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M ANUALNO:P10352

C)TE
DA|HENcoroorctron

OWNER'S MANUAL
FOR
DIGITALINVERTER
DP4OO
M O D E LD
: P-400 P10352

I N V E R T E R C O N T R O L L E D W E l . l ) l N ( i I ) () \ \ l - R S O t I R ( ' l l

DO NOT DESTROY

IMPORTANT: Read and understand the entire contents of this


nual, with special emphasison the safety materialthroughout
ma n u a l , b e fo re i n s talling, oper ating, or maintainingthis
ipment. This equipmentand this manual are for use only by
personstrainedand experiencedin the safetyoperationof welding
equipment.Do not allow untrainedpersons to install, operateor
maintain this equipment.Contact your distributor if you do n
f ul l v u n d e rsta n dth i s ma nual.

DAIHEN
Co ration pRODUC'r's
wELDTNG DrvrsroN
January'6.
2005
TABLEOF CONTENTS

1 . S A F E T YIN F OR MA TION 2

2 . A R C WE L D IN GS A F ETYPRECAUTIONS. 2

3 . GE N E R A LN OT IC EOF OPERATION B

4. STANDARD
C O M P O S I T I OANN D A C C E S S O R I E S I

5 FUNCTION
OF EQUIPMENT
. 11

6. NECESSARP
Y O W E RS O U R C EE Q U I P M E N T 12

7 . T R A N S P OR T
A N D INSTALLATION 13

B CONNECTIOP
N R O C E D U RA
EN D G R O U N DF O RS A F E T YU S E . 15

9 W E L D I N GP R E P A R A T I O N . 1B

1O OPERATION 29

1 1 A P P L I E DF U N C T I O N 56

1 2 M A I N T E N A N CAEN D T R O U B L E S H O O T I N G 65

1 3 P A R T SL I S T . 72

14. SPECIFICATIONS 74

15. SERVICE
A N DS U P P O R T 7B
1 . S A F E T YINFORMATION
The followingsafety alert symbols and signal words are used throughoutthis manualto
identifyvarious hazardsand special instructions.

regardingpossiblepe

UTIONrefers to minor personal injury or eq t


! cnuroru mage.

2 . A R C WE L D IN GS AFETYPRECAUTIONS

! wlRtttttc
ARC WELDINGcan be hazardous.
1. PROTECTYOURSELFAND OTHERSFROM POSSIBLESERIOUSINJURYOR DEATH.
Be sure to:
. Keep childrenaway.
. Keep pacemakerwearers away until consulting a doctor.

2. Readand understandthe summarizedsafety informationgiven below and the original


principalinformationthat will be found in the PRINCIPALSAFETYSTANDARDS.

3. Haveonly trainedand experiencedpersons perform installation,operation,and


maintenanceof this equipment.

4. Use only well maintainedequipment.Repairor replacedamagedparts at once.


ARC WELDINGis safe when precautionsare taken.
( continued)
2 . A R C WE L D INGSAFETYPRECAUTIONS

sHocK
cankirr'
- lELEcrRrc
U
Touching live electricalparts can cause fatal shocks or severeburns.The electrodeand
circuits are electricallylive wheneverthe output is on. The power line and internalcircuits of
is equipmentare also live when the line disconnectswitch is on. When arc welding all metal
componentsin the torch and work circuits are electricallylive.
1. Do not touch live electricalparts.
2. Wear dry insulatinggloves and other body protectionthat are free of holes.
3. Insulateyourselffrom work and ground using dry insulatingmats or covers.
Be sure to disconnectthe line disconnectswitch beforeinstalling,changingtorch parts
or maintainingthis equipment.
5. Properlyinstalland ground this equipmentaccordingto its Owner'sManualand national,
state,and local codes.
. Keep all panelsand covers of this equipmentsecurelyin place.
. Do not use worn, damaged,undersized,or poorly spliced cables.
8. Do not touch electrodeand any metal object if POWERswitch is ON.
. Do not wrap cablesaround your body.
10. Turn off POWERswitch when not in use.

RC RAYS can burn eyes and skin: FLYINGSPARKSAND HOT METAL can
injury.NOISEcan damagehearing.

rays lrom tne we process tense strong rays at can


burn eyes and skin.
Noisefrom some arc welding can damagehearing.
1. Wear face shield with a proper shade of filter (SeeANSIZ 49.1listed in PRINCIPAL
SAFETYSTANDARDS)toprotectyour face and eyes when welding or watching a welder
work.
Wear approvedsafetygoggles.Side shields recommended.
Use protective screens or barriers to protect others from flash and glare: warn others not
to look at the arc.
Wear protective clothing made from durable, flame-resistantmaterial (wool and leather)
and foot protection.
5. Use approvedearplugsor earmuffsif noise level is high.
Chippingand grinding can cause flying metal.As welds cool, they can throw off slag.
6. Wear approvedface shield or safetygoggles.Side shields recommended.
7. Wear proper body protection to protect skin.
( continued)
2 . A R C WE L D IN GS A F E TYPRECAUTIONS

sparks and hot metal,


ying sparks
Sparks and spatter fly off from the welding arc. The flying spatter,not
metal,spatter, hot
base metal,and hot equipmentcan cause fire and explosion.Accidental contact of electrodeor
weldingwire to metal object can cause sparks,overheating, or fire.
1. Protectyourselfand others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammablematerial.
3. Removeall flammableswithin 10m (33ft)of the welding arc. lf this is not possible,tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metalsfrom welding can easily pass through cracks
and openingsinto adjacentareas.
5. Watch for fire, and keep a fire extinguishernearby.
. Be awarethat welding on a ceiling,floor, bulkhead,or partitioncan ignite a hiddenfire.
. Do not weld on closed containerssuch as tanks or drums.
. Connectbase metal side cable as close to the welding area as possibleto preventthe
welding currentfrom travelingalong unknown paths and causing electricshock and fire
hazards.
L Removestick electrodefrom holderor cut off welding wire at contacttip when not in use.
10. Does not use the welding power source for other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connectioncan cause sparks and excessiveheating.
1 3 . T i g h t e na l l c a b l ec o n n e c t i o n s .
14. When there is an etectricalconnection between a work piece and the frame of wire feeder or
the wire reel stand, are may be generatedand cause damageby a fire if the wire contacts
the frame or the work piece.

F U M E SA N D can be hazardousto your hea

Arc welding producefumes and gases.Bre umes and gases can be hazardousto
your health.
1. Keep your head out of the fumes. Do not breathethe fumes.
2. Ventilatethe area and/or use exhaustat the arc to removewelding fumes and gases.
3. lf ventilationis poor, use an approvedair-suppliedrespirator.
4. Readthe MaterialSafetyDataSheets(MSDS)andthe manufacturer'sinstructionson
metals,consumables,coatings,and cleaners.
5. Do not weld or cut in locationsnear degreasing,cleaning,or sprayingoperations.
The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
6. Work in a confinedspace only if it is well ventilated,or while wearingan air-supplied
respirator.Shieldinggases used for welding can displaceair causing injury or death.
Be sure the breathingair is safe.
( continued)
2 . A R C WE L D INGSAFETYPRECAUTIONS

CYLINDERcan explode

shieldinggas cylinder containshigh-pressuregas. lf damaged,a cylindercan explode.


ince gas cylindersare normallypart of the welding process,be sure to treat them carefully.
. Use only correctshieldinggas cylinders,gas regulator,hoses,and fittings designedfor the
specificapplication;maintainthem in good condition.
2. Protectcompressedgas cylindersfrom excessiveheat,mechanicalshock, and arcs.
3. Keep the cylinder upright and securelychainedto a stationarysupport or a rack to prevent
f a l l i n go r t i p p i n g .
. Keep cylindersaway from any welding or other electricalcircuit.
Nevertouch cylinderwith welding electrode.
Readand follow instructionson compressedgas cylinders,associatedequipment,and the
CGA publicationP-1 listed in PRINCIPALSAFETYSTANDARDS.
. Turn face away from valve outlet when opening cylindervalve.
. Keep protectivecap in place over valve exceptwhen gas cylinderis in use or connectedfor
use.
. Do not disassembleor repairthe gas regulatorexceptfor the person authorizedby the
manufacturerof them.

Rotatingparts may cause injuries.Be sure to observethe following

lf hands, fingers, hair or clothes are put near the fan's rotating parts or wire feeder'sfeed roll,
injuriesmay occur.
'1. Do not use this equipmentif the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair,certifiedor experienced
operatorsmust perform the work. Erect a fence, etc. around this equipmentto keep others
away from it.
3. Do not put hands,fingers,hair or clothes near the rotatingfans or wire feed roll.
2. ARCWELDING (continued)
SAFETYPRECAUTIONS

a
r work areas are potentially hazardous.

FALLINGor MOVINGmachinecan cause serious injury.


1. When hangingthe welding power source by a crane,do not use the carryinghandle.
2. Put the welding power source and wire feeder solidly on a flat surface.
3. Do not pull the welding power source across a floor laid with cables and hoses.
4. Do not put wire feeder on the welding power source.
5. Do not put the welding power source and wire feederwhere they will pit or fall.

WELDINGWIREcan cause puncturewounds.


1. Do not press gun trigger until instructedto do so.
2. Do not point gun toward any part of the body, other people,or any metalwhen threading
welding wire.
P R INCIPAL
SAFETYSTANDARDS
- Installation
Arc weldingequipment and use,TechnicalSpecification
IEC62081,from International
ElectrotechnicalCommission

Arc weldingequipmentPart1 WeldingpowersourcesIEC60974-1,from International


Electro
technicalCommission

SafetyrnWeldingand Cutting,ANSI StandardZ49.1,


fromAmericanWeldingSociety

Safetyand HealthStandardsOSHA29 CFR 1910,from Superintendent


of Documents,
US
Government PrintingOffice.

Recommended Practices
for PlasmaArc Cutting,AmericanWeldingSocietyStandardAWS C5 2,
from AmericanWeldingSociety

RecommendedSafe Practicesfor the Preparationfor Weldingand Cuttingof ContainersThat Have


HeldHazardousSubstances,
AmericanWeldingSocietyStandardAWS F4.1,fromAmerican
WeldingSociety.

NationalElectricalCode, NFPAStandard70 from NationalFire ProtectionAssociation

SafeHandlingof Compressed
Gasesin CylindersCGA PamphletP-1,from Compressed
Gas
Association.

Codefor Safetyin Weldingand Cutting,CSA StandardW117.2, fromCanadianStandards


Association,
StandardsSales

Safe PracticesFor OccupationAnd EducationalEye And Face Protection,


ANSI StandardZST1,
from AmericanNationalStandardsInstitute

CuttingAnd WeldingProcesses,NFPAStandard5'18,from NationalFire ProtectionAssociation

NOTE:The codeslistedabovemay be improvedor eliminatedAlwaysreferto the updatedcodes


3 . GE N E R A LN OTICEOF OPERATION

3.1 RatedDutyCycle

! GAUTTON
Use this welding power source at or under the rated duty cycle. Exceedingthe rated duty
le limitationmav result in damaqeto the weldinq machine.
o The rateddutycycleof the weldingpowersourceis the following

4004 50% (forpulsemode)


4004 60% (for DC mode)

o The duty cycle of 60% means the way the machineis restedfor 4 minutesafter 6
minutesof continuousweldinqat the ratedcurrent.

l
Ilrl
|
.
omin
* amin
I
1 0m i n
'l I
@qE
o Failureto observeduty cycle limrtations
may causean excessof the toleranceof the
temperatureinsidethe weldrngmachine Thrs may contributeto prematurewelding
machinefailureor productdamage.
27OA or less)
100
o The figure shown rtght indicatesthe relation
betweenweldingcurrentand duty cycle Use uJ
8
the weldingmachinewithin its usablerange JO DP-400
the dutycyclefor the weldingcurrent (-) 50
following Usable range

o The duty cycleof the weldingpowersourceis Fl


also limitedby the duty cyclesof accessories o o
100 2o,0 300 350400
combinedwith such as weldingtorches Use
\AELDING CURRENT (A)
the weldingmachinewithtnthe lowest rated (PULSE MODE)
duty cycleof the accessories.

31OA or less)
s
LU
- DP-400
Usable range

l
o

\AELDING CURRENT (A)


(DC MODE)

3 2 Applicable WeldingProcessand Wire Diameter


" S e t t i n g oW
f e l d i n g M o d e " f o r d e t a i l sa op fp l i c a b l e w e l d i n g m e t h o d a n d
R e f e r t o S e c t i o1n0 . 1 . 1 ,
wirediameter.

of use
3.3 Limitation
O Do not usethisweldingpowersourcefor pipethawing
AND ACCESSORIES
4 S T A N D ARDCOM POSITION

4.1 StandardComposition

. The parts names indicatedin the boxes are standardparts.They are not suppliedwith this
welding machine.Preparationof the standardparts except the welding power source is
requiredto use the weldingpowersource
o I n p u tc a b l ea n d g r o u n d i ncga b l e
For a switchbox,the 2m inputand groundingcablesare fromthe backpanelof weldingpower
source.

I n p u tc a b l e A W G 1 2 4 m m with 1Ommrl termina x 3


Groundingcable A W G 1 2 4 m m with '1Omm
<,tterminal x 1

For air cooling torch


Pressure regulators for gas cylinders

Digital remote control


Optionally avarlable l Gas hos 3m

Control €ble with wire feeder 2m

lPower €ble for wire feeder 2m

Vvblding torch l
Base retal
l .lelding pwer sour€

Pwer Gble for base rretal 2m

Analog remote control wrth 3m @ntrol cable


Groundrng cable rOptionally available

For water cooling torch


Pressure regulatoc for gas cylrnders

\AHer cooler
Gas hose 3m

e6nirot eble wrth wire t"eoer2m

lPwer €ble for wire feeder 2m i

V\,blding torch
Base metal
V\,eldino Diler souT€

P.-"r'-or" t". o."" -ari )- l


j?--i.--.Analog remote control wrth 3m control €ble
(t cr c:-t i Optlonally available
- -- -- --J J1 l ,\ t s , \A/ I \ r
Diqitat remote contror {i----l-J
I sltonailv availaDte

*Extension
cables/ hoses(5m 10m,15mand 20m)are available
( continued)
AND ACCESSORIES
4 . ST AN D A R DC OMP OS IT ION

4.2 Accessory

Make sure you have the item belowbeforeyou startusingthe weldingpowersource.


Specification Q'tv Partnumber Remarks
a For the fan on the rear panelof
Dustfilter 109-1000M3 4 5 19 - 0 3 1 weldinoDowersource
NOTE:
r When using the dust filter, perform40% (pulse),50% (DC) or less duty-cycleoperation
(withoutclogging).Otherwisethe weldingmachinemay be damaged Referto Section3.1,
"RatedDutyCycle".

3 Preparation for welding


of consumables

(l) ShieldGas
Use a suitablegas for weldingmethoc
o Carbondioxidegas (CO2gas)
Forwelding(purity:99.9%or more,moisturecontent0.002%or less)
O MAG gas
80% argon(Ar) + 26"1,carbondioxidegas (CO2gas)
o MIG gas for stainless
steel
98% argon(Ar) + 2"1"oxYgen(O2)
. M I Gg a sf o r A l u m i n u m
Pureargon(Ar)

(2) WeldinqWire
5. FUNCTION
OF EQUIPMENT

5 1 WeldingPowerSource

0
o
o
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o o o aa
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o c D e
6 NECESSARP
Y O W E RS O U R C EE Q U I P M E N T
6.1 WeldingPowerSourceEquipment(forcommercial
use)

! WARNING
When the welding machineis used in such a humid environmentas constructionsite, on
steel plate, or on steel structure, install a leakagebreaker.

! CAUTTON
Be sure to installa switch with fuse or a circuit breaker(for motor) to the input sides of each
weldinq machine.

of Nece PowerSourceUti
D I G I T A LI N V E R T E R
MODEL
DP-400
Powersu 400V Three
Tolerancer of fluctuationof 400v!15%
Installed 22kVA or more
of switch/circuit
breaker 504

6.2 Precautions
for Useof the EnqineGenerator

! CAUTTON
Use the auxiliarypower of enginewelder whose voltagewaveformhas been improved.Some
of the engine welders have poor electricity,which may cause product damage.Contact an
engine welder manufacturerfor improvementof waveform.

To preventthe enginegeneratoror auxiliarypower from being damaged.followthe instructions


below.
o Set the outputvoltageof the enginegeneratorto the voltagerange between400 and 410V at
no-loadweldingoperationSettingto extremelyhrghoutputvoltagemay resultin productdamage
o Use the enginegeneratorwith a damperwindingof whichcapacityis morethantwiceas muchas
the rated input of the weldingmachine Generally,the recoverytime of the enginegenerator's
inputpowersource,and if the engine
voltagefor loadchangeis slowerthanthat of the commercial
generatordoes not have sufficientcapacitysuddencurrentchangesuch as arc startwill occur
This may resultin abnormaldecreasein outputcurrentor arc loss. Ask an enginegenerator
manufacturer for a damperwinding
. Do not combinemore than two weldingmachineswith an enginegenerator.The affectof each
weldingmachinemay causeeasy lossof arc.
7 . T R A N SPORT
AND INSTALLATION

7.1Transport

I WARNING
Follow the instructionsbelow to avoid trouble and product damagewhen carryingthe welding
machine.

+
O Do not touch the chargingparts insideor outsidethe welding machine.
O Be sure to disconnectthe line disconnectswitch when carryingthe welding
machine.

O When hangingthe welding power source by a crane,do not use the carrying
handle.

7 2 Installation

! WARNTNG
Wheninstallingthe welding machine,follow the instructionsbelow to avoid a fire caused by
weldinqand physicaldamaqesbv fume qas.
, Do not placethe welding machinenear combustiblematerialsand flammable
gas.
O Remove combustible materialsto prevent dross coming into contact with
combustibleobjects.lf that not possible,cover them with noncombustible
covers.
O To avoid gas poisoningand dangerof suffocation,wear a gas mask or
adequatelyventilatewhen the welding machineis used in the place regulated
by a local law.
O To preventdisorderor poisoningcaused by fume, wear a gas mask or weld at
a partialexhaustfacilityapprovedby the local regulation.
O Adequatelyventilateor wear a gas mask when using the welding machinein a
tank, a boiler,a hold of a ship, becauseheaviergas such as carbon dioxide or
argon gases are drifting there.
O When using the welding machineat a narrow space,comply with a trained
supervisor'sdirections.And be sure to wear a gas mask.
O Do not operatethe welding machinenear the place where degreasing,
cleansing,and spraying are performed.Otherwise,poisonousgas may be
generated.
O ge sure to wear a gas mask or adequatelyventilatewhen welding a coating
steel plate.(Poisonousqas and fume mav be qenerated.)
7 . T R A N S P OR T ( continued)
A N D IN STALLATION

! CAUTTON
To preventelectromagnetictroubles,read the following.Also, if electromagnetic
troublesoccur, check the following again.

Since largecurrent abruptlyflows insidethe welding machineduring welding,other machines


near the welding power source may be troubleddue to electromagneticnoise
O Oo not ground the welding power source commonlywith other machines.
O Close and fix all doors and covers of the welding machine.
O Do not use an unnecessarilylong cable.
O Placea base metal cable and a torch side cable as closely as possible.

ln the event of electromagnetictrouble,follow the instructionsbelow.


O Changethe installationplace of the welding machine.
O Keep the machineswhich may be affectedaway as far from the welding machine,cables and
welding site as possible.
O Add a noise filter to the input cables.
O Mount an input cable in the groundedmetallicconduit.
O Shieldthe whole welding placesfrom electromagnetictrouble.lf electromagnetictroublesare
still not solved after followingthe above instructions,consult your nearestDAIHENdealer.

I CAUTION
Follow the instructionsbelow when selectinqan installationplace of the source.
O Do not installthe welding power source in the placesubjectto direct sunlight and rain.
O Placethe welding machineon a strong and stable surface.
O Installthe welding machine in the place where the ambienttemperatureis between-10'C and
+ 4 0" C F t q " f a n d + 1 0 4" F ) .
O Do not installthe welding machinein the placewhere metal materialsuch as spatterentersthe
welding power source.
O Keep the install distance of 30 cm betweenthe welding power source and the wall or other
welding power.
O Installa wind shield to protectarc from wind.
O Fix the gas cylinderto the stand only for gas cylinder.
C O N N E C T I OP E N D G R O U N DF O RS A F E T YU S E
NR O C E D U R A

! WARNTNG
Follow the instructionsbelow to avoid electricshock.
tl
* Do not touch the chargingparts,as this will result in fatal shock and severeburn.
O Do not touch the chargingparts of the welding machine.
O Havea qualifiedelectricengineerground the case of the welding power source and the base
metalor jig electricallyconnected,following a local low.
O With the line disconnectswitch insidethe switch box all turned off, ground and connectthe
w e l d i n gm a c h i n e .
O Do not use a cable with lack of capacityor a cable seriouslydamaged.
O Tightenand insulatethe connectionsof cables.
O Surelyattachthe cover of the welding machineafter connectionof the cables.

8 1 Connecting
of the WeldingPowerSource

@ery'e! s'tht e{-*qfed t0_rq


-
Gas fl()w rslulator
,'d
-- \\'_
i A a
Porer €ble for wre leqier
@

Gble for wre f@der@

[]ase rnetal
l-.->/),
, { ,) ,
.F-W
Ml U terDinal

FnqJ *i. g'th"'*"t""""d"d f.r"hl


Gas flcrw rate regulator
\ Surelyinsertthe connectorplugs
\Abterhose 7r
rfor condensed urater) into the socketsfor wire feeder
and for analogremotecontrolup
V\bter c-oler to the stoo bv turnrna them
Shield gas

For feeding water Control cable for wrre feeder

Pcrwer cable for wre feeder

rT- 1\

Wre feeder
base rrretal .l Base rretal
Control cable for rerncte control Analog rernote control
i Optionally available) M1O terminal

"Abnormal signalintothe weldingpowersource


waterpressure"
NOTE,In caseof puttingthe
1 1 2
A N D GROUNDFOR SAFETYUSE ( continued)
P R OC E D U R E
8 . C O N N EC T ION
Followthe steps below to attachthe cablesto the outputconnectorsof the weldingpower source
"Connection
referringto the illustrations
of of the WeldingPowerSource"on the previouspage
"base
1. Connectbetweenthe metal (.r" terminaland the base metal usingthe powercable for
base metal
a "torch
z Attachthe oowercablefor wire feederto the G)"outputterminal
J Removethe right-sideplateof the wire feeder,and then attachthe powercablefor wire feederto
the M10 terminal Surelyfix the powercable in positionnot to contactwith the bottomof the
frameand the terminalboard.Put aroundthe terminalswith insulating tape.
4 lnsertthe controlcablefor wire feederintothe socketfor wire feeder
5 Attachthe gas hose to the gas inleton the wire feeder.
Connectthe weldingtorchto the wire feeder.
7 Connectthe hosesfor watersupplyand for condensed waterto the watercooler.(Whenusinga
water-cooled torch )

of the Gas Hose


8.2 Connectino

! WARNING
O You may suffer from danger of suffocation caused by lack of oxygen when

f8 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.

! CAUTTON
O Be strte
from falling down of gas cylinder.
O Attach a proper gas flow regulatorto a gas cylinder. Fallureto observe the demand may
result in phvsicaliniuries.The qas flow requlatorfor as mustbe used.

1. Securelyattachthe gas hose to the gas inletlocatedon the rear side of the wire feederwith a
monkevwrench.etc.
gas cylinderto the gas cylinderwitha monkeywrench.etc
t Fixthe nut for attaching
Securelyattachthe gas hoseto the gas outletwitha monkeywrench,etc

Gas flow rate regulator Nut for attaching gas qylinder

/6\ Gas qllinder


\q/
8 . CON N E C T ION AND GROUNDFOR SAFETYUSE ( conti nued)
P R OC EDURE

! WARNING
Follow the instructions below to avoid electric shock.
tl
x Touchingthe chargingparts may result in fatal electricshock and severeburn.
O Do not touch the chargingparts of the welding machine.
O Havea qualifiedelectricengineerground the case of the welding power source and the base
metalor jig electricallyconnectedin accordancewith a local low.
O With the line disconnectswitch in the switch box all touched off, ground and connectthe
welding machine.

! CAUTION
O ge sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each
machine.

Mount a switch with fuse or a circuit breaker


on each vvelding rnachine

Surely connect the input and grounding cables


A\ 1312(4mm') to the circuit breaker .

! CAUTTON
Be sure to
Use a qroundinqcable of which thicknessis more than 14mm'
O lf the welding power source which is not grounded is used, voltage will be generatedin the
case through the capacitorbetweenthe welding power source input circuit and the case or
floating capacity (electrostaticcapacity naturally generated between the input conductor and
the case metal). lf you touch the case or the base metal, you may suffer from electric shock.
Be sure to qround the case of the source.
9 . W E L D I N GP R E P E R A T I O N
9.1 Preparing
the Protective
Equipment

o protectyou from gas generatedfrom welding,fume, and lack of oxygen,


r protectiveequipment

o To avoid gas poisoningand dangerof suffocation,wear a gas mask or adequatelyventilate


when the welding machineis used in the place regulatedby a local law.
o To preventdisorderor poisoningcausedby fume, wear a gas mask or weld at a partial
exhaustfacilityapprovedby the local regulation.
o Adequatelyventilateor wear a gas mask when using the welding machinein a tank, a boiler,
a hold of a ship, becauseheaviergas such as carbon dioxideor argon gases are drifting
o When using the welding machineat a narrowspace,comply with a trainedsupervisor's
directions.And be sure to wear a gas mask.
o Do not operatethe welding machinenear the placeswhere degreasing,cleansing,and
sprayingare performed.Otherwise,poisonousgas may be generated.
o Be sure to wear a gas mask or adequatelyventilatewhen welding a coatingsteel plate.
(Poisonousgas and fume may be )

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

! CAUTTON
Use the protective equipment to protect you and other workers from arc rays,

difr
spatteringdross, and noise from welding operation.

O When performingor monitoringwelding operation,wear an eye protectorwith a good light


blockingeffector face shield.
O Wear protective glasses to protect your eyes from the spattering dross.
O Wear protective equipment such as protective gloves, long-sleeveclothes, leg covers, and
leatherapron.
O Install protective screens or barriers to protect the eyes of others in the work area from arc
ray.
O Wear an ear protectorwhen noise level is high.
( continued)
L WE L DINGPREPARATION

9 2 Operating
the Switchesand Controlling for gas cylinders
the Pressureregulators

! CAUTTON
O Keep your face away from the outlet when turning on gas at the main of the gas cylinder,as
burst of hiqh-pressureqas mav result in phvsicaliniuries.

NOTE:Gas checkingautomaticallystops in two minutes.

I Turn on the line disconnectI


switch

t Set the pressureregulatorsfor gas 1


t!y!!ers t9 q|ltrr ,!!9! lgln q! 99sq! ]
[- i; Set the gas flow rate adlustrngknob
flowr
1j"_?:_1_t"jdjustthesas
i rl P r e s st h e G A S C H E C K
key (TheGAS CHECK
l a m pl i g h t su p )

"1"(ON)
i;; Press the GAS CHECK Placethe powerswitchin the
buttonagarn.(The GAS -11)
-v
LJ position.
C H E C Kl a m pg o e so u t . )

I Operation
WARNING I
O Do not look into the tip hole to check for the rate of wire feedingwhile inching.

{
! CAUTTON
O Keep away your hands, fingers, hair or clothes from the rotating parts of the feed
roll, etc. to preventyou from being caught into the rotatingparts while inching.

Afterstraightenrng the weldrngtorch,feed the wire while pressingthe adjustingknob


Parameter
i n c h i n gb u t t o n ( " l N C H l N Gl"a m p l i g h t su p ) W h e n t h e w i r e a p p e a r s
from the end of the torch,releasethe INCHINGkey Cut the wire at
about10 mm from the end of the torch When adjustingwirefeed rate,
use the parameterad.lusting knob Inchingoperatton can be controlled
by usingthe INCHINGbuttonon the analogremotecontrol(optional
accessory). Whencontrolling inchingoperation withthe remotecontrol,
the INCHINGkev on the frontpaneldoesnot function.

I N C H I N Gk e y
9. WELDINGPREPARATION(continued)
9 4 WeldingConditions

the followingtroubleswilloccur
Whensettingto the improperweldingconditions,

Trou
extensionis too long .LongArc length
'Wide beadwidth
' P o o rs h i e l d
Wire extensionis too short 'Shortarc length
.Easygeneration of spatter
c voltages too high. .Longarc length
.Widebeadwidth
'Shallowoenetration and flat bead
Arc voltageis too low .Stickto base metaland easy generationof spatter
.Narrowbeadwidth
.Deeppenetration and highexcessmetal
ing currentis too high 'Wide beadwidth
'Deep penetration and h h excessmetal
ing speedis too fast. 'Narrowbeadwidth
'Shallowoenetration and low excessmetal
9. WELDING (continued)
PREPARATION
The data in the tablesbelowis onlyfor referencePleasefindthe optimumweldingconditions
for
weldmentshapeand weldingposition.

I4.1 E x a m p l eC O zW e l d i n gC o n d i t i o n s

(1) ExampleWeldingConditions
of Horizontal
Fillet

Plate Leg Wire Welding Arc Welding CO2 gas


thickness length diameter current voltage speeo flow rate
t (mm) l ( m m ) (mm r/r) (A) (v) (cm/min) (f/min)
1 2 2 5 3 0 0.9 0 '1 70 100 1B 19 50 60 10 15
LO 2.5 3 0 0 9 1 2 90 120 18 20 50 60 10 15
20 3.0 0 9 1 2 100 130 19 20 50 60 15 20
2.3 ? n3.5 0 . 9 1 2 120 140 19 21 50 60 15 20
30 40 09 12 13 0 1 7 0 19 21 45 55 15 20
A E .
4.0 1 2 190 230 zz z4 45 55 15 20
o.u 50 60 1 2 250 280 zo zv 40 50 15 20
LU 6.0 70 1 2 280 300 29 32 35 40 lc zv
12.0 70 80 1.2 300 340 32 34 ?n ?6 20 25

(2) ExampleWeldingConditrons
of DownFillet

Plate Leg Wire Welding Arc Welding UU2 gas


thickness length drameter current voltage speeo flow rate
t (mm) | (mm) (mmo) (A) (v) (cm/min) (t/min)
1 2 2.5 30 0 . 9 ,1 . 0 70 100 18 19 50 60 10 15
LO 25 30 0.9 1.2 90 120 18 20 50 60 10 15
2.U 30 35 1.0 12 100 130 19 20 50 60 15 20
2.3 30 35 1.0 1Z 120 140 21
19 50 60 15 20
3.2 3.0 4.0 1 0 1 2 1 3 0 1 7 0 20 22 45 55 15 20
4 5 4.0 4.5 1.2 200 250 23 26 45 55 15 20
60 50 60 1 2 280 300 29 32 40 50 1 5 2 0
9.U o.u 8 0 1 2 300 350 32 34 40 45 15 20
120 1 00 1 2 . 0 1.2 320 350 25 35 20 25
( continued)
9 . WE L D IN GP R E PARATION
of I ShapeButtwithoutBackingPlate
(3) ExampleWeldingConditions

,9..

. f i\ , .
/L-_+_}.4 \ l l l | /

Plate Root Wire Welding Arc Welding Uu2 gas Number


thickness gap diameter current voltage flow rate of
t (mm) g (mm) ( m m , ' ). , (A) (v) (cm/min) (Umin) layers
1.2 0 . 9 ,1 0 70 80 17 18 45 55 10
,18 1 9
t o 0 n o 1 0 B0 '100 45 55 10 15
2.0 0 . 9 .1 0 '10 19 20 50 55 10 15 1
0 0.5 100 1
23 05 1.0 0.9 12 1 1 0 130 19 20 50 55 10 15 1
32 1.0 l z 09 1.2 130 150 21
I Y 40 50 10 IJ
4.5 1 2 t.z 1 5 0 170 21 2 3 40 50 10 15
=ront1
60 1 2 1.5 1.2 220 260 24 26 40 50 15 20 2
Back 1
F r o n t1
90 12 1.5 1.2 320 340 32 34 45 55 1 5 20 2
tsack1

(4) x a m p l e W e l d i n g C o n d t t l o n so t S l i n o DoubleGroov
Plal Wire Welding Arc Welding uu2 gdr Number
Root Root
thickness Bevel gap 1^^^
tdug diameter current voltage speeo flow rate of
t shape
g (mm) h ( m m ) ( m m , '), (A) (v) (cm/min) ( U m i n ) rayers
(mm)
300 350 32 35 30 40 20 25 Front
' l )

12 300 350 32 35 45 50 20 2 5 B a c k
60' 380 420 32 35 35 50 20 2 5 Fronl
\--7 LO
t{-\ /- 380 420 32 35 45 50 20 25 Back
I li )f'-'i 0 05 4 6
Ll---Jl ln
300 350 32 35 30 40 20 25 Fronl
1 2
300 350 32 35 45 50 20 25 Back
16
380 420 32 35 35 50 20 25 F r o n t Z
t.o
380 420 32 35 45 50 20 25 B a c k
300 350 32 35 30 35 20 25 F r o n t
1 2
16 300 350 32 35 30 35 20 25 Back
4 6
380 420 36 39 35 40 20 25 Front
380 420 36 39 35 40 20 25 Back
400 450 36 42 25 30 20 25 Front
0
400 450 36 42 ZJ JU 20 25 Back
19 1 6
400 420 Jt) JV 40 4 5 20 25 1 F
5 7
400 420 39 42 30 35 20 25 2 B
400 424 36 39 40 45 20 25 1 F 4
25 400 450 39 42 ?n ?A 2A 25 a tJ
L WELDING (continued)
PREPARATION
ExampleWeldingConditions
of Lap Fillet
A

f-"F--=,
Plate Wire Welding Welding Welding UU2 gas
Mark
Thicknessdrameter current voltage speed flow rate
position
t ( m m ) ( m m , 1) , (A) (v) (cm/mrn) (Umtn)
1 2 0 9 1 0 80 100 18 19 AA EA A 10 15
1 6 0 9 1 2 1 0 0 120 18 20 AA AA A 10 15
2 0 1 0 1 . 2 100 130 18 20 45 55 AorB 15 20
23 1 0 1 2 120 140 19 21 45 50 B 15 20
1 0 1 2 130 160 19 22 45 50 B 15 2A
4 5 1 2 150 200 zl z4 40 45 B 1 5 20

9 4 2 ExampleWeldingConditions
of Wire COzwith Flux

(1)Example
WeldingConditrons
of Horizontal
Fillet

tlt l
rl_b--t
-____+l_t-

-Weldrng
Leg Wirediameter I WetOing
current Arc voltage
] length (mm) (A) (v) (cm/min)
L l!rr) l - 1 2 zso
i I | 50
l 4 f t t l -3 3 o 100
I l l.6 350 1 31
i |r l
1 l. 2 - - .
2.7 0 - .
I ,
2. e -: 5 0
r tr | 14 330 30 YU
-.+ -

t_ I 16 I _!10_ | 33
I I
tz _ _ I _
270 | 2e
6 1.4 330 i 31
t '16 i l

I I . . . - - '|
- - . . i - z380
ln i
I
34
i li- i122 280 li 3 00
3
7 14 i ASO I 32
e-

16 380 34
f-----
1 2 300
1 B 1 4
I
j 4 2
l l l
i 6 - < t
i v 1..+
i r 1 6
i _ _ _ _ . _ l
( continued)
9 . WE L D IN GP R E PARATION
I4.2 of MAG ShortArc
ExampleWeldingConditions

gas of Ar + COz
A S : IMixture
Material.Softsteel,Gas: VIIX 2 t(10
l u 15 {/min)n
Ptate Wire drameter Gap weldrng Arc voltage Welding
Joint thickne (mmd) (mm) current (A) (v) speeo
Geometry (cm/min)
t (mm)
1.0 0.8 10 0 50 55 1 3 '15 40 5 5
1.2 08 1.0 t l
60 70 14 16 30 5 0
1 6 0.8 1.0 100 1 1 0 16 17 40 60
Butt
z.J 10 1.2 0 1.0 110-120 17 18 30 40
32 10 1.2 1 0 1 6 120-140 17 19 25 JU
4.0 10 1.2 1.520 15 0 - 17 0 18 21 25 40

I 4 4 ExampleWeldingConditionsof PulseMAG

(1) Example
xa Welding of Honz
I n g Conditions
tronsot FilletWeld
Horizontal
Plate Leg Aim angle Number Welding Welding Welding
thickness length and of current voltage speed
(mm) position layers (A) (v) (cm/min)
(mm)

3-4 1 150 26-27 60


4.5 1 170 26-27 40

60 60 1 200 27-28 40
Focushere
Angle.of advance

80 BO 1 250 29-30 35

1 180-200 a E a - 7 45
120 1 00 2 180-200 . E ' Q 45
J 1 8 0 - 2 0 0 25-28 45

1 220-230 25-28 45
16.0 120 Z 220-230 25-28 45
210-230 25-28 45

( 2 )Exampleweldrnguondrtrons waro Weldinq


of Downward
o
Conditions
Plate Snapeor Weldrng Welding Welding
thicknesslointweld currenl voltage speeo Remarks
t (mm) (A) (v) (cm/min)
2.3 butt 100 22-23 70 Backbeadappearance is good
Leglengt4h -: 5 m m ,
fillet 100 z t-zz 70
Throatdepth:2 5mm
( continued)
9 . WE LDINGPREPARATION
( 3 )ExampleWeldingConditions
of Upward
Plate Welding Welding
thickness Shapeof jointweld current voltage Remarks
t (mm) (A) (v)
Weaving
12
Stooat bothendr 1 0 0 -'11 0 20-21 L e g l e n g t h1: 0 O m m

(4) BothSideWeldingConditions
of (Semi-automatic)
Plate NumDeroI Welding Welding Welding
thickness Grooveshape rayers current voltage speeo
(mm) (A) (v) (mm/min)

1 170 25-26 JU
60
z 180 26-27 30

1 270 29-30 30
90
.)
290 30-31 30

v60Y
1 280 30-31 40
120
2 330 JJ-J+ 40

A60'A
Y- 60' -/
Front1 300 31-32 45
Front 2 300 J I-JZ

1 90 Rear1 340 JZ-JJ 45


Rear2 280 30-31 45
3* sl'A

\.e 60' r/ Front1 300 31-32 45


Front2 320 JZ-JJ 45
Front3 320 32-33 45
25.0 Rear1 340 JZ-JJ 45
Rear2 320 JZ-35 45
14* ,th
Rear3 320 32-33 45
60-
( continued)
9 . WE L D IN GP R E PARATION
/ 6 \ t rxam Conditions
t l t o n sof Sinqle
l e sSide itions(Automatic
r d eWeldinqConditions d

P l aIE Numbeo rf Weldrng Welding Welding


thickness Grooveshape layers current voltage speeo
T (mm) (A) (v) (cm/min)

i_ ___JL_
r r
_- _ t
t
3.2 140 a A atr
50
'lF-
{,, r ,l

130 23-24 25
o.u
150 25-26 IJ

180 aA aE
25
120
290 30-32 25
-+ F- rl l:r

\f, .15 -r

1 18 0 - 19 0 25
120 2 200 25-26 25
3 200 26-27 z3

1 180 .A 'E
25
1 90 2 300 29-30 25
? 300 29-30 25

width 2 mm
Oscillation
times 'l20times/min
Oscrllatron
( continued)
9 . WE LDINGPREPARATION
(6) SingleBevelGroovePenetration
WeldingConditions (Semi-automatic)
N u m b eo
rf Weldrng Welding
Grooveshape rayers current voltage Remark
(A) (v)
t posrtron 1 100 20-21
45
2 280 26-27
280 26-27
f;
Oscillatron
5
4 280 26-27
j i
5 280 26-27
2
n 280 26-27
U n i t .m m
3 2 7 280 26-27
po
Vertrc-at 1 100 20-21
130 z t-zz
a4 a.)
130
4 130 21-22 Oscillatinn
6 IJU 21-22
6 120 19-20
Unit

1 100-200 20-22
t 200 .A 'E

'' /Q 4
200
200
24:2
24:Z

L ,l]'Jil
t _;r'
.,r? 7
8
5
o
200
200
200
200
24-25
24:2
24:2
24-25
No
oscillation

3 2 \ I 180 24-25
32 10 180 24-25
1 U n r tm m
11 180 24-25
4 -
tz 180 4-25
Wire diameter. 1.2 rfln1rJ. Gas 20o/oCO, + Ar
9. WELDINGPREPARATION(continued)

9.4.5ExampleWeldingC o n d i t i o nosf A l u m i n u mP u l s eM I G

( 1 )ExampleWeldinqConditions of I S utt
Plate Wire dia Welding Welding Welding Wire Gas flow
thickness (mm) current voltage speed extensron rate
(mm) (A) (v) (cm/min) (mm) (l/min)
LC 1 2 60-80 16-18 60-80 12-15 20
2.0 1 2 70-80 1 7- 1 8 40-50 15 20
30 1.2 B0-100 17-18 40-50 15 20
40 1.2 90-120 18-21 40-50 14 20
6.0 1 2 . 1 . 6 15 0 - 18 0 ZU-ZJ 40-50 15-'18 20

( 2 ) Exam Fillet
of Horizontal
Conditions
Plate Wire dia Welding Welding Welding Wire Gas flow
thickness (mm) current voltage speeo extension rate
(mm) (A) (v) $m{ryn) (mm) (t/min)
1.5 4. ) 60-80 16-18 60 15-20
3.0 1 2 100-120 19-21 60 t3 15-20
60 1 2 ,1 . 6 15 0 - 18 0 20-23 50-60 20

of AluminumMIG
9 4 6 ExamoleShortWeldinqConditions

(1) tExample
xample S h o r t Welding
Short Cq@!!!e!!
W e l d r n qU !lt L9hape
o n dI t t o n so I Snaoe bryu t t
Plate Wire dia Welding Welding Welding Wire Gas flow
thickness (mm) current voltage speeo
J extensron rate
(mm) (A) cm/mrn mm
? n 1 2 120-140 20-22 60-!q
40 1 2 15 0 - 17 0 aa al
ZZ-Z+ 6o:qq
60 1 6 ' 1 8 0 - 2 1 0 zJ-zc 40-60 17-20 20-25

( 2 ) txamole ShortWeldrnoUon(itionsof Hr) nzontal Fillet


Plate Wire dia Welding Welding Welding Wire Gas flow
thickness (mm) current vorrage speeo extensron rate
(mm) (A) (v) (cm/min (mm) (t/min)
30 1 2 140-160 21-22 I 0o-ZO 15 15-20
40 1 2 1 5 0 - ' 1 7 0 22-24 50-60 15-18 15-20
o.u
'1.6 200-230 23-25 50-65 17-20 zu-t3
1 0 .O P E R A T I O N
10 FrontPanel

1211t201
[1e] I4l telt10l

[ 17 ] t 1 B[ l11 ] t7l t12lt3l [14] l2l [16] t1l


[1]WELDING M E T H O Dk e y [ 9 ] A R CC O N T R O Lk e y l l T l G A S C H E C Kk e v
[2] WIRE/GAS selectorkeys [ 1 0 ] W A V EP U L S Ek e y( o p t i o n a l ) 1 8 1I N C H I N G
key
3 l W | R ED I A( m m )k e y 1 1 1S P O TT I M Ek e y 191LOADkey
4l A/m/minselectorkey [ 1 2 ]F ( F U N C T I o N
k e) y [20lSAVEkev
5lV/t selectorkey [ 1 3 ]l N l T l A LC U R R .k e y [ 2 1 ]E N T E R
key
[6] Parameteradiustingknob [ 1 4 ] V O L TC . O N T R O Lk e y
[7] CRATER-FILL key t15l CONSTANTPENETRATION kev
l'81DISPLAYCHANGEkev [16]TORCH key
1 0 OP E R A TION( continued)

! CAUTION
O This welding machineshould be operatedby personsonly after readingand understandingi
contentsof this owner's manualand having knowledgeand skills for handlingthe welding I
machinesafely. I
O Use this welding power source at or under the rated duty cycle. Exceedingthe rated duty i
cycle limitationmay result in damageto the welding machine. _ |

When readingthe operatinginstructions describedbelow,unfoldPage 76 so that you can read them


confirmingthe locationof the keyson the frontpanel
'101 BasicSettings

10.1.1 Settingof WeldingMode


Choosethe weldingmodeusingthe WELDINGMETHODkey[1],the WIRE/GASselector
keys[2],the WIRE DIA (mm) key [3] the in accordwiththe weldingmethodand wirediameter
weldingmodesare shownon the nextpage
used, The selectable

When settingthe weldingmode,selectthe weldingmethodusingthe WELDINGMETHOD


wirediameters
key [1] first Oncethe weldingmethodis set the available are automatically
decidedaccording to the weldingmethod.Then,selectwire/gasusingthe WIRE/GASselector
keys[2].Finally,set the wirediameterwiththe WIRE DIA (mm)key [3].
"WAVEPULSE"whilesetting"DC HARDSOLID
For example,for DP-400,whenselecting
" M I L DS T E E LS O L I DC O z "l a m pb l i n k s ,
C O 2d 1 . 0" w i t ht h e W E L D I N GM E T H O Dk e y[ 1 ] t h e
whichmeansthe presetcombination is incorrect.In thatcase,selectmaterialand gas again
usingthe WIRE/GASselectorkeys[2] or resetthe weldingmethodusingthe WELDING
METHODkey [1].Selecting the propercombination of materialand gas can canceltheerror
and activatethe weldingpowersource
"---"and"---"
Wrongcombination of weldingmodeand wirediameterwillcause in the displays
to blink,the LED lamps to light,and the welding power source to stop

tableshowsthe selections
The following of wirediameterfor settingcurrentat alumtnum
welding Referto the tablefor selectinga wire

I
I
| ' ! 1 ?
AI /PUilF r S a r F Tt I
T
I
I l'tr r {i

*.r,',t.,,,,.,,,, O

NOTE:
o The data shown above differ dependingon actualwelding conditionssuch as
welding rate and welding position,etc.
o Observethe maximumcurrent and the ratedduty cycle.Optionalaccessoriesare
necessaryfor some combinations of a torch and a wire feeder.
10. OPERATION( continued)

Tableof the WeldinqMode


Weldrngmode WIRE
DP-400
Weldinomethod Tvpe of wire D I A( i r )

09
M I L DS T E E L
DC
I SOLID
l

i
--1
I

I
I

MAG 10
(80%Ar+20%COz)

M I L DS T E E L MAG
DC PULSE (80%Ar+20%COz)
SOLID

STAINLESS MIG
STEEL (99o/oAr+2ohOz)
SOLID
I

STAINLESS MIG
DCpulse STEEL (98okAr+2o/oOz)
SOLID

M I L DS T E E L
COz
CORED
DC
CO, o
.
DC o
LO
-12
MIG
DCPULSE (Ar) LO
na
WAVE PULSE

AL/MG MIG
DCPULSE (HARD (Ar)
ALUMTNUM)
I
i
u w
WAVE PULSE

supported - : Not supported


O: Supported o : Optionally
10 . OP E R ATION( continued)

10.1.2 Settingthe Parameter

Pressingthe key whilethe A/m/minlamp (located Pressingthe key while the V/t lamp (locatedat the
at the upper left of the A/m/minselectorkey) is lit upper left of the V/+ selectorkey) is lit changes over
changesover displaysof currentsettingand wire displaysof currentsettingand wire feed rate. Pressing
feed rate Pressing the fum/min selector key the V/t selectorkey whilethe V/t lamp is not lit causes
while the A/m/min lamp is not lit causes the the V/t lamp to light While the V/t lamp is lit, current
A/m/minlampto light Whilethe tum/minlamp is can be adlustedusingthe parameter adlustingknob[6]
lit, currentcan be adjustedusing the parameter
adjustingknob[6]

Selecta parameterusingthis key

selector]
IParameter

Choosea desiredparameterusrngthe DISPLAYCHANGEkey [8] Drsplayrnthe


to the parameters
displaysare changedaccording you selectand the UNITlampof
the parameterlightsup
U N I Tl a m p s

DigitalMeter

displays]
IParameter

When the wire feed speedis displayedyou can not set to the maximumfeed speed
usingthe parameter adjustingknob[6] depending on the weldingmodesettings
(especiallyfor largediameter)You are only allowedto set the wire feed rateto the
valuethat can achievethe currentsettingdeterminedby the ratedoutputcurrent

The valuesshownin the displaysare not the actualdata but the settingvaluesof
voltage,current,and wire feed speed.Use the valuesin the displaysas approximates
10. OPERATION( continued)
10.1.2 Settingthe Parameter (continued)
(1) Pre-flowTime Setting
Oncethe pre-flowtime is chosen,the settingvalueis displayedin the leftdisplayand the
"sec."lamplights At thiscondition,you can set pre-flowtimewhileturningthe parameter
adlustingknob [6]. The settingrangeof pre-flowtime covers0 secondto 10 seconds

(2) Settingof the InitialConditions


The initialconditions can be chosenonlywhen initialcurrentis set to ON. Oncethe initial
conditions are chosen,the settingvaluesof initialconditions
are displayed in the displays.

(3) Settingof the MainConditions


Oncethe mainconditions are chosen,the settingvaluesof the mainconditions
are
displayed in the displays

(4) Settingof the CraterConditions


Onlyfor ON (-) or ON (nn) the craterconditions
can be selectedOncecraterconditions
are chosen,the settingvaluesof the craterconditions
are displayed
in the display.

(5) Settingof the Post-flowTime


Oncethe post-flow time is selected,
the settingvalueis displayedin the rightdisplayand
"sec."lamplights At
the up thisconditions,the postflowtimecan be set whileturningthe
parameterad.yusting knob [6] The settingrangeof post-flowtime covers0 secondto 10
seconds
1 0 . OP E R A TION( continued)

1 0 . 1 . 3S e t t i n go f t h e C R A T E R - F I LFLu n c t i o n s

Crateris a depressionleft at the


terminationof the weld As it may cause
cracksand poorweldinga cratertreatment
ts usedto fillrnthe
calledcrater-filler
oeoressron.

NOTE:When "DC" welding method is selected,you can not set to ON(-).


When treatinga crater,set to "ON(-)"or "ON( n-n)""

keyto "ON(-)"or "ON(nn1'


In the eventthatcraterfill is carriedout set the CRATER-FILL

Eachpressof the CRATER-FILL modein order


key [7] changesthe crater-fill

"OFF' + "ON (-)" -; "ON (m)" + "SPOT"

Trmrng
Chart

I l o F F
Torch Switch Pre-flowtrme
I
GasFlow
_Post-flowtrme

W e l d r n gV o l t a g e

W e l d i n gC u r r e n l

o Keepthe torchswrtchpressedanOnetOduringwetOing
10 . OPERATION( continued)

TimrngChart

ON ON

TorchSwitch
l l o F F l l o F F
. -Pre-flowtrme A n t r - s t r c( kB u r n b a c kt i)m e

GasFlow
P o s t - f l o wt i m e
Voltage Between
Slow-downspeed
OFF O u t p uT
t ermrnals
ON
W e l d r n gC u r r e n t
Wire feedpe
lllF)
Welding
or

ON
lllf0It) ON ON

Torch Switch
l l o F F l l o F F
, "Pre-flowtime A n t i - s t i c(kB u r n b a c kt i)m eI

Gas Flow
Post-flowtime
Voltage Between
O u t p uT
t erminals

ON
Wire feed speed

t-
o Evenif the torchswitchrs switchedoff durtngweldingstartsignalwrllbe self-hold
The torchswitchshouldbe keptpressedand helddurrngthe lNlTlALand CRATER
times
o Evenif the CONSTANTPENETRATION switchis set to "ON"durinothe CRATER
time,constantpenetration willnot be carriedout
o Settrngthe CRATER-FILL "ON( "ON(-)" "DC
key [7]to nn)" or afterselecting PUSLE"
"DC
or WAVE PULSE".pulseweldingis performedduringthe CRATERtime
r Whenselectrng "ON(-)
. no-pulseweldingis performed duringthe CRATERtime
of the settingsof the weldingmethod.
regardless
o Weldingmethodat the lNlTlALtime is the sameas thatat the MAINWELDING
10 . OP E R A TION( continued)

10.1.4
Settingof ArcSpotTime t Ut I
Whenarc spottreatmentis carriedout usingthe CRATER-FILL key [7],set to "SPOT" Then,
when pressingthe SPOTTIME key [11] the SPOTTIME lamp(locatedat the upperleftof
the CRATER-FILL key)lightsup the settingvalueis displayed in the rrghtdisplaythenthe
"sec."lamplights the ARC SPOTtimecan be set whileturningthe
up. At thatcondition,
parameter adjustingknob[6].The ARC SPOTtime between0 1 secondand 10 secondscan
be set Press the SPOTTIME keyagainor pressthe DISPLAYCHANGEkey [8] to returnto
the last parameteritem lt is also possibleto changethe displayto a current-related
parameterusingthe A/m/minselectorkey [a] and to a voltage-related parameterusingthe
V/+ selectorkey [5]

The SPOTTIME keyfunctionsonlyduringArc Spottime

Torch Switch

I
I
I
_->iI
I
ARC SPOT time-
i<_
I
I

W e l d i n gC u r r e n t
OutputCurrent

o Keepthe torchswitchpressedand heldduringthe Arc Spottime

NOTE:When the welding machineis in the ARC SPOTmode,the penetrationcontrol


"SPOT" while the
does not function.When settingthe CATER-FILLfunction to
CONSTANTPENETRATION function is "ON", the setting of the CONSTANT
PENETRATION function is automaticallychangedto "OFF".
10. OPERATION( continued)

10 1.5AdjustingWeldingVoltage
Usingthe VOLT.CONTROLkey [14]allowsyou to selectone of the following
voltage
adjustmentmethods

(1)Makingthe INDIVIDUAL Adjustment


The INDIVIDUAL adjustmentcan be achievedwhenthe VOLTCONTROLlamp(locatedat
the upperleftof the VOLT CONTROLkey [1a])is off. In the caseof the INDIVIDUAL
adjustment, weldingcurrentand weldingvoltagemustbe adjustedindividually.Whenyou want
to set weldingvoltagemakesurethatthe VOLT.CONTROLlampis lit,thenadjustthe
weldingvoltagewhileturningthe parameter knob[6] Whenyou wantto set welding
ad.lusting
voltage,makesurethatthe VOLT CONTROLlampis lit,thenset weldingvoltagewhile
turningthe parameter adlustingknob[6]

NOTE:When selectingHARDALMINUMor SOFTALUMINUM,the INDIVIDUAL


adjustmentcan not be achieved.The SYNERGIGadjustmentfunction is automatically
activated.

( 2 ) M a k i ntgh e S Y N E R G I C
Adjustment
The SYNERGICadjustment can be achievedwhenthe VOLT CONTROLlamp(locatedat the
upperleftof VOLT CONTROLkey [1a])is on For the SYNERGICadjustment, the proper
weldingcurrentfor the currentsettingis automatically set.Whenthe VOLT CONTROLlamp
is lit,weldingvoltagecan be finelyadjustedusingthe parameter adjustingknob[6] ln addition
it is also possible to changeoverthe displaysetting tn the right
displayusingthe V/+ selector
key [5] The selectable displaysettingsare the INDIVIDUAL mode (V) and the SYNERGIC
mode(t adlustment)In the SYNERGICdisplaymode,the standardvalueis 0 The setttng
rangeof weldrngvoltagers 0 to t30 .

NOTE:Use of mixturegas other than the mixture ratio of the following gas may not
properlyadjust welding voltageat Synergiccontrol,etc.

o Carbondioxidegas (CO2gas)
Forwelding(purity99.9%or more,moisturecontent0.002%or less)
o MAG gas
80% argon(Ar) + 29"1o
carbondioxidegas (CO2gas)
. MIG gas for stainlesssteel
98% argon(Ar) + 2o7" oxygen(O2)
o M I Gg a sf o r A l u m i n u m
Pureargon(Ar)
1 0 OP E R A TION( continued)

1 0 . 16 CONSTANT P E N E T R A T I OFNu n c t i o n
For conventional COz/MAGwelding.as the wireextension changesweldingcurrent
changesand basemetalpenetratron depthand beadwrdthchange.By settrngthe constant
penetration functronto "ON wrrefeedspeedrs automatrcally adlustedso thatconstant
currentcan be alwaysobtarned evenwhenwrreextension varies As a result effectsof
reducrng changein penetration depthand in beadwidthof the basemetalare ableto be
obtainedWhen penetration depthrs partrcularly heldconstant,set the CONSTANT
P E N E T R A T I OfN P E N E T R A T I OkNe y[ 1 5 ]
u n c t i o tno O N " u s i n gt h e C O N S T A N T

Penetratron controlON/OFFselection can be doneby usingthe CONSTANT


P F N E IR A T I O Nk e y[ 1 5 ] W h e ns e t t r n tgh e C O N S T A N T P E N E T R A T I OfN u n c t t o tno O N
the CONSTANTPENETRATION lamp(locatedat the upperleftof the CONSTANT
P E N E T R A T I OkNe y )l i g h t su p W h e ns e t t r n tgh e C O N S T A N T P E N E T R A T I OfN u n c t i o tnc r
O F F t h eC O N S T A N T P E N E T R A T I OlN a m pg o e so u t S e tt h e C O N S T A N T
PENETRATION functionto ON to holdconstantpenetratron depthby ustngthe
CONSTANT P E N E T R A T I OkNe y[ 1 5 ] r h e C O N S T A N T P E N E T R A T I OfN u n c t t o tns
a c t i v a t eodn l yd u r i n gt h e l N l T l A La n d M A I Nw e l d r n tgr m e sl t d o e sn o t f u n c t i odnu r t n gt h e
CRATERtrme

NOTE:The CONSTANTPENETRATION function is not availablein the combination


of the followingwelding conditions,and the CONSTANTPENETRATION function is
automaticallyset to "OFF".
o S P O TT I M E' O N s e t t i n g
O S e l e c t i oonf A L / P U R E( S O F T )o r A L / M G( H A R D )

10 1 7 Arc Characteristics Function


When p r e s s i n t h eA R C C O N T R O Lk e y[ 9 ] w h r l et h e l N l T l A LC O N D I T I O NM, A I N
g
C O N D I T I O No r C R A T E R - F I LCLO N D I T I O N r s s e l e c t e tdh eA R C C O N T R O Ll a m p( l o c a t e d
at the upperleftof the ARC CONTROLkey [9])lrghtsup the settingvalueis displayed tn the
rightdisplay,and the V/i lamplrghtsup At thatcondrtrontt rs posstbletc sei arc
characteristrcs by usrngthe parameter adjustrng knob[6j The setttngrangers 0 to t'10
k e y
P r e s s i ntgh eA R C C O N T R O L [ 9 ]a g a i n o r p r e s s i n tgh e D I S P L A YC H A N G Ek e y[ 8 ]
returnsto the previous parameter settrngIn additronrt is also posstble to changeoverthe
displayto a current-related parameterby usrngthe A/m/minselectorkey [3] and to a voltage-
relatedparameter by ustngthe V/t selectorkey [4]

The standardsettingvalueof arc characteristrc rs C As the settrngvalueof the arc


characteristicis set rnttrenegativedrrection (rrptc -10) arc conditionbecomeshardei-A.s
the settingvalueof the arc characteristicis set rnthe positivedtrecttonarc conditton
becomessofter (up to 10) When you use the weldrngpowersourceIn the low currentrange
set the settingvalueof the arc characterrstrcrn the posrtivedirecttonto obtarngoodweldtng
resultsWhenyou use the weldrngmachinernthe hrghcurrentrange set the setttngvalueof
the arc characteristrc rnthe positivedirectionto obtaingoodweldingresultslf youcan not
obtainoptimumarc condition due to use of the extension cables set the setttngvalueof the
arc characteristicin the neqativedtrection
10. OPERATION( continued)

10 1 8 WAVE PULSEFunction(optronal)
In wavepulsewelding,the npplebeadappearance is changedby applyingtwo separate
pulsescyclically
at lowfrequencyThisfeaturewrllalsoassistin weldrnglorntsthathave
somepoorfit up or gaps Although, the wavemodeis usuallymostapplicable for fully
automaticweldrng, benefrtsare alsoachievedevenin semi-automaticapp[cationsGood
beadappearances are obtainedby settingthe wavefrequencyto 5Hzor moreevenfor
semi-automatrc

Whensettingwavepulsefrequency, "DC WAVE PULSE"


select withthe WELDING
M E T H O Dk e y[ 1 ] N o r m a l l yt h eW E L D I N GM E T H O Dk e yd o e sn o tf u n c t i o d
n u r i n gp u l s e
weldtng e e l d r n gW h e nt h e W A V EP U L S Ek e yi s p r e s s e d
o r n o - p u l sw whrle'lNlTlAL
C O N D I T I O N '' M
/ A I NC O N D I T I O N""C /
RATER-FILL
C O N D I T I O Ni s" s e l e c t e dt h eW A V E
PULSElamp(locatedat the upperleftof the WAVE PULSEkey)lightsup the settingvalue
appearsrnthe leftdrsplaythe "Hz" LED lamplightsup. Undertheseconditions. wavepulse
frequency can be adlustedwhileturningthe parameteradlustingknob The settrngrangeof
wavepulsefrequencyrs 0 5 Hz to 32 Hz.Ad.lust wavepulsefrequencyuntilyou can obtarn
the desiredbeadappearance

When pressingthe WAVE PULSEkeyor DISPLAYCHANGEkeyagain returnto the last


parameter thatyou haveset When changingthe displayto a current-relatedparameter
pressthe tum/minselectorkey [ ] When changingthe displayto a volt-related
parameter,
pressthe V/t selectorkey [5].

lowfrequency

highfrequency

NOTE:
o Wave patternof the welding bead varies dependingon the heat input during
welding.
o When using annealedwire, bead surface may blackensomewhatif shorting occurs
frequentlyduring the welding operation.

.10 (withgas savefunction)


1 9 GAS CHECK f Functron
Thisfunctionis usedwhenopeningthe discharge valveof the shieldgas and whenadjustrng
the g a sf l o wr a t e W h e np r e s s i n tgh e G A S C H E C Kk e y[ 1 7 ] o n c et,h e G A S C H E C Kl a m p
(locatedat the upperleftof the GAS CHECKkey)lightsup and allowsgas to flow Pressing
the GAS CHECKkeyagarnturnsoff the GAS CHECKlampand stopsdischarging gas In
morethantwo minutesafterthe GAS CHECKkey rs pressed,gas drscharge automatically
stopsand the GAS CHECKlampgoesout In the eventthatthe machineis startedwhrlegas
ts berngchecked.gas stopsflowingafterweldingis completed(uponcompletion of post-flow)
and gas doesnot continueto flowdunngdownperiod.

olo frn"tion
101 10INCHING
W h e n p r e s s i n g t h e l N C H | N G k e yt h[ 1e8l N
] CH|NGlamp(locatedattheupperleftofthe
INCHINGkey)lightsup and beginsfeedrngwire Releasing the key stopswirefeedingand
causesthe INCHINGlampto go out When changrng the wirefeedrateby turnrngthe
parameter adjustingknob[6].makesurethatthe INCHINGlamplightsup When connecting
to the analogremotecontrol(optronally available). the INCHINGkeyon the frontpanelcan
not be usedfor inchingoperationWhen connecting to the analogremotecontrol,usethe
inchinoswitchon the remotecontrolto activatethe INCHINGfunction
10 . OP E R ATION( continued)

1 0 ' 111 TORCHWATER/AIRSelection


SelectWATER/AIRaccording to yourtorchby usingthe TORCHkey [16].When usinga
"WATER" pressing
water-cooledtorch,select by the TORCH key once When "WATER' is
the TORCHlamp(locatedat the upperleftof the TORCHkey)lightsup When
selected,
torch,makesurethatthe TOCH lampgoesout.When lackof water
usingan air-cooling
pressureand no waterflowoccurwhile "WATER"is selected, the WARNINGlamplightsup

1 0 . 112 Verifying
the Parameters in the Displays
The displayson the frontpanelprovidesthe followingfunctions.
1 Displayof ParameterSettingValue
When settingto "parameter settingvaluesdisplay"modeduringdownperiod(excluding
the resultdisplayperiodrightafterthe completion of welding)and duringwelding,values
of parameters underadlustment are displayed.

2. Displayof OutputCurrentDuringWelding
The parameters shownin the displaysautomatically changeto averagevaluesof output
currentand outputvoltageaccording to the outputconditionseveryabout0 5 second
The displayaccuracyis Class2.5 or equivalent and is the sameas thatof a general
needletypemeter Whenyouwantto changethe parameters duringweldingswitchto
"parameter
the settingvaluesdisplay modeby usingthe DISPLAYCHANGEkey [8]
When no weldingoperationis not carriedout for about5 secondsor the DISPLAY
CHANGEkey [8] is helddown,the displaymodeautomatically returnsto the "average
parameter settingvaluesdisplay"mode.Whenthe TORCHkey is pressedthe LED
lampsof the sequenceparameters go on sequentially accordingto the welding
operations. Whenthe displaysettingis switchedto the "parameter settingvaluesdisplay"
mode,each LED lamps(locatedat the sequenceparametersettingsection)of the
"Using
sequencethat is currentlyoutputting
beginblinkingRefertoSection10 1 13 the
ParameterAdlustingKnob"for the parameters that can be adlustedusingthe parameter
adjustingknob[6] duringwelding

3. Displayof WeldingResultsafterCompletion of Welding


Uponcompletion of weldingthe averageoutputcurrentand voltagefor lastone second
blinkfor about20 seconds(however, of craterfillare ignored).
the outputconditions
Therefore,the operatorscan verifythe weldingconditionsrightafterthe completionof
weldingand can usethem as approximates whenadjusting the weldingconditions. This
displayis cancelledby startingthe nextweldingor by pressingany keyon the front
panelwithoutwaiting20 secondsafterthe completion of weldrngThe resultdisplaytime
can be presettoF8 by usingthe F key [12] The settingvalueis displayed in the left
digitaland the "sec"lamplightsup.The settingrangeof the resultdisplaytime is 5
secondsto 60 seconds

NOTE:In the case where the less than one-secondwelding such as tack welding,
etc. is performed,the correct results of the welding are not displayed.

4. Displayof ErrorMessage
lf an erroris detectedin the powersourceof electricwelding,an error numberindicating
errormessagesblinks.See Section11.1 "Troubleshooting".

NOTE:The averageoutputvaluesshownin the displaysare processedby


softwareand are not guaranteedas controldataof measuringinstruments.
Displayaccuracy: Class2.5or equivalent).
10. OPERATION( continued)
' 1 0 ' l1 3 Usingthe Parameter AdjustingKnob
Whenadjustingparameters usingthe parameter adjustingknob[6] duringweldingchange
overthe displaymodeto the "parameter settingvaluedisplay"modeby pressingthe
DISPLAYCHANGEkey [8]. The initialconditions, the mainconditions,and the fillcrater
conditionscan be changedduringthe lNlTlALwelding,MAINweldingand CRATER
weldingrespectivelyPressingthe ARC CONTROLkey [9] afterchangingto the
"parameter
the pulsearc characteristicsPressingthe
settingvaluedisplay"mode ad.yusts
WAVE PULSEkey adjuststhe wavefrequencyln the "averageparameter valuedisplay"
mode,you can not adjustthe parameter.

1 0 1 1 4 Usingthe AnalogRemoteControlK5416H(optional accessory)


The weldingmachineautomatically recognizes the analogremotecontrolwhenthe power
switchis turnedon When the analogremotecontrolis connectedto the weldingpower
source,the analogremotecontrolis recognizedfirst Therefore,evenwhen selecting
weldingcurrenUvoltage the weldingcurrenUvoltage can not be adjustedby usingthe
parameter adjustingknob[6] on the frontpanel Whenthe analogremotecontrolis
connected, the parameter
ad.lust whileturningthe WELDINGCURRENTA/OLTAGE knobs
on the analogremotecontrollt is possibleto verifythe parameter settingvalueswhichare
presetwtththe analogremotecontrol,in the displaysof the frontpanel.Oncethe analog
remotecontrolis disconnected, the settingvaluespresetwith the remotecontrolare erased

NOTE:With the power switch turned off, connect or disconnectthe analogremote


control.

.-"1.1\S
..1 I
A4
,, rll'tr
o-\ 1l,.t
-A.v l l l c ll
lNCl-l N(l ,j,r..1
f i1. t fli / , \ t) ,

WELDING
CURRENT
knob
To set weldingcurrent

I N C H I N Gb u t t o n VOLTAGEknob
Pressingthis switchfeedswire only. The < INDIVIDUAL adjustment>
wire feed rate changes by turning the Set weldingvoltage.
WELDINGCURRENTknobon the left. < SYNERGICadlustment >
" "
Aligningto mark o achievesthe standard
setting.Turn the knobin the "HlGH"directionto
increasevoltageand in the "LOW" directionto
decreasevoltage.
10 . OP E RATION( continued)
1n 1 1A Usrngthe AnalogRemoteControlK54'16H accessory)
loptronal (contrnued)
o W h e nm a k i n gt h e I N D I V I D U AaLd j u s t m e n t
Selectingthe "lNDlVlDUAL" adyustment allowsyou to set weldingcurrentand welding
voltageindividually

NOTE: INDIVIDUALadjustment is actlvated when selecting AL/PURE (SOFT


A L U M I N U M )o r A L / M G ( H A R D A L U M I N U M ) I. n p u l s e w e l d i n g , e v e n w h e n t h e
INDIVIDUALadjustmentis selected,the scales on the analog remote control may
not correspondwith the actualwelding current/voltage.

o W h e nm a k r n gt h e S Y N E R G I C adlustment
When selectrng the 'SYNERGlC" adlustmentweldingvoltagers automatrcally adlusted
o n l yb y t u r n i n gt h e W E L D I N GC U R R E N Tk n o b[ 6 ] .T o f r n e l ya d l u s w
t eidrng
v o l t a g eu s e
the VOLTAGE.knob

NOTE: lt is possibleto adjust low-currentregion,where a small-diameterwire is


used for weld, and to finely adjust welding current by replacingwith the full-scale
200Aplate (supplied).To replacethe scale plate,press the F key [12] and change
the initialvalue of F9 to 200.Referto Section10.2.1(9), "Selectionof scale plate of
analog remotecontrol".
10.OPERATION( continued)

10 2 AppliedSettings

10 2 1 UsingInternalFunction
. HowTo Use InternalFunctions
I When holdrngdownthe F key [12]fora few seconds,the functionnumberin the
left-side
displayblinks and the statusof functionassignedto the function
nurnberlightsup and is displayedin the rrght-side
displayUnderthiscondition,
a functionnumbercan be presetby usingthe parameter adjustingknob[6]

The numberof functionblinks The conditrons


of functionhqhts

A functionnumOercan be presetwiththe parameter knob[6]


ad.lusting

The aboveexampleindicates "on"


that F19 is set to

When pressingthe F key [12]againafterpresetting the desiredfunctionnumber,


the functionnumberlightsand the functronconditionsblinks Underthrs
condition,functionscan be presetby usingthe parameter adjustingknob[6]

The numberof functionliohts The condition


of functionblinks

can be set whileturningthe parameter


Conditrons adjustlngknob
"off'
The aboveexamoleindicates
that F4 is set to

Pressingthe F key[12]againcausesthe functionnumberto lightup and returns


to the step To cancelthefunctionmode,holddownthe F key [12]fora few
seconos.

NOTE: ln the function mode. no confirmationof the function is carriedout


when it is changed.Upon changeof the setting by using the parameter
adjustingknob [5], the change becomesvalid. Therefore,beforechanginga
function setting,carefullycheck to make sure that the correctfunction number
is selectedand that the proper settingvalue for the function number is set.
10 . OP E R A TION( continued)

The following
weldingconditionscan be adjustedby usingthe F key [12]andthe
parameter adjustingknob[6],but only the welding conditionswith* next to the
function numberscan be presetto the welding condition numbers.

(1) FineAdjustment (Burnback)


of Anti-Stick Time:Fl*
Anti-stick(Burnback) time meansthe processingtimeto preventelectrode wire
from fusingto basemetalwhenweldingis completedAnti-stick (burnback) time
is presetto properconditions accordingto weldingmethodsand wirediametersat
shipment,but it can be finelyadjustedby activatingF1. The standardanti-stick
(burnback) time is presetto "0",timedecreasesin the negativedirectronand
increasesin the positivedirectionThe fineadjustment rangeis 0 to t50 and the
unitis 0 01 seconds.

Ex 1) When the settingvalueof anti-stick(burnback)time is 25 seconds,add


0 25 secondto the standardanti-stick(burnback)trme
Ex 2) (burnback)time
Whenthe settrngvalueof anti-stick is -10 subtract0 1
secondfromthe standardanti-stick (burnback)time

(2) FineAdjustment of Anti-stick(Burnback) VoltageF2.


Anti-stick(Burnback) voltagemeansthe voltagewhichis outputwhenprocessing
is carriedout to preventelectrodewire from fusingto base metalat the end of
welding Anti-stick (Burnback) voltageis presetto properconditions accordingto
weldingmethodsand wirediameters at shipmentbut it can be finelyadjustedby
activatingF2 The standardanti-stick (burnback) voltageis presetto "0" When
the voltageis set in the negativedirection,it decreasesWhenthe voltageis set in
the positivedirection, it increasesThe fineadlustment rangeis 0 V to t9 9V

(3) FineAdlustmentof Slow-downSpeed F3*


Slowdownspeedmeansthe speedto feed wire that is slowerthan the feed rateat
normalwelding duringthe periodfrom startupto arc start The slowdownspeedis
presetto properconditions accordingto weldingmethodsand wirediameters at
shipment,but it can be finelyadjustedby activating
F3 The standardslow-down
speedis presetto 0 Whenthe slowdownspeedis set in the negativedirection,
Whenthe slowdownspeedis set in the positivedirection,it
it decreases.
increasesThe fineadjustment rangeis 0 m/minto tl 0 m/min When poorarc
startoccurred,lowerthe slowdownspeed Evenwhen arc startis good,the slow-
down soeedcan be increasedto shortentact time.

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


10. OPERATION( continued)

( 4 ) Selectionof Auto/Semi-automatic:F4
Use thisfunctionwhencombining witha robotor an automaticmachine
Selectionof Auto allowthe weldingpowersourceto do the followingoperation.
. OperationStop can be cancelledby short-circuiting
OperationStop terminals
o Initialsettingof this functionis semi-automaticTo quit OperationStop,startup
t h e m a c h i n eu p a g a i n
o Afteranti-stick(burnback)voltagetime,the voltageto canceldepositionis
appliedfor approximately
0.2 second.

When usingthe weldingpowersourceby combininga robot etc.and inputting


weldingcurrentand weldingvoltageby utilizing
externalvoltageset to the Auto
mode
"Auto "on".
To activate mode,set F4 to

NOTE:Even when supplyingexternalsetting voltageto a remotecontrol


receptaclein the "semi-auto"mode,the values presetat the front panelare
valid. Regardlessof auto/semi-automode,when the analog remotecontrol
is connected,the values presetwith the analog remotecontrol are
recognizedfirst.

o Whenweldingcurrentand weldingvoltageare inpututilizing


externalsetting
as illustrated
voltaoe.makethe connections below

n
o
3
o
o
o
=
o
o
o
o
o
o)
o
o
C,oN2 (\Ablding Voltage) (\Ablding Current)

! CAUTTON

controlcircuitof theweldingpowersource.
'100milliseconds
O Be sure to finishsettingof and inputtingto El and E2 within befo
or at startsignalsmay resu
startingsignalsare input Inputtingafter100 milliseconds
in affectinqstart
10 . OP E R A T ION( continued)
'10VF5
(5) For externalsetttngvoltagerangesbetween0 and
automatlc
when the weldingmachinets used by combiningwrtha robotor an
when the maximum command voltage from the robot ts outputup
machineand
is p r e s e t t o o F F ' a t s hipment
t o . 1 0 V s e t F 5 u s i n gt h e F k e y [ 1 2 ] T h i sf u n c t i o n
u s t n gt h e
S e t F 5 a n d F 4 t o ' o n ' t o a c t t v a t teh ef u n c t i o n F k e y [12]

o The relatronshrpbetweencurrenuvoltage commandvoltagefromoutstdeand


weldrngcurrentand weldtngvoltageis shownas follows The weldtngcurrent
and weldrngvoltagecorrespondtng to weldingcondtttons settlngvoltagentay
tn the
drfferfromthe rndicatrons graphs due to wlreextenslon lengthand
draggrng of outputcable These graphs are onlyfor reference

,
,/ a/
,
t I
o

, a
//
' , ., IJ

, r ' ,/ : '. --
J

'. ,r, ,/
J

Vo lage comrnandvoltagetVt
C u t r e n t c o r l l n r a r r ' lv o l t a g e l V i

'1 when commandvoltageis externallysuppltedin the range


- Signal
Settrng
from0V to 15Vunderthe standardse-+ttings
SettingSrgnal When commanovoltageis externally
2 supplredin the range
"on"
from 0V to 10VwrthF 5 set to

NoTE:Thecurrentandvoltageindicatedinthegraphsabovearenot
measuredafterfineadjustmentofunitpu|seconditions'Youmaynot
adjustable
obtain such the resultsas the graphs show dependingon finely
range of Pulseunit conditions.

(6) Settingof UPsloPe Time F6*


Upslopetime meansthe time for increasing weldrngcondtttons stepwtsewnert
time at shipment is set to 0
initialcurrentts changedto frnalcurrentTha upslope
The settingrange is 0 second to 10
second,but can be idjusted by usrngF6
wire burnsup while conditions are changed
second.This functronis usedwhen
and main
over due to the great differenceof settingbetweeninitialcurrent
current.

(7) Settingof Down-sloPe Time FT-


Down-slopettme means the time for decreasingweldrngconditionsstepwtse
when marncurrent is changed to cratercurrent The down-slopetime at th-ettme
F7 The
of productshipmentis sei to 0 second,but can be adlustedby uslng
functionis used when wire
settingrangecovers0 secondto 10 second.This
are changed over due to the
crash6sinto tne base metalwhilethe condttions
greatdifferenceof settingbetweenmain currentand cratercurrent
1 0 .O P E R A T I O N
(continued)
lR\ Settingof ResultDisplayHoldingTrme.F8
Aftercompletron of welding,the averagevalueof outputcurrentand output
voltagefor lastone secondblinksfor about20 seconds,but the resultdisplay
holdrngtimecan be set by F8 usrngF key [12].The settingrangeof result
drsplayholdingtime is 5 secondsto 60 seconds

/Qr Selectionof ScalePlateof AnalogRemoteControl.F9


when the analogremotecontrol(optionalaccessory) rs used,it is possrbleto
frnelyadlusta low-current regionwherea small-diameter wire is usedfor weld
by replacing the full-scale
3504 scaleplatewrththe full-scale
2004 scaleptate
(supplred)The analogremotecontrolscaleplatels changedover by usingthe
F selectorkey [12] Set to "200"by usrngF9

(1C)Settrngof FeedMotorLoadCurrentErrorDetection Level F10


ln the eventthatcontactresistancers applredto the wirefeed linesectiondue to
worn liners,defectivetips etc , the currentsuppiledto the motor increases
(whenfeed roll lackssmoothmovement) Monitoring currentof this motorcan
detectdefectivefeed The motorloadcurrentdetectionlevelat shipmentts70o/o
(2 0A) of the ratedmotorcurrent2 BA (contrnuous) and rf the currentexceeds
the settrngvalue "E-" and "820" rn the drsplaysare displayedafter welding
operationts stopped But rn this case. the weldrngmachinestops operatron
automaticallythen it self-restoresby re-weldrngThrs detectionlevel can be
changedby changrngthe settingof F10 usingF selectorkey [12] The setting
rangeof motorload currenttroubledetectronlevelis 20ohIo 1S0o/o

NOTE:Adjust the detectionlevel optionallyand use it in the best detection


level, because the application environment and judgment criteria vary
dependingon wires and torches and customersrespectively.

t1'1S
) e t t r no
g f J o b M e m o r yF i n eA d l u s t m e nFt 1 ' 1
Underthe weldtngconditionsalreadystoredin JOB MEMORY currentcan be
finelyadjustedwith the WELDING CURRNETknob locatedon the optronal
analogremotecontroland voltagewrththe VOLTAGEknob.The rnrtial settrngof
F11 is "oFF When activatingthe function set F11 to "on" Settingboth
CURRENTand VOLTAGEknobsto the centerof the scalesallowsthe machine
to work underthe conditions alreadystoredrn the weldrngconditions memories
To increaseweldingcurrentsIghtly turn the knob clockwiseand to decrease
sltghtlyturn it counter-clockwise Weldingvoltagecan be adjustedin the same
manner The frneadlustment rangeis x20o/o.

NOTE:
o When no data is stored in the JOB MEMORY,the function cannot be
activated.
o For the conditionsstored in memory in synergicmode, adjust them in
individualmode.

P l a c et h e s ek n o b si n t h e c e n t e rp o s i t i o n s
10 . OP E R A TION( continued)

('12)ArcvoltagedirectdetectionON/OFFselection: F12
When usingan extension cableresultsin abnormalgeneration of spatteror
when unstableweldingis causedfrom malfunction of pulseweld,use a voltage
detectioncable(optionalaccessoryK5416G00)for directlydetectingarc
When usingan extensioncablethatis morethan30 m long,use an
voltage(-).
arc voltagedirectdetectioncable.Connectbetweenbase metaland wire
feederor the directvoltagedetection(-) terminalinsidethe weldingpower
source.(Voltagedetectioncable K5416G00is a 30 m singlecore cab tyre
cable Cut it as necessary)

Afterconnectingthe voltagedetectioncable,activatethe functionof voltage


"on" The functionis presetto "oFF' (invalid)
directdetectionby settingF12to
at factory

NOTE:When using the equipmentwith such as brush for feedingparts


like a turn table,connectingthe voltagedetectioncable to the terminal
for the base metal power cable after setting F12to "on" is recommended.

(13)FineAdjustment of PulsePeakCurrent
The unitpulseconditions (pulsepeakcurrenVttme and basecurrent)at pulse
weldingis set properlyaccording to weldingmethodand wirediameter,but you
can makethe fineadjustment of unitpulse
to obtainthe optimumconditions
according to the wirebrandor weldingposition

o The finelyadlustablerangeof pulsepeakcurrentis 0 A to i150 A The peak


currentis set by 1A
o The finelyadjustable rangeof pulsepeaktime is 0 ms to r1.5 ms The pulse
peaktime is set by 0.1 ms
o The fineadjustable
rangeof basecurrentis 0 A to t60A. The basecurrentis
setbylA

In functionmode.whenpressingthe DISPLAYCHANGEkey [8] duringthe fine


adjustment of pulsewidth,the DISPLAYCHANGElamplightsup (locatedat
the upper of the DISPLAYCHANGEkey) Underthiscondition,
left you can
switchthe fineadjustment valueshownin the rightdisplayto the modulus(the
valuewhichis substrusted valuefromthe
or addedthe fineadjustment
standardvalue) When pressingthe DISPLAYCHANGEkey you can returnto
the fineadlustment valuedispiaymode.

[Exampleof FineAdlustment of the UnitPulseConditions]


When makinga fineadjustment of the unitpulseconditions,adlustthe pulse
peaktimefirst Take longerfineadjustment timewhenlargedropletand
unstablearc (droplettransfer)occurs.Take shorterfineadlustment timewhen
sharptip of wireand extremely strong arc occurs.Adjustthe pulsepeak current
followingthe samestepsas pulse peak time adlustment

[Precautionfor the FineAdjustmentof the UnitPