OTC
 ÓN
MANUAL NO:P10464-2
OTE
DAIHEN Corporation
OWNER'S MANUAL
FOR
DIGITAL INVERTER
DA300P
MODEL: DA-300P P10464
INVERTER CONTROLLED WELDING POWER SOURCE
DO NOT DESTROY
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual. |
DAIHEN Corporation wELDING PRODUCTS DIVISION
June 28, 2005
[Upon contact, advise MODEL and MANUAL NO.|
_/
10.
11.
12.
13,
14.
15.
No. P10464
TABLE OF CONTENTS
SAFETY INFORMATION.............e.eereeeeece ner ssn 2
ARC WELDING SAFETY PRECAUTIONS.....4 4444444400000 Le 2
GENERAL NOTICE OF OPERATION.............1-.0eeeencnenen nen 8
STANDARD COMPOSITION AND ACCESSORIES.................e-eee—s 9
FUNCTION OF EQUIPMENT.............eeeeeenoreennnn ens a, 10
NECESSARY POWER SOURCE EQUIPMENT. ...........-.e=0e0emennees 12
“TRANSPORT AND INSTALLATION.......--<.eeer<eei0eeeemiarnennnenne neen 13
CONNECTION PROCEDURE AND GROUND FOR SAFETY USE.............- 15
WELDING PREPARATION............---r-reenernrn nen os 21
OPERATION... Se eee 27
APPLIED FUNCTION.….…..….…..…<caccscsecrarsenneenes see cenenenecet en sc ete sance 56
MAINTENANCE AND TROUBLESHOOTING..........00 4444000004440 65
PARTS LIST... EEE sees res ananas 73
SPECIFICATIONS..….……….….w…cweererererereeeneen creer een ceneenene ne cs nes cette 76
SERVICE AND SUPPORT..…….……..<…-<sirercenereceeneenn een cinnen eenes nec seres eee 80
No. P10464
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.
7 WARNING gives information regarding possible personal injury
A
+. WARNING or loss of life.
CAUTION refers to minor personal injury or possible equipment
7 CAUTION damage.
2. ARC WELDING SAFETY PRECAUTIONS
/Ÿ 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.
—— —————— —_ кан еее неее сем ———
No. P10464
2. ARC WELDING SAFETY PRECAUTIONS (continued)
ELECTRIC SHOCK can kill.
W
С
С
1.
2.
3.
4
a
299N9
omponents in the torch and work circuits are electrically live.
Do not touch live electrical parts.
Wear dry insulating gloves and other body protection that are free of holes.
Insulate yourself from work and ground using dry insulating mats or covers.
or maintaining this equipment.
state, and local codes. |
Keep all panels and covers of this equipment securely in place.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not touch electrode and any metal object if POWER switch is ON.
— Do not wrap cables around your body.
0. Turn off POWER switch when not in use.
Be sure to disconnect the line disconnect switch before installing, changing torch parts
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
ircuits 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
Properly install and ground this equipment according to its Owner's Manual and national,
ARC RAYS can burn eyes and skin: FLYING SPARKS AND HOT METAL can
AB cause injury. NOISE can damage hearing.
“7
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 ANSIZ 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a welder
work.
Wear approved safety goggles. Side shields recommended.
to look at the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather)
and foot protection.
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.
Wear approved face shield or safety goggles. Side shields recommended.
Wear proper body protection to protect skin.
Use protective screens or barriers to protect others from flash and glare: warn others not
еее (ее —_———— ——\———
No. P10464
2. ARC WELDING SAFETY PRECAUTIONS (continued)
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, spatter, hot
base metal, and hot equipment can cause fire and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metals.
2 Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 10m (33ft) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easily pass through cracks
and openings into adjacent areas.
5 Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
|7. Do not weld on closed containers such as tanks or drums.
8. Connect base metal side cable as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire
hazards.
9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
10. Do not use the welding power source for other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connection can cause sparks and excessive heating.
13. Tighten all cable connections.
14. When there is an electrical connection between a work piece and the frame of wire feeder or
the wire reel stand, are may be generated and cause damage by a fire if the wire contacts
the frame or the work piece.
FUMES AND GASES can be hazardous to your health.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2 Ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturer's instructions on
metals, consumables, coatings, and cleaners.
5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
6. Work in a confined space only if itis 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. |
No. P10464
2. АВС WELDING SAFETY PRECAUTIONS (continued)
CYLINDER can explode if damaged.
- LH “Nu
2.
3
pus
A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
1.
Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the
specific application; maintain them in good condition.
Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
Keep the cylinder upright and securely chained to a stationary supportora rack to prevent
falling or tipping.
Keep cylinders away from any welding or other electrical circuit.
Never touch cylinder with welding electrode.
Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when gas cylinder is in use or connected for
use.
Do not disassemble or repair the gas regulator except for the person authorized by the
manufacturer of them.
Rotating parts may cause injuries. Be sure to observe the following.
+
If hands, fingers, hair or clothes are put near the fan's rotating parts or wire feeder's feed roll,
injuries may occur.
1.
2.
Do not use this equipment if the case and the cover are removed.
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.
Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
No. P10464
2 ARC WELDING SAFETY PRECAUTIONS (continued)
— ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
When hanging the welding power Source by a crane, do not use the carrying handle.
Put the welding power source and wire feeder solidly on a flat surface.
Do not pull the welding power source across a floor laid with cables and hoses.
Do not put wire feeder on the welding power source.
Do not put the welding power source and wire feeder where they will pit or fall.
hoon
WELDING WIRE can cause puncture wounds.
1. Do not press gun trigger until instructed to do so.
12. Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.
Я, ) This equipment uses high frequency for arc starting.
Wi
High-frequency may enter nearby units as shown below, causing electromagnetic trouble.
* Input cables, signal cables, telephone cables
* Radio sets, TV sets .
* Computers and other contro! equipment
* Industrial detectors and safety units
* Pacemakers, hearing-ald sets
For preventing electromagnetic trouble,
Make the cable as shortest as possible.
Install cables along the floor or the ground as close as possible.
Put the base metal side cable together with the torch side cable.
Do not use a common base metal ground with other machines.
Tightly close all of the doors and covers of this equipment, and secure them.
Do not press the torch switch other than when ready to start the arc.
When electromagnetic trouble occurs, take the measures shown in this instruction manual
until trouble is corrected. o
но оком >
Please contact OTC-DAIHEN , when necessary. |
8. Pacemaker wearers must not come near this equipment during operation until consulting
your doctor.
Operation of the pacemakers will be affected badly by high frequency.
No. P10464
PRINCIPAL SAFETY STANDARDS
Arc welding equipment — Installation and use, Technical Specification
IEC 62081, from International Electro technical Commission
Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro
technical Commission
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office. :
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS С5.2,
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.
T040803
No. P10464
3. GENERAL NOTICE OF OPERATION
3.1 Rated Duty Cycle
‚1. CAUTION
O Use this welding power source at or under the rated duty cycie. Exceeding the rated
duty cycle limitation may result in damage to the welding machine.
® The rated duty cycie of the welding power source is the following:
- TIC WELDING: 40% (300 A)
. STICK WELDING: 40% (250 A)
NOTE:
e When using a dust-proof fan filter as standard equipment, observe the duty cycle listed
above.
e Use of any other filter may lead to an excess of the duty cycle limitations or damage to
the welding power source. Be sure to use the specified dust-proof fan filter. (Part
number: 4519-031)
eThe duty cycle of 40% means the way the
machine is rested for 6 minutes after 4 minutes of
continuous welding at the rated current.
e Failure to observe duty cycle limitations may
cause an excess of the tolerance of the
temperature inside the welding power source.
This may cause to premature welding power
source failure or product damage.
e The figure shown right indicates the relation
between welding current and duty cycie. Use
the welding power source within its usable
range, following the duty cycle for the welding
current.
e The duty cycle of the welding power source is
also limited by the duty cycles of accessories
combined with such as welding torches. Use
the welding power source within the lowest
rated duty cycle of the accessories.
® Choking the filter by dust may cause decrease
duty cycle. And also it may cause damage fo
the welding power source. So check the filter
periodically.
| OFF
Duty cycle (%)
Duty cycle (%)
al |. il
4 min. 6 min.
10 min.
Operation cycle of 40% duty cycle
50
100 y
50
_100% (190A or less)
: Usable range
at TIG welding 40% (300A)
=
100 200 300
Welding current (A)
_100%(160 A or less)
=Usable range > о
dat STICK welding 40% (250 A)
= \ 60% (204 A)
ke Hf le
т
ЦН
100 200 250
Welding current (A)
No. P10464
4. STANDARD COMPOSITION AND ACCESSORIES
4.1 Standard Composition
e The parts names indicated in the boxes are standard parts. They are not supplied with this
welding machine. Preparation of the standard parts except the welding power source is
required to use the welding power source.
e 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 AWG12 4mm’ with 10mm¢ terminal 3
~ Grounding cable AWG12 4mm” with 10mm¢ terminal x 1
Gas regulator
36 400V
Ell Input cables (2m) * Ground a work piece if
— (| 5 © a local law requires.
Digital remote control
(Optionally available)
| | a Welding_power source => } NT
| N
[Base metal cable]
Tap water or water cooler / Analog remote control (Optionally available)
(not needed for STICK welding and for use of the air-cooied torch) Connect to the water waste treatment equipment
Base meta!
or the water cooler (when using the water-cooled forch).
4.2 Accessory
Check the quantity of parts when opening the package.
"Description | Specification Q'ty Part number Remarks
Power
Cable DIX SK 50 1 4734-016 For base metal and holder cable
_ connector
4.3 Other Equipment
(1) TIG Welding
e Use argon gas for welding with 89.9 % or more purity.
® Use the proper filler wire for material, plate thickness, etc.
(2) STICK Welding
® Use the proper stick welding electrode for purpose of use, welding position, shape of joint,
etc. |
e Use the electrode holder electrically insulated.
No. P10464
5. FUNCTION OF EQUIPMENT
5.1 Welding Power Source
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—10—
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No. P10464
5 FUNCTION OF EQUIPMENT (continued)
52 Welding Torch
Torch switch 2P
Water in hose
(5/8- 18UNF) se
Gas hose
=
Water out hose |
(5/8 18UNF) >
Power cable connector D) a A
ES o Et 3 |
Torch body |
a €
Nozzle
Tungsten electrode
No. P10464
5. NECESSARY POWER SOURCE EQUIPMENT
6.1 Welding Power Source Equipment (for commercial use)
Y. WARNING
—
@ When the welding machine is used in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
A CAUTION
—_—
O Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
welding machine.
Capacity of Necessary Power Source Utility
AC-TIG DC-TIG | STICK
Power supply voltage 400 V, three phase
Tolerance range of fluctuation of power | 400V+15%
_supply voltage
Installed capacity 12.5kVA or more 11.9KVA or more 13.2kVA or more
Capacity of switch/circuit breaker 50 A 50 A 50 A
6.2 Precautions for Use of the Engine Generator
A. CAUTION
——
® Use the auxiliary power of engine welder whose voltage waveform has been improved. Some of
the engine welders have poor electricity, which may cause product damage. Contact an engine
welder manufacturer for improvement of waveform.
To prevent the welding power source from being damaged because of engine generator, follow the
instructions below.
e 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.
e Use the engine generator with a damper winding of which capacity is more than twice as much as
the rated input of the welding power Source. Generally, the recovery time of the engine generators
voltage for load change is slower than that of the commercial input power Source, and if the engine
generator does not have sufficient capacity, sudden current change such as arc start will occur.
This may cause abnormal decrease in output current or arc loss. Ask an engine generator
manufacturer for a damper winding. |
e Do not combine more than two welding machines with an engine generator. The affect of each
welding machine may cause €asy loss of arc.
No. P10464
7 TRANSPORT AND INSTALLATION
7.1 Transport
+ WARNING
—]]——
following.
To prevent accidents and damage of the welding machine during transportation, observe the
O Be sure to disconnect the line disconnect switc
machine.
e Do not touch charging parts inside or outside the welding machine.
h when carrying the welding
7 y a
PB
a
O When hanging the welding power
source with the cover or the case and tighten eye-bolis.
@ Lift one welding power source with two wires. Lifting the welding power
source by a crane, cover the power
source and other equipment to
gether may cause them to drop.
scotch-block.
handle.
O When carrying the welding machine with a fork lift, etc., securely make
O When hanging the welding power SOUrce by a crane, do not use the carrying
7.2 Installation
т
7
WARNING
When installing the welding machine, follow the
welding and physical damages by fume gas.
® Do not place the welding machine near combustible materials or flammable
instructions below to avoid a fire caused by
AE
gas.
combustible objects. If that is not po
@ Remove combustible materials to prevent dross coming into contact with
ssible, cover them with
noncombustible covers.
regulated by a local law.
at a partial exhaust facility approved by the loc
@ Adequately ventilate or wear a gas mask when
in a tank, in a boiler or in a hoid of a ship, beca
carbon dioxide or argon gases are settie there.
supervisor's directions. And be sure to wear a
ventilate.
© To avoid gas poisoning and danger of suffocation, wear a gas mask or
adequately ventilate when the welding machine is used in the place
@ To prevent disorder or poisoning caused by fume, wear a gas mask or weld
@ When using the welding machine at a narrow space, comply with a trained
al regulation.
using the welding machine
use heavier gasses such as
gas mask or adequately
—13—
No. P10464
7. TRANSPORT AND INSTALLATION (continued)
7.2 Installation (continued)
1 CAUTION
(= To prevent electromagnetic troubles, read the following.
eh 3) ) Also, if electromagnetic troubles occur, check the following again.
® Change the installation place of the welding machine.
® Mount an input cable in the grounded metallic conduit.
€ Provide electromagnetic shield to the whole welding places.
A. CAUTION
Follow the instructions below when selecting an installation place of the welding power
source. Ш
@ Do not put heavy things on the welding machine.
@ Do not cover the ventilation port of the welding machine.
@ Do not install the welding power source in the place subject to direct sunlight or rain.
@ Do not place the welding power source, wire feeder, torch, control unit, conduit and
control cable (including the extension cable) in an area where the equipment can become
wet. Place the welding machine on a strong and stable surface.
O Install the welding machine in the place where the ambient temperature is between -10 "С
and +40 °С (+14 ‘F and +104 °F).
@ Do not install the welding machine in the place where metal material such as spatter
enters the welding power source.
O Keep the install distance of 20 cm between the welding power source and the wall or other
welding power source.
O Install a wind shield to protect arc from wind.
O Fix the gas cylinder to the stand only for gas cylinder,
—14—
нежен те AE
No. P10464
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE
A. WARNING
/^ Observe the following to prevent electric shock.
Do not touch the charged sections; otherwise, you might receive serious electric shock or
get burned.
€ Do not touch the charged sections.
O Have a qualified electric engineer ground the case of the welding power source. Have a
qualified electric engineer ground the base metal or jig electrically connected, following a
local low. |
@ Connect the welding machine with all the line disconnect switches inside the switch box
turned off.
@ Do not use a cable with lack of capacity or a damaged cable.
@ Tighten and insulate the connections of cables.
O Attach the case properly after connecting the cable.
8.1 Connecting of the Welding Power Source
A CAUTION
To prevent electromagnetic troubles, read the following.
АЖ), ) Also, if electromagnetic troubles occur, check the following again.
'® Do not use an unnecessarily long cable.
® The welding cable is placed as closely on the floor or ground as possible.
€ Place a base metal cable and an electrode cable as closely as possible.
180 Do not ground the welding power source commoniy with other machines.
Noah =
No. P10464
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY
8.1.1 TIG WELDING (water-cooled torch)
Torch switch
Torch switch cable
— N
6 ебу % NN
0 orch power cable
os +
USE (continued)
И
Torch
|
Water supply hose*
0
© (Gas hose
0=— -
©
Zar
Base metal cable
(38 mnFor more) u
| —Condensate hose" / Base metal
(Firmniy attach the cable to the base metal. )
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”.
Ground the base metal (if required by local laws or codes).
Attach the torch cable to the “torch © " output terminal.
Connect the water supply hose to the cooling water connection.
Connect the gas hose to the gas connection.
Connect the torch switch or foot switch to the socket for torch switch.
Make drainage treatment (when using tap water).
When using the circulation system, attach the water out hose to it.
* When using the air-cooled torch, the water hose is not necessary.
Firmly attach the torch switch to the torch with the supplied bands.
(Pu the other ends
through the loops, then
length of the bands.
With the rough sides of the bands
facing inside, put the bands around the
handle of the torch body,
—16—
a A TE
Connect between the “base metal €) ” terminal and the base metal with the base metal cable.
cut down the excessive —
No. P10464
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
8.1.2 STICK WELDING
The following figure shows the cable connections for stick welding with DC electrode positive
(welding stick positive, base metal negative). When using DC electrode negative, switch the
holder cable with the base metal cable.
Holder
eZ ree a
(COM
\ Base metal
Base metal cable
0 | (38mm> or more)
0 Ori ру
ot O — |
0< EA 7
(+) я ( Firmly attach the base metal cable to the base metal)
1. Ground the base metal (if required by local laws or codes).
2 Connect the base metal cable to the negative © output terminal on the welding power
source,
3. Connect the holder to the positive @ output terminal on the welding power source.
8.2 Connecting of the Base Metal Cable and Stick Holder Cable
When connecting the base metal cable and stick holder cable to the welding power source,
attach the cable plug DIX SK 50 (supplied).
Groove Cable Conductor Biss
—17—
No. P10464
8 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
8.3 Connecting of the Gas Hose
+ WARNING
e You may suffer from danger of suffocation caused by lack of oxygen when
shield gas keeps drifting in a closed place. Be sure to turn off the shield gas
at the main when the welding power source is not in use.
i. CAUTION
O Be sure to connect the gas hose after fixing gas cylinder to the stand, as physical injuries
may result from falling down of it. |
O Attach a proper gas regulator to a gas cylinder. Failure to observe the demand may result in
physical injuries. 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 Welding power source
with a monkey wrench, etc.
2 Fix the nut for attaching gas cylinder to the gas cylinder with a monkey wrench, etc.
3. Securely attach the gas hose to the gas outlet with a monkey wrench, etc.
Nut for attaching gas cylinder Gas regulator
\ <— Pressure gauge
Gas cylinder © 3 >
Gas outlet
Welding Power source
NN
8.4 Grounding and Connecting of Input Power Source
A
Do not touch the charged sections; otherwise, you might receive serious electric shock or get
burned.
€ Do not touch the charged sections.
@ Have a qualified electric engineer ground the case of the welding power source. Have a
qualified electric engineer ground the base metal or jig electrically connected, following a
local low.
® Connect the welding machine with ali the line disconnect switches inside the switch box
turned off. |
@® Attach the case properly after connecting the cable.
@ When the welding machine is used in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
A. WARNING
Observe the following to prevent electric shock.
—18—
No. P10464
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
A. CAUTION
(= To prevent electromagnetic troubles, read the following.
A 3) ) Also, if electromagnetic troubles occur, check the following again.
e Add a noise filter to the input cables.
@ Do not ground the welding power source commonly with other machines.
A. CAUTION
@ Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
welding machine.
The following figure shows the cable connections. When using the air-cooled torch, the water supply
hose is not necessary. For STICK welding, the water/gas hoses are not necessary.
(DGas regulator @Pressure gauge
Mount the line disconnect switch with fuse
or each no-fuse breaker on each welding machine.
GREEN/YELLOW cable for grounding cable
Base metal or jig
3) * Ground a work piece
if a local law requires.
J ;
@Water-cooling hose / |
®lnput cables oo connect the input and me
and Grounding wire .
(Gas hose 3 Cables 4mm? to the circuit breaker .
A. CAUTION
Be sure to ground the case of the welding power source.
Use a grounding cable of which thickness is more than 4mm’,
O 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
stray capacity (electrostatic capacity naturally generated between the input circuit and the
metal enclosure). If you touch the case or the base metal, you may suffer from electric shock.
Be sure to ground the case of the welding power source or Jig.
No. P10464
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)
e Cooling Water
Connect a water-cooled hose as illustrated below.
a С
(5)
|
Direct insertion of the | Using a faucet that a 1/2 gas Employing a stop valve
rubber hose into a faucet. | thread is cut.
No. Parts No. Remarks
ap water
BBDW-3001
—20—
No. P10464
9. WELDING PREPERATION
9.1 Preparing the Protective Equipment
1 CAUTION
Check the followings before welding.
e The whole doors and covers of the welding machine are surely closed and fixed.
® The welding cable is placed as closely on the floor or ground as possible.
O Place a base metal cable and an electrode cable as closely as possible.
® Proper flow rate of shield gas is supplied. Improper flow rate may lead to bad arc start and
unnecessary high frequency.
И CAUTION
d——
Use the protective equipment to protect you and other workers from arc rays,
AB spattering dross, and noise from welding operation.
XX
@® 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.
O Install protective screens or barriers to protect the eyes of others in the work area from arc
ray.
O Wear an ear protector when noise level is high.
—21—
No. P10464
9. WELDING PREPARATION (continued)
9.2 Operating the Switches and Controlling the Gas Regulator
A. CAUTION
——
O Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as
burst of high-pressure gas may result in physical injuries.
NOTE: Gas checking automatically stops in two minutes.
(MD Turn on the line disconnect
switch. (400V, 36)
Gas flow rate adjusting knob
O Set the gas regulator to “SHUT” ,
then turn on gas at the main valve.
® Set the gas regulator adjusting knob
to “OPEN” to adjust the gas flow rate.
@ Press the GAS CHECK
key. (The GAS CHECK
lamp lights up.)
O Place the power switch in the “I” (ON)
position.
© Press the GAS CHECK
button again. (The GAS
CHECK lamp goes out.)
9.3 Selecting the cooling method
A. CAUTION
® When using the water-cooled torch, supply water-cooled torch from the outlet for cooling
water on the rear panel of the welding power source. And turn torch change-over key to the
"WATER COOLED" side.
O If cooling water is supplied directly to the torch with the welding power source bypassed,
and the water-cooled torch is used with the torch selector key set at air side, it cannot be
detected whether cooling water is flowing, and in case where no cooling water is flowing, the
torch may be burnt.
When using a water-cooled torch, select "WATER" by pressing the
() WATER TORCH key once.
+ [WATER]: The TORCH lamp is on.
[AIR]: The TORCH lamp is off.
TORCH
—272—
No. P10464
WELDING PREPARATION (continued)
94 TIG Welding Condition (for reference)
—23—
(1) TIG Welding Condition (PULSE “OFF”)
; Plate | Electrode Dia. | Filer Wire Dia. | Current | “807228 | No.of | Bevel
Material Thickness (mm) (mm) (A) Flow Rate Layer | Shape
(mm) (min)
0.6 1, 1.6 0-16 20 - 40 4 1 | (а), (5)
| 1.0 1,16 0-16 30 - 60 4 1 | (a), 5)
es 16 1,6, 2.4 0-16 60 - 90 4 1 (b)
DC. 2.4 1.6, 2.4 16-24 80 - 120 4 1 (b)
Electrode 3.2 2.4, 3.2 24-32 110 - 150 5 1 (b)
Negative) - 4.0 2.4, 3.2 24-32 130 - 180 5 1 | @, ©
4.8 2.4, 3.2, 4 2.4 - 4.0 150 - 220 5 1 | @ (©
6.4 3.2, 4, 4.8 32-48 180 - 250 5 1-2 | (a), (©)
0.6 1,16 0-16 50 - 70 3-4 7 | (a), (b)
1.0 1.6 0-1.6 60 - 90 3-4 1 lat
se 1.6 24 1.6 - 2.4 80 - 120 3-4 1 (b)
De 24 2.4, 3.2 2.4 - 3.2 110 - 150 4 1 (b)
Clectróde 3.2 3.2,4 32-48 140 - 200 4-5 1 (©)
Negative) 4.0 3.2, 4, 4.8 4.0-4.8 180 - 250 4-5 1 Ido
4.6 4, 4.8 4.8 - 6.4 250 - 300 5-6 1 | @, (с)
6.4 4, 4.8, 6.4 4.8 - 6.4 300 - 400 5-6 1-2 | (a), (©
Aluminum 1.0 1.6 0-16 50 - 60 5—6 1 | (@, ©)
(АС) 1.6 1.6, 2.4 0-1.6 60 - 90 5-6 1 | (@), ©)
2.4 1.6, 2.4 1.6 - 2.4 80 - 110 6-7 1 (b)
3.2 2.4, 3.2 2.4 — 4.0 100 - 140 6-7 1 (b)
4.0 3.2, 4.0 32-48 140 - 180 7-8 1 (b)
4.8 3.2, 4.0, 4.8 4.0 - 64 170 - 220 7-8 1 (b)
6.4 4.0, 4.8 4.0-64 200 - 270 B—12 1-2 | (@), (©)
1.0 1.6 0-1.6 30 - 40 3-4 1 (a)
1.6 1.6, 2.4 1.6 - 2.4 40 - 70 4-5 1 (b)
Magnesium 24 1.6, 2.4 1.6 - 2.4 60 - 90 4-5 1 (b)
(AC) 3.2 1.6, 2.4 2.4 — 3.2 75-110 5-6 1 (b)
4.0 2.4, 3.2 3.2 - 4.0 90 - 120 5-6 1 | (9). (9)
4.8 3.2, 4.0 32-48 110-150 5-6 1 | (d),()
6.4 3.2, 4.0 4.0 — 4.8 130 - 170 6-7 1-2 | (à), (e)
t
| Л A “905
A = < = pe и
с = #3
(а) (5) (с) (а)
No. P10464
9 WELDING PREPARATION (continued)
(2) Welding Condition of DC ПС Pulse
€ Flat position and butt joint welding
Pulse Condition Welding Wire
. . Gap G | Pulse | Base Pulse Feeding
Material Joint Geometry (mm) | Current |Current Frequency Width tel Speed
(A) (A) (%) (cm/min)
| и 0 200 | 50 2.5 50 60 60
Mo 5 U 1.2 | 150 | 20 1.5 46 30 60
2 Je 1.6 | 130 | 20 1 50 15 40
— Stainless 0 150 | 50 3.1 50 80 0
Steel ii 12 | 150 | 20 1 35 17 40
SUS304 | > ZN a 16 | 130 | 20 0.8 30 10 40
с 20 | 130 | 20 0.8 30 83 40
— 0 280 | 50 3.1 50 80 0
Copper | 42 | 280 | 50 2 50 50 75
ke 16 | 280 | 30 1.5 42 25 75
Titanium. SD 7
ToT HAE o | 200 | 100 1 30 25 0
G
Shield gas : Argon (10 !/min)
Filler Wire : 1.2mm 6
Electrode : Thoriated Tungsten (3.2mm @)
Arc Length : 2mm
—24—
Ф Weld joints with different heat capacity
9.
No. P10464
WELDING PREPARATION (continued)
Pulse condition Welding | Filler wire
No. of | Pulse | Base |Pulse|Pulse| Speed Feeding
Material Joint geometry Layer |Current|Current | Freq. | Width Speed
(A) (A) (Hz) | (%) | (cm/min.) | (em/min.)
Copper Г —
; ! 60
+ 7 1 | 250 | 50 | 08 | 20 10
Mild Steel NN Eno a
SPCC
Stainless Vv a
Steel | de 1 170 60 | 25 | 50 50 60
+ N SUS (805)
Mild Steel
SPCC
1.2. |
Mild Steel т ЧИ log 1 | 120 | 50 | 2 | 50 | 20 30
y
PC —
=
> 3.2 Cu
> К
1.8 SUS 1.6 SUS
Stainl + TF
ainiess AN 4 | 160 | 50 | 15| 46 | 85 60
Steel La A
19
| \
Length: 7mm
SUS 304
Shielding Gas : Argon (10f/min.)
Filler Wire : 1.2mm ¢
Electrode : Thoriated Tungsten ( 2.4mm ф)
Arc Length : 2 - 3mm ¢
—25—
No. P10464
0. WELDING PREPARATION (continued)
Pulse condition Welding | Filler wire
| No. of | Pulse | Base |Pulse Pulse | Speed | Feeding
Material - Joint geometry Layer Curren [Current |Freg.| Width Speed
t (A) (Hz) | (%) | (cm/min.) | (cm/min.)
—_— (A)
1.0 70 25 1 50 1.6 75
1.5 80 40 1 50 1.6 95
1.5 90 29 1 50 1.6 75:
re 1.5 85 25 1 50 1.2 95
e | 3.2 | 170 25 1 | 50 1.2 290
3.0 170 25 I 50 1.6 170
6.0 220 25 1 50 1.6 250
TV] | 6.0 | 180 25 1 | 50 1.6 250
Aluminum
3.2 170 25 1 50 1.2 290
a 6.0 220 25 1 50 1.6 270
{1h
3.0 | 120 25 1 50 1.6 60
(4) Post-Flow Time |
Adjust to the proper post-flow time for the electrode diameter.
Does Post-Flow Time (s)
16 3-9
2.4 5-8
32 8-12
4.0 - 12-17
64 21-26
—26—
10.
- Fully employ the “Quick Manual” on 14.2: this manual
10. Front panel
Pen
[16] [9] [5] [10] [2]
[15][18] [17] [3] [11]
No. P10464
OPERATION
[13]
[12] [1]
[14] [3]
в
[15]
is a brief summary of the operation, etc.
[4] [6] 17]
[8]
[1] WELDING METHOD change-over key
[9] ARC SPOT TIME setting key
[17] LOAD key
[2] AC WAVE change-over key
[10] Function selection key
[18] SAVE key
[3] Parameter selection Key
[11] INITIAL CURR. selection key
[19] ENTER key
[4] Parameter adjusting knob
[12] PULSE selection key
[5] CRATER FILL. key
[13] LIFT START key
[6] AC FREQ. key
[14] SLOPE selection key
[7] AC BALANCE key
[15] TORCH change-over key
[8] AC-DC change-over frequency settup
key
[16] GAS CHECK key
—27—
No. P10464
10. OPERATION (continued)
1 WARNING
на
Observe the following to prevent electric shock.
3 *Do not touch the charged sections; otherwise, you might receive serious
y electric shock or get burned.
@ Do not touch the electrode while pressing the TORCH switch.
® Disconnect the welding power source form input power supply before
replacing the electrode.
O Wear dry clothes and gloves during welding.
` a
Ги
AN CAUTION
@ This welding machine should be operated by persons only after reading and
understanding contents of this owner's manual and having knowledge and skills for
handling the welding machine safely. | |
€ Use this welding power source at or under the rated duty cycle. Exceeding the rated duty
cycle limitation may result in damage to the welding machine.
A CAUTION
Observe the followings to perform TIG welding safely.
7;
O Adjust the amount of shield gas with the GAS CHECK key. Using the torch switch for
adjustment of shield gas may result in generating unnecessary high frequency for a long
time period.
® Using improper electrode may cause failure of arc start, and generate useless high
frequency.
® Improper shielding gas flow may cause failure of arc start, and generate useless high
frequency. |
When reading the operating instructions described below, unfold page (section 14.2) so that you can
read them confirming the location of the keys on the front panel.
10. 1 TIG Welding
10.1.1 DC TIG Welding
Set the welding process to DC TIG (77777), AC TIG AR) or AC-DC Tic
with the WELDING METHOD key [1].
10.1.2 Parameter setting
Choose parameter by anti-clockwise direction Choose parameter by clockwise direction
[ Part of sequence parameter setting]
—28—
_—— = ое —
No. P10464
10. OPERATION (continued)
The parameters listed below may be selected with the parameter selection key [3] and
adjusted with the parameter adjusting knob [4]. The set value of the parameter
selected appears on the digital display with the respective unit indicator LED turned
ON.
(1)
(2)
(3)
(4)
(5)
Unit LED
Digital meter
[Part of Indication]
Pre flow time
When the parameter “pre flow time” is selected, the set value appears on the
right digital display with the unit indicator LED for “second (sec) turned ÓN. In
this state, the pre flow time may be adjusted in the range between 0 and 20
seconds by the use of the parameter adjusting knob [4].
For lift start mode, however, the parameter “pre flow time” may not be selected.
Initial current
This parameter may be selected only if the initial current setting 15 "ОМ".
When this parameter is selected, the set value appears on the left digital
display with the unit indicator LED for “ampere (A) ” turned ON. In this state,
the initial current may be adjusted in the range as specified in the table shown
on the following page by the use of the parameter adjusting knob [4].
Upslope time
This parameter may be selected only if both initial current and slope settings -
are "ON". When this parameter is selected, the set value appears on the right
digital display with the unit indicator LED for “second (sec) * tumed ON. In this
state, the upslope time may be adjusted in the range between 0 and 10
seconds by the use of the parameter adjusting knob [4].
Pulse current |
This parameter may be selected only if the pulse setting is "ON”. When this
parameter is selected, the set value appears on the left digital display with the
unit indicator LED for "ampere (A) ” turned ON. In this state, the pulse current
may be adjusted in the range as specified in the table shown on the following
page by the use of the parameter adjusting knob [4].
Welding current (or Base current)
When this parameter is selected, the set value appears on the left digital
display with the unit indicator LED for “ampere (A) " turned ON. In this state,
the welding current may be adjusted in the range as specified in the table
shown on the following page by the use of the parameter adjusting knob [4].
If the pulse setting is "ON", the base current may be set and adjusted in the
range same as that for the welding current.
—29—
(6)
(7)
(8)
(9)
No. P10464
10. OPERATION (continued)
Pulse frequency
This parameter may be selected only if the pulse setting is "ON". When this
parameter is selected, the set value appears on the right digital display with the
unit indicator LED for “hertz (Hz) * turned ON. In this state, the pulse
frequency may be adjusted in the range between 0.1 and 500 Hz by the use of
the parameter adjusting knob [4].
Down slope time
This parameter may be selected only if the crater setting is "ON", “REPEAT” or
“ARC SPOT" and the slope setting is “ON”. When this parameter is selected,
the set value appears on the right digital display with the unit indicator LED for
“second (sec) * turned ON. In this state, the down slope time may be adjusted
in the range between 0 and 10 seconds by the use of the parameter adjusting
knob [4].
Crater current |
This parameter may be selected only if the crater setting is “ON”, "ON
(REPEAT)" or “ARC SPOT". When this parameter is selected, the set value
appears on the left digital display with the unit indicator LED for “ampere (A) ”
turned ON. In this state, the crater current may be adjusted in the range as
specified in the table below by the use of the parameter adjusting knob [4].
Post flow time
When the parameter “post flow time” is selected, the set value appears on the
right digital display with the unit indicator LED for “second (sec)” turned ON.
In this state, the post flow time may be adjusted in the range between 0 and
30 seconds by the use of the parameter adjusting knob [4].
For suitable electrode diameter and post-flow time, see Section 9.4, “TIG
Welding Condition”.
¢ Setting Current range
Welding |
method AC wave form DA-300P
pe TG 4A - 300A
. STANDARD
Output Current Setting Range AC TIG HARD 10A - 300A
AC-DCTIG SOFT 10A - 200A
No. P10464 -
10. OPERATION (continued)
10.1.3 AC TIG Welding
The AC TIG welding process is such that the polarity of electrode plus (+) from which cleaning
action is obtained and that of electrode
minus (-) in which electrode consumption is small are
inverted alternately to take advantage of the feature of both polarities. This type of welding is
suitable mainly for aluminium welding.
10.1.4 AC-DC TIG Welding
The AC-DC TIG welding process is such that the alternating current period during which
cleaning action is obtained and the direct current period during which deep penetration is
obtained are outputted alternately in a cyclical manner. This type of welding is suitable mainly
for automatic welding of aluminium.
10.1.5 Notice of using AC TIG mode
When using AC TIG mode, observe the followings not to damage the welding power
source
1. Use proper extension cable and use as short cable as possible.
2. When using the extension cable, refer to following figure.
ol В - SY A | possible.
в неа нежен
Bind the torch cable and base metal
cable each other with tape.
Straighten the cables as much as
If cable setting mentioned above
у cannot be performed by all means,
lay the torch cable on the base
\ metal.
Se Ц
[|
i
—31—
No. P10464
10. OPERATION (continued)
3. If too long torch side cable is used reluctantly, wind it according to following figure of
"Good example’.
Bad example Good example
Do not wind the excess part of cable inthe | + Refer to the figure below “winding method of
same direction. excess cable”, and make two windings in opposite
Top view
Side view
Explanation [Separate the excess cable — |Place B over A in the After placing B over A, bind
| into A and B. opposite direction. {the winding cable not to be
Wind it respectively as loose.
followings.
- Same winding direction.
> Same turns of winding.
- Same diameter of
Windings.
—32—
No. P10464
10. OPERATION (continued)
10.1.6 AC Waveform
In the case of AC TIG and AC-DC TIG welding, the following three output current waveforms
can be selected with the AC waveform selection key (O). Use these current waveforms while
taking advantage of the respective features.
Also, the AC frequency and cleaning width are stored in memory for each AC waveform.
Mode Output current wave-form _ Characteristic
| Rectangular pulse wave- [Welding operation can be carried out in
|| || ES form which peak value of |a wide range from thin to thick plates.
STANDARD | | straight and reverse polarity (Also, since stable welding operation
current are equal. can be performed in the whole current
area, this waveform can be utilized
| most generally.
Rectangular pulse wave- [Such centralized arc as in DC HG
form which peak value of — |welding is obtained. This waveform is
straight polarity currentis — |effective for fillet welding of a thin plate
different from reverse and for the 1* layer of bevel or the like.
HARD — — polarity current. Among these three modes, electrode
|| || consumption is the smallest in this
mode, but an arc sound becomes
larger.
Sine wave-form which peak |Soft arc is obtained. This mode is
SOFT A A A values of straight and effective for thin plate butt welding, etc.
reverse polarity current are |Also, the arc sound level is low.
| equal. Maximum welding current is 200A.
* CAUTION
If the welding current exceeds 200A in the hard mode, the bead width is larger than the cleaning width,
thus ceasing to place a favorable bead. Accordingly, the hard mode is suitable for the case when the
welding current is smaller than 200A.
10.1.7 AC Frequency
When the initial conditions, main conditions or crater filler conditions are being selected, press
the AC frequency setup key (®), and the LED in the left upper part lights up, the set point is
displayed on the right-side digital meter, then the “Hz” LED lights up. On the left-side digital
meter, the standard value is flashing on the display. In this condition, it is possible to set up the
AC frequency in AC TIG and AC-DC TIG welding, using the parameter adjusting knob (©). The
setup range is 50Hz to 200Hz.
By pressing the AC frequency setup key again or the parameter selection key (@), the system
display screen returns to the parameter item in which the parameter was adjusted to the value
of one step ago.
If the AC frequency is made high, the arc concentration will increase and if it is lowered, the arc
spread is on the increase. Also, even when AC frequency is changed, the depth of penetration
remains unchanged — constant.
In the condition that the AC waveform is "Standard" and “Soft”, the standard value for AC
frequency is 70Hz, while the standard value becomes 100Hz in “Hard”.
—33—
No. P10464
10. OPERATION (continued)
10.1.8 Cleaning Width Setup (т
By pressing the AC BALANCE key (©) when the initial conditions, main conditions or crater
filler conditions are being selected, the left-upper LED lights up and the set point is displayed
on the right-side digital meter. (At this time, all unit LEDs are going out.) In this condition, it is
possible to set up the intensity of arc cleaning action indispensable to AC TIG welding of
aluminium or the like with the parameter adjusting knob (@). The setup range is 0 to +20.
By pressing the AC BALANCE key again or parameter selection key (3), the parameter item
in which the parameter was adjusted to the value of one step ago is selected.
For the cleaning width set point, with “0” as standard, the cleaning width becomes small in the
minus direction, whose set point is “-20” max., and in the plus direction, the cleaning width
becomes large, whose set point is "20" max.
The relationship between the cleaning width setup and welded results & electrode consumption
extent or degree is as shown in the table below. :
Minus Direction D n
Small
Deep n
Less
Low ratio
"EN? refers to the period in which the base metal is positive in polarity (+) and the torch is
negative in polarity (-), and “EP” refers to the period in which the base metal is negative in
polarity (-) and the torch is positive in polarity (+).
The EP ratio is such that the current ratio
of EP polarity at one cycle of alternating
current is expressed in “percent”, which
is defined by the following equation:
iep
EP ratio= x 100%
len + lep
By adjusting this cleaning width, the EP ratio changes by 1% in relation to the manipulated
variable “1”. The EP ratio standard value (when the center position is “0”) differs among AC
waveforms, and the maximum and minimum values that can be set up as EP ratio also differ.
The value indicated on the digital meter can also be used as EP ratio in cleaning width setup.
For details, see *10.1.17 — Internal Function”.
The AC waveform, standard EP ratio and settable maximum and minimum values are as
shown in the table below.
AC Wave form Standard Value Value mum Value
10%
SOFT 30% 10%
HARD 20%
—34—
No. P10464
10. OPERATION (continued)
10.1.9 AC-DC Change-over Frequency Setup ( “III ›
When the initial conditions, main conditions or crater filler conditions are being selected, press
the AC-DC change-over frequency setup key (®), and the LED in the left upper part lights up,
the set point is displayed on the right-side digital meter, then the "Hz" LED lights up. In this
condition, it is possible to set up the AC-DC change-over frequency in AC-DC TIG welding,
using the parameter adjusting knob (@). The setup range is 0.1Hz to 50Hz.
By pressing the AC-DC change-over frequency setup key again or the parameter selection key
(O), the system display screen returns to the parameter item in which the parameter was
adjusted to the value of one step ago.
DC period В АС репой | DC period NC period
Tn |
_—_—" —"—"—— —_———# . -_—_ _ min —
EN (—)
AC-DC change-over frequency (Hz)
EP (+) 1
lel
—
— — | b (sec)
ha -_
The relationship between AC-DC change-over frequency setup and filler wire insertion interval is as
shown in the table below.
AC-DC Change-over
ncy is low
When frequency is lo Frequency Setup
When this frequency is high
The insertion interval is long. Filler wire insertion interval The insertion interval is short.
The ripple spacing becomes The ripple spacing becomes
. Bead ripple
wide, Narrow.
For low-speed welding Welding speed For high-speed welding
(1) Manual insertion
In case where the AC-DC change-over frequency is 0.5Hz to 2Hz, insert a filler wire in synchronism
with AC period. Since the arc sound becomes large during AC period and it becomes smail during
| DC period, insert this filler wire with changes in arc sound as a guide.
(2) Automatic insertion
In case where a filler wire is inserted automatically, set it so that it is fed intermittently in
synchronism with the AC period.
The standard AC ratio is 70%. The AC ratio is such that the rate of AC period to one cycle of AC-
DC is represented in “%”, which is defined by:
AC ratio (%) = a/b x 100
Also, this AC ratio can be changed by using the internal function. For details, refer to “10.1.17;
Internal Function”.
35
No. P10464
10. OPERATION (continued)
10.1.10 Pulse setting ( JUL )
Pulsing is a technique to cyclically vary the welding current for st
abilized arcing, controlled
penetration geometry and/or controlled heat input, where arcing may be rigidified during high
current period for improved stability, and penetration geometry and heat input may be
controlled with the high/low current period ratio varied.
Pulse setting "ON” and “OFF” may be selected with the PULSE selection key [12]. The LED _
located on the upper left corner of the selection key indicates the status of pulse setting "ON”
and “OFF” when it is turned ON and OFF respectively. If the pulse setting is "ON, the
parameters “pulse current” and “puise frequency” may be selected with the parameter
selection key [3]. And the welding current becomes the base current.
Further, in case where the welding process used is “AC-DC TIG”, no pulse selection key can
be selected.
Subject Timinng Chart
ON
+ Tack welding
Pulse | © Repeat of short | Torch Switch — — |
OFF welding |
* Thin plate welding
Welding Current |
ON
Pulse |
ON + Preventing bead Torch Switch
hanging down in
Low Pulse | URANAMI welding |
frequency | orin fillet welding In | wei
(0.1Hz - vertical position. elding Current |
15Hz) Pulse Current Base Current
ON
Pulse
ON Torch Switch — LL —
High Pulse | - Thin plate welding
frequency ‘
(15Hz - Welding Current
500Hz)
Pulse Current
Base Current
The standard pulse peak ratio is 50%, which may be adjusted with the internal function.
Furthermore, in the case of DC TIG welding, the internal function also makes changing to a
soft pulse possible.
See Section 10.1.17, “Internal Functions” for further details.
—36—
No. P10464
10. OPERATION (continued)
10.1.11 Slope setiing
Slope setting “ON” and “OFF” may be selected with the SLOPE selection key [14] if the crater
setting is "ON", “REPEAT” or "arc spot”. The LED located on the upper left corner of the
selection key indicates the status of slope setfing “ON” and “OFF” when it is turned ON and
OFF respectively. If the slope setting is "ON, the parameters “upslope time (only if the initial
current setting is ON) ” and “down slope time” may be selected with the parameter selection
key [3]. But if the crater setting is “OFF”, no selection may be made with the SLOPE
selection key.
10.1.12 Crater setting
At the end of welding, there remains a dent called “crater”.
This dent that might cause cracking or other welding defects
must be minimized in size: this operation is called as "crater
filler”.
Pool
Depressing the CRATER FILL. key [5], the crater setting is selected in the sequence
as shown below:
> Crater OFF >> Crater ON > Crater ON (REPEAT) — ARC SPOT —
For crater-fill operation, select the setting “Crater ON" or “Crater on (REPEAT)".
Crater InitialCurrent Timinnig Chart
ON
OFF
1 Torch Switch
Yau Welding Current | |
» The torch switch hold turned ON during weld.
ON ON
Torch Switch |
OFF
Welding Current
Welding Current Crater Current
ON | ON ON
] Torch Switch
u )
hi | Î | Welding Current
A = ON rT Ea
Initial Current Crater Current
Welding Current
eWhen the torch switch is turned OFF during weiding, the welding current is designed to
be self-held. The torch switch must be held turned ON during initial current and crater-
fill operation.
—37—
No. P10464
10. OPERATION (continued)
Initial
Welding Current
Crater Current Timinnig Chart
ON ON ON
Torch Switch
Welding Current
OFF
Welding Current
Crater Current
ON ON ON .
ON
(REPEAT) Torch Switch
| Welding Current
— CE
nil) mai
+
Initial Current Crater Current
e Even ifthe torch switch is turned OFF during welding, the welding current will be self-
held. When the torch switch is turned ON again, it is switched to crater-fill current.
During crater-fill operation, the torch switch must be held turned ON. If the torch switch
is turned OFF during crater-fill operation, it is switched back to welding current again.
Those switching operation will be repeated cyclically. lt is therefore needed to perform
it with the torch lifted up to turn OFF arcing.
@ In addition to turning OFF arcing with the torch lifted, it is also possible to turn OFF
arcing with the torch switch held depressed for a longer time during repetition. See
Section 10.1.17, “Internal functions” for further details.
@ Welding with various functions combined
With crater-fill, pulsing, and slope functions combined, it is possible to perform welding as shown below:
Torch Switch
Welding Current
ON
ON
Up slope
initial Current
Pulse Current
Base Current| Down slope
Crater Current
—38—
No. P10464
10. OPERATION (continued)
10.1.13 ARC SPOT setting Fs
For arc spot gins “set the CRATER FILL. key [5] to ARC SPOT. Then, upon depression
of the Arc SPOT TIME key [5], the indicator LED located on the upper left corner of the setting
key turns ON and the set value appears on the right digital display with the unit indicator LED
for "second (sec)” tumed ON. In this state, the arc spot time may be adjusted in the range
between 0.1 and 10 seconds by the use of the parameter adjusting knob [4].
Depression of the arc spot time setter key or the parameter selection key [3] will bring you back
to the previous parameter setting stage last adjusted.
In the modes other than arc spot, the arc spot time key may not be selected.
ON 10000 ( ON) Cl. Controlled by
Torch Switch | OFF i Torch Switch
„4— Arc Spot Period. y. a— Down slope
, Period
Output Current Welding
(Slope ON) Current
|
Possible adjustable parameters; |
Arc spot time, Down slope time, Welding current, Crater current
so Ci ==
Crater Current
1 Setting
1
5
1
|
-4—Arc Spot Period— Possible adjustable
I i
| parameters;
Arc spot time, Welding current
Output Current | |
(Slope OFF)
Welding
Current
e The current once provided with the torch switch turned ON will be held supplied
during arc spot period (including down slope period if the slope setting is ON) even if
the torch switch is turned OFF.
eFor arc spot process, it is possible to turn OFF arcing even during arc spot period if
the torch switch is turned OFF. |
See Section 10.1.17, “Internal functions” for further details.
—30—
No. P10464
10. OPERATION (continued)
10.1.14 START setting (Lift start or High frequency start)
Start mode may be selected with LIFT START key [13]. Start mode may be indicated with
the indicator LED on the upper left of the mode selection key that turns ON or OFF for “Lift
start” or “High frequency start” respectively.
(1) High frequency start
@ Depress torch switch with electrode separated from base
metal. |
@ Arc is generated between electrode and base metal by
means of a high frequency spark.
UA
In the event that arcing does not start within approx. 5 seconds after high frequency is
generated, the high frequency and output voltage generation automatically stops. IT
high frequency generation stops in such way, the torch switch must be turned OFF and
then it should be depressed again.
If such problem remains unsolved,
. check if the cable and the torch are properly connected, and/or
- if the electrode tip has any irregularities.
(2) Lift start
This is a method to start an arc generation by supplying current to a circuit formed
with an electrode and a base metal contacted and separating the electrode from
the base metal. Neither high frequency nor high voltage is generated at the stari,
and no electromagnetic interference is caused.
“o O ©
70
1)Depress torch switch with electrode not contacted with base metal.
2) Bring electrode in touch with base metal. |
It is also possible to depress torch switch with electrode touched with base metal.
3) Draw the electrode apart from the base metal to generate arc.
Notes:
1) Even if torch switch is depressed with electrode not contacted with base
metal, no-load voltage is not applied (though gas is released).
2) Frequent arc starts may cause electrode surface to be stained (whitened),
due to which smooth arc start may be prevented. in such events, regrind the
electrode.
3) Nonexistence of pre flow period allows immediate arc start when electrode is
drawn apart from base metal. But if any defects were caused to an area to
start welding, adjust the time between touching and separation of electrode
and base metal as needed to provide suitable pre flow period so that the
electrode and the parts to be welded may be isolated from ambient air with
argon.
AD —
EL] i —— 6 LH Ph TT TT =“
10.1.15
10.1.16
No. P10464
10. OPERATION (continued)
Gas check 8 with gas-saving function. |
Used to adjust gas flow rate when the gas cylinder discharge valve is opened.
When the GAS CHECK key [16] is depressed once, the gas is discharged with the
indicator LED on the upper left corner of the key turned ON. When this key 15
depressed once again, the gas discharge will discontinue with the indicator LED
turned OFF. :
And this is also designed to automatically stop gas discharge in two minutes afte
the GAS CHECK key is depressed. If the welding started during gas check period,
the gas flow is to be automatically prevented when the welding is finished (after the
end of post-flow period), and it is unlikely to occur that the gas continues to flow out
during down period.
Cooling torch selection de +
With TORCH change-over key [15], set the cooling mode for the torch to be used.
The LED on the upper left of the key indicates the status of cooling mode selected,
[water-cooled] or [air-cooled] when itis turned ON or OFF respectively.
If cooling water is not supplied or the water pressure is lower than specified, an
error will be issued.
—41—
No. P10464
10. OPERATION (continued)
10.1.17 Internal Functions
This welding machine has various special functions that may be used by setting
with F-key (Function selection key) [10].
e How to use internal functions
@ When Function selection key [10] is depressed, the function No. starts blinking on
the left display described below and the status assigned to that function No.
appears on the right display. In this state, the function No. desired may be set
with the parameter adjusting knob [4].
Function No. blinks Status of function appears
|
it is possible function No. is changed by parameter adjusting knob [4].
XThe example given above shows that the function [F1] is set to [ON].
O When Function selection key [10] is depressed while the desired function No.
appears on the display, the function No. will light up while its status indication will
start blinking. In this state, the desired status can be selected with the parameter
adjusting knob [4].
| |
Function No. appears Status of function blinks
1
It is possible function No. is changed by parameter adjusting knob [4].
The example given above shows that the function [F4] is set to [OFF].
® When Function selection key [10] is depressed again, the displays will go back to
the state as shown above in CO) while the function No. will stop blinking. To exit
this function setting mode, hold Function selection key [10] depressed for a longer
time.
Note:
When the function settings are changed in this mode by selecting with the
parameter adjusting knob [4], they become effective immediately at once (without
asking you to confirm). Therefore itis needed to carefully check, before exiting
this mode, if the status is properly assigned to those functions as desired.
—42—
No. P10464
10. OPERATION (continued)
The following functions cari be adjusted by F selection key [10].
*Some parameters of F (function) can be memorized for each condition No. of the feeding condition
memory function, and others apply to all feeding conditions (The parameter cannot be memorized for
each condition No.). O or X is described to the right end of each parameter item of F function to show
which is applicable to the parameter.
O: The parameter can be set for each feeding condition.
X: The parameter is common to all feeding conditions.
(1) Selecting start current level: Function No. 1 —X
The factory setting of this function is [ON] that means [high] start current. |f any holes are
caused at the start of welding, the [low] start current should be selected by setting the status of
Function No. 1 to [OFF].
(2) Changing sequence in arc spot mode: Function No, 2 ne X
It is possible to change the operation sequence so that arcing may discontinue even during arc
spot process if the torch switch is turned OFF in “ARC SPOT” mode. To change the sequence
in such way, the status of Function No. 2 should be set to [ON].
If this function status is set to [ON], the torch switch must be kept turned ON during arc spot
process.
(3) Changing sequence in crater ON (REPEAT) mode: Function No. 3 — X
It is possible to change the operation sequence so that the following welding operation may be
performed by momentarily (within 0.3 sec) depressing torch switch in “crater ON (REPEAT)
mode. With torch switch undepressed, the level is self-held during initial current and crater
current periods as well as welding current period. To terminate the welding, depress torch
switch for longer time (not shorter than 0.3 sec). To change the sequence in such way, the
status of Function No. 3 should be setto [ON],
Pre flow Up slope Down slope
Initial Main Crater
a | | | -
\ / NN / Xx Post flow
Л
Welding | | End of Weld
Current =
ON | i | Е |
Torch
Switch
OFF — Lo
se >< >< > JL <—>
Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec 0,3sec
—43—
No. P10464
10. OPERATION (continued)
(4) Selecting AUTO or MANUAL mode: Function No. 4 —— X
Selecting AUTO mode allows operation stop to be cancelled with operation stop terminal short-
circuited. In addition, select AUTO mode to utilize external voltage supply to feed welding
current (base current) or pulse current for the operation combined with robot etc.. The factory
setting of this function is “MAN UAL” and the operation stop is only cancelled by turning power
supply switch to OFF and then to ON. |
To select [AUTO] mode, the status of Function No. 4 should be set to “ON”.
Note:
e The set values on the front panel are effective even though external voltage supply is
connected to the remote control receptacle with [MANUAL] mode selected.
e When the analog remote control is connected, the set values on the remote control
have the highest priority regardless of AUTO or MANUAL mode.
e To use Function No. 5 or No.6, [AUTO] mode must be selected.
e To set the current and the voltage by the use of external power supplies, they must be
connected as shown below. If the pulse setting is "OFF", only the power supply E2 should
be used.
8 > MAX 0.5mA
a MAX 0.5mA
ES CL
a - 0/—15Y
O + ]
o Е 1 E 2
CONZ (Pulse Current) (Welding Current)
Available Plug: (Base Current)
Spec DPC25-4A
—Part No. | 4730-005
N PROHIBITION
O Supply 0V to 15V to E1 and E2. Exceeding 15V may result in damage to the control circuit of
the welding power source. |
A. CAUTION
@ Be sure to finish setting and inputting before 100 milliseconds when starting signal is input.
Inputting after starting signal is input or at starting signal may result in unstable start.
— AA —
No. P10464
10. OPERATION (continued)
(5) External voltage (0-12V) control: Function No. 5 -—— X
When used in AUTO mode combined with INVERTER ARGO, selecting [ON] status for this function
allows to use the machine with almost same conditions by slightly adjusting external control voltage
(puise current and welding current or base current).
As the factory setting of this function is [OFF], select the status [ON] for Function No. 5 to activate
this function.
(6) External voltage (0-10V) control: Function No. 6 — XK
When used in combination with robot whose maximum control voltage is 10 volts or less, this
function should be utilized.
As the factory setting of this function is [OFF], select the status [ON] for Function No. 6 to activate
this function.
If the status of Function No. 6 is set to [ON], the status of Function No. 5 will be automatically set
to [OFF].
e The following chart shows the relationship between external current control voltage and output
current.
< Ext. control voltage 1 (factory setting) >
= вони мойке ' External control range is OV(min.)-15V(max.).
= —— Ext control voltage Ÿ
= cantrol a < Ext. contro! voltage 2 (function No.5 is
ON) >
5 External control range is OV(min.)-1 2V(max.).
=
— < Ext. control voltage 3 (function No.6 is
0 5 gaye 111V 189v | ON?
External current control voltage (V) External control range is OV(min.)-10V(max.).
(7) Pulse peak ratio adjustment Function No. 7 — O
The factory setting is 50%, which may be adjusted by selecting Function No. 7. When selected,
the set value appears on the left digital display with the unit indicator LED for “%” turned ON.
Pulse peak ratio can be adjusted in the range between 5% and 95%.
Pulse Current Base Current
Pulse peak ratio is defined as
the percentage of pulse current
period in a cycle as follows.
D
fp a
| Pulse peak ratio = — x100%
— Y I b
a
et >
—A5—
No. P10464
10. OPERATION (continued)
(8) Result display holding time setup: Function No. “9” — X
After completion of welding, the mean value of output current during last 1-second period is
displayed by flashing for approx. 20 seconds, but this time can be set up with Function No. “9”, The
setup range is O to 60 seconds,
(9) AC Ratio Adjustment: Function No. “10 ---- О
The AC ratio is factory preset to 70% before shipment. The adjustment of AC ratio can be set up
with Function No. 10”. At this time, the set point is indicated on the left-side digital meter, and the
"%" LED lights up.
The AC ratio is set up in the range from 10% to 80%.
(10) Operating sound switching: Function No. "117 vn X
By turning Function No. “11” OFF, the operating sound or noise arising when the panel key is
manipulated can be arrested. However, no operating sound volume can be controlled.
(11) External output terminal 1 switching: Function No. 12” -——- Х
External output terminal 2 switching: Function No. “13” —— X
The assignment of external output terminal 1 and that of external output terminal 2 can be
changed with Function No. “12” and Function No. “13” respectively.
The relationship between the function to be assigned and the number to be set up is as described
in the table below:
Setup No. [Description Function :
1 Power source preparations |This function works for use in power source preparation
relay.
The operation is carried out when no abnormality is
present, such as open phase, operation stop and
temperature error, and the power switch is "ON",
Function No. "12" is factory set before shipment.
2 Pulse synchronizing output [When the pulse is “ON”, the section across terminals is
closed during puise duration.
Function No. “13” is factory set before shipment.
3 EN synchronizing output In AC TIG welding, the circuit is closed between
terminals during EN period (the electrode is minus).
4 AC synchronizing output In AC-DC TIG welding, the circuit is closed between
terminals during AC period.
(12) Pulse synchronizing input signa! switching: Function No. “14" —x |
By turning Function No. 14 “ON”, the puise current and base current can be changed over by
inputting external signals into the pulse synchronizing input terminal. At this time, the panel pulse
must be set to “ON”, Also, the panel pulse frequency setting becomes impossible.
Closed circuiting across terminals produces pulse current and open circuit produces base current.
* CAUTION
Even when the pulse synchronizing input terminal is closed during initial current and crater current
period, no pulse output is produced.
Only when the input signal level was held at least 2 ms, the status can be switched.
(13) Cleaning width display change-over: Function No. “15” — x
By turning Function No. 15 “ON”, the value indicated on the digital meter can be used as EP ratio
in cleaning width setup, and the “%" LED is also lit on the unit LED. Further, on the left-side digital
meter, the standard value is displayed by flashing.
No. P10464
10. OPERATION (continued)
(14) Soft pulse: Function No. “16° — x
By turning Function No. 16 “ON”, it is possible to change pulse welding to “soft pulse” In case
where the pulse is “ON” in DC TIG welding. in soft pulse, current is changed smoothly, and soft
arc is produced, compared with “standard” pulse, thereby reducing a welding sound. This soft
pulse is suitable for thin plate welding since itis hard to burn through or melt down, compared with
“standard” pulse at the same average current. |
In case where a soft pulse is used, it is recommended that the pulse frequency should be set at
10Hz or more and the pulse width should be set at 40% to 60%.
(15) Current adjustment by torch switch: Function No. “17” — x
By turning Function No. 17 “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.
Function No. “18”: The current change amount is set up by single clicking.
Function No. “19”: The current change amount is set up by double clicking.
The current change amount setup range is —50A to +50A.
(Example)
Crater-ON, no initial current, welding current 60A and crater current 20A
F18: -10A | |
F19: 20A
Г, LL
Po 00000 70A
BOA GDA
50A Crater
Welding Current
Current _ double 20A |
clicking
ON Г i
Torch
Switch
OFF. LI | || SE
md Le Ste Te > < > >
Within D.3sec Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec 0.3sec
<Precautions>
1) this function is set to “Effective” (ON), the function of F3 becomes invalid (OFF) automatically,
while this function becomes invalid (OFF) automatically by validating "F3" (ON).
2) Itis necessary to press the switch for as long as 0.3 second or more during transfer to crater at
startup.
3) In case where the operation is transferred from crater to the main welding in the “Crater-ON”
(Repeat) mode, the operation starts with the welding current outputted before transferring to the
crater.
—AT —
No. P10464
10. OPERATION (continued)
(16) Current offset adjustment: Function No. “20" — x
If a welding cable is made long in case for AC TIG welding in point of welding current
characteristics, the actual average welding current (value indicated on the ammeter) becomes
smaller than the set current, and as the welding current is larger, its difference becomes larger.
In such a case, the difference between the set current and actual average welding current can be
made smaller by regulating welding current with Function No. “20”. This function is effective If used
when no actual current reaches 300A, for example in case where the welding cable was extended.
This function also works in the case of DC TIG or DC manual welding.
The setup range is 0 to 30. If the set point is incremented by 1, as a standard, the average welding
current increases by approx. 1A. Also, the set adjustment amount is constantly added in all current
ranges.
10.1. 18 Analog remote control (K5048B) (optional accessory)
When the power switch was turned ON, the analog remote control is automatically recognized.
When the analog remote control is connected to the machine, the only remote control is
effective and the parameters “welding current (base current)” and/or “pulse current” selected
on the front panel may not be adjusted by the parameter adjusting knob [4] on the front panel.
They must be adjusted on the analog remote control that is connected to the machine. Those
set values may be monitored on the digital display on the front panel.
When take off the remote control, setting figure disappear.
* Insert and withdraw the remote control always after turning the power switch "OFF".
—48—
No. P10464
10. OPERATION (continued)
1. CAUTION
For electrode stick, follow the instruction below.
@ Keep the electrode stick in a place with low humidity.
@ Dry the electrode stick sufficiently before using.
@ When the gas burner is used for pre-heating or removing moisture of the base metal, be
sureto heat to 100°C or above.
@ Slag and fume generated when tack welding will cause wetting the part of base metal to be
welded. Remove slag and fume immediately after tack welding.
O When welding is performed outdoors and wind velocity exceeds 10ft/sec, use a wind
shield.
102 DC STICK welding
10.2.1 DC STICK welding ог
Set the welding process to DC STICK welding ( "*e. )
with the WELDING METHOD key [1].
The welding current setting mode is automatically selected and setting value is indicated on
the left digital display with the unit indicator LED for amperage “A” turned ON.
When switched to DC STICK welding, or when turn on the switch with DC STICK welding is
selected, no-load voltage is not provided for approx. 5 seconds for safety. 5 seconds later, the
voltage is automatically provided.
10.2.2 Welding current setting
The welding current may be set with the parameter adjusting knob [4] in the range specified in
the table shown below:
Current range is 10A-250A.
10.2.3 Internal function sefting
The function listed below may be adjusted with Function selection key [10]. See Subsection
10.1.17 for internal function setting.
(1) Hazard reducing function: Function No. 8
| This is a safety function that reduces risks of an electric shock by limiting no-load voltage of
welder to lower level at any time except welding period.
It is therefore recommended to utilize this function when the machine is used at high site or
in confined environment.
The factory setting of this function is [OFF]. To activate this function, set Function No. 8 to
[ON].
10.2.4 Analog remote control (K5048B)
This machine automatically recognizes the analog remote control. When the analog remote
control is connected to the machine, the only remote control is effective and the parameters
“welding current (base current)” and/or “pulse current” selected on the front panel may not be
adjusted by the parameter adjusting knob [4] on the front panel. They must be adjusted on
the analog remote control that is connected to the machine. Those set values may be
monitored on the digital display on the front panel.
When take off the remote control, setting figure disappear.
—49—
No. P10464
10. OPERATION (continued)
10.3 Information common to all models
10.3.1 Indication on digital display
Digital displays are designed to indicate the items listed below:
(1) Parameter set values
In the Set Value Indication mode during down period (except result indication period
immediately after welding process) and during welding period, the parameter set value
under adjustment is indicated.
(2) Output current at welding
During welding period, the indication of parameter set value on the digital display is
automatically switched to the indication of average output current which is updated every
0.5 seconds to reflect the latest output condition.
if it is required to change each parameter setting with its set value monitored during welding,
depress the parameter selection key [3] to change the indication mode into the "Set Value
Indication” mode where the parameter indicator LED starts blinking. If no action is applied
for 5 seconds more or less, or when a selectable parameter is back where it started, the
indication mode automatically returns to the “Average Indication” mode.
When the torch switch is depressed, the sequence parameter indicator LEDs will turn ON
sequentially in response to the welding process in operation. When switched to the "Set
Value Indication” mode, the indicator LED of sequence parameter selected with the
parameter selection key [3] will start blinking.
The average display of the output current is possible adjust offset in the range of + 10A by
Function No.10. Adjustment quantity is added(subtracted) at the all current range. For this
adjustment, gain adjustment which is change adjust amount is not possible.
See Section 10.3.2, “Adjustor Knob” for the parameters that may be adjusted during
welding with the parameter adjusting knob [4].
(3) Result after the end of welding
When the welding is finished, the average output current for the last 1 second is indicated
for approx. 20 seconds by blinking (with no consideration given to the output conditions for
crater filler process). This indication may be used for a welding personnel to check the
conditions on which the welding has been completed and to adjust the conditions for
better result. This indication will disappear in 20 seconds or when the next welding starts
or any key on the front panel is depressed.
The indication period may be adjusted in the range between 0 and 60 seconds by
selecting Function No. 9 with Function selection key [10] where the set value will be
indicated on the left digital display with the unit indicator LED for “second (sec)” turned ON.
(4) Errors
Any error caused to the machine will be indicated with blinking numeral assigned to each
error type. See Section 11.1, “How to Solve an Error” for further details including error
numbers. | |
Notes:
The mean value of output displayed on the digital meter is processed with
software, which cannot be guaranteed as measuring instrument management
data.
—-50—
No. P10464
10. OPERATION (continued)
10.3.2 Adjustor knob |
To adjust parameters with adjustor knob [4] during welding, depress the parameter selection
key [3] to change the mode into the Set Value Indication mode. The initial conditions, main
conditions and crater filler conditions become changeable during initial current, main welding
and crater, respectively.
During welding period, the welding current (base current) may be adjusted immediately after it
is switched to the Set Value Indication mode. In addition to welding current (base current), two
other parameters (pulse current and pulse frequency) may be also adjusted during welding
period with the parameter selection key [3] depressed. Also, even by pressing the AC FREQ.
key [6], AC BALANCE key [7] and AC-DC change-over frequency setup key [8], the set point
mode is selected, and the adjustment becomes possible during any period.
During welding period, the parameters may not be adjusted in the Average Indication mode.
© 10.3.3 Key Lock (available only at TIG welding)
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 Parameter selection key [3] and the Arc
SPOT TIME setting key [9].
a Holding down both the F [10] key and ENTER key [19]
8 simultaneously
Holding down both the F key [10] and ENTER key [19]
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. |
10.3.4 JOB MEMORY Function (available only at TIG welding)
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 100.
—51—
No. P10464
10. OPERATION (continued)
1 CAUTION
O The welding conditions (electronic information) stored by this function are
susceptible to occurrence of static electricity, impact, repair, etc., and there is a
possibility that the storage contents may be changed or lost. BE SURE TO MAKE A
COPY FOR IMPORTANT INFORMATION.
We shall not assume any responsibility for any change or loss of electronic
information resulting from repair, which you should note in advance.
Once the machine enters the memory mode and read-out mode, all the key operations are
denied except the SAVE key, LOAD key, and ENTER key. To exit the mode, press the LOAD
key [17] if it is in the memory mode and the SAVE key [18] if in the read-out mode. Memory
can be copied to a different condition number after reading the welding conditions to be copied.
Note:
Even when welding conditions are read out while the analog remote control is
connected to the welding power source, the setting values preset at the analog remote
control are valid.
@ 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 [18], the machine enters memory mode, the SAVE
lamp (located at the upper left of the SAVE key) lights up. See the following picture.
In the right display, 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 [4].
WARNING
4
Welding Current setting value Condition number blinks
held in memory
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).
—52—
No. P10464
10. OPERATION (continued)
(2) When pressing the ENTER key [19] 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 Parameter
selection key [3]. The setting value of the parameter you selected blinks.
Note:
In the save mode, you can not change the welding condition number or select any
memory/readout mode. To reset the condition number, press the SAVE key [18], then
return fo the step (1).
To quit the setting and exit from the memory mode, press the LOAD key [17].
(3) Pressing the ENTER key [18] again holds the data in memory and allow you to exit from the
memory mode.
® LOAD Function
The welding conditions stored in memory are read out from the memory inside welding power
source. |
Note:
The welding conditions currentiy used are overwritten with the welding conditions
that are read out. When you wan 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 [17], 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 ™" in the right-side display blinks and the JOB No. LED [amp 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 [4].
waæe Ë
a
E
1 i
Welding Current held in memory Condition blinks
In the event that any memory data is preset to the condition number you selected, the
CRATER lamp, the WELDING METHOD lamp, etc. also lights up. When no memory data
is preset to the condition number, "__ "in the left-side display appears and blinks. See the
figure below.
ea e hear
(2) When pressing the ENTER key [19] 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 Parameter selection key [3].
The setting of the parameter you selected blinks.
—53—
No. P10464
10. OPERATION (continued)
Note:
You are not allowed to change condition number or select a welding method, etc. To
reset the condition number, press the LOAD key [17], then return to the step (1). To
quit the setting and exit from the readout mode, press the SAVE key [18].
(3) When pressing the ENTER key
from the readout mode.
[19] again, you can read out the preset welding conditions and exit
e Operation flow in the memory mode
Press the MEMORY key. |
y
Discontinue| Set the welding condition number while
tuming the parameter adjusting knob.
y
Press the ENTER key. | | Press the MEMORY key. |
Discontinue
Press the parameter selector key
to check the parameter value. Reset the welding condition number,
Y
Press the LOAD key
The welding conditions are set to the number you selected,
\
| | Press the ENTER key. |
> | The memory mode quits.
e Operation flow in the readout mode
¡Press the LOAD key.
V
Discontinue
Set the welding condition number whil
tuning the parameter adjusting knob.
V
Press the ENTER key. | | Press the LOAD key. |
Discontinue
Press the parameter selector key
to check the parameter value. Reset the welding condition number.
Y
Press the SAVE key
The welding conditions are set to the number you selected.
\
| Press the ENTER key. |
>| The readout mode quits. |
—54—
No. P10464
10. OPERATION (continued)
® Erasing the Welding Conditions
When you erase the welding conditions stored in memory, you can select either erasing all or
erasing one.
® Erasing the welding conditions
(1) Turn off the power switch and turn on the power switch with both the LOAD key [17] and
SAVE key [18] pressed. Release the keys after turning on the power switch, and then
"dEL" appear in the left-side display. See the picture below.
Sec
gral
vw
"dEL" display means the machine Condition number to be deleted biinks.
in the delete mode.
(2) Set the condition number to be deleted while turning the parameter adjusting knob [4].
When turning the knob counterclockwise, "ALL" appears in the right-side display as
illustrated below and you can erase all the welding conditions.
"dEL" is displayed "ALL" blinks
Note:
When the welding conditions are deleted by selecting "ALL" welding
conditions currently in use are also deleted. Consequently, all the parameters
return to the initial settings.
(3) Pressing the ENTER key [19] blinks "dEL." Confirm the condition number again and if you
want to cancel erasing of the condition number, press any key other than the ENTER key
[19] to return to step (2). To quit the delete mode, turn off the welding power source.
(4) Pressing the ENTER key [18] 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 machine.
Note:
When pressing the ENTER key [19] twice in the deletion mode, you can not
recover the erased welding conditions. When you attempt to delete a welding
condition that is held in memory, make sure that the condition number you
want to erase is surely selected.
No. P10464
10. OPERATION (continued)
10.3.5 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 held 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 [10] and GAS CHECK key [16] held down. When "End"s appear in the displays after
turning on the power switch, release the keys, turn off the power switch, then turn it on again.
See the picture below.
See “SPECIFICATIONS" for initial values of each parameter and function.
10.36 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 [10] held down. After powering the
welding power source, the version number appears in the display.
(Example)
Right and left displays : "P10464"« Software number (P10464) is displayed.
| Press the F key [10].
Left display : "001" < Main software version (Ver. 001) is displayed.
Right display : "000" « Sub software version is displayed.
| Press the F key [10].
Left display : "---" |
Right display : "000" < Combination is displayed.
+ Press the F key [10].
The welding power source starts up as usual and gets ready to perform welding.
10.3.7 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.
10.3.8 Fan noise reducing function
To reduce the fan noise level during welding suspension, the fan rotation is decelerated.
However, this function is effective only when used at the output current 250A max.
No. P10464
11. APPLIED FUNCTION
11.1 How to Solve an Error
‘ >.
. > E
+ >
я ‘
+ .
1 +
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+ x
+ „
+
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=
ай
Y. WARNING
—
Observe the following to prevent electrical shock.
® Do not touch charging parts inside or outside the welding power source.
O Only the certified operators or the person who understand the welding machine well can
change wiring or switch setting in the welding machine.
O Turn OFF all power switches in the switch box and wait for 3 minutes or more before
touching the inside parts of the welding machine.
If an error occurs during use, an error code shown in the displays on the front panel blinks, then the
welding power source stops automatically. In this case, check the errors in the following table.
No. spars at panel Classification of errors
Left | Right
1 dAI ' HEn | Torch switch off state waiting
2 E- 1 000 Operation Stop
3 Е - 100 Control power supply error
4 Е - 200 | Primary / secondary current detection error
5 E- |! 300 | Thermal overload
6 E- | 500 |Abnormal water pressure
7 Е - 510 Water cooling unit error
8 E- ‘ 600 |Replacement of batteries (warning)
9 E- | 710 |Open-phase detection error
10 Е - 751 Secondary side over voltage error
11 E- | 9 XX | Microcomputer error
—57—
1)
2)
3)
4)
5)
6)
No. P10464
11. APPLIED FUNCTION (continued)
dAIHEn Display
Е "ад!" and “HER” 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 “dAl" and "Hen" for one
sec., 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 "dAl” 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.
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
213) on the 12P external connection terminal block (TM), *E-" and “000” in the displays blink and
the welding power source stops. In this case, after turning off the power switch and eliminating the
possible causes of the stoppage of the welding power source, short-circuit the STOP terminals and
turn on the power switch to cancel the error.
Note:
When canceling the operation stop, it is also possible to solve the error only by short-
circuiting the Operation Stop terminals again without starting the welding power source up
again. Refer to Section 10.1.17, “Internal Functions”.
E-100 Display
1 “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.
E-200 Display
IF “E- and “200” in the displays blink, it indicates the ' Primary/Sec.ary 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 P10464U are surely
connected.
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 (3 also will be lit. In this case, wait more than 10 minutes with the
power switch pressed and the fan tumed. When restart welding, turn off the power switch and
restore the system after lowering the duty cycle and the welding current. Such action will cancel the
error. Repetitious welding without more than ten-minute rest may lead to damage to the welding
machine. Refer to Section 3.1, “Rated Duty Cycle” for the rated duty cycle of the welding power
source.
E-500 Display
IF "E-" and “500” in the displays blink, it indicates the “Abnormal water pressure”.
If no cooling water is going through the water-cooled hose or shortage of water pressure is
occurred, the WARNING lamp will light up, “=- and “500” in the display will blink, then the welding
machine will automatically stop. In this case, check to make sure that the water-cooled hose does
not leak water and that adequate cooling water is going through the hose. When using an air-cooled
torch, make sure that the TORCH lamp on the front panel is OFF (AIR).
7)
8)
No. P10464
11. APPLIED FUNCTION (continued)
E-510 Display
If "E-* and “510" in the displays blink, it indicates the "Water cooling unit error”.
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.
E-600 Display
IF "E-" and “600" in the displays blink, it indicates the "Replacement of batteries (warning).
This welding power source uses batteries so that it can hold the welding conditions in memory even
when no operation is carried out for long time. "E-" and “600” in the displays blink when the batteries
get low. "E-" and 600" are displayed only when the front pane! and the welding power source are
temporarily not in use. To cancel the display of the error , press any key. Even when "E-" and “600”
appear in the displays, welding can continued to be performed, but when the batteries run down,
the preset welding condition functions and the settings of functions are all erased. The last
welding conditions before power is applied to the welding machine can not be stored. Each
time power is applied to the equipment, all the parameters are reset to initial values. Refer to
Section 12.4, " Replacement of batteries” for details.
9) E-710 Display
If "E-* and “710" in the displays blink, it indicates the "Open-phase detection error".
By detecting primary input open phase, the malfunction lamp lights up and “E-710" is displayed by
flashing, and then the welding machine comes to an automatic stop. In this case, check the primary
input voltage for each phase.
10) E-751 Display
If "E-* and "751" in the displays blink, it indicates the "Sec.ary side over voltage error”.
In case where the sec.ary-side transistor surge voltage has become abnormally high, for example
since an extension cable was used, the malfunction lamp lights up, and “E-751" is displayed by
flashing, whereby the welding power souce comes to an automatic stop. In this case, take an action
therefor in accordance with the description given in 10.1.5 "Notice of using AC TIG mode”, and then
turn the power switch “ON” again.
11) E-9XX Display
IF "E-OXX" in the displays blink, it indicated the "Microcomputer error’.
There could be an error in the built-in microcomputer, Please contact your dealer immediately.
When contacting your dealer, you are required to provide the details of the problem you are facing.
—59—
No. P10464
11. APPLIED FUNCTION (continued)
1 WARNING
rari
Observe the following to prevent electrical shock.
ra -
‚”
, .
wo
€ Do not touch charging parts inside or outside the welding power source.
O Only the certified operators or the person who understand the welding machine well can
change wiring or switch setting in the welding machine.
@ Turn OFF all power switches in the switch box and wait for 3 minutes or more before
touching the inside parts of the welding machine.
A. CAUTION
O Try to move the control cable which is pulied out from the automatic connection terminal on
the printed board father away from the welding power cable or the torch cable when making
an external connection. Otherwise, equipment failure may be caused by noise, etc., during
welding operation.
€ 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 of Inside Terminal Block of Automatic Machine
When taking off the upper cover of the welding power source, you will find there is a 12P terminal
block (TM12P) on the printed board P10293T on the chassis. Use the 12P terminal block to
connect with an automatic machine. Refer to 12.7, “Parts layout” for the locations of the terminal
blocks.
Note: |
* Wait more than three minutes after turning off the fine disconnect switch or no-fuse
breaker and the power switch on the front panel to remove the cover.
* To pull out the external connecting wire, break the grommet with film on the rear surface
so as hot to come into contact with the printed circuit board parts and sheet metal edge or
the like.
[12P terminal block]
seleee eae eee ®
DO Y © © © ® © © © ©
`` NA + `_ A J ‘_/
© © e
| | вон оно |" |
EXT3
+ - + = PLS IN
EXT GAS STOP WCR
—60—
No. P10464
11. APPLIED FUNCTION (continued)
12P terminal block (TM 12P)
Pin No. Signal name | Function
dD" - © EXT1 (Output) From among the power source preparation, pulse | "1
External output synchronizing output, EN synchronizing output and AC
terminal 1 synchronizing output functions, select the required one for
@- © EXT2 (Output) use. For the setup method, see 10.1.17 “Internal Functions”.
External output
terminal 2
o — (M7 | GAS (INPUT) The terminals used for controling the gas solencid valve by | *2
Solenoid Valve external signals. (If the terminals are short-circuited, the gas
Control valve will open.)
© - ® PLSIN (Input) Short-circuiting across terminals outputs pulse current. For
Pulse synchronizing | details, see 10.1.17 “Internal Functions”.
input signal
D - 0 EXT3 (INPUT) The terminals used for special specifications. These | *2
Extra Input Signal terminals should not be used for normal use.
o — O STOP (INPUT) To stop welding externally. Release the wiring between two | "2
Operation Stop terminals to run Operation Stop. Welding machine Is
stopped by running Operation Stop. Close the terminals
after turning off the torch switch to restart welding. To avoid
accidental restart, use of a Pushlock Turn reset switch is
suggested.
D — ® WCR(OUTPUT) Contact Output of welding current relay used for detection of | *3
Current Detection welding current. The contacts close while welding current IS
flowing.
Precaution for connection with terminals on the terminal block
The wires from the terminal blocks should be twisted for each signals to avoid accidental operation.
Take care that the wires form the terminal blocks do not cross other signal wires from other welding
power Source.
*{ Equivalent circuit is as the figure shown right. Maximum capacity of TR is 80V, 100mA. When
connecting such as relay to two terminals, do not exceed 80% of the maximum capacity of TR. (Figure
1)
*2 Equivalent circuit is as the figure shown right. Connect allowable contacts (10mA or more) to two
terminals. (Figure 2)
*3 Rating of the provided relay contacts is 125V AC, 0.5A, 30V DC, 1A. Do not exceed 80% of the
rating of the provided relay contacts.
*A Be careful that no-load voltage (100V or less) is applied to between the terminals during welding.
TR wc =
+ Ш
К 7] mo
AA
Figure 1
Figure 2
No. P10464
11. APPLIED FUNCTION (continued)
11.3 Optional Accessories
11.3.1 Welding Torch
Model AW(PY-17 . | AW-18 | AWD-18 AW-26 | AWD-26
Rated DC 150 A 300 A 200 A
Current AC 130 A 260 A 160 A
Cooling Method Air Water Air
_ Duty Cycle 50% 100% 50%
Electrode Dia. 0.5 - 2.4mm 0.5 - 4.0mm 0.5 - 4.0mm
Cable Length 4 or 8m 4 or 8m 4 or 8m
When using the welding power source by combining the following torches, use the proper torch
adapter.
Torch type Torch adapter
AW(P)-17 BBAWD-1701
AW-18 BBAWD-1801
AW-26 BBAWD-2601
Connecting to the Extension Torch Cable/Hose
(1) Water Cooled Torch
Connect the extension cables/hoses (optional accessories) as the figures shown below.
Do not confuse the water feeding hose with the condensate hose.
Extension gas hose
| " Extension hose (for feeding water)
See Tapie
7] (three points)
Aa =i" /
TT
I
на) To water cooled torch
N
Connecting cover H558M01
Extension power cable (for condensate water)
(2) Air Cooled Torch
Taping
Ext 0 ble
xtension power ca и (three points)
re
Е на) To air cooled torch
— 7) |
Connecting cover H558M01
Ц
—62—
No. P10464
11. APPLIED FUNCTION (continued)
11.32 Optional Accessories
Description Part number Remarks
Analog Remote Control K5048B00 With 4-meter cable
Digital Remote Control Е-2452 CAN Communication module and CAN
communication cable is necessary.
CAN communication module K5422B00
CAN communication cable BKCAN-04XX XX:10(10m),20(20m)
Foot-Operated Current Regulator K1104F00
Foot Switch 4259-004 With 5-meter cable
Push-Button Torch Switch K509B00 With 4-meter cable
Push-Button Torch Switch K509C00 With 8-meter cable
11.3.3 Extension Cable/Hose
| Extension Torch Cable H954B00 1 am
Extension Remote Control Cable | P1043R00 1 4m
(4 conductors)
Parts for extending AW(P)-17 | Control Cable for Torch Switch P1043500 1 4m
(cable length: 4m) to 8m (2 conductors)
Adapter P1600N02 1
Connecting Cover H558M01 1
Extension Torch Cable H955B00 1 ¡11m
BAWH-1511 | (a conduct emote Control Cable | K527H00 1 ¡11m
Ce angle Amo 15m Control Cable for Torch Switch — |K527K00 T [1m
(2 conductors)
Adapter and connecting cover is equivalent to BAWS-1504.
Extension Torch Cable H956B00 1 16m
BAWH-1516 a Conductor Control Cable |K527J00 1 16m
Parts for extending AW(P)-17 Control Cable for Torch Switch K527L00 1 16m
(cable length: 4m) to 20m (2 conductors)
Adapter and connecting cover is equivalent to BAWS-1504.
Extension Torch Cable H957B00 1 4m
Extension Remote Controi Cable |P1043R00 1 Am
(4 conductors)
Control Cable for Torch Switch P1043500 1 Am
Parts for extending AW(D)-26
(cable length: 4m) to 8m (2 conductors)
Adapter and connecting cover is H558M01 1
equivalent to BAWS-1504.
a Extension Torch Cable H958B00 1 [11m
[Extension Remote Control Cable K527H00 1 11m
BAWH-2011 (4 conductors)
Parts for extending AW(D)-26
(cable length: 4m) to 15m Control Cable for Torch Switch K527K00 1 11m
(2 conductors)
Connecting Cover H558M01 1
a Extension Torch Cable H959B00 1 16m
BAWH-2016 Extension Remote Control Cable |K527J00 1 [16m
Parts for extending AW(P)-17 (4 conductors)
Control Cable for Torch Switch K527L00 1 16m
(cable length: 4m) to 20m (2 conductors)
Connecting Cover H558M01 1
|
—63—
No. P10464
11. APPLIED FUNCTION (continued)
Extension Gas Hose P1043K00 1 4m
Extension Water Hose P1043L00 1 4m
(for feeding water)
Extension Torch Cable H593H00 1 4m
Parts for extending AW-18 Extension Remote Control P1043R00 1 4m
{cable length: 4m) to 8m (4 conductors)
Control Cable for Torch Switch P1043500 1 4m
(2 conductors)
Connecting Cover H558M01 1
Extension Gas Hose K527B00 1 11m
Extension Water Hose K527D00 1 11m
(for feeding water) |
BAWS-3011) Extension Torch Cable H593J00 1 [11m
Parts for extending AW(D)-18 | Extension Remote Control Cable |K527H00 1 11m
(cable length: 4m) to 15m (4 conductors)
Control Cable for Torch Switch K527K00 1 11m
(2 conductors)
Connecting Cover H558M01 1
Extension Gas Hose K527C00 1 16m
Extension Water Hose K527E00 1 18m
(for feeding water)
Extension Torch Cable H593K00 1 16m
Parts for extending AW(D)-18 | Extension Remote Control Cable K527J00 1 16m
(cable length: 4m) to 20m (4 conductors)
Control Cable for Torch Switch K5271.00 1 16m
(2 conductors)
Connecting Cover H558M01 1
O Cable Hose
Grounding Cable Gas Hose Tap Water Kit Water Hose
3m 3m 5m 2m
Model BKPDT-3803 BKGFF-0603 BBDW-3001 BBPU-3002
11.4 Optional parts
11.4.1 TIG BOY (Wirestorch integrated compact ty
pe TIG automatic welding machine)
TIG BOY special torch Controller
Model AWG-1501 AWGW-3001 Model HC-81
Rated current 150A 300A — Rated input voltage Single phase 200V
Duty cycle 40% 40% Rated input power 200VA
Cooling type Air Water
Cable lengih 8m 8n
—64—
No. P10464
11. APPLIED FUNCTION (continued)
11.4.2 Tungsten Electrode
Use cerium-Tungsten Electrode (grey mark) or thoriated tungsten electrode (red mark). Using
DAIHEN cerium-tungsten electrode that is hardwearing realizes good arc start and better work
efficiency.
= Cerium-Tunosten Electrode
Part No Electrode Dimension{mm) | Max. Tolerance Current(A)
Dia. Length DC Straight Polarity AC
© 0870-016 | 1.6 150 150 130
0870-024 24 150 250 220
0870-032 3.2 150 400 290
u Thoriatd Tungsten Electrode
Part No Electrode Dimension(mm) Max. Tolerance Current(A)
Dia. Length DC Straight Polarity AC
0831-005 0.5 150 20 -
0831-010 1.0 150 80 -
0831-016 1.6 150 150 130
0831-316 1.6 75 150 130
_ 0831-020 2.0 150 200 180
_ 0831-024 2.4 150 250 220
0831-324 2.4 75 250 220
0831-032 3.2 150 400 290
0831-332 3.2 75 400 290
0831-040 4.0 150 500 360
—85—
No. P10464
12. MAINTENANCE AND TROUBLESHOOTING
_{. WARNING
„^^ Observe the following to prevent electric shock.
[Lal =.
Pa - “
a a
a :
.
. +
@ Do not touch the charging parts inside or outside the welding power source.
O Turn off all of the line disconnect switches before touching the parts inside the welding
machine.
® Perform the maintenance checks periodically. If any damaged parts are found, only use the
welding machine after troubleshooting or repairing.
O Only certified operators should maintain, inspect, or repair the welding machine.
O 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.
O Have qualified operators or the persons familiar with this welding power source test
withstand voltage. And install a protective wall around the welding machine to keep away
others from the welding machine.
‚|, CAUTION
a [Rotating parts may cause injuries. Be sure to observe the following.
A
O Only certified operators should maintain, inspect, or repair the welding machine.
® Install a fence around the welding machine to keep others away from it.
€ Do not put your hands, fingers, hair and clothes near the fans and wire feed roil rotating.
/f. 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. inmediately
after welding is performed, as the parts are extremely hot. Wait until the parts cool
bibi down, when touching. Failure to observe the demand may result in burn.
A". CAUTION
FE
@ The welding conditions (electronic information) stored using the JOB MEMORY keys are
likely to be affected by occurrence of static electricity, and there is a possibility that the
preset data contents may be changed or erased. We recommend taking notes of important
data.
@ We shall not assume any responsibility for any change or erase of the electronic information
resulting from repair.
No. P10464
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.1 Carrying out Maintenance on the Welding Power Source
(1) Periodical checking
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 surely made.
There is 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.)
e Check the following each three to six months:
- The dust protective filter located on the inlet of the fan does not clog, which may result in |
12 2 Precaution for Replacement of the Printed Circuit Board
e Make sure that the connector number inscribed on the
printed circuit board matches the number marked on
the connector.
e Turn off the control power switch and line disconnect
switch before carrying out maintenance on the welding
power source, and wait three minutes until the
capacitors inside the welding power source discharge.
® This welding power source uses à high-frequency
inverter system, be careful of accidental connection of
the line disconnect switch at input side.
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.
damage to the welding power source. Be sure to inspect it periodically.
NOTE: Match the number on the printed
circuit board with that on the connector.
e Surely connect the connectors until the connector clicks. Failure to do so may result in
damage to the printed circuit board and to the machine.
® With the connectors disconnected, do not turn on the power switch on the front panel.
® Do not use organic solvent such as thinner, trichloroethylene, gasoline, etc., to clean the
plastic cover and carrying handle of the welding machine. Deformation and flaw may result
from the adherence of the organic solvent.
—87—
No. P10464
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.3 Insulation Resistance Test
—
À WARNING
d—a—
= Te,
ra "
” >
7 *
7 :
* * =
"a, e
о 2
"a 7
[Observe the following to prevent an electrical shock.
tu
® Have qualified operators or the persons familiar with this welding power source measure
insulation resistance and test withstand voltage. And install a protective wall around the
welding machine to keep away others from the welding machine. Check to make sure that
charging voltage does not exist before carrying out the maintenance before carrying out
measurement of insulation resistance and withstand voltage test.
When measuring insulation resistance and testing withstand voltage, follow the steps below. And,
refer to the schematic diagram, parts layout, and parts list for maintenance.
1. Disconnect the grounding cable (wiring number: 80) from the earth.
2 Short-circuit on AC side and commutation side of DR1.
Short-circuit between TR1 (C1) and (E1), TR2 (C2) and (E2), TR3 (C1) and (E1), TR4 (C2)
and (E2), TR5-6 (C1) and (E1), TR5-6(C2) and (E2).
Be sure to reconnect the cables after carrying out measurement of insulation resistance and
withstand voltage test.
12.4 Replacement of Batteries
This welding power source uses lithium batteries to hold welding conditions in memory. The life of
the batteries differs depending on the environments. “E-" and "600" shown in the displays on the
front panel blinks when the batteries gets low. Replacement of the batteries every 5 years or so
are recommended even when “E-' and “600” do not blink. Replace the batteries following the
steps:
1. Turn off the line disconnect switch in the switch box or the no-fuse breaker, and the power
switch of the welding power source.
2 After more than three minutes, remove six screws that secure the front panel, and then pull
the front panel out. Do not pull it forcibly. With the wiring inside the equipment disconnected,
do not turn on the power switch. Failure to do so may result in damage to the welding power
source.
3. Remove the connectors on the PCB P10263R to replace the printed circuit board. Refer {0
the position for “Rear side of the front panel” in Section 12.7, * Parts List”.
A. Insert the disconnected connectors into the PCB P10263R.
5. Screw the front panel in position.
—68—
No, P10464
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.5 Troubleshooting
When an error code is displayed,
e Check the troubleshooting information listed below before contacting y
refer to Section 11.1, “How To Solve an Error”.
our dealer for service.
No. Trouble | Cause Solution
The power Never turn it on again. Contact your dealer.
1 switch on the
front panel is
tripped.
The main When turning on the | Trouble with PL. Inspect PL.
power lamp power switch, the
PL will not displays light.
2 light. When turning on the | The line disconnect switch in | Inspect the power
power switch, nothing | the switch box is not turned box.
appears in the on.
display. The input cables are not Inspect the input
surely attached. cables.
— | When tuning | The main power lamp Refer to No.2 in this list.
on the power | PL will not light. _
switch, nothing Shortage of the input voltage Check for proper
3 appears in the input voltage.
display. PL lights Trouble with the power After inspecting
circuit. PCB P10263Q,
replace it if
necessary.
When turning on the power switch, the
4 | WARNING and temperature lamp (©)
light up and an error code appears in
Refer to Section 11.1, "How
To Solve an Error”.
the display.
Shield gas is Gas is not generated | The discharge valve of the Open the gas valve.
not generated | when the GAS gas cylinder is closed.
| when the torch | CHECK key is Lack of gas pressure of the Check for proper
switch is pressed. gas cylinder. gas pressure.
pressed. T
rouble with the gas Inspect the gas
5 electromagnetic valve SOL, electromagnetic
valve SOL.
Gas is generated Disconnection of the torch Check the wiring
when the GAS switch cable or incomplete numbers 160, 161,
CHECK key is insertion to receptacle. 168, 169, 258 and
pressed. 259,
Shield gas does not stop. The GAS CHECK lamp lights | Stop gas checking
up. by pressing the
6 GAS CHECK key.
: Trouble with the gas solenoid | Check for operation
valve SOL
of the gas solenoid
valve of wire feeder.
When the torch
switch is pressed,
no high frequency
spark is not
7 | generated
between electrode
and base metal.
The sound of
spark discharge
can be heard.
Electrode gets whiten.
Polish electrode.
Base metal cable is
connected to the negative (-)
terminal output. (High
frequency voltage is leaking.)
Properly connect
the torch and the
base metal cable.
"The sound of
spark discharge
can not be heard.
The connectors on the high
frequency generating circuit
are not firmly inserted.
Check for proper
insertion of the
connectors on PCB
P10263X.
—69—
No. P10464
12. MAINTENANCE AND TROUBLESHOOTING (continued)
No. Trouble Cause Solution
When pressing | When electrode | Electrode gets white. Polish electrode.
the torch touches on the |
switch, high base metal, arc | Electrode 15 100 thick. Current Set to the proper
frequency is is output. setting is too low. electrode and
generated but current. a
no arc is output. | When Trouble with the main circuit of After turning off the
measuring inverter. power switch, contact
8 output voltage your dealer.
in STICK mode,
no —load
voltage is
generated. |
No-load voltage | Trouble with the control circuit. Check for PCB
is generated. P10293P and
P10464U.
WCR keeps working. Trouble with the hole current Inspect the hole
detector CT2 current detector CT2.
9 Trouble with the WCR circuit After inspecting PCB
P10293P, replace it If
necessary.
No. P10464
"This page is intentionally left blank.”
No. P10464
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.6 Schematic Diacram
PL Ce paz DAS DRA
1 L168 71 £ | Ç A TT | _ 35 36 Ç +36
U OR [о a | e + = BETES e >
2 2 M352 Ri Re к 1a > > ' 24 8 PCBG(Inverier | ' Ln eh dj опр un [PLB |
y OA | - | | 4 A À à À À À [25 5 [Snubber circuit]
AE: Zw |, = | 812 ‘ТАЗ P10327M 8 PTT EE ES P10293X |
W 73105 1R3-k1 25 "ЕЙ |] | A a |
15 84 rot] 4 | ETT ca
2007 ña te 148 cel : | 2 54] | coat 3
+ 1 2 C
GND >) NF | m0 | i | el | 777777
Bo |a0 [mo > La| +, Ts ta--#a TRE CAE on Ti = TH3
| 32 Li u
7 z ! й - я
8 | cal | Lo) al МА
! 116 Gil J
g | #R fad J 24 АТ
! -
- „= + „= un o : !
y. > L7 HTH SEE |, Е ВЯ all | Ez
tell aio [ TRATES ев „ве НРУ 27 4e; RAR A т, а 39
о 6 37 TP Ta THM6| THS
OY ML CUA — ый ый - 38
CON3 7 eal IRS ORG 37
2 ER ag 39
75
m я 74
EN Mu |
' ~~ PUN mM) <TH ID 1 = io ol © m
| = >
| M. | "ее ECEEMEECE
PCB3(Power supply] PCBALIGBT driver] | В Ш Io Psrs_ps SES
| P10263Q P10327V | |. to Water Cooling Unit | ><cn6 => я | | a >
Lire {EEE ST TT TT TT TT TT TT ae | | | PC810 P10293V
| | 1 | (Secondary transistor
1 -
| | | | | CHi driver]
! I | | ae — i =
| | i I I | 1 m <
y a a
| | | | oy eu 7
| [ —j—- - = Lo т -
| i DEA | 184 | = сы - mn -
1 CNS CNB CHiD I | | ! ] El =
| | — — À OH UD LON TK MY ui — — = - -
1
| ска pa7 VW | PCB3 P10293R | ENT m] 36 (ap
| : ; (Restriking control circuit}
18 38
| 1 3 | CN3 "(+ <8
| Lo 269 L-—-—-—— —-
I
a |
| 2 mo = —~ =| Y
E 193 ul m
| PCB1 (PWM] «| ses
a
CNB P< = CE — 31816
| P10464U > 2.77 189 1150 ol =
| 1 rl |
|
| NET A TT |
CN11 CN!3 CN22 CNI18
enas| | len7 — P0B2(CPU)
P10293P |
CN? CNAÍ CNS |
—] il - — = = — — — — A = —!
POST СС ее с) (О YN тн Нет С 7 — -
| г -—1
| EN ome
SE
T a | pPCBi{ (Front panel) |
t
=] ее) | an aw e ev A265 C9a.b | P10346R bo PS —-
СК SAS gas 7 1 | |] 7
ons PCBS 4/81 p103467 ‘ a8 | ром
1 er I -
CN40 nO a I, NC ua), va)( E ; 1 I 1
| | CN2 C102 Cid | | | PCB12 |
| pcB13{Terminal) P10293T 254 | | (Battery) |
no ı 1 P10263R ‹
7 an № | | |
Lo ee р _
Used wiring number
17-265
175 176
Hissing wiring number
40: 4d, 15:33
135. 143. 145. 147. 149
153. 155. 157. 187
237. 239. 241. 243
Remote control box
No. P10464
12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.7 Parts Layout LL
TT PCB11
PCB12
PCB1
Under frame | PCB2
CON3
!
o ] CON1
y Г ‚Behind of | - 5 CON?
a МИ | | — ront Fane Solo = A
| СТ! __ |olole ©
\___ pcB7 NN — Ri8abe ©
R19a,b,c
| THP2 |
Bottom Chassis | TR12 — 77 pere [Back Side of Front Pane! | |
tn / TR3,4 — = ==
\ ff <= ==> == | Front Panel |
E AA
Кб — ——— Г В el . Cl a
oo Heat sink | @
T1| © |
5 1 Heat sink =
Po I Ee] |
DR1 ——/ THP1 DR2-6
| Middle Chassis |
| | | Rear Panel |
| R25 .
РМ!
)
LES ©
No. P10464
13. PARTS LIST
e Please contact your dealer to order parts. (See the back cover for telephone and fax numbers, and mailing
addresses.)
— Symbol Part No. Description Specifications Q'ty Remarks
NF 4614-101 |Circuit protector CB3-X0-10-072-42D-C | 1
LF 4519-022 Line filter CF3030C-DJ 1
PL 4600-366 |Pilot lamp N46010A7KW-01 1
DRA 4531-204 |DR&SCR complex module DFA75BA160 1
— DR2-6 | 4531-308 [High speed diode module DBA200UA60 4
DRY 4531-710 |Diode D1N60 1
TR1,2 4534-418 |IGBT module CM150DY-12NF 2
TR3, 4 4534-407 |IGBT module 2MB!150TA-060 2
— TR5,6 4534-410 |IGBT module CM300DU-12F 2
em 4810-030 [CT W-W03029 1
CT? 4406-009 |Hole current detector HA400S3EH 1
T1 P10293B00 (inverter transformer P10293B00 1
TA W-W02936 |Auto transformer W-W02936 1
С.С P10464C00 |Coupling coil P10464C00 4
К P10293L00 |DC reactor P10293L00 1
Là 4739-497 |Ferrite core E04RA400270150 3
L3 4739-543 |Ferrite core FO4RA310190100 1
= LA, 5,6 4739-497 |Ferrite core E04RA400270150 3
L7 4739-497 \Ferrite core E04RA400270150 1
RE: 4739-497 [Ferrite core E04RA400270150 2
| 9 — 14 4739-543 |Ferrite core E04RA310190100 6
L15, 16 4739-543 |Ferrite core F04RA310190100 2
197 4739-543 |Ferrite core E04RA310190100 1
L18 4739-497 \Ferrite core E04RA400270150 2
THP1 4258-033 [Thermostat 67L070 | 1 |Side of DR2-6
~~ THP2 4614-057 |Thermostat 67L080 1 |Side of TR1-4
THP3 4258-033 |Thermostat 67L070 1 |Side of TR5, 6
SOL 4813-046 [Solenoid valve TYPE5511DC24V 1
FM 4805-074 |Fan — 4715SL-05W-B60-D00 | 1 [me ne)
FM2 4805-046 |Fan 4715KL-05W-B40-P00 | 1 |Upper side
— (Low speed type)
CR 4341-139 |Relay G2R-1-T DC24V 1
SC1-8 4519-029 [Surge clamper 1.5KE250CA 8
R1—4 4536-119 |Surge absorber ENC911D-14A 4
R5 Missing number |
RE 4509-819 |Cement resistor 40SH 2000) 1
RY 4500-825 (Cement resistor 205H 15kQJ 1
— R8-13 4509-704 Carbon film resistor RD1/4W 1 kQJ 5
R14 -17 | 4509-121 |Metal film resistor RNP-50SC 100F 4
R18a, b, € 4504-411 {Non-inductive resistor NCRF24V 30QJ 3
R19a, b, C 4504-411 |Non-inductive resistor NCRF24V 300J 3
—74—
No. P10464
13. PARTS LIST (continued)
a Symbol | Part No. Description Specifications Q'ty Remarks
—R20-23 | 4509-704 ¡Carbon film resistor RD1/4W 1k0J 4
— R24 | 4504-503 |Wire wound resistor GGBOW 2000) 1 a
© R25 4509-922 Cement resistor 20SH 100JA 1
© R26 4500-113 |Metal oxide film resistor RS3B 20kQJ 1 a
© R27 4500-046 |Metal oxide film resistor RS1B 10kQJ 1 a
R28 4536-112 |Surge absorber ENC821D-14A 1
— R29 “4509-704 ¡Carbon film resistor RD1/4W 1kQJ 1
— R30, 31 4500-704 Carbon film resistor RD1/4W 1kQJ 2
— R32.33 | 4500-905 |Cementresistor MHR20A513JI 2
A Missing number
C2 -5 4518-519 |Film capacitor MIC-ST3D182J 4
C6a, b 4518-411 |Film capacitor EM351200DOBA1HP 2
87 2518-411 |Film capacitor EM351200DOBA1HP 1
re: 4517-458 |Ceramic capacitor 2kV 0.001uF 1
C9a, b 4517-459 |Ceramic capacitor DEHR32E103KA2B 2
C10 4517-459 |Ceramic capacitor DEHR32E103KA2B 1
en 4518-538 |Film capacitor US16X563JBASA 1 a
012 4518-530 |Film capacitor US18X154JAASA 1
013 4518-402 |Film capacitor 50V 0.47uF 1 a
— COM 4730-002 [Metal consent socket DPC25-2BP 1 |2P
— CON 4730-006 |Metal consent socket DPC25-4BP 4 Jap
© CONS P10484X02 |Cable with 3P connector P10464X02 1
© CON4 P10464X04 |Cable with 6P connector P10464X04 1
— coN4 | P10454X08 |Jumper plug P10464X08 1
I PCB1 P10464U00 |Printed circuit board P10464U00 1
PCB2* | P10293P00 |Printed circuit board P10293P00 1 ner to “NOTE
—pcg3 | Р10263000 [Printed circuit board P10263Q00 1
— pcB4 | P10327V00 [Printed circuit board P10327V00 1
PCB5 P10346T00 |Printed circuit board P10346T00 1
— pcBs | P10327M00 |Printed circuit board P10327M00 1
© PCBY P10283X00 [Printed circuit board P10263X00 1
PCBS P10293X00 |Printed circuit board P10293X00 1
pose | p10293RO0 |Printed circuit board P10293R00 1
— rcB10 | P10293V00 |Printed circuit board P10293V00 1
BCB11 | P10346R00 |Printed circuit board P10346R00 1 a
— pcBi2 | P10263R00 ¡Printed circuit board P10263R00 1
— pcg13 | P10293T00 |Printed circuit board P10293T00 1
*NOTE: When ordering a prin
label below a nameplate attac
P10464 Ver. i61HE.3HHE.000
Replace the #H #5 with software version.
ted circuit board P10293P00, provide the software version on a
hed to the rear side of the welding power Source.
No. P10464
13. PARTS LIST (continued)
Е Symbol Part No. Description Specifications Q'ty Remarks
SO 4739-474 |Grommet with film W-W02805 4
. 0 4735-038 |Knob K-100 22RSB 1 Ш
© 4735-039 |Cap K-100 22CSBL 4 Aejusting Knob
O 4739-475 |Rubber foot C-30-RK-3220 4
B® P10464W02 |Contro! panel sheet P10464W02 1
— E 4739-476 Cap W-W02814 2
D P5801G03 |Carrying handle |P5801G03 2.
P10263G12 [Bush P10263G12 4
O P10263J01 [Front cover P10263J01 1
O P10263J02 |Control panel cover P10263J02 1
. 0 4734-007 Machine socket DIX BE 50/70 2 [Output terminal
4734-016 |Power cable connector DIX SK 50 1 [For base meta
4519-030 (Filter kit 109-1000F13 1
4519-031 Dust filter 109-1000M13 1
4730-001 [Plug DPC25-2A (1) |For СОМ!
о 4730-005 |Piug DPC25-4A (1) |For CON2
—76—
14.1 Specifications
(1) Welding power source
Specificaitons
No. P10464
14. SPECIFICATIONS
Digital Elecon DA300P
Model DA — 300P
Welding method DC TIG АС ПС AC -DC TIG DC STICK
Number of phase Three
Rated frequency 50/60 Hz
Rated input voltage 400 V
Input voltage range 400 V #15 %
Rated input current 17.3 À 18.1 A 19.1 A
Rated output current 300A 3004 250 A
Rated output current range 4 A — 300 А 10 A — 300 À 10 А — 250 А
Rated load voltage 22V 22V 30 V
Max. no-load voltage 58 V
“Rated duty cycle 40 %
Pre flow time 0.1 — 20 sec.
Post flow time 0.1 — 30 sec.
Up slope time 0.1 — 10 sec.
Down slope time 0.1 — 10 sec.
Arc spot time 0.1 — 10 sec.
Crater-fill operation ON / OFF / REPEAT
Pulse frequency 0.1 ~ 500 Hz
"Pulse peak ratio 50 % ( Changing with F(function)key from 5 % to 95 % )
AC frequency 50 — 200 Hz
AC balance — 30 — 30 ( EP ratio : 5 — 50 % )
AC-DC frequency 0.1 ~ 50 Hz
Number of JOB MEMORY 100 |
( welding condition )
Temperature rise + 160 °C
Operating temperature range „10°C — + 40 С
Operating humidity range 20 % ~ 80 % { without dew condensation )
“ Strange temperature range —10 С — + 60 С
Storage humidity range 20 % — 80 % ( without dew condensation )
External dimension 250 mm x 640 mm x 544 mM
(WxDxH) ( without carrying handle )
Mass — 45 kg
Degree of protection IP21 5
Torch cooling method Water / Air
Start method
High frequency start / Lift start
*The welding power source complies with the requirements of IEC 60974-1.
—77—
No. P10464
14. SPECIFICATIONS (continued)
14.2 External View
SC E
O
O
EE
PL вю
Эл
398
Sa
500
640
250
_ 524 >
_ 544 |
577
—78—
No. P10464
"This page is intentionally left blank."
—70—
ож. ee 2 — rer = ——›
No. P10464
14. SPECIFICATIONS (continued) @ In reading the “Operation” paragraph described in “10.1 Basic Setup” and in the subsequent paragraphs,
| consult this page to check the key location or the like.
O Initial Values and Setting Range of Parameters
Initial value | Setting range [19][18] [17] [3] [11] [13] [14] [3] [4] [6] [7]
Pre flow time 0.3 sec. 0 - 20 sec. I i | | | | mena
Up siope time 1 sec. 0 — 10 sec. |
Welding current for stick welding 10 A 10 — 250 A | |
= DC NG LOAD VOLTACE *
- Initial current DC TIG 4 — 300 À | po
- Welding current ВЕ
- Pulse current ACTIG 104 HARD. 10 - 300 А
AC-DC TIG
- Crater current SOFT 10 — 200 A |
Pulse frequency 2 Hz 0.1 — 500 Hz
Down slope time 1 sec. 0 — 10 sec. | re В
Post flow time 7 sec. 0 — 30 sec. | | NL
Arc spot time 3 sec. 0.1 — 10 sec. | E PUERRO AC |
AC frequency 70 Hz 50 — 200 Hz | ou —
Cleaning width 0 -20 — 20 | DOAN SOE > FREQ.
AC-DC change frequency 1 Hz 0.1- 50 Hz | |
Condition number 1 1 — 100 | Ne
© Function , œsepui 4 7 =}
Initial value Setting range | i“ eo =,
Crater OFF OFF / ON / REPEAT / ARC SPOT | AC BALANCE
AC TIG / AC-DC TIG . we
Welding method ACTIG DC TIG / DC STICK welding |
AC wave form STANDARD STANDARD / SOFT / HARD
Initial current OFF ON/OFF
Pulse OFF - ON/OFF
Lift start OFF Lift start / High frequency start
Slope OFF ON / OFF
Torch AIR Water / Air
© Internal function <Refer to 10.1.17 Internal Functions for detail.> i
What can and cannot be stored in memory by each welding conditions memory number are
discriminated by “OQ” and "X" given in the table below.
Memory | Initial value Setting range
F1 | Start current x ON ON (HIGH) / OFF (LOW)
F2 | Change in sequence at arc spot time X OFF ON (VALID) / OFF (INVALID) To
F3 | Termination of repetition X OFF ON (VALID) / OFF (INVALID) |
F4 | Automatic/Stick X OFF ON (AUTOMATIC) / OFF (STICK) | rene
F5 | External command 12 V MAX x OFF _ ON (VALID) / OFF (INVALID), |
F6 External command 10V MAX X OFF ON (VALID) / OFF (INVALID) | | |
F7 | Pulse peak ratio O 50 % 5-95% | | | | | |
F8 | Voltage reducing function X OFF ON (VALID) / OFF (INVALID) 6 Ш 5) no (A " En 115) и
F9 | Result display holding time X 20 sec. 0 — 60 sec.
F10 | AC ratio 70 % 10-90% [1] WELDING METHOD change-over key — | 19] ARC SPOT TIME setting key — | [17] LOAD key
F11 | Change of operation sound X ON ON (VALID) / OFF (INVALID) [2] AC WAVE change-over key [10] Function selection key [18] SAVE key
F12 | Change of external output terminal 1 X 1 Pe raie d output [3] Parameter selection key [11] INITIAL CURR. selection key — | [19] ENTER key
3:EN synchronized output [4] Parameter adjusting knob [12] PULSE selection key
F13 | Change of external output terminal 2 x 2 4:AC synchronized output [5] CRATER FILL. key [13] LIFT START key
| Gorge nie ne MA | от | ones (PRE Sore sent —
£15 Indication change of cleaning width x OFF ON (EP ratio indication) / OFF [8] AC-DC change-over frequency setup [16] GAS CHECK key
indication (tindication) key
F16 | soft pulse X OFF ON (soft pulse) / OFF (standard)
* Further, F17 to F20 have the functions as well. For details, see 10.1.17 “Internal Functions”.
QUICK MANUAL
For details, refer to “10. OPERATION”.
DjBefore Using the Welding Power Source]
1.
3.
4,
Settings of Welding Method
DC TIG" or “DC STICK" by
using the WELDING
METHOD key. |
For DC STICK welding, skip
steps 1, 2, 3, and 4.
In the case of AC TIG and
AC-DC TIG welding, select
“STANDARD”, “SOFT or
“HARD” with the AC WAVE
selector key.
Settings of Crater/Arc Spot
: Use the CRATER-FILL
on key to select
art OFF / ON / REPEAT / SPOT.
REFEAT
[ ДОя
TALA
HN
| Setings of Functions
LU TORGH
® For using INITIAL CURRENT, press the INITIAL CURR.
key to set the function to “ON”,
[ON]: INITIAL CURR. lamp is on.
[OFF]: INITIAL CURR. lamp is off.
® For pulse welding, set to “ON” by using the PULSE key.
[ON]: PULSE lamp is on.
[OFF]: PULSE lamp is off.
e For LIFT START, set to “ON” by using the LIFT START
key. For HIGH FREQUENCY START, set to “OFF” with
this key.
[ON]: LIFT START lamp is on.
[OFF]: LIFT START lamp is off.
Select "AC TIG", "AC-DC TIG",
No. P10464
. SPECIFICATIONS (continued)
e For using SLOPE function, set to "ON" with the SLOPE
selection key. о
[ON]: LIFT START famp is on.
[OFF]: LIFT START lamp is off.
e For using the water-cooled torch, set to "WATER" with
the TOCH key, and then run cooling water.
[WATER]: TORCH lamp is on.
[AIR]: TORCH lamp is off.
NOTE:
There may be unavailable functions in some crater
settings. Refer to “OPERATION” for details.
5. Settings of Parameter
© PULGE FRE RQ
EIT al | | | NU Lo a
3 NELDINO CURE.
Ji i * uE cure Y Eo
Lm = GUEBR. pe A TE
TE ER Pd
J
Use the parameter selection keys to select the parameter
you want to set, then adjust it while turning the parameter
adjusting knob.
sa When the arc spot time is set up, select the
. key shown in the figure on the left, and then
+ + ‘ use the parameter adjusting knob for time
a setting.
SAL
Using the parameter adjusting knob, adjust
the AC frequency after selecting the key
shown in the figure on the left in the case of
AC TIG and AC-DC TIG welding.
Using the parameter adjusting knob, set up
the EP ratio after selecting the key shown in
the figure on the left so that the required
cleaning width is obtained in the case of AC
..TIG and AC-DC TIG welding.
NOTE:
® Turning the parameter adjusting knob clockwise
increases the parameter. To decrease the parameter,
turn the parameter adjusting knob counter-
clockwise. The parameters largely increase or
decrease by turning the parameter adjusting knob
quickly.
e There may be unavailable parameters in some crater
settings and function settings. Refer to Section 10,
“OPERATION” for details.
6. 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.
Now you have completed the preparations that are required to
start welding. Press the torch switch to start welding.
@ [Protecting the Keys and Releasing the Key Protection]
e e Protecting of the keys
Hold down the ENTER key + the F key at a
time for a few sec.s. The F lamp starts blinking.
Blinking of the F lamp means the welding
machine is in the key protection mode.
® Releasing the key protection
Hold down the ENTER key + the F key at a
time for a few sec.s. When the F lamp turns off,
the key protection function is released.
Presefting the Welding Conditions
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
VE you selected is available. When “—” is
not displayed in the left display, the
number you selected is unavailable. In.
this case, select another number.
Otherwise, the welding conditions preset
to the number are erased and
overwritten with the welding conditions
you newly set.
3) Press the ENTER key fo check the
parameter that is preset to the number.
4) When pressing the ENTER key again,
the welding conditions are set.
[Press the MEMORY key. |
Discontinue | Set the welding condition number witil
. |tuming the. parameter adjusting knob.
Press the ENTER key. | | Press the MEMORY key. |
Press the parameter selector key 1
Discontinue
The welding conditions are set to the number you selected.
y
LOAD key | Press the ENTER key. |
| The memory mode quis,
@ Loading the Welding Conditions
1) Pressing the LOAD key enters 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.
—81—
©
to check the parameter value. Reset the welding condition number.
3)
4)
Press the ENTER key to check for the parameter
preset to the number.
When pressing the ENTER key again, the welding
conditions preset to the welding condition number are
retrieved.
(Press the LOAD key.
у
[Press the SAVE key
Discontinue| Set the welding condition number ve
Discontinue
tuming the parameter adjusting knob.
[Press the ENTER key. | + | Press the LOAD key.
y
Press the parameter selector key
to check the parameter value. Reset the welding condition number.
The welding conditions are set to the number you selected.
y
| Pres es |
| The > mode quits. | |
© [Settings of the (Internal) Functions)
1)
2
3)
4)
9)
When holding down the F key for a few sec.s, the
function mode is activated. The function number blinks
in the left display, the function status is displayed in
the right display. |
Set the function number while turning the parameter
adjusting knob.
When pressing the F key, the function number lights
up, then the function status blinks.
Set the function status while turning the parameter
adjusting knob.
To cancel the function mode, hold down the F key for
a few minutes.
code
o Displays on the
Classification of errors
dAl Hen orch switch off state
E- 000
E- 100 ¡Control error
= 200 current
E- 300
E- 500 water
E- 510 unit error
E- 600 of
E- 710 error
E- 751 side over error
- error
No.P10464
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:
e Address
e Name
e Telephone number
e Product model
e Manufacture year
e Serial number
e Software version number
e Details of troubles
+ MODEL: DA-300P
- DATE: 20XX
- SERIAL NO.: P10464 Y XXX3XOX/OOX
O O 09 P10464 Ver.iHHE.1HHf.000
D 4 o
—82—
OTC
DAIHEN Corporation
CE
DAIHEN Corporation
5-1, Minamisenrioka, Settsu-shi, Osaka 566-0021, Japan
Phone: +81-6-6317-2506, Fax: +81-6-6317-2583
DAIHEN, INC.
DAYTON OFFICE
1400 Blauser Drive
Tipp City, Ohio 45371, USA
Phone: +1-937-667-0800, Fax: +1-937-667-0885
OTC DAIHEN EUROPE GmbH.
Krefelder Str. 677, D-41066 Monchengladbach, F.R. GERMANY
Phone: +49-2161-69-49710, Fax: +49-2161-69-49711
OTC Industrial (Shanghai) Co.,Ltd.
7G Majesty Building, 138 Pu Dong Da Dao Shanghai
The People's Republic of China
Post Code: 200120 |
Phone: +86-21-58828633, Fax: +86-21-58828846
OTC (Taiwan) Co.,Ltd.
No. 63-4, Nan Yuan 2 Rd., Chung Li,
Taoyuan Hsien, Taiwan R.O.C.
Phone: +886-3-461-3962, Fax: +886-3-434-2394
OTC DAIHEN Asia Co.,Ltd.
60 / 86 Moo 19. Navanakorn Industrial Estate Phase 3,
Klong Nueng, Klong Luang, Pathumthani 12120
Phone: +66-2-909-4163, Fax: +66-2-909-4166
Upon contact, advise MODEL and MANUAL NO.
040317
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