable/Hose”.
● Input cable and grounding cable
For a switch box, the 2m input and grounding cables are from the back panel of welding power
source.
Input cable
4mm2 with 10mmφ terminal x 3
Grounding cable
4mm2 with 10mmφ terminal x 1
4.2 Preparation of consumables for welding
(1) Shielding gas
Use a suitable gas for welding method.
• Carbon dioxide gas (CO2 gas)
For welding (purity: 99.9% or more, moisture content: 0.002% or less)
• MAG gas
80% argon (Ar) + 20% carbon dioxide gas (CO2 gas)
(2) Welding Wire
-9-
No.P30190
5. FUNCTION OF EQUIPMENT
Main power lamp
5.1 Welding Power Source
- 10 -
No.P30190
6. NECESSARY POWER SOURCE EQUIPMENT
6.1 Welding Power Source Equipment (for commercial use)
WARNING
● When the welding power source is used in a humid environment such as a construction site,
on a steel plate, or on a steel structure, install an earth leakage circuit breaker.
CAUTION
● Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
welding power source.
Capacity of Necessary Power Source Utility
Power supply voltage
Tolerance range of fluctuation of power supply voltage
Installed capacity
Capacity of switch/circuit breaker
400V, 3 phases
400V±15%
18kVA or more
40A
6.2 Precautions for Use of the Engine Generator
CAUTION
● Use the auxiliary power of 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 waveform.
To prevent the engine generator or auxiliary power from being damaged, follow the instructions below.
● Set the output voltage of the engine generator to the voltage range between 400 and 420V at no-load
welding operation. Setting to extremely high output voltage may result in product damage.
● Use the engine generator with a damper winding that has twice that of the rated input of the welding
power source. 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, this may result in abnormal decrease in output current with arc loss during arc start etc. Ask
an engine generator manufacturer for a damper winding.
● Do not combine more than two welding power sources with an engine generator. The effect of each
welding power source may cause easy loss of arc.
- 11 -
No.P30190
7. TRANSPORT AND INSTALLATION
7.1 Transport
WARNING
Follow the instructions below to avoid trouble and product damage when carrying the welding
power source.
● Do not touch the live electrical parts inside or outside the welding power source.
● Be sure to disconnect the line disconnect switch when carrying the welding
power source.
● When hanging the welding power source by a crane, do not use the carrying
handle.
7.2 Installation
WARNING
When installing the welding power source, follow the instructions below to avoid a fire caused by
welding and physical injury from gas fumes.
● Do not place the welding power source near combustible materials and
flammable gas.
● Remove combustible materials to prevent dross coming into contact with
combustible objects. If that not possible, cover them with noncombustible
covers.
● To avoid gas poisoning and danger of suffocation, wear a gas mask or
adequately ventilate when the welding power source is used in the place
regulated by a local law.
● To prevent injury or poisoning caused by fume, wear a gas mask or weld at a
partial exhaust facility approved by the local regulation.
● Adequately ventilate or wear a gas mask when using the welding power source
in a tank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide
or argon gases are drifting there.
● When using the welding power source at a narrow space, comply with a trained
supervisor’s directions. And be sure to wear a gas mask.
● Do not operate the welding power source near the place where degreasing,
cleansing, and spraying are performed. Otherwise, poisonous gas may be
generated.
● Be sure to wear a gas mask or adequately ventilate when welding a coating
steel plate. (Poisonous gas and fume may be generated.)
- 12 -
No.P30190
7. TRANSPORT AND INSTALLATION (continued)
7.2 Installation (continued)
CAUTION
To prevent electromagnetic troubles, read the following.
Also, if electromagnetic troubles occur, check the following again.
Since large current abruptly flows inside the welding power source during welding, other
machines near the welding power source may be troubled due to electromagnetic noise
● Do not ground the welding power source commonly with other machines.
● Close and fix all doors and covers of the welding power source.
● Do not use an unnecessarily long cable.
● Place a base metal cable and a torch side cable as closely as possible.
In the event of electromagnetic trouble, follow the instructions below.
● Change the installation place of the welding power source.
● Keep the machines which may be affected away as far from the welding power source, cables
and welding site as possible.
● Add a noise filter to the input cables.
● Mount an input cable in the grounded metallic conduit.
● Shield the whole welding places from electromagnetic trouble. If electromagnetic troubles are
still not solved after following the above instructions, consult your nearest DAIHEN dealer.
CAUTION
Follow the instructions below when selecting an installation place of the welding power source.
● Do not install the welding power source in the place subject to direct sunlight and rain.
● Place the welding power source on a strong and stable surface.
● Install the welding power source in the place where the ambient temperature is between -10
and +40˚C.
● Altitude above sea level up to 1000m.
● Do not install the welding power source in the place where metal material such as spatter
enters the welding power source.
● Keep the install distance of 30cm between the welding power source and the wall or other
welding power source.
● Install a wind shield to protect arc from wind.
● Fix the gas cylinder to the stand only for gas cylinder.
- 13 -
No.P30190
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.
● Do not touch the live electrical parts of the welding power source.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected, following a local low.
● With the line disconnect switch inside the switch box all turned off, ground and connect the
welding power source.
● Do not use a cable with lack of capacity or a seriously damaged cable.
● Tighten and insulate the connections of cables.
● Surely attach the cover of the welding power source after connection of the cables.
8.1 Connecting of the Welding Power Source
Gas flow regulator
Power cable for wire feeder
②
Control cable for wire feeder ③
Shielding
gas
Gas hose ④
Wire
feeder
Welding power source
Welding torch ⑤
Power cable for base metal
①
Analog remote control
Control cable for remote control
(Optionally available )
Base metal
Ground a base metal if
a local law requires.
M10 terminal
Follow the steps below to attach the cables to the output connectors of the welding power source referring
to the illustrations of “Connection of the Welding Power Source” above.
①
②
③
④
⑤
⑥
Connect the power cable for base metal between the “base metal ○
- ” terminal and the base metal.
Attach the power cable for wire feeder to the “torch ○
+ ” output terminal.
Insert the control cable for wire feeder into the socket for wire feeder.
Attach the gas hose to the gas outlet on the wire feeder.
Connect the welding torch to the wire feeder.
Connect the hoses for water supply and for condensed water to the water cooler. (When using a
water-cooled torch.)
- 14 -
No.P30190
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
8.2 Connecting of the Gas Hose
WARNING
● There is a danger of suffocation caused by lack of oxygen when shielding gas is
left flowing in a closed place. Be sure to turn off the shielding gas at the main
when the welding power source is not in use.
CAUTION
● Be sure to connect the gas hose after fixing gas cylinder to the stand, as physical injury may
result from the gas cylinder toppling over.
● Attach a proper gas regulator to a gas cylinder. Failure to observe the demand may result in
physical injury. The gas regulator for high pressure gas must be used.
① Securely attach the gas hose to the gas inlet located on the rear side of the wire feeder with a wrench,
etc.
② Fix the nut for attaching the gas cylinder with a wrench, etc.
③ Securely attach the gas hose to the gas outlet with a wrench, etc.
Nut for attaching gas cylinder
Gas regulator
②
③
Gas outlet
Wire feeder
①
Gas Hose Fitting Size: 9/16-18 UNF
- 15 -
Gas cylinder
No.P30190
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
8.3 Grounding and connection of input side
WARNING
Follow the instructions below to avoid electric shock.
Touching the live electrical parts may result in fatal electric shock and severe burn.
● Do not touch the live electrical parts of the welding power source.
● Have a qualified electric engineer ground the case of the welding power source and the base
metal or jig electrically connected in accordance with a local low.
● With the line disconnect switch in the switch box all touched off, ground and connect the
welding power source.
CAUTION
● Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
welding power source.
Mount a switch with fuse or a circuit breaker
on each welding power source.
Base metal
Grouding cable
Ground a base metal if
a local law requires.
Input cables
Surely connect the input and grounding cables(4mm2)
to the circuit breaker .
CAUTION
Be sure to ground the case of the welding power source.
Use a grounding cable 4mm2 or more cross section.
● 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, you may suffer from electric shock. Be sure to ground the case of
the welding power source.
- 16 -
No.P30190
9. WELDING PREPARATION
9.1 Preparing the Protective Equipment
To protect you from gas generated from welding, fume, and lack of oxygen, wear
protective equipment
● To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately ventilate
when the welding power source is used in the place regulated by a local law.
● To prevent disorder or poisoning caused by fume, wear a gas mask or weld at a partial exhaust
facility approved by the local regulation.
● Adequately ventilate or wear a gas mask when using the welding power source in a tank, a
boiler, a hold of a ship, because heavier gas such as carbon dioxide or argon gases are
drifting.
● When using the welding power source at a narrow space, comply with a trained supervisor’s
directions. And be sure to wear a gas mask.
● Do not operate the welding power source near the places where degreasing, cleansing, and
spraying are performed. Otherwise, poisonous gas may be generated.
● Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate.
(Poisonous gas and fume may be generated.)
NOTE: Install a windshield to protect arc from wind when using an electric fan for ventilation or
when welding outdoors. Failure to observe the demand may result in poor welding.
CAUTION
Use the protective equipment to protect you and other workers from arc rays,
spattering dross, and noise from welding operation.
● When performing or monitoring welding operation, wear an eye protector with a good light
blocking effect or face shield.
● Wear protective glasses to protect your eyes from the spattering dross.
● Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, and
leather apron.
● Install protective screens or barriers to protect the eyes of others in the work area from arc ray.
● Wear an ear protector when noise level is high.
- 17 -
No.P30190
9. WELDING PREPARATION (continued)
9.2 Operating the Switches and Controlling the Gas Flow Rate Regulator
CAUTION
● Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as
burst of high-pressure gas may result in physical injury.
NOTE: Gas checking automatically stops in two minutes.
Gas flow rate adjusting knob
① Turn on the line disconnect
switch. (400V, 3φ)
③ Set the gas flow rate regulator to
“SHUT” , then turn on gas at the
main.
⑤ Set the gas flow rate adjusting knob
to “OPEN” to adjust the gas flow rate.
④ Press the GAS CHECK
key. (The GAS CHECK
lamp lights up.)
② Place the power switch in the “I” (ON)
position.
⑥ Press the GAS CHECK
key again. (The GAS
CHECK lamp goes out.)
9.3 Inching Operation
WARNING
● Do not look into the tip hole to check for the rate of wire feeding while inching.
● Do not bring torch tip close to face, eyes and body.
CAUTION
● Keep away your hands, fingers, hair or clothes from the rotating parts of the feed
roll, etc. to prevent you from being caught into the rotating parts while inching.
Parameter adjusting knob
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 10mm from the end of the torch. When
adjusting wire feeding speed, 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 from the remote control, the
INCHING key on the front panel does not function.
INCHING key
- 18 -
No.P30190
9. WELDING PREPARATION (continued)
9.4 Welding Conditions
When setting to the improper welding conditions, the following troubles will occur.
Cause
Wire extension is too long.
Wire extension is too short.
Welding voltage is too high.
Welding voltage is too low.
Welding current is too high.
Travel speed is too fast.
Trouble
・Long Arc length
・Wide bead width
・Poor shield
・Short arc length
・Easy generation of spatter
・Long arc length
・Wide bead width
・Shallow penetration and flat bead
・Stick to base metal and easy generation of spatter
・Narrow bead width
・Deep penetration and low excess metal
・Wide bead width
・Deep penetration and high excess metal
・Narrow bead width
・Shallow penetration and low excess metal
- 19 -
No.P30190
9. WELDING PREPARATION (continued)
9.4 Welding Conditions (continued)
The data in the tables below is only for reference. Please find the optimum welding conditions for
weldment shape and welding position.
