CM-144 - OTC Daihen

CM-144 - OTC Daihen
No. U3793
INSTRUCTION MANUAL
FOR
MODEL CM-144
WIRE FEEDER FOR TRANSISTOR PULSED MIG
DAIHEN Corporation
No. U3793
P. 1/18
CONTENTS
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No. U8793
P. 2/18
1. GENERAL
Thank you for your purchase of OTC Model CM-144 wire feeder. The CM-144 is in-
tended for MIG welding of aluminum and stainless steel, and MAG welding of mild
steel as combined with Model TRANSISTER PULSE AUTO 350 or COMPUTER MIG 500 welding
power source. The CM-144 features not only high wire feeding power but also high
accuracy owing to use of tachogenerator for feeding speed detection. Before using
the CM-144, please read this INSTRUCTION MANUAL carefully, at least section
"OPERATION". The section "MAINTENANCE" should be referred to as necessary when
checking or repairing the CM-144.
2. CONSTITUTION
2.1 Specification
Model CM-144 (Air-cooled type)
Aluminum 1.2mm ¢
Applicable wire dia. Stainless steel (0.8)(1.0) 1.2mm ¢
Mild steel (0.8)(0.9)(1.0) 1.2mm ¢
Wire feed speed 0.9~ 18m/min.
Shaft dia. 50mm à
Applicable wire reel Max. outside dia. | 300mm ¢
Width 103mm
Weight of wire mounted | Мах. 25kg
Weigh 10kg
2.2 Combination power source
TRA-350 (PULSED AUTO 350)
TRA-500 (PULSED AUTO 500)
2.3 Combination torch
Stainless steel MIG
Rated curr. | for Aluminum MIG | for Mild steel MAG Remarks
250A WICA-2501
curved
No. U3793
P. 3/18
Table i
Description Part No. | @ Бу Remarks
Feed roll
(for Aluminum 1.28) K1821G00 (1)
Pressure roll built in body
(for Aluminum 1.28) K1821H00 2
Gas hose U2878H00 1 3m
Torch side cable U1997H00 1 |60mm x1.6m
Base metal side cable 01997.700 1 60mm” x 1.8m
Feed roll (for Steel 1.24 ) | K1376H01 1
Feed roll (for Steel ) К1821М00 1
№. 5 1 M6
Hex. wrench No. 6 ; M8
2.5 Optional accessories
Table 2 Extension cables and hoses
Model BTRA-3505
Welding cable 1 K1131F
5m | Control cable (5P) 1 K1837B
Gas hose i K1838B
Remote control cable (6P) 1 K1136B
Model BTRA-3510
Welding cable 1 K1131G
10m | Control cable (5P) 1 K1837C
Gas hose 1 K1838C
Remote control cable (6P) 1 K1136C
Model BTRA-3515
Welding cable 1 K1131H
15m | Control cable (5P) 1 K1837D
Gas hose 1 K1838D
Remote control cable (6P) 1 K1136D
Model BTRA-3520
Welding cable 1 K1131J
Control cable (5P) 1 K1837E
20m | Gas hose 1 K1838E
Remote control cable (6P) 1 K1136E
Table 3 Others
ВОВ Lies EE af et
P. 4/18
Description Parts No. | Q' ty Remarks
Feed roll (1.06) K1821R00 1 for brazing
Pressure roll (1.0¢) K1821500 1 for brazing
Feed roll (0.8, 1.04) U1376H02 1 for steel
Feed roll (0.9, 1.09) U1376H07 1 for steel
Feed roll (0.9, 1.2¢) U1376H08 1 for steel
Argon gas flow meter RF-16 I | Max. flow 282 /min
regulator
resiator (with heater) FCR-8032 | 1 |Max. flow 25{/min.
regulator (without heater) | "?201 | 1 |Max. flow 20¢/min
Caster U1997G 1
# When use of Stainless, Mild steel for pressure roll, use a for
steel (K1821M00) of standard accessories.
No. U3793
P. 5/18
3. INSTALLATION
3.1 Installation place
Select a place of less humidity, dirt and dust as far as possible. Place the PUIl
Feeder and other application on stable floor such as concrete, taking care so that
they are not exposed to direct sun light, wind and rain.
3.2 Wind shielding
When welding is performed in open air where wind blows, or when fan is used during
welding in summer, use a wind shield to protect arc from wind, otherwise blow hole
may be caused.
Wind | Ventilation]
Shielding
Fig. 1 Ventilation and Wind Shielding
3.3 Light shielding
The welding arc emits particularly intensive ultraviolet rays. Therefore, for
welding use a helmet or hand shield with sufficient light shut-off effect without
fail. In addition, do not fail to protect your neck, face, hands and
fee against arc light and spatter completely.
Fig. 2 Light Shielding
No. U3793
P. 6/18
4. EXTE
17
RNAL CONNECTION
E E + E e $ # x 7 i Ft
ESE Y PEN EL E EE i Fi E
connection.
* Securely tighten connecting parts of cable and hoses.
4.1 Secondary side connection
‚Open terminal cover (Fig. 3) and be sure to connect. (See Fig. 4)
| Terminal cover
DA (Remove two scrwews)
Fig 3
Output terminal
and Receptacle
A Receptacle for REMOTE CONTROL”
ARV Receptacle for "WIRE FEEDER”?
> á ON Reco: termimal © (Torch)
> Receptacle for MAG/CO2 welding
Output terminal F) (Torch)
Receptacle for PULSED arc welding
Output terminal ©) (Base metal)
; The plus (+) side output terminal to be used for short arc welding is :
different from that for pulse arc welding. Perform connection correctly fo
the respective welding processer.
г
F
ME ML EL LE NL
Welding
power source Gas flow meter regulator
,” Sas hose (3m)
— Wire Feeder CM-144
Torch (3m)
— ‘ * UA Remote control box
L Torch side cable (1.6m) y Im
\ \
Control cable (1.7m) Base metal side cable
(1.8m)
Fig 4 Secondary side connection
4.2 Gas cylinder N
Please select according to welding method.
Welding Gas flow meter
method Wire Gas regulator Torch
| Aluminum Ar WICA-2501
MIG P
19 | Stainless steel | Ar + 02 (2%) rte WTCS-2501
MAG Pulse | Mild steel Ar + CO2 (5~ 20%) WTCS-2501
со2 Mild steel CO2 FCR-8032 | WTCS-2501
4.3 Connection of torch
Connect torch power cable
and welding cable from "+"
terminal of the welding
power source. Connect
torch switch cable and
gas hose to the respective
connectors provided on
the front face of the wire
feeder.
Connect torch cable to the
connector on the front
face of the wire feeder.
Y
Completion of connection
5. PREPARATION FOR WELDING
Set feed roll of size
suitable for diameter of
velding wire to be used.
No. U3793
P. 7/18
Torch power cable's make
connector connects to the
female connector with welding
cable (+ side) after through
the insulation bush fitted
feeder front, and locked up
the cable by cable clamp.
Push down press spring provided
by feed roll, and remove guide
adaptor. Connect the guide
adaptor to the torch cable with
outlet guide fitted in.
Then, connect the guide adaptor
to the wire feeder in the revers
sequence to that of the removal.
The CM-144 is delivered with
feed roll for "1.28 aluminum
wire" installed. When using
wire of other kind of size for
welding, replace the feed roll
referring to Table 4 below.
Table 4 Roll list
Material | Wire size | Feed roll Press roll Remarks
Aluminum 1.2 K1821G00 K1821H00 Standard
Brazing 1.0 K1821R00 K1821500 Optional
1.0-1.2 | K1376H01 Standard
Da 055 0.8-1.0 [U1376H02 | oo
0.9-1.0 | U1376H07 Optional
Mild steel
1.0-1.2 U1376H08
The feed roll for steel or stainless steel have two size of
grove, therefor they usable two size of welding wires.
In case of setting the feed roll, set to this side the wire
nF pep em Fre ow YE | om gw we Bor
No. U3793
P. 8/18
Adjust wire pressing force.
Ÿ
@ Install wire reel on spool
shaft.
Y
Set wire on the feed roll.
Turning the pressure handle,
and apt wire pressure.
Table 4 Recommended wire pressing force
Aluminum | Stainless | Pressure
Hard | Soft ea nar handle
1.6 - 1.2 5-6
1.2 1.6 1.0, 0.9 3~4
- 1.2 0.8 2-3
Increase the pressing force setting
a little from the above-mentioned
graduation if welding torch conduit
is bent sharply.
Turn the pressing handle this
side to release pressing roll
holder.
Then, pass the wire
through straight roll, outlet
® Press wire.
Y
Adjust wire straightener.
Y
D Depressing "INCHING" switch
on remote control box,
feed wire to the torch tip.
|
guide, and ensure that the wire
is fitted into the groove in the
feed roll snugly.
Turn the pressing roll holder
toward this side, and set the
pressing handle.
Turn straightener. adjusting
knob to the indicated gradua-
tion.
Feed the wire until it pro-
trudes about 10mm from the tip.
No. U3793
P. 9/18
,
o Adjust gas flow rate. Set "GAS CHECK" switch on the
front face of welding power
source to "CHECK" position and
adjust knob of gas flow meter
regulator fitted to gas flow
rate suitable for welding
condition. Set "GAS CHECK"
switch to "WELDING" position
after adjusting.
Y
Finish of welding preparation.
Note: As for welding operation, refer to the instruction manual of welding
power source. |
4% Fe LA IE Pa
P. 10/18
The maintenance work comprises of periodical inspection for
prevention of troubles and repair of damages. Since it is
impossible to cover both of them in full details, please per-
form maintenance and checking work by fully grasping the con-
struction of the Model CM- 144 Wire Feeder.
6. PERIODICAL INSPECTION
As to periodical inspection of welding. power source and
torch, please refer to respective instruction manuals.
6.1 Dally checking
1) Clean groove of the wire feed roll once every three pieces
of wire consumed. When the slots are worn to the extent
to cause unstable wire feeding, replace the feed roll.
M4 screw
Pressure roll
pin
Pressure roll
grève
>> Feed roll
> MÍO nut
Fig.5 Roll replacement
Replacement of wire feed roll and pressure roli
(1) Remove M10 nut and pull out wire feed roll.
(2) Remove M4 screw, and pull out wire pressure roll pin,
Replace the wire feed roll and pressure roll with now ones.
2) Check to see that oil or dust is not stuck to the wire
passage on the wire straightener or other parts.
3) Check for abnormal heating of wire connections.
4) Check to see that cables are duly connected and insulated.
5) Check for cables which are about to be broken.
No. U3783
P. 11/18
6.2 Yearly inspection
1) Wire feed motor
Usually service life of brush is about 4,000 hour
(about two yeas, if it works six hours a day), though
it may vary a little with loading condition and ambient
temperature. | |
Since construction of the motor dose not allow easy
access to the brush for checking of wear or replacement,
periodically replace the whole motor.
2) Grease replacement of reduction gear
After removing aged grease, apply new one to the gear
tooth surface and side faces as shown in Fig. 6.
When delivered, the reduction gear 1s grease with "Sun
Light Grease No.1" of Shell 0il1 Co., Ltd
this brand name.
If this grease is not available, use lithium grease No.1
of each manufacturer.
., use grease of
Gear output shaft Note: Apply grease on the side
K1123B04 face of gear as shown in
Fig. 6. Never fill the.
gear box with grease,
otherwise motor will be.
|
Grease LI Double gear burnt.
K1821B02
HF
Grease
> Pinion
72D K1821BO1
Motor
output shaft H—
Fig.6
6.3 Precautions for checking speed reduce (See Fig. 9)
1) Do not remove pinion of print motor except for replacement.
2) It is recommended to clean the parts by brushing with use of benzine, except
plastic gear for which due care should be taken not to damage it.
3) Be careful not to give impact to the print motor output shaft, otherwise
the armature in the motor may be put into contact with magnet to result in its
damage. |
4) After overhauling the speed reducers, check it for abnormal meshing noise,
and also ensure that motor current is not higher than 1.4
whore wire Ta Trond Par ah ER aa ve Ma de A AI ÍA
A in the condition
No. U3793
P. 12/18
6.4
1)
2)
Precautions for checking speed reduce (See Fig.7,9)
Tachogenerator for speed detection
Service life of the tachogenerator brush is about 1,500
hours when used in the rated conditions (approximately one
year with daily operation of 6 hours), although the actual
service life may vary considerably depending on operating
conditions and ambient temperature. Since it is very dif-
ficult to check the brush for extent of wear because of
structure of the tachogenerator, replace the tachogenerator
periodically. |
Precautions for replacement of timing belt
If used in wet conditions, the timing belt may be damaged
easily because of properties of the core wires. So, do not
fail to protect it, if it is used in environment where the
belt may be exposed to water drops or splashes.
The timing belt is soft but not elastic. Therefor, do not
attempt to apply it, passing it over flange of toothed pul-
ley forcibly, otherwise it may be damaged. Reduce shaft
center distance when applying the timing belt.
“If the timing belt should be bent to small radius, its core
wires may be bent to result in significant spoiling of their
properties. So, sufficiently be careful not to bent it
sharply when handling.
‚The outer faces and faces constituting pressure angle of the
toothed pulley play an important role in power transmission.
Therefor, use utmost care not to damage those faces when
handling the pulley.
DC tachogenarator
Toothed pulley
Timing belt
Toothed pulley
Fig.7
7. TROUBLESHOOTING
ER a RFE RS RSF
P. 13/18
In many cases, cause of trouble in welding relates to control system and
mechanical system of the welding equipment.
welding power source.
to the wire feeder.
Therefore, as for the comprehensive
Below is given troubleshooting guide only for, and related
Complaint
Cause
Correction
1) Wire is not fed out.
Pressure roll is not set.
Press wire.
Motor is not running.
Check motor lead wire con-
nection to terminal strip
for loosening. Replace
motor if defective.
2) Wire is not fed
smoothly.
Wire slipping between
wire feed roll and
pressure roll.
Tighten pressure handle.
Wire feed roll assembled
in is not suitable for
wire size.
Replace wire feed roll to
one suitable for diameter of
wire used. (See Table 4.)
Torch cable bent too
sharply.
Correct too sharp bend of
torch cable.
Dust or dirt accumulated
in liner.
Clean or replace liner.
Tip liner faces roughene
Replace tip.
3) Shielding gas is not
fed out.
Main cock closed.
Open.
Gas pressure too high.
Reduce gas pressure to
5 kg / cm or less than.
Gas solenoid valve is
trouble.
Replace.
4) Wire comes out as
bent. adjusted.
Wire straightener is not
adjusted.
Adjust properly.
Torch cable bent too
sharply.
Straighten torch cable.
8. PARTS LIST
8.1 Wire reduction gear unit (See Fig. 9)
directly.
= 4 4 8 % # я я ; + +
Item
No.
Description
Q ty
Remarks
1
K1821B03
Gear case
4802-006
Print motor
PMEE-12CBB
K1821B01
Pinion
Screw
M5-5
K1821B02
2-step gear
K1123B04
Geared output shaft
Key
4X 4X8
K1123B05
Bush
K1123B06
Insulating spacer
3311-001
Radial ball bearing
No.6000ZZ
10
K1821C01
Gear case
11
K1821C02
Insulating board
12
K1123C04
Insulating sleeve
13
3311-008
Radial ball bearing
No.6001ZZ
14
K1821F00
Bracket assembly
15
K1821C03
Pressure roll holder
16
K1821C04
Pressure roll pin
17
K1821C05
Fulcrum pin
18
E-type snap ring
for ¢5
19
K1123B07
Spacer
20
K1821G00
Feed roll(1.2-1.6)
for Aluminum
21
U1821H00
Pressure roll(1.2-1.6)
for Aluminum
22
U2344B09
Guide adaptor
P. 15/18
Item
No. Part No. Description Q ty Remarks
23 U785C09 Plate spring 1
24 U785C11 Protection cover 1
25 K1123C08 | Remote stopper 1
26 Washer 1
27 Spring washer 1
28 Nut 1
29 K1821D00 | Pressure handle 1
30 E-type snap ring 1 for 6¢
31 K1821E01 | Tachogenerator bracket 1
32 K1821E02 | Tooth pooly 2 for Aluminum
33 Timing belt 1
34 K1821F03 | Generator adaptor 1
35 K1821E04 | Shaft 1
36 Micro bearing 2 RF-1560ZZ
37 K1821E05 | Oldam joint 1
38 K1821E06 | Coupling 1
39 D.C tachogenerator 1 2225U4.3GS
39-1 Screw 2 M2-5
40 K1821E07 | Cup 1
41 K1821E08 | Cover 1
K1821J00 re or alehtener (1)
42 K1821J01 | Wire straightener body 1
43 K1821J02 | Fit plate 1
44 K1821J03 | Control screw 1
45 U2344C04 | Roller shaft 2
46 Radial ball bearing 9 No 89977
No. U3793
P. 16/18
Item
No. Part No. Description Q'ty Remarks
47 E-type snap ring 3 for ¢7
48 U2344C05 | Slide shaft 1
49 |U69C02 | Radial ball bearing 1
50 U2344C07 | Adapter 1
51 U2344C08 | U2344C08 1
52 Narld knob 1 KN15
53 U2344C10 | Inlet guide 1
8.2 Others (See Fig. 4)
Item
No. Part No. Description Q ty Remarks
54 U3569B00 | Frame body 1
55 Gas solenoid valve 1 W-31156 D.C25V
56 U2878D00 | Gas hose assembly 1
57-1 | U3569E00 | 5P plug 1 DCPC25-5A
58 K536A00 Spindle type wire reel 1 with brake
59 U2878F00 | Wire reel cover assembly 1
09-1 | U2884E00 | Wire reel cover 1
59-2 | U2878F01 | Wire reel cover 1
59-3 | U2878F02 | Seal rubber 2
60 U1997C01 | Cab le clamp 1
17/18
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Disassembly drawing of Wire reduction gear unit
Fig. 9
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