9.4.1 Example CO2 Welding Conditions
(1) Example Welding Conditions of Horizontal Fillet
ℓ
Plate
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
6.0
9.0
12.0
Leg
length
ℓ (mm)
2.5 - 3.0
2.5 - 3.0
3.0 - 3.5
3.0 - 3.5
3.0 - 4.0
4.0 - 4.5
5.0 - 6.0
6.0 - 7.0
7.0 - 8.0
Wire
diameter
(mmφ)
1.0
1.0 - 1.2
1.0 - 1.2
1.0 - 1.2
1.0 - 1.2
1.2
1.2
1.2
1.2
Welding
current
(A)
70 - 100
90 - 120
100 - 130
120 - 140
130 - 170
190 - 230
250 - 280
280 - 300
300 - 340
Welding
voltage
(V)
18 - 19
18 - 20
19 - 20
19 - 21
19 - 21
22 - 24
26 - 29
29 - 32
32 - 34
Travel
speed
(cm/min)
50 - 60
50 - 60
50 - 60
50 - 60
45 - 55
45 - 55
40 - 50
35 - 40
30 - 35
CO2 gas
flow rate
(ℓ/min)
10 - 15
10 - 15
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
20 - 25
Travel
speed
(cm/min)
50 - 60
50 - 60
50 - 60
50 - 60
45 - 55
45 - 55
40 - 50
40 - 45
25 - 35
CO2 gas
flow rate
(ℓ/min)
10 - 15
10 - 15
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
20 - 25
(2) Example Welding Conditions of Down Fillet
ℓ
Plate
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
6.0
9.0
12.0
Leg
length
ℓ (mm)
2.5 - 3.0
2.5 - 3.0
3.0 - 3.5
3.0 - 3.5
3.0 - 4.0
4.0 - 4.5
5.0 - 6.0
6.0 - 8.0
10.0 - 12.0
Wire
diameter
(mmφ)
1.0
1.0 - 1.2
1.0 - 1.2
1.0 - 1.2
1.0 - 1.2
1.2
1.2
1.2
1.2
Welding
current
(A)
70 - 100
90 - 120
100 - 130
120 - 140
130 - 170
200 - 250
280 - 300
300 - 350
320 - 350
- 20 -
Welding
voltage
(V)
18 - 19
18 - 20
19 - 20
19 - 21
20 - 22
23 - 26
29 - 32
32 - 34
33 - 36
No.P30190
9. WELDING PREPARATION (continued)
9.4 Welding Conditions (continued)
9.4.1 Example CO2 Welding Conditions (continued)
(3) Example Welding Conditions of I Shape Butt without Backing Plate
ℓ
Plate
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
Root
gap
g (mm)
0.0
0.0
0.0 - 0.5
0.5 - 1.0
1.0 - 1.2
1.2 - 1.5
Wire
diameter
(mmφ)
1.0
1.0
1.0
1.0 - 1.2
1.0 - 1.2
1.2
Welding
current
(A)
70 - 80
80 - 100
100 - 110
110 - 130
130 - 150
150 - 170
Welding
voltage
(V)
17 - 18
18 - 19
19 - 20
19 - 20
19 - 21
21 - 23
Travel
speed
(cm/min)
45 - 55
45 - 55
50 - 55
50 - 55
40 - 50
40 - 50
CO2 gas
flow rate
(ℓ/min)
10
10 - 15
10 - 15
10 - 15
10 - 15
10 - 15
6.0
1.2 - 1.5
1.2
220 - 260
24 - 26
40 - 50
15 - 20
9.0
1.2 - 1.5
1.2
320 - 340
32 - 34
45 - 55
15 - 20
Number
of
layers
1
1
1
1
1
1
Front 1
2
Back 1
Front 1
2
Back 1
(4) Example Welding Conditions of Single and Double Grooves
Plate
thickness
t (mm)
Bevel
shape
Root
gap
g (mm)
Root
face
h(mm)
Wire
diameter
(mmφ)
Welding
current
(A)
Welding
voltage
(V)
Travel
CO2 gas Number
flow rate
of
speed
layers
(cm/min) (ℓ/min)
30 - 40
Front
12
0.0 - 0.5
4-6
16
1.2
300 - 350
32 - 35
45 - 50
25 - 30
30 - 35
Back
Front 2
20 - 25
Back
g
16
30 - 35
Front
30 - 35
Back
0.0
g
(5) Example Welding Conditions of Lap Fillet
A
B
Plate
thickness
t (mm)
1.2
1.6
2.0
2.3
3.2
4.5
Wire
diameter
(mmφ)
1.0
1.0 - 1.2
1.0 - 1.2
1.0 - 1.2
1.0 - 1.2
1.2
Welding
current
(A)
80 - 100
100 - 120
100 - 130
120 - 140
130 - 160
150 - 200
Welding
voltage
(V)
18 - 19
18 - 20
18 - 20
19 - 21
19 - 22
21 - 24
- 21 -
Travel
speed
(cm/min)
45 - 55
45 - 55
45 - 55
45 - 50
45 - 50
40 - 45
Aim
position
A
A
A or B
B
B
B
CO2 gas
flow rate
(ℓ/min)
10 - 15
10 - 15
15 - 20
15 - 20
15 - 20
15 - 20
No.P30190
9. WELDING PREPARATION (continued)
9.4 Welding Conditions (continued)
9.4.2 Example CO2 Welding Conditions of Wire with Flux
● Example Welding Conditions of Horizontal Fillet
ℓ
Leg length
ℓ (mm)
4
5
6
7
8
9
Wire diameter
(mmφ)
1.2
1.2
1.2
1.2
1.2
1.2
Welding current
(A)
250
270
270
280
300
320
Welding voltage
(V)
27
29
29
30
31
32
9.4.3 Example Welding Conditions of MAG Short Arc
Material: Mild steel, Gas: Mixture gas of Ar + CO2 (10-15 ℓ/min)
Wire
Plate
Welding
Joint
Gap
diameter
thickness
current
Geometry
(mm)
t (mm)
(A)
(mmφ)
1.0
0.8 - 1.0
0.0
50 - 55
1.2
0.8 - 1.0
0.0
60 - 70
1.6
0.8 - 1.0
0.0
100 - 110
Butt
2.3
1.0 - 1.2
0.0 - 1.0
110 - 120
3.2
1.0 - 1.2
1.0 - 1.5
120 - 140
4.0
1.0 - 1.2
1.5 - 2.0
150 - 170
- 22 -
Travel speed
(cm/min)
50
50
45
40
30
30
Welding
voltage
(V)
13 - 15
14 - 16
16 - 17
17 - 18
17 - 19
18 - 21
Travel
speed
(cm/min)
40 - 55
30 - 50
40 - 60
30 - 40
25 - 30
25 - 40
No.P30190
10. OPERATION
● Use "Quick Manual" in the section 14. For reference.
Front Panel
[17] [16]
[13] [14]
[15]
[3]
[6]
[10]
[9]
[2]
[1] ▼ (WELDING METHOD) key
[2] φ mm (WIRE DIA) key
[3] A/m/min selector key
[4] V/± selector key
[5] Parameter adjusting knob
[6] ▼ (CRATER-FILL) key
[7]
(DISPLAY CHANGE) key
[8] ARC (CONTROL) key
[9] F (FUNCTION) key
[4]
[7]
[11]
[1]
[10] START (INITIAL CURR.) key
[11] VOLT. CONTROL key
[12] CONSTANT PENETRATION key
[13] GAS CHECK key
[14] INCHING key
[15] LOAD key
[16] SAVE key
[17] ENTER key
- 23 -
[5]
[12]
[8]
No.P30190
10. OPERATION (continued)
CAUTION
● This welding power source 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 power source safely.
● Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle
limitation may result in damage to the welding power source.
When reading the operating instructions described below, unfold Page 77 so that you can read them
confirming the location of the keys on the front panel.
10.1 Basic Settings
10.1.1 Setting of Welding Mode
Choose the welding mode using the WELDING METHOD key [1] and the WIRE DIA (mmφ) key
[2] in accordance with the welding method and wire diameter used. The selectable welding modes
are shown in the table below.
WELDING METHOD
TYPE OF WIRE
GAS
G3Si1
(MILD STEEL SOLID)
MAG
G3Si1
(MILD STEEL SOLID)
CO2
G3Si1 (Fill)
(MILD STEEL CORED)
CO2
WIRE DIA. (mmφ)
0.8
1.0*
1.2*
0.8
1.0
1.2
1.2
NOTE:
● MAG gas is mixture gas of 80% argon and 20% carbon dioxide gas.
● * shows soft arc modes in standard. Refer to Section 10.2.1 (12), “Setting of Soft Arc
Mode: F12” on page 38 for more information on soft arc mode.
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, set the wire diameter with the WIRE DIA (mmφ) key [2].
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 then the welding power source to stop.
For example, when selecting “MILD CORED CO2” while setting "MILD SOLID CO2 φ1.0 " with the
WELDING METHOD key [1], the " MILD CORED CO2" lamp blinks, which means the preset
combination is incorrect. In that case, select a wire diameter using the WIRE DIA (mmφ) key [2] or
reset the welding method using the WELDING METHOD key [1].
- 24 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (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 [3]) is lit changes over displays of
current setting and wire feeding speed.
Pressing the A/m/min selector [3] 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
Pressing the key while the V/± lamp (located at
the upper left of the V/± selector [4] key) is lit
changes over displays of voltage setting and
SYNERGIC fine adjust. Pressing the V/±
selector key [4] while the V/± lamp is not lit
causes the V/± lamp to light. While the V/± lamp
is lit, voltage can be adjusted using the
Parameter adjusting knob [5].
Select a parameter using this key.
[Parameter selector]
Choose a desired parameter using the DISPLAY CHANGE key [7]. Display in the displays
are changed according to the parameters you select and the UNIT lamp of the parameter
lights up.
UNIT lamps
!
A
sec
m/min
V
±
JOB No.
displays
[ Parameter displays]
● When the wire feeding speed is displayed, you can not set to the maximum feeding speed
using the Parameter adjusting knob [5] depending on the welding mode settings (especially
for large diameter). You are only allowed to set the wire feeding speed 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 feeding speed. Use the values in the displays as approximations.
- 25 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (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 the pre-flow time while turning the Parameter adjusting
knob [5]. The setting range of pre-flow time covers 0 to 10 seconds.
(2) Setting of the Initial Conditions
The initial conditions can be chosen only when initial current is 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 REPEAT crater, a crater condition can be selected. Once a crater condition is
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 [5]. The setting range of post-flow time covers 0 to 10 seconds.
- 26 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.3 Setting of the CRATER-FILL Functions
Crater
Crater is a depression left at the termination
of the weld. As it may cause cracks and poor
welding, a crater treatment called crater-filler
is used to fill in the depression.
Bead
Pool
Pressing CRATER-FILL key [6] changes the crater-fill mode.
When giving a crater treatment, set the CRATER-FILL key [6] to "ON" .
Crater
Initial
Current
Timing Chart
ON
OFF
Torch Switch
Pre-flow time
No-load voltage
Anti-stick (Burnback) time
Gas Flow
Post-flow time
Welding Voltage
OFF
Wire Feeding Speed
Slow-down speed
Welding Current
MAIN WELDING
● Keep the torch switch pressed and held during welding.
- 27 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.3 Setting of the CRATER-FILL Functions (continued)
Crater
Initial
Current
Timing Chart
ON
ON
OFF
OFF
Torch Switch
Anti-stick (Burnback) time
Pre-flow time
No-load voltage
Gas Flow
Post-flow time
OFF
Welding voltage
Slow-down speed
Wire Feeding Speed
Welding current
Crater current
Welding Current
ON
MAIN WELDING
CRATER
ON
ON
OFF
OFF
Torch Switch
Pre-flow time
No-load voltage
Anti-stick (Burnback) time
Gas Flow
Post-flow time
ON
Welding Voltage
Slow-down speed
Wire Feeding Speed
Welding current
Initial current
Crater current
Welding Current
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 period.
● Even if the CONSTANT PENETRATION switch is set to "ON" during the CRATER period,
constant penetration will not be carried out.
- 28 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.5 Adjusting Welding Voltage
Using the VOLT. CONTROL key [11] 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 [11]) 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 [5]. When changing the voltage adjustment method from
INDIVIDUAL to SYNERGIC, the present voltage setting value is reflected. The voltage setting
value after the voltage adjustment method is changed is not that of synergic center.
(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 [11]) 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 [5]. In addition, it is
also possible to change over the display setting in the right display using the V/± selector key [4].
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 -30 to +30. Even when changing the voltage adjustment method from
SYNERGIC to INDIVIDUAL, the voltage setting value right before the voltage adjustment method
is changed reflected.
The welding voltage at SYNERGIC control, etc. may be not adjusted properly with use of mixture
gas other than the mixture ratio of the following gas
●
MAG gas
80% argon (Ar) + 20% carbon dioxide (CO2)
- 29 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.6 CONSTANT PENETRATION Function
For conventional CO2/MAG welding, as the wire extension changes, welding current changes
and base metal penetration depth and bead width change. By setting the constant penetration
function to “ON”, wire feeding speed is automatically adjusted so that constant current is 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 [12].
Penetration control ON/OFF selection can be done by using the CONSTANT PENETRATION
key [12]. 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.
NOTE: The PENETRATION CONTROL function does not function during the INITIAL and
CRATER period. When setting to Arc Spot, the PENETRATION CONTROL function
can not be used. The PENTRATION CONTROL function is automatically set to
“OFF”.
10.1.7 Arc Characteristics Function
When pressing the ARC CONTROL key [8] 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 [8]) 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 [5]. The setting range is -99 to +99. Pressing the ARC CONTROL key
[8] again or pressing the DISPLAY CHANGE key [7] 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 (down to -99), arc condition becomes harder. As the setting value
of the arc characteristic is set in the positive direction, arc condition becomes softer (up to 99).
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
power source in the high current range, set the setting value of the arc characteristic in the
positive direction to obtain good welding results. If you cannot 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 GAS CHECK
Function (with gas save function)
GAS
This function is used when opening the discharge valve of the shielding gas and when adjusting
the gas flow rate. When pressing the GAS CHECK key [13] 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 [13] again turns off the GAS CHECK lamp and stops discharging gas. In more than
two minutes after the GAS CHECK key [13] 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 even continue to flow during down period.
- 30 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.9 INCHING
Function
When pressing the INCHING key [14], the INCHING lamp (located at the upper left of the
INCHING key) light up and begins feeding wire. Releasing the key stops wire feeding and the
INCHING lamp to go out. When changing the wire feeding speed by turning the Parameter
adjusting knob [5], make sure that the INCHING lamp lights up. When connecting to the analog
remote control (optionally available), the INCHING key [14] on the front panel cannot 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.
10.1.10 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 seconds. When you want
to change the parameters during welding, press the DISPLAY CHANGE key [7] to go to the
“parameter setting values display” mode. When no welding operation is not carried out for about
5 seconds or the DISPLAY CHANGE key [7] 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 10.1.11, “Using the Parameter Adjusting
Knob” for the parameters that can be adjusted using the Parameter adjusting knob [5] 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 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 [9]. The
setting value is displayed in the left digital and the "sec" lamp lights up. The setting range of the
result display time is 0 to 60 seconds.
NOTE: In the case where the less than one-second welding such as tack welding, etc. is
performed, the correct results of the welding are not displayed.
(4) Display of Error Message
If an error is detected in the power source of electric welding, an error number indicating error
messages blinks. See Section 11.1, " How to Solve an Error ".
NOTE: The average output values shown in the displays are processed by software and
are not guaranteed as control data of measuring instruments.
- 31 -
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.11 Using the Parameter Adjusting Knob
When adjusting parameters using the Parameter adjusting knob [5] during welding, change over
the display mode to the “parameter setting value display” mode by pressing the DISPLAY
CHANGE key [7]. The initial conditions, the main conditions, and the crater fill conditions can be
changed during the INITIAL welding, MAIN welding, and CRATER welding respectively.
Pressing the ARC CONTROL key [8] after changing to the “parameter setting value display”
mode adjusts the pulse arc characteristics.
10.1.12 Using the Analog Remote Control K5416Z (optional accessory)
The welding power source 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 cannot be adjusted by using the Parameter
adjusting knob [5] 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 at the analog
remote control, in the displays of the front panel. Once the analog remote control is
disconnected, the setting values preset at the remote control are deleted.
NOTE: With the power switch turned off, connect or disconnect the analog remote
control.
WELDING CURRENT knob
To set welding current.
WELDING VOLTAGE knob
INCHING button
Pressing this switch feeds wire only. The
wire feeding speed changes by turning
the WELDING CURRENT knob on the
- 32 -
< INDIVIDUAL adjustment>
Set welding voltage.
< SYNERGIC adjustment >
Aligning to mark “●” achieves the standard
setting. Turn the knob in the "HIGH"
direction to increase voltage and in the
"LOW" direction to decrease voltage.
No.P30190
10. OPERATION (continued)
10.1 Basic Settings (continued)
10.1.12 Using the Analog Remote Control K5416Z (optional accessory) (continued)
● When making the INDIVIDUAL adjustment:
Selecting the "INDIVIDUAL" adjustment allows you to set welding current and welding voltage
individually.
● When making the SYNERGIC adjustment:
When selecting the "SYNERGIC" adjustment, welding voltage is automatically adjusted only
by turning the WELDING CURRENT knob. To finely adjust welding voltage, use the
VOLTAGE. knob.
NOTE: It is possible to adjust low-current region, where a small-diameter wire is used
for weld, and to finely adjust welding current by replacing with the full-scale
200A plate (supplied). When replacing the scale plate, press the F key [9] and
change the initial value of F9 to 200. Refer to Section 10.2.1(9), “Selection of
Scale Plate of Analog Remote Control”.
- 33 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings
10.2.1 Using Internal Functions
● How To Use Internal Functions
① When holding down the F key [9] 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 selected
by using the Parameter adjusting knob [5].
!
blink
A
m/min
light
sec
V
±
JOB No.
The above example indicates that F5 is set to “on”.
② When pressing the F key [9] again after selecting the desired function number, the function
number lights and the function conditions blinks. Under this condition, functions can be set
by using the Parameter adjusting knob [5].
!
light
A
m/min
sec
blink
V
±
JOB No.
The above example indicates that F4 is set to “0”.
③ Pressing the F key [9] again causes the function number to light up and returns to the step.
To leave the function mode, hold down the F key [9] for a few seconds.
NOTE: In the function mode, no confirmation for changing the function is carried out
when it is changed. Upon change of the setting by using the Parameter
adjusting knob [5], the change becomes valid. Therefore, before changing a
function setting, make sure that the correct function number is selected and
that the proper setting value for the function number is set.
- 34 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.1 Using Internal Functions (continued)
The following functions can be adjusted by using the F key [9].
(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 -50 to +50
and the unit is 0.01 seconds.
Ex. 1)
Ex. 2)
When the setting value of Anti-stick (Burnback) time is “25”,0.25 seconds is added to
the standard Anti-stick (Burnback) time.
When the setting value of Anti-stick (Burnback) time is “-10”,0.1 seconds is subtracted
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 method and wire diameter 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 -9.9 to +9.9V.
(3) Fine Adjustment of Slow-down Speed: F3
Slow-down speed means the speed to feed wire that is slower than the feeding speed 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 slowdown 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 -1.0 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.
- 35 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.1 Using Internal Functions (continued)
(4) Selection of Auto/Semi-automatic: F4
"Automatic machine mode" and "Semi-automatic mode" can be switched by using F4.
Welding power source has two Automatic modes. Settings and functions of each mode are listed
below.
F4
0 (factory setting)
1
2
Mode
Semi-automatic
Automatic 1
Automatic 2
The operation stop terminal
By turning on the
Return from error
(Open → Short-circuit)
power supply again
Or by turning on the power supply again
Return from operation
By turning on the
By short-circuiting the operation stop
stop
power supply again
terminal
Applied for approx. 0.2 seconds after the
Stuck wire removal
Not applied
anti-stick completion
voltage
By panel, analog
By panel, analog
remote control or
Welding current and
By external voltage
remote control or
digital remote
(*1)
voltage setting
digital remote control
control
Inching from interface (*2)
Unusable
Usable
*1: The current and the voltage of main condition cannot be set with the Parameter adjusting
knob [5] on the front panel.
*2: This is a case for short-circuited between 5 and 6 of CON2 without using analog remote
control.
● Automatic 1 mode
For combination with the robot etc., this is used when the current and the voltage setting are
input by using an external voltage. And connection is shown in the figure below. For
connection, current capacity of an external power source must be 0.5mA or more.
4
Remote control
receptacle
Acceptable plug
Spec.
Part No.
3
1
DPC25-6A
4730-009
0V~15V
E1
capacity
MIN0.5mA
CON2 (Welding Voltage
signal)
E2
(Welding Current
signal)
CAUTION
● Supply 0 to 15V to E1 and E2. Exceeding 15V may result in damage to the control
circuit of the welding power source.
● Be sure to finish setting and inputting before 100 msec when starting signal is
input. Inputting after starting signal is input or at starting signal may result in
unstable start.
● Automatic 2 mode
Use this mode when setting all settings from front panel or JOB memory function, even
though you use the welding power source with an automatic machine.
Use this mode when you combine digital remote control with an automatic machine.
- 36 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.1 Using Internal Functions (continued)
(5) External Input Voltage : F5
Activate F5 when using the welding power source in combination with a robot or an automatic
machine, and also the maximum command voltage output by the robot is up to 10 or 14V.
Factory setting is set to “15.0”. For changing the setting, set F5 to “14.0” or “10.0” to activate the
function.
* It is necessary to set F4 to “Automatic 1 mode” to make this function valid.
The relationship between external current command voltage, external voltage command voltage,
welding current, and welding voltage is shown as follows. Use these graphs as guidelines only as
the values (of welding current and welding voltage corresponding to welding conditions setting
voltage) may differ from the indications in the graphs due to wire extension length and dragging
of output cable.
40
350
35
300
30
Welding voltage (V)
Welding current (A)
400
250
200
150
100
External voltage15V MAX
External voltage14V MAX
External voltage10V MAX
50
0
0
5
10
15
25
20
15
10
External voltage15V MAX
External voltage14V MAX
External voltage10V MAX
5
0
0
5
10
15
External command voltage (V)
External command voltage (V)
※External command voltage 15V MAX. : When setting [F5] to [15.0] (At factory setting)
※External command voltage 14V MAX. : When setting [F5] to [14.0]
※External command voltage 10V MAX. : When setting [F5] to [10.0]
(6) Setting of Up-slope Time: F6
Upslope time means the time for increasing welding conditions stepwise when initial current is
changed to main current. The upslope time at shipment is set to 0 seconds, but can be adjusted
by using F6. The setting range is 0 to 10 seconds. This function is used when wire burns up
while conditions are changed over due to the great difference of setting between initial current
and main current.
(7) Setting of Down-slope Time: F7
Down-slope time means the time for decreasing welding conditions stepwise when main current
is changed to crater current. The down-slope time at shipment is set to 0 seconds, but it can be
adjusted by using F7. The setting range covers 0 to 10 seconds. 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.
(8) Setting of Result Display Holding Time: F8
After completion of welding, the average value of output current and output voltage for last one
second blinks for about 20 seconds, but the result display holding time can be set by F8 using F
key [10]. The setting range of result display holding time is 0 to 60 seconds.
- 37 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings
10.2.1 Using Internal Functions (continued)
(9) Selection of Scale Plate of Analog Remote Control: F9
When the analog remote control (optional accessory) is used, it is possible to finely adjust a
low-current region where a small-diameter wire is used for weld by replacing the full-scale 350A
scale plate with the full-scale 200A scale plate (supplied). The analog remote control scale
plate is changed over by using the F key [9]. Set to "200" by using F9.
(10)
Setting of Feed Motor Load Current Error Detection Level: F10
In the event that contact resistance is applied to the wire feed line section due to worn liners,
defective tips, etc., the current supplied to the motor increases (when feed roll lacks smooth
movement). Monitoring current of this motor can detect defective feed. The motor load current
detection level at shipment is 70% (2.0A) of the rated motor current 2.8A (continuous), and if the
current exceeds the setting value, "E-" and "820" in the displays are displayed after welding. In
that case, the welding power source does not stop operation immediately. And it self-restores by
re-welding. This detection level can be changed by changing the setting of F10 using F key [9].
The setting range of motor load current trouble detection level is 20 to 150%.
NOTE: Adjust the detection level optionally and use it in the best detection level, because
the application environment and judgment criteria vary depending on wires and
torches and customers respectively.
(11)
Setting of Job Memory Fine Adjustment: F11
Under the welding conditions already stored in JOB MEMORY, current can be finely adjusted
with the WELDING CURRNET knob located on the optional analog remote control and voltage
with the VOLTAGE knob. The initial setting of F11 is “oFF”. In case of changing this function to
valid, set the F11 to numeric values other than “oFF”. The JOB MEMORY fine adjustment can be
activated by F11 using F key [9]. The function is preset to “oFF” at shipment. Setting both
CURRENT and VOLTAGE knobs to the center of the scales allows the machine to work under
the conditions already stored in the JOB MEMORY. To increase welding current slightly, turn the
knob clockwise. To decrease slightly, turn it counter-clockwise. Welding voltage can be adjusted
in the same manner. F11 performs the fine adjustment. The setting range is from ±1 to ±30% .
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.
(12)
Setting of Soft Arc Mode: F12
The welding power source features SOFT ARC mode. Use of the SOFT ARC mode enables you
to obtain softer arc. To switch the arc mode from STANDARD to SOFT, set F12 to “on”. When
setting a wire method to CO2 MILD STEEL SOLID and a wire diameter to 1.2/1.0, the ARC
CONTROL lamp (located at the left upper side of the ARC CONTROL lamp) lights up. The mode
can be held in memory for each welding condition number.
- 38 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.1 Using Internal Functions (continued)
(13) Changeover to Wire feeding speed Setting: F15
When F15 is set to “oFF”, welding condition can be set by current setting. Meanwhile, when F15
is set to “on”, welding condition can be set by wire feeding speed.
● Characteristics : [F15][oFF]
・ Wire feeding speed is changed depending on each welding mode even if current setting value
is the same.
・ Refer to Section 10.2.1(4) “External Input Voltage” for details regarding external command
voltage and setting current.
Wire feeding speed(m/min.)
● Characteristics : [F15][on]
・ Output current is changed depending on each welding mode even if wire feeding speed setting
is the same.
・ See the relation between external voltage and wire feeding speed indicated below.
ワ
イ
ヤ
送
給
速
度
20
15
10
(m/分) 5
External
voltage15V MAX
外部指令電圧15VMAX
External
voltage14V MAX
外部指令電圧14VMAX
External
voltage10V MAX
外部指令電圧10VMAX
0
0
5
10
15
External電流(ワイヤ送給速度)指令電圧(V)
command voltage(V)
※External command voltage 15V MAX. : When setting [F5] to [15.0] (At factory setting)
※External command voltage 14V MAX. : When setting [F5] to [14.0]
※External command voltage 10V MAX. : When setting [F5] to [10.0]
※When command voltage is the maximum, maximum wire feeding speed is 22m/min. However, it
may not reach to the maximum depending on the welding mode.
※Minimum wire feeding speed is about 1.1-2.8m/min. (It depends on the welding mode.)
Minimum wire feeding speed does not change if command voltage is supplied, which may be in
1.1-2.8m/min. or below.
- 39 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.1 Using Internal Functions (continued)
(14) Change of a peculiarly crater-filler sequence: F17
Setting of initial time: F18
Setting of crater-filler time: F19
INITIAL condition and CRATER-FILL. condition can be outputted by using Crater ON. In case of
connecting to an automatic machine, it is necessary that torch switch signal of crater-sequence
is generated by external sequence. If this function is activated, INITIAL condition and CRATERFILL. condition can be outputted by torch switch signal sequence which is the same as Crater
OFF.
INITIAL and CRATER times can be set with F18 and F19. The setting range is 0 to 10 seconds.
The INITIAL and CRATER-FILL. conditions can be set from the front panel. The INITIAL
condition can be selected when INITIAL is “ON”.
“OFF” LED of Crater-filler blinks by turning F17 to “on” in case that crater-filler is “OFF”. If this
function is valid, CRATER-FILL. key [6] cannot be used.
Initial
condition
Timing chart
ON
OFF
Torch switch
Pre-flow time
Anti-stick time
No-load voltage
Gas flow
Post-flow time
OFF
Voltage of between
output terminals
Slow-down speed
Crater-filler time(F19)
Wire feeding speed
Welding current
Crater-filler current
Welding current
Main welding
Crater
ON
OFF
Torch switch
Pre-flow time
Anti-stick time
No-load voltage
Gas flow
Post-flow time
ON
Voltage of between
output terminals
Initial time (F18)
Slow-down speed
Crater-filler time(F19)
Wire feed speed
Welding current
Initial current
Crater-filler current
Welding current
Initial
Main welding
Crater
● In case that the INITIAL condition is “ON” and the torch switch is turned on and current is
flown, the INITIAL condition is outputted and measurement of initial time starts. The
condition shifts to main condition after the initial time.
● When the torch switch is turned “OFF” while the INITIAL condition is outputting, CRATERFILL. condition is not outputted. Continue to operate anti-stick and finish welding.
● When the torch switch is turned “OFF” during welding, CRATER-FILL. condition is
outputted and measurement of CRATER time starts. Carry out anti-stick after finishing
crater-filler time.
● In case of using this function, be sure to use “operation stop” signal without fail. If you
want to stop outputting during crater-filler, open the “operation stop” signal.
- 40 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.1 Using Internal Functions (continued)
(15) Current adjustment by torch switch: F20
Function No. “21”: The current change amount is set up by single clicking.
Function No. “22”: The current change amount is set up by double clicking.
By turning Function No.20 “ON”, the output current can be changed by the current change
amount set up in advance by torch switch clicking operation only during the self-holding period in
the “Crater-ON” or “Crater-ON (Repeat)” mode.
The current change amount setup range is –50 to +50A.
(Example)
Crater-ON, no initial current, welding current 150A and crater current 80A
F21: -10A, F22: 20A
Crater
Current
160A
150A
150A
150A
140A
140A
130A
Welding
Current
80A
single clicking
double clicking
ON
Torch
Switch
OFF
Within 0.3sec
Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec
Within 0.3sec 0.3sec
NOTE: It is necessary to press the switch for as long as 0.3 sec. or more during transfer
to crater at startup.
(16) Initial current and crater current setting in percentage (%): F23
Setting of initial current in percentage: F24
Setting of crater-filler current in percentage: F25
By turning Function No.23 “ON”, It becomes possible to set the initial current and the crater
current by the percentage to the welding current.
The setup range of F24 and F25 is 10 to 300%.
- 41 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.2 Key Lock
Key lock is a function to prevent the welding conditions from being changed by accidentally
operating keys and knobs on the front panel. Only the keys and parameter adjusting knob 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 [7].
Holding down both the F key [9] and ENTER key [17]
simultaneously
Holding down both the F key [9] and ENTER key [17]
simultaneously for a while brings the key-lock condition.
While keys are locked, the F lamp (located at the upper
left of the F key) blinks. Key lock can be cancelled by
holding both the F key and ENTER key simultaneously for
a while again. Key lock cannot be cancelled by starting the
machine up again.
While keys are locked, the F lamp blinks
Even when the keys are locked, GAS CHECK, INCHING, and JOB MEMORY function can be
activated.
10.2.3 Key Lock with the password
The primary purpose of Key lock is to avoid changing welding conditions accidentally. In other
words, everybody can un-lock it easily. On the other hand, this Key Lock with the Password
make possible to avoid any change by those who does not know the password.
The basic operation is the same as the standard Key Lock. If the password was entered, the
welding power source will ask the password to un-lock. Until you enter the correct password, the
welding power source never un-lock itself.
NOTE: If the Key Lock with the Password is activated, entering the correct password is
the only way to un-lock the welding power source. Neither Initialize process nor
power-on reset can un-lock it. If you want to enter a new password, you have to
enter the current password first.
Therefore, please manage the password well and never forget it.
In the password setting and entering stage, the welding power source disregards
for the torch switch (start signal).
- 42 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
There are two (2) modes in the key lock with the password.
Listed below is the description of each option:
Option
Description
When OP1 is "on", the welding power source asks the password at every
power-on. The welding power source can start welding after the correct
password is entered. If the password is incorrect, the welding power
source never starts welding.
Mode #1
(OP1)
Prohibit welding
NOTE: If the password is not set (indicated "000"), this option does
not mean anything. To activate this, please make sure to set
the password except "000".
When OP2 is "ON" during key lock, it is impossible that changing the
welding condition by external setting voltage and job memories save or
load.
Mode #2
(OP2)
Prohibit to change the
welding conditions
NOTE: Job change by “EXT in” can work even OP2 is on.
OP1 Prohibit welding
ON
Impossible until entering the correct
password at power-on.
Welding start
OP2 Prohibit to change the
welding conditions
Parameter adjusting knob,
variety of welding setting
External setting voltage including
analog remote control
Welding condition memory
Inching
Gas check
OFF
Valid
ON
OFF
Invalid
Invalid
Invalid
Valid
Invalid
Valid
Valid
Valid
Valid
Valid
NOTE: Both OP1 and OP2 are activated at the same time.
OP1 works even the standard Key Lock described in previous section is not activated.
OP2 works only when the standard Key Lock is activated.
① Procedure to set the password and the lock option
(1) Turn off the welding power source and back on with pressing F key [9] and ENTER key [17]
together. After the power source are properly turned on, Digital Meters show "PAS PAS" as per
below.
If the password is not set or the password is "000", go to (2) which is the next step.
If the password was already set, go to 2. (2) to clear the current password.
!
A
m/min
±
V
sec
JOB No.
- 43 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
(2) After digital meter shows "PAS PAS" in a few seconds, the power source enters the password
setting mode and shows "Loc 000". Left digit (hundred's place) of right meter blinks as per below.
Rotate the Parameter adjusting knob [5] to set the hundred's place of the password.
Following description sets the password "123" as an example.
!
light
blink
light
light
A
m/min
±
V
sec
JOB No.
The number of blinking place can be set
by the Parameter adjusting knob [5].
The range is from 0 to 9.
!
light
blink
A
m/min
light
light
±
V
sec
JOB No.
(3) Move to next digit (place) by pressing DISPLAY CHANGE key [7]. Then the center digit (ten's
place) can be set by the Parameter adjusting knob [5].
!
light
A
m/min
light
blink
light
±
V
sec
JOB No.
(4) Move to next digit (place) by pressing DISPLAY CHANGE key [7]. Then the right digit (one's
place) can be set by the Parameter adjusting knob [5]. If the DISPLAY CHANGE key [7] is
pressed again, the digit to set will be back to left again.
!
light
light
A
m/min
light
blink
±
V
sec
JOB No.
- 44 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
(5) Finish the password setting by pressing ENTER key [17]. To confirm the password, the Digital
Display blinks "Loc" on the left meter and the password on the right meter alternately. If the
password is NOT correct, press any key except ENTER key [17]. It will be back to the previous
stage to re-set the password.
If the password is correct, press ENTER key again to activate the password.
Blink alternately
!
blink
blink
A
m/min
±
V
sec
JOB No.
(6) If there is no correction in the password, the password is fixed by pressing the ENTER key [17]
again and the lock option setting mode is displayed.
“OP1” on left meter display and the condition on right meter display are displayed.
!
blink
light
A
m/min
(a)
±
V
sec
JOB No.
Condition (a) or (b) can be selected by pressing DISPLAY
CHANGE key [7]. The parameter of blinking side can be
changed by the Parameter adjusting knob [5].
!
light
(b)
blink
A
m/min
±
V
sec
JOB No.
(7) To finish setting password, press ENTER key [17]. At this point, the condition is not locked.
For locking, push F key [9] and ENTER key [17] at the same time for a while (if password is not
set, it is key lock state), and upper left of the F selection key blinks.
- 45 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
② The way to input the password to clear the Key Lock with the password
(1) When the lock is released by pushing F key [9] and ENTER key [17] at the same time for a while
from the state of the lock with the password, when the power is turned on during lock option 1 is
‘on’, and when the password has already been set during the password setting; the welding
power source becomes password input mode, 'PAS' 'PAS' is displayed in a digital meter as
shown in the figure below.
!
±
A
V
m/min
sec
JOB No.
(2) After Digital Meter shows "PAS PAS" in a few seconds, the power source enters the password
request mode and shows "Loc 000". "Loc" on the left meter and the left digit (hundred's place) of
right meter blinks as per below. Rotate the Parameter adjusting knob [5] to set the hundred's
place of the password. To change the digit, press DISPLAY CHANGE key [7]. The value of the
blinking digit can be changed by the Parameter adjust knob [5].
!
blink
blink
A
m/min
±
V
sec
JOB No.
(3) After entering the correct password, press ENTER key [17]. If the password is correct, the Digital
Display shows "good" and the power source is unlocked. If the power source is in the password
setting mode, go back to ① (2).
!
A
m/min
±
V
sec
JOB No.
If the password was incorrect, the Digital Display shows "bAd" and the power source is NOT
unlocked.
!
A
±
V
m/min
sec
JOB No.
- 46 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2. 3 Key Lock with the password (continued)
③ The way to cancel entering or setting the password
● If the power source is in the password setting mode, just turn it off. In this case, the password
can not be set.
● If the power source is in the password setting mode, press F key [9]. In this case, the Key Lock
with the password can not be cleared.
● In case of the password option1 (OP1) was activated, the power source can not work until
entering the correct password.
- 47 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
● The flow chart of the password setting
Turn on with pressing "F" and
"ENTER"
Was a password already
set?
Goto Reset (unlock).
Return here after
Reset
Yes
No
Set the 1st digit of the
password by the knob.
Press "DISPLAY CHANGE"
Press "DISPLAY CHANGE"
Set the 2nd digit of the
password by the knob.
Press "DISPLAY CHANGE"
Set the 3rd digit of the
password by the knob.
Press any key other
than "ENTER"
Press "ENTER"
Abort
Confirm the password
Set again
OK
Turn off the power
source
Press "ENTER"
Goto Options
- 48 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
● The flow chart of the password option setting (continue from the password setting)
After setting the
password
SetOPtion
optionnumber
numberbyby
the
Set
the
knob
knob
Press "DISPLAY CHANGE"
Press "DISPLAY CHANGE"
Set
Set the
thefunction
functionininthe
theOPtion
option
by
by the
the knob
knob
Press "ENTER"
Abort
Turn off the power
source
Finish to set the password
Activate key lock by pressing
"F" and "ENTER" together in
long time.
● The flow chart when the power source is turned on in case of OP1 is on
Turn on the power
source
Password requested
Enter
password
as per
Enter
password
as per
described
beforebefore
described
Wrong password
Correct password
Can operate the power
source
CanNOT
not operate
Can
operate the
the power
power
sourceuntil
untilentering
entering
source
the the
correct password.
password
correct
- 49 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.3 Key Lock with the password (continued)
● The flow chart of unlock
Press "F" and "ENTER" in long
time
Set the 1st digit of the
password by the knob.
Press "DISPLAY CHANGE"
Press "DISPLAY CHANGE"
Set the 2nd digit of the
password by the knob.
Press "DISPLAY CHANGE"
Set the 3rd digit of the
password by the knob.
Press "ENTER"
Abort
Press "F"
End without unlock
Password check
Came from Set
password
Turn off the power
source
Display "bAd"
Wrong password
Correct password
Came from Set password
Display "good" and
unlock
- 50 -
Return to Set password
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.4 JOB MEMORY Function
The JOB MEMORY function enables welding conditions to be reproducible by storing the welding
conditions in memory inside power source and by reading out the stored data at any time. The
number of welding conditions that can be held in memory is up to 30.
NOTE: The parameters of F functions can not set by using the JOB MEMORY function.
CAUTION
● 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
storage contents may be changed or lost. BE SURE TO MAKE A COPY FOR
IMPORTANT DATA.
● 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 key, LOAD key,
and ENTER key can be operated. To exit the mode, press the LOAD key [15] if it is in the memory
mode and the SAVE key [16] if in the read-out mode. Memory can be copied to a different
condition number after reading the welding conditions to be copied.
NOTE: Even when welding conditions are read out while the analog remote control is
connected to the welding power source, the setting values set at the analog remote
control are valid.
- 51 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.4 JOB MEMORY Function (continued)
① SAVE Function
Welding conditions being currently in use are stored in the memory inside the welding power
source.
● Holding the welding conditions in memory
(1) When pressing the SAVE key [16], the machine enters memory mode, the SAVE lamp
(located at the upper left of the SAVE key) lights up. See the following figure. In the right
display, 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" is displayed. Under this condition, a condition number can be set while turning
the Parameter adjusting knob [5].
!
light
A
blink
sec
m/min
Welding Current setting value
stored in memory
V
±
J OB No.
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, “- - -” in the left display
blinks. In this case, the system skips the parameter check condition of Step (2) and
jumps to Step (3).
!
blink
A
m/min
sec
blink
V
±
J OB No.
(2) When pressing the ENTER key [17] 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 [7]. The setting value of the parameter you selected blinks.
NOTE: You are not allowed to change the welding condition number or select a
welding method, etc. To reset the welding condition number, press the SAVE
key [16], then return to the step (1). To quit the setting and exit from the
memory mode, press the LOAD key [15].
(3) Pressing the ENTER key [17] again holds the data in memory and allow you to exit from the
memory mode.
- 52 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.4 JOB MEMORY Function (continued)
② LOAD Function
The welding conditions stored in memory are read out from the memory inside welding power
source.
NOTE: The welding conditions currently used are overwritten with the welding conditions
that are read out. When you want to save the welding conditions that have been
used until now, set the welding conditions to any condition number, then carry out
readout.
● Reading out the preset welding conditions
(1) When pressing the LOAD key [15], the machine enters the readout mode, LOAD lamp (located at
the upper left of the LOAD key) lights up. See the figure below. The condition number "1" in the
right-side display blinks and the JOB No. LED lamp lights up. In the left-side display, the setting
of welding current preset to condition number "1" lights up. Under this condition, a condition
number can be set while turning the Parameter adjusting knob [5].
!
light
A
blink
sec
m/min
V
±
J OB No.
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 lights up. When no memory data is preset to the
condition number, "- - -" in the left-side display appears and blinks. See the figure below.
!
blink
A
blink
sec
m/min
V
±
JOB No.
(2) When pressing the ENTER key [17] 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 [7]. The setting of the
parameter you selected blinks.
NOTE: You are not allowed to change the welding condition number or select a welding
method, etc. To reset the welding condition number, press the LOAD key [15], then
return to the step (1). To quit the setting and exit from the readout mode, press the
SAVE key [16].
(3) When pressing the ENTER key [17] again, you can read out the preset welding conditions and
exit from the readout mode.
- 53 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.4 JOB MEMORY Function (continued)
●
Memory mode operation
Press the SAVE key.
Discontinue
Set the welding condition number while
turning the parameter adjusting knob.
Press the ENTER key.
Discontinue
Press the SAVE key.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
The welding conditions are set to the number you selected.
Press the ENTER key.
Press the LOAD 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.
Discontinue
Press the LOAD key.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
The welding conditions are set to the number you selected.
Press the ENTER key.
Press the SAVE key.
The readout mode quits.
- 54 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.4 JOB MEMORY Function (continued)
③
Deleting the Welding Conditions
When you delete the welding conditions stored in memory, you can select either deleting all or
deleting one.
● Deleting the welding conditions
(1) Turn off the power switch and turn on the power switch with both the LOAD key [15] and SAVE
key [16] pressed. Release the keys after turning on the power switch, and then "dEL" appear in
the left-side display. See the figure below.
!
light
A
blink
sec
m/min
V
±
J OB No.
”dEL" display means the machine
in the delete mode.
Condition number to be deleted blinks.
(2) Set the condition number to be deleted while turning the Parameter adjusting knob [5]. When
turning the knob counterclockwise, "ALL" appears in the right-side display as illustrated below
and you can delete all the welding conditions.
!
light
A
blink
sec
m/min
V
±
J OB No.
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 [17] blinks "dEL." Confirm the condition number again and if you want
to cancel deleting of the condition number, press any key other than the ENTER key [17] to
return to step (2). To quit the delete mode, turn off the welding power source.
(4) Pressing the ENTER key [17] again deletes the welding condition that is preset to the condition
number. When "End" is displayed after end of data deletion, turn off the power switch, then start
up the welding power source.
NOTE: When pressing the ENTER key [17] twice in the deletion mode, you can not recover
the deleted welding conditions. When you attempt to delete a welding condition
that is held in memory, make sure that the condition number you want to delete is
surely selected.
- 55 -
No.P30190
10. OPERATION (continued)
10.2 Applied Settings (continued)
10.2.5 Resetting to Initial Values
When resetting to the welding conditions to initial values, the welding conditions that are currently
used (including the welding condition currently used) are all reset to initial values. But, even when
resetting to initial values, the welding conditions stored in memory are not changed. To reset to
initial values, turn off the power switch, and then turn on the power switch with both the F key [9]
and GAS CHECK key [13] 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 figure
below.
!
A
V
sec
m/min
±
J OB No.
See “SPECIFICATIONS” for initial values of each parameter and function.
10.2.6 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 [9] held down. After powering the welding
power source, the version number appears in the display.
(Example)
Right and left displays : "P30190"← Software number (P30190) is displayed.
↓ Press the F key [9].
Left display : "001"
← Main software version (Ver. 001) is displayed.
Right display : "000"
← Sub software version is displayed.
↓ Press the F key [9].
Left display : "- - -"
Right display : "002"
← Combination is displayed.
↓ Press the F key [9].
The welding power source starts up as usual and gets ready to perform welding.
10.2.7 Automatic Stop of Fan
The cooling fan automatically stops in 10 minutes after welding is finished and automatically starts
turning when welding is started. When turning on the welding power source, the cooling fan is also
turning but automatically stops in 10 minutes when no operation is carried out.
- 56 -
No.P30190
11. APPLIED FUNCTION
11.1 How to Solve an Error
WARNING
Observe the following to prevent electrical shock.
When touching live electrical parts, critical electric shock and burn may occur.
● Do not touch live electrical parts inside or outside the welding power source.
● Grounding to the case of the welding power source should be performed by persons qualified
electric work and according to the laws and regulations in your area.
● When touching the parts inside the welding power source, wait more than three minutes after
powering off all input power supply by turning off the line disconnect switch in the switch box.
If an error occurs during use, an error code shown in the displays on the front panel blinks, then the
welding power source stops automatically. In this case, check the errors in the following table.
When using this product with a robot of our company, refer to “Application” in owner’s manual of the robot.
Displays
on
the
front panel
No.
Classification of errors
Left
Right
1
dAI
HEn
Torch switch off state waiting
2
E-
000
Operation Stop
3
E-
100
Control power supply error
4
E-
200
Primary / secondary current detection error
5
E-
210
Error in the voltage detection
6
E-
300
Thermal overload
7
E-
510
Lack of water pressure
8
E-
600
Battery low (warning)
9
E-
700
Output over current
10
E-
710
Lack of phase
11
E-
800
Encoder in the wire feeder error
12
E-
810
Thermal overload in the governor circuit
13
E-
820
Motor over current (warning)
14
E-
830
Motor over current (error)
15
E-
9XX
Microcomputer error
- 57 -
No.P30190
11. APPLIED FUNCTION (continued)
11.1 How to Solve an Error (continued)
(1) dAIHEn Display
If “dAI” and “HEn” in the displays blink, it indicates the “Torch switch off state waiting”.
When turning on the power switch, the displays on the front panel shows “dAI” and “HEn” for one
second, then the welding power source becomes operable. But, if the torch switch remains on, the
safety circuit will function, the welding power source will hold a halt condition, then the WARNING
lamp and "dAI” and “HEn” shown in the displays will blink. In this case, turn off the torch switch to
reset the safety circuit and make the welding power source operable.
(2) E-000 Display
If “ E-” and “000” in the displays blink, it indicates the “Operation Stop”.
When disconnecting the wiring of the STOP terminals (Operation Stop terminals: wiring number
143) on the 12P external connection terminal block (TM1), “E-” and “000” in the displays blink and
the welding power source stops. In this case, after turning off the power switch and eliminating the
possible causes of the stoppage of the welding power source, short-circuit the STOP terminals and
turn on the power switch to cancel the error.
NOTE: If error occurs, open between the operation stop terminals once and short-circuit
them again. All errors will be released.
However, if abnormal condition has been continuing, the error is not be released
and an error code will be displayed. Refer to Section 10.2.1 (4) “Selection of
Auto/Semi-automatic”.
(3) E-100 Display
If “E-” and “100” in the displays blink, 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 P10327U 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 plus voltage detection line (+), the warning lamp will light up, “E-” and
“210” in the displays will blink, then the welding power source will stop automatically. In this case,
after checking to make sure that the wire feeder control cable (10P) is not damaged and that CN3
and CN6 on the printed circuit board P10264T are surely connected.
(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 power source. Refer to Section 3.1, “Rated Duty Cycle” for the rated duty cycle of the
welding power source.
- 58 -
No.P30190
11. APPLIED FUNCTION (continued)
11.1 How to Solve an Error (continued)
(7) E-510 Display
If “E-” and “510” in the displays blink, it indicates the “Lack of water pressure”.
As this welding power source connect the OTC water cooling unit.
If CON4 connector 1-2pin is open circuit for error signal comes from OTC water cooling unit, “E-”
and “510” are displayed. See the manual of OTC water cooling unit and checking for the solution.
(8) E-600 Display
If “E-” and “600” in the displays blink, it indicates the “Battery low (warning)”.
This welding power source uses battery 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 battery
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 battery run
down, the preset welding condition functions and the settings of functions are all deleted.
The last welding conditions before power is applied to the welding power source 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 over current”.
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 blink, 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 power
source will stop automatically. In this case, make sure that there is no damage in the encoder
connector (4P) on the top of the motor inside the wire feeder, the control cable for the wire feeder
(10P), and the printed circuit board P10261Q.
(12) E-810 Display
If “E-” and “810” in the displays blink, it indicates the “Thermal overload in the governor circuit”.
If thermal overload in governor circuit (printed circuit board P10261Q) is detected, the WARNING
lamp will light up, “E-” and “810” in the displays will blink, and then the welding power source will
stop automatically. In this case, check for printed circuit board P10261Q, short circuit on the motor
power supply lines, rough feeding of wire, and error in the torch or the wire feeder.
- 59 -
No.P30190
11. APPLIED FUNCTION (continued)
11.1 How to Solve an Error (continued)
(13) E-820 Display
If “E-” and “820” in the displays blink, it indicates the “Motor over current (warning)”.
Contact resistance to the feeding parts causes motor current to increase. If the motor current
exceeds 70% of the rated motor current, “E-” and “820” in the displays will blink only while no
operation at the front panel is carried out. When pressing any key or starting welding again, “E-”
and “820” in the displays will disappear (, but welding power source does not stop automatically).
In this case, check for short circuit in the motor power transmission line, rough feeding of wire, and
an error in the torch or the wire feeder. Refer to Section 10.2.1(10) “Setting of Feed Motor Load
Current Error Detection Level”.
(14) E-830 Display
If “E-” and “830” in the displays blink, it indicates the “Motor over current (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 power source will automatically stop. In this case, check for
short circuit in the power supply line, rough feeding of the wire, and an error in the torch or the wire
feeder.
(15) E-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.
- 60 -
No.P30190
11. APPLIED FUNCTION (continued)
WARNING
Observe the following to prevent electrical shock.
● Do not touch live electrical parts inside or outside the welding power source.
● Grounding to the case of the welding power source should be performed by persons qualified
electric work and according to the laws and regulations in your area.
● When touching the parts inside the welding power source, wait more than three minutes after
powering off all input power supply by turning off the line disconnect switch in the switch box.
CAUTION
● Try to move the control cable which is pulled out from the automatic connection terminal on
the chassis 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.
● Do not pull out the wiring on the printed circuit board to outside except the wiring to the
● external connection terminal block.
11.2 External connection for the automatic machine
When taking off the upper cover of the welding power source, you will find there is a 12P terminal
block (TM1) on the chassis. Use the 12p terminal block to connect with an automatic machine. Refer
to Section 12, “Parts layout” for the locations of the terminal blocks.
NOTE: Wait more than three minutes after turning off the line disconnect switch or no-fuse
breaker and the power switch on the front panel to remove the cover.
NOTE: Break the grommet with film located on the rear side of the welding power source to
lead in the external connecting wires. When leading in the external connection wires,
do not touch the parts on the printed circuit board and the edges of the steel plate.
①
+
A
②
-
③
+
V
④
-
⑤
+
⑥
-
READY
⑦
+
EXT1
⑧
+
GAS
[12P terminal block]
- 61 -
⑨
+
⑩
STOP
-
⑪
⑫
WCR
No.P30190
11. APPLIED FUNCTION (continued)
11.2 External connection for the automatic machine (continued)
12P terminal block (TM1)
Pin No.
Signal name
+
_
AMMETER
①
②
+
③ _ ④
VOLTMETER
READY (OUTPUT)
Ready Power
+
⑤
_
⑥
-
+
⑦ _ ⑩
+
⑧
_
+
_
⑨
EXT1 (INPUT)
Extra Input Signal 1
GAS (INPUT)
Solenoid Valve
Control
STOP (INPUT)
Operation Stop
-
⑩
⑩
-
⑪ _ ⑫
WCR(OUTPUT)
Welding Current
Detection
Function
Terminals for connecting an ammeter.
Use the ammeter (400A/60mV, part number: 4403-057).
Terminals for connecting a voltmeter.
Use the voltmeter (full scale 75V, part number: 4401-016).
The terminals used for ready power for prep. relay. When
there is not any error such as open phase, Operation Stop,
output overcurrent, and thermal overload, the terminals work,
etc. while the power switch is on,
⑤ and ⑥ terminals are short-circuit through the output
transistor.
The terminals used for special specifications. These
terminals should not be used for normal use.
The terminals used for controlling the gas solenoid valve by
external signals. (If the terminals are short-circuited, the gas
valve will open.)
To stop welding externally. Release the wiring between two
terminals to run Operation Stop. Welding power source 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.
All error codes can be released by short-circuiting terminals
again.
Contact Output of welding current relay used for detection of
welding current. The contacts close while welding current is
flowing.
*4
*1
*2
*2
*2
*3
NOTE: Precaution for connection with terminals on the terminal block
The wires from the terminal blocks should be twisted for each signals to avoid accidental
operation. Take care that the wires form the terminal blocks do not cross other signal wires
from other welding power source.
*1 Equivalent circuit is as the figure shown below. 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 below. Connect allowable contacts (10mA or more)
to two terminals.(Figure 2)
*3 Rating of the provided relay contacts is 125V AC, 0.5A, 30V DC, 1A. Do not exceed 80% of
the rating of the provided relay contacts.
*4 Be careful that no-load voltage (75V or less) is applied to between the terminals during
welding.
TR
+
PC
-
24V
2.7kΩ
4.7kΩ
Figure 2
Figure 1
- 62 -
+
-
No.P30190
11. APPLIED FUNCTION (continued)
11. 3 Combining with an Automatic Machine
When combining with an automatic machine, use the external receptacles and the sockets for remote
control or for wire feeder. Refer to Section 11.2, “External connection for the automatic machine” for
the details of the terminal block inside the welding power source.
(1) Current/Voltage Settings and Inching Signal
As the analog remote control (optionally supplied) is replaced in use, resistor R1 for current setting,
resistor R2 for voltage setting, and switch PB for inching, which are all listed in Section 13. “Parts
List”, should be used. For setting current/voltage on external voltage, refer to Section 10.2.1(4),
“Selection of Auto/Semi-automatic”.
Analog remote control
Current setting
93
1
94
2
94
Voltage setting
94
R24
R2
R23
R1
96
95
95
3
93
96
93
4
PB
97
5
98
6
98
97
Inching
(2) Start Signal
When removing the right-side plate of the wire feeder, you will find a 10P terminal block. See the
figure below. Welding is carried out by the start signal when terminals of wiring numbers 306 and
307 are closed. Welding stops when the terminals are open.
*Outgoing lines of start signal and direct detection signal are located next to the 10P control cable.
Break the grommet with film.
Terminals for start signal
- 63 -
No.P30190
11. APPLIED FUNCTION (continued)
11.4 Optional Accessories
11.4.1 Other Optional Accessories
Description
Part No.
Analog remote control
K5416Z00
Digital remote control
E-2454
CAN I/F board
K5422C00
CAN communication cable
BKCAN-04XX
Wheel kit
K5416B00
Remarks
With a 3m cable
Not including a cable
XX: 05 (5m),10 (10m),15 (15m),20 (20m)
11.4.2 Extension Cable/Hose (Extension of Work Space)
CAUTION
● Do not connect an unnecessarily long extension cable.
● When using an extension cable, roll it out. Failure to observe the demand may result in
unstable arc.
Choose a proper torch cable (separately sold) for work space. When extending the work space, use
other extension torch cables/hoses (separately sold ) that match the work space.
③ Gas hose
④Control cable for wire feeder
① Power cable for wire feeder
② Power cable
for base metal
Wire
feeder
⑤Control cable for remote control
Analog remote control
Welding power source
(Optionally available)
- 64 -
No.P30190
11. APPLIED FUNCTION (continued)
11.4 Optional Accessories (continued)
11.4.2 Extension Cable/Hose (Extension of Work Space) (continued)
①
②
③
④
Power Cable ( For wire feeder)
2m
7m
Model
BKPDJ-3802
BKPDJ-3807
* Male DINSE plug - Female DINSE plug
12m
BKPDJ-3812
Power Cable ( For base metal)
5m
10m
Model
BKPDT-3807
BKPDT-3812
* Male DINSE plug - M10 terminal
15m
BKPDT-3817
20m
BKPDT-3822
10m
BKGG-0610
15m
BKGG-0615
20m
BKGG-0620
Control Cable for Wire Feeder (10 P)
2m
7m
Model
BKCPP-1002
BKCPP-1007
*Male plug – Male plug
12m
BKCPP-1012
Gas Hose (For CO2 and for MAG)
5m
Model
BKGG-0605
④-1. Extension Control Cable for above control cable (10P)
5m
10m
Model
BKCPJ-1005
BKCPJ-1010
*Male plug – Female plug
⑤
Control Cable for Analog Remote Control (6P)
5m
10m
Model
BKCPJ-0605
BKCPJ-0610
15m
BKCPJ-1015
20m
BKCPJ-1020
15m
BKCPJ-0615
20m
BKCPJ-0620
NOTE: When you use automatic machine or with the current that is near to a rated current, use a
thick cable more than one rank.
- 65 -
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING
WARNING
To avoid electric shock, follow the below instructions.
● Do not touch live electrical parts inside or outside the welding power source.
● Turn off all of the line disconnect switches before touching the parts inside the welding power
source.
● Perform the maintenance checks periodically. If any damaged parts are found, only use the
welding power source after troubleshooting or repairing.
● Only certified operators should maintain, inspect, or repair the welding power source.
● When carrying out the maintenance, wait more than three minutes after powering off all input
power supply by turning off the line disconnect switch in the switch box. Capacitor may be
discharging even after powering off all input power supply. Check to make sure that charging
voltage does not exist before carrying out the maintenance.
● This welding power source uses a high-frequency inverter system, be careful of accidental
connection of the line disconnect switch at input side.
● Have qualified operators or the persons familiar with this welding power source test withstand
voltage. And install a protective wall around the welding power source to keep away others
from the welding power source.
CAUTION
Rotating parts may cause injury. Be sure to observe the following.
● Only certified operators should maintain, inspect, or repair the welding power source.
● Install a fence around the welding power source to keep others away from it.
● Do not put your hands, fingers, hair and clothes near the fans and wire feed roll rotating.
CAUTION
● Do not touch the parts for the main circuit which are located inside the power
source, such as single-phase transformer, DC inductor, heat sink, etc.
immediately after welding is performed, as the parts are extremely hot. Wait until
the parts cool down, when touching. Failure to observe the demand may result in
burn.
CAUTION
● The welding conditions (electronic 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 deleted. We recommend taking notes of important data.
● We shall not assume any responsibility for any change or loss of the electronic data resulting
from repair.
CAUTION
● Do not use moisture-free compressed air for cleaning the fan. Dust may penetrate into fan by
compressed air pressure, or fan blades may be rotated at excessive rotation speed. It causes an
abnormal wear in the bearing and fan failure. Use soft cloth for removing dust.
● Do not vacuum the space between main body and rotating part. Otherwise the grease may be
vacuumed up and result in damage to fan.
- 66 -
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.1 Carrying out Maintenance on the Welding Power Source
Periodically check the welding power source to ensure the safety of the equipment and the efficiency
of work.
● Check the following daily:
- 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 securely 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 the front panel.
● Check the following 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.
● Replacement of High voltage electrolytic capacitor:
The high voltage electrolytic capacitor supplies stable D.C. to the Primary inverter transistor and
tries to improve the operation stabilization of the welding power source.
However, it is an enclosed electrolyte with battery and the electrolyte may be leak from the
capacitor. Therefore it is recommended that this is changed every 5years. If use continues
without changing this part, it may result in damage with high voltage electrolytic capacitor and
other parts. Replace PCB6 (Part No.P10538M00).
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
1
the connector.
● Turn off the control power switch and line disconnect
switch before carrying out maintenance on the welding
power source, and wait three minutes until the
capacitors inside the welding power source discharge.
C N1
● This welding power source uses a high-frequency
inverter system, be careful of accidental connection of
NOTE: Match the number on the printed
the line disconnect switch at input side.
circuit board with that on the
● Surely connect the connectors until the connector clicks.
connector.
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 power source. Deformation and flaw may result from
the adherence of the organic solvent.
- 67 -
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.3 Insulation Resistance Test
WARNING
Observe the following to prevent an electrical shock.
When touching live electrical parts, a critical electric shock and burn may occur.
● Have qualified operators or the persons familiar with this welding power source measure
insulation resistance and test withstand voltage . And install a protective wall around the
welding power source to keep away others from the welding power source. 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 DC side of DR1.
(3) Short-circuit between TR1 (C1) and (E1), TR2(C2) and (E2), TR3(C2) and (E2).
Be sure to reconnect the cables after carrying out measurement of insulation resistance and withstand
voltage test.
12.4 Replacement of Battery
WARNING
Observe the following precautions listed below without fail, in order to prevent
fire, explosion and rupture.
● Do not charge, short-circuit, disassemble, heat, deform and/or solder batteries. Do not throw
batteries into a fire.
● Make sure the positive and negative polarity is correctly connected.
● Make sure battery terminals are insulated with insulation tapes when disposing batteries.
Otherwise, if batteries come in contact with other metal or batteries, generation of heat, rupture
or ignition may occur.
● Batteries must be replaced by an experienced repairman or engineer.
This welding power source uses lithium battery to hold welding conditions in memory. The life of the
battery differs depending on the environments. “E-“ and “600” shown in the displays on the front
panel blinks when the battery gets low. Replacement of the battery every 5 years or so are
recommended even when “E-“ and “600” do not blink. Replace the battery following the steps:
(1) Turn off the line disconnect switch in the switch box or the no-fuse breaker, and the power switch
of the welding power source.
(2) After more than three minutes, remove six screws that secure the front panel, and then pull the
front panel out. Do not pull it forcibly. With the wiring inside the equipment disconnected, do not
turn on the power switch. Failure to do so may result in damage to the welding power source.
(3) Remove the connectors on the P.C.B.P10533R to replace the printed circuit board. Refer to the
position for “Rear side of the front panel” in Section 12.7, “ Parts Layout”.
(4) Insert the disconnected connectors into the P.C.B.P10533R.
(5) Screw the front panel in position.
- 68 -
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.5 Troubleshooting
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
The power switch on the front panel is
Never turn it on again. Contact your dealer.
1
tripped.
The main
power lamp
PL1 does not
light.
2
3
4
When turning
on the power
switch,
nothing
appears in the
display.
When turning on the
power switch, the
displays light.
When turning on the
power switch, nothing
appears in the
display.
The main power lamp
PL1 does not light.
PL1 lights.
When turning on the power switch, the
WARNING and TEMPERATURE
lamps light up and an error code
appears in the display,
Shielding gas
Gas is not generated
is not
when the GAS
generated
CHECK key is
when the torch pressed.
switch is
pressed.
5
Gas is generated
when the GAS
CHECK key is
pressed.
Shielding gas does not stop.
Trouble with PL1.
Inspect PL1.
The line disconnect switch in
the switch box is not turned
on.
The input cables are not
surely attached.
Refer to No.2 in this list.
Inspect the power box.
Shortage of the input voltage
Check for proper input
voltage.
After inspecting PCB
P10263Q, replace it if
necessary.
Trouble of the power circuit.
Refer to Section 11.1, “How
To Solve an Error”.
The discharge valve of the
gas cylinder is closed.
Lack of gas pressure of the
gas cylinder.
Trouble of the gas
electromagnetic valve SOL.
Disconnection of the torch
switch cable or incomplete
insertion to receptacle.
The GAS CHECK lamp lights
up.
6
Trouble with the gas solenoid
valve SOL
When the torch switch is pressed, noload voltage is not output but shielding
gas is generated.
Inspect the input cables.
Trouble with the inverter
main circuit
7
Trouble with the control
circuit
- 69 -
Open the gas valve.
Check for proper gas
pressure.
Inspect the gas
electromagnetic valve
SOL.
Check the wiring
numbers 306 and 307.
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 PCB
P10492P or P10327U
replace it if necessary.
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.5 Troubleshooting
No.
Trouble
Current and voltage can not be
set.
Cause
Trouble with the control circuit
Trouble with the filter circuit
8
Trouble with the remote control
Error in wire voltage detection
Wire is not fed.
Incomplete insertion or breaking
of the control cable for wire feeder
Trouble with the motor control
circuit
9
Trouble with the filter circuit
WCR keeps working.
10
Trouble with the hole current
detector CT2
Trouble with the WCR circuit
- 70 -
Solution
After inspecting PCB
P10492P or P10327U
and replace it if
necessary.
After inspecting PCB
P10264T, replace it if
necessary.
After inspecting the
cable/plug for remote
control or the remote
control, replace them if
necessary.
Inspect connections of
CN4 on PCB P10327U.
After inspecting the
contacts of the plug and
cable, replace them if
necessary.
After inspecting PCB
P10261Q, replace it if
necessary.
After inspecting PCB
P10264T, replace it if
necessary.
Inspect the hole current
detector CT2.
After inspecting PCB
P10492P, replace it if
necessary.
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.6 Schematic Diagram
(P10538M)
(P10264T)
(P10263Q)
(P10327V)
(P10492P)
(P10327U)
(P10533R)
(P10264T)
(P10261Q)
--71
71--
No.P30190
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.7 Parts Layout
Right Side
C8, R18
Around DR
Rear Side
C5, R15
DR2-5
DR1
R1-4
P10327V
Chassis
LF
①
⑪
CT2
SH
L1
FM1
CR1
P10261Q
C4,R14
R22
12P terminal block for automatic machine
C2a, b
C7,R17
Back Side of Front Panel
Left side
⑦⑧
P10533R
P10264T
②,③
P10263Q
R19,R20
P10327V
⑩
T2
⑨
⑤
PL1
CON1
CON2
NF
⑥
P10538M
⑪,⑫
TR1-4
(Indicated under P10538M)
CT1
⑥
T1
P10327U (UP)
⑬
P10492P (DOWN)
--72
72--
⑬
④
No.P30190
13. PARTS LIST
•
Please contact your dealer to order parts. (See the back cover for telephone and fax numbers, and
mailing addresses.)
Symbol
Part No.
Description
Specifications
Q’ty
Remarks
NF
LF
PL1
DR1
DR2 – 5
DR6
TR1 – 4
CT1
CT2
T1
T2
L1
L2,3,7
L4
L5,6,8,9
L10
THP1
THP2
FM1
CR1
SH
R1 - 4
R6
R7
R8 – 13,
17,25,26
R14,15
R19,20
R23,24
C2a, b
C4,5
C7
CON1
CON2
TM1
4614-101
4519-022
100-0171
4531-204
4531-308
100-0188
4534-407
4810-030
4406-009
P10538B00
4810-916
P10538C00
4739-497
4739-497
4739-543
4739-358
100-0123
4615-057
4805-074
4341-139
4403-116
100-1528
4509-918
4509-825
Circuit protector
Line filter
Pilot lamp
Diode module
High speed diode module
Silicon diode
IGBT module
Current transformer
Hole current detector
Inverter transformer
Auto transformer
DC reactor
Ferrite core
Ferrite core
Ferrite core
CB3-XO-10-072-42D-C
CF3030C-DJ
N46010A7KW-01(RoHS)
DFA75BA160
DBA200UA60
D1N60-5060
2MBI150TA-060-50
W-W03029
HA400S3EH
P10538B00
W-W02936
P10538C00
E04RA400270150
E04RA400270150
E04RA310190100
Ferrite core
Thermostat
Thermostat
Fan
Relay
Meter shunt
Surge absorber
Cement resistor
Cement resistor
RI-17.5-28.5-10.7
US-602SXTTAS 130˚C
67L080
4715SL-05W-B60-D00
G2R-1-T DC24V
KY400A 400A/60mV
TND14V-911KB0LLAA0
40SH 200ΩJA
20SH 15kΩJA
1
1
1
1
4
1
4
1
1
1
1
1
3
2
4
1
1
1
1
1
1
4
1
1
100-0234
Carbon resistor
RD20S 1kΩJ (RoHS)
9
4509-138
4509-905
4501-039
4518-515
4518-542
100-0227
100-1435
100-0178
4739-505
Metal film resistor
Cement resistor
Carbon variable resistor
Film capacitor
Film capacitor
Film capacitor
Metal socket
Metal socket
Terminal block
RNP-50SA 5ΩJ
MHR20A513JI
RV24YN20SB 5kΩ
FKS1600VDC683JSL
US20X472JAASA
0.47μF 50V (QYX1H474JTP)
DPC25-10BP
25-6BK-Z
TB10-01-12P
2
2
2
2
2
1
1
1
1
- -73
73- -
No.P30190
13. PARTS LIST (continued)
Symbol
Part No.
PCB1
PCB2*
PCB3
PCB4
PCB5
PCB6
PCB7
PCB8
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
⑫
⑬
P10327U00
P10492P00
P10263Q00
P10327V00
P10264T00
P10538M00
P10261Q00
P10533R00
4739-604
4735-038
4735-039
4739-475
P10325W02
4739-476
P5801G03
P10263G12
P10260J01
P10263J02
P10329X02
P10538X04
4734-007
4734-016
Description
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Printed circuit board
Grommet with film
Knob
Cap
Rubber foot
Control panel sheet
Cap
Carrying Handle
Bush
Front cover
Control panel cover
Cable with 3P connector
Cable with 6P connector
Machine socket
Power cable connector
Specifications
P10327U00
P10492P00
P10263Q00
P10327V00
P10264T00
P10538M00
P10261Q00
P10533R00
C-30-SG-32A
K-100 22RSB
K-100 22CSBL
C-30-RK-3220
P10325W02
W-W02814
P5801G03
P10263G12
P10260J01
P10263J02
P10329X02
P10538X04
DIX BE 50/70
DIX SK 50
Q’ty
1
1
1
1
1
1
1
1
3
1
1
4
1
2
2
4
1
1
1
1
2
1
Remarks
Refer to “NOTE” below.
Adjusting knob
Output terminal
For ⑬
*NOTE: When ordering a printed circuit board P10492P00, provide the software version on a label
below a nameplate attached to the rear side of the welding power source.
P30190 Ver. ###.###.000
Replace the ###.### with software version.
Parts list for analog remote control (optional accessories)
Symbol
Part no.
Description
R1,2
4501-039 Carbon variable resistor
R3
100-0487 Resistor
PB
4250-077 Push button switch
100-0102 Metal socket plug
4735-007 Knob
K5416Z02 350/500A scale plate
--74
74--
Specifications
RV24YN20SB 5KΩ
RD20STP-52 12ΩJ
A2A-4R
DPC25-6A-Z
K-2195 (large)
K5416Z02
Q’ty
2
1
1
1
2
1
Remarks
No.P30190
14. SPECIFICATIONS
14.1 Welding power source
Model
Digital Inverter M380S
Specifications
Number of phase
Rated frequency
Rated input voltage
Rated input power
Rated output current
Rated load voltage
Rated output current range
Rated output voltage range
Maximum no-load voltage
Rated duty cycle
Number of welding condition
Usable temperature range
Usable moisture range
Storage temperature range
Storage moisture range
External dimensions(W x D x H)
Degree of protection
Mass
3 phase
50 / 60Hz
400V±15%
17.1kVA, 15.1kW
380A
34.0V
30 – 380A
12 – 36V
58V
50%
30
-10 – +40˚C
20 – 80% (without dew condensation)
-20 – +55˚C
20 – 80% (without dew condensation)
250mm x 640mm x 430mm (without the carrying handle)
IP 21
30kg
The welding power source complies with the requirements of IEC60974-1, IEC60974-10 and
directive 2011/65/EU (RoHS).
--75
75--
No.P30190
14. SPECIFICATIONS (continued)
14.2 External View
-- 76
76 --
No.P30190
14. SPECIFICATIONS (continued)
● Front Panel
●Initial Values and Setting Range of Parameter
Initial value
Setting range
0.1 seconds
0 – 10 seconds
Current
30 A
30 – 400 A (0.4 – 22.0 m/min.)
Voltage
Fine adjustment
of voltage
10 V
12 – 38 V
0
-30 – 30
0.1 seconds
0 – 10 seconds
3 seconds
0
1
0.1 – 10 seconds
-99 – 99
1 – 30
Pre-flow time
・ Initial condition
・ Main condition
・ Crater filler condition
Post-flow time
Arc spot time
Arc characteristic
Welding conditions numbers
[17] [16]
[15]
[3]
[10]
[4]
[7]
[5]
●Functions
Crater
Welding method
Initial value
OFF
Setting item
OFF/ON
G3Si1 MAG
(20%CO2)
G3Si1 MAG(20%CO2) / G3Si1 CO2 /
G3Si1(Fill) CO2
1.2
0.8/1.0/1.2
Wire diameter
Initial current
Adjustment of welding voltage
Penetration control
OFF
ON/OFF
INDIVIDUAL
OFF
SYN./INDIV.
ON/OFF
●Internal Functions <Refer to Section 10.2.1, “Using of internal functions >
F3
Fine adjustment of anti-stick
(burnback) time
Fine adjustment of anti-stick
(burnback) voltage
Fine adjustment of slow-down speed
F4
Selection of automatic/semi-automatic
F5
F6
F7
F8
External Input Voltage
Setting of up-slope time
Setting of down-slope time
Result display holding time
Selection of scale plate of analog remote
control
Setting of feed motor load current error
detection level
Fine adjustment of JOB MEMORY
Fine Adjustment
Setting of Soft Arc Mode
Changeover to Wire feeding speed Setting
Change of a peculiarly crater-filler
sequence
Setting of Initial time
Setting of crater time
Current adjustment by torch switch
Current change amount by single click
Current change amount by double click
Initial current and crater current setting in
percentage (%)
Setting of initial current in percentage
Setting of crater-filler current in percentage
F1
F2
F9
F10
F11
F12
F15
F17
F18
F19
F20
F21
F22
F23
F24
F25
Initial value
Setting range
0
-50(0.50 seconds down) –
50(0.50 seconds up)
0.0
-9.9 – +9.9 V
0.0
15.0
0.0
0.0
20
-1.0 – +1.0 m/min.
2(Automatic mode 2) /
1(Automatic mode 1) /
0(SEMI-AUTOMATIC)
15.0V / 14.0V / 10.0V
0 – 10.0 seconds
0 – 10.0 seconds
0 – 60 seconds
350
200/350/500
70
20 – 150 %
OFF
OFF(INVALID) / 1 - 30 %(VALID)
OFF
OFF
ON(SOFT) / OFF(STANDARD)
ON(Wire feeding) / OFF (Current)
OFF
ON(VALID)/OFF(INVALID)
0
0
OFF
0
0
0 – 10.0s (Peculiarly Crater only)
0 – 10.0s (Peculiarly Crater only)
ON(VALID)/OFF(INVALID)
-50 – 50 A
-50 – 50 A
OFF
ON(VALID)/OFF(INVALID)
100
100
10 – 300%
10 – 300%
0
[13] [14]
[6]
[9]
[2]
[1] ▼ (WELDING METHOD) key
[2] φ mm key
[3] A/m/min selector key
[4] V/± selector key
[5] Parameter adjusting knob
[6] ▼ (CRATER-FILL) key
[7]
(DISPLAY CHANGE) key
[8] ARC (CONTROL) key
[9] F (FUNCTION) key
- 77 - 77 -
[11]
[1]
[10] START (INITIAL CURR.) key
[11] VOLT. CONTROL key
[12] CONSTANT PENETRATION key
[13] GAS CHECK key
[14] INCHING key
[15] LOAD key
[16] SAVE key
[17] ENTER key
[12]
[8]
No.P30190
14. SPECIFICATIONS (continued)
QUICK MANUAL
Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”.
① Before Using the Welding Power Source
1.
Settings of Welding Method
Set a welding method,
then wire diameter by
using the ▼ (WELDING
METHOD) key, and the
φ mm (WIRE DIA.) key
respectively.
To adjust the desired arc characteristic
(HARD/SOFT), after turning on the ARC
lamp by pressing the ARC key, set the
level of the arc characteristic.
[ON]: ARC lamp lights.
[OFF]: ARC lamp does not light.
NOTE:
• Turning
2. Settings of Crater/Arc Spot
Use the ▼ (CRATERFILL)key to select
OFF/ON.
•
•
• There may be unavailable parameters in some
crater settings and function settings. Refer to
Section 10, “OPERATION” for details.
4. Checking the Rate of Gas Flow
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.
3. Settings of Functions
•
the Parameter adjusting knob
clockwise increases the parameter. To
decrease the parameter, turn the Parameter
adjusting knob counter-clockwise.
For using INITIAL CURRENT, press the START
key to set the function to “ON”.
[ON]: START lamp lights.
[OFF]: START. lamp does not light.
For controlling voltage in the SYNERG. way,
select “SYNERG.” by pressing the
SYN./INDIV. key.
[SYNERGIC]: SYN./INDIV. lamp lights.
[INDIVIDUAL]: SYN./INDIV. lamp does not light.
For activating a CONSTANT PENETRATION
function, set the function to “ON”.
[ON]: CONTANT PENETRATION lamp lights.
[OFF]: CONSTANT PENETRATION lamp does
not light.
Settings of Parameter
Parameter adjusting knob
5. Inching the Wire
After pressurizing the wire mounted on
the wire feeder using the pressure roll,
feed the wire up to the end of the torch
while using the INCHING key. When
pressing the INCHING key again, the wire
feeding stops.
③ Presetting the Welding Conditions
Press the LOAD key.
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 - 30 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 deleted and overwritten
with the welding conditions you newly
set.
3) Press the ENTER key to check the parameter
preset to the number.
4) When pressing the ENTER key again, the welding
conditions are set.
Press the SAVE key.
Discontinue
Set the welding condition number while
turning the parameter adjusting knob.
Press the ENTER key.
Discontinue
② Protecting the Keys and Releasing the Key Protection
Discontinue
Discontinue
Press the ENTER key.
Press the SAVE key.
The readout mode quits.
⑤ 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.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
Press the ENTER key.
ENTER
• 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.
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.
- 78 - 78 -
1
2
3
Displays on the
front panel
Left
Right
dAI
HEn
E000
E100
Press the LOAD key.
• 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 power source is in the
key protection mode.
Press the DISPLAY CHANGE key
Reset the welding condition number.
to check the parameter value.
The welding conditions are set to the number you selected.
Press the SAVE key.
The welding conditions are set to the number you selected.
4
E-
200
5
6
7
8
9
10
EEEEEE-
210
300
510
600
700
710
11
E-
800
12
E-
810
13
14
15
EEE-
820
830
9XX
The memory mode quits.
④ Loading the Welding Conditions
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 – 30 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.
Press the ENTER key.
No.
Now you have completed the preparations that are
required to start welding. Press the torch switch to start
welding.
Set the welding condition number while
turning the parameter adjusting knob.
Classification of errors
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 overcurrent
Lack of phase
Encoder in the wire feeder
error
Thermal overload in the
governor circuit
Motor overcurrent (warning)
Motor overcurrent (error)
Microcomputer error
When using this product with a robot of our company,
refer to “Application (arc welding)” in owner’s manual of
the robot.
No.P30190
15. SERVICE AND SUPPORT
Please contact your local dealer for service. (See the back cover for telephone numbers, fax numbers, and
mailing addresses.)
NOTE:
1) See Section 12, “MAINTENANCE AND TROUBLESHOOTING” before contacting your dealer
for service.
2) When contacting your dealer for service, you are required to provide the following
information:
• Address
• Name
• Telephone number
• Product model
• Manufacture year
• Serial number
• Software version number
• Details of troubles
・ MODEL: M-380S
・ DATE: 20XX
・ SERIAL No. P30190YXXXXXXXXXXX
P30190 Ver ###.###.000
K8174
- 79 - 79 -
DAIHEN Corporation
4-1, Koyocho-nishi, Higashinada-ku, Kobe, Hyogo 658-0033, Japan
Phone: +81-78-275-2006, Fax: +81-78-845-8159
DAIHEN Inc.
1400 Blauser Drive Tipp City, Ohio 45371, USA
Phone: +1-937-667-0800, Fax: +1-937-667-0885
OTC DAIHEN EUROPE GmbH
Krefelder Strasse 677, D-41066 Mönchengladbach, Germany
Phone: +49-2161-6949710, Fax: +49-2161-6949711
OTC Industrial (Shanghai) Co.,Ltd.
6F, Building B,ORIENTO Plaza, 388 North Fuquan Road,
Changning District,Shanghai, China 200335
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
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 INDIA Pvt.Ltd.
V. M. TOWER, Plot No. 54A, Ground Floor Unit-1,
Sector-18, Gurgaon-122015 Haryana, India
Phone:+91 124-4239368, Fax:+91 124-4300820
PT.OTC DAIHEN INDONESIA
Blok G1A-20, Jl. Kenari ll, Dalta Silicon V,
Lippo Cikarang Industrial Park, Bekasi 17550 Indonesia
Phone:+6221-2957-7566, Fax:+6221-2957-7567
DAIHEN Korea Co., Ltd.
11B/L Hyeongok Industrial Complex, 463-1 Hyeongok-ri,
Cheongbuk-myeon, Pyeongtaek, Gyeonggi-do, 451-831, Republic of Korea
Phone: +82-31-686-7445, Fax: +82-31-686-7464
Upon contact, advise MODEL and MANUAL NO.
150413
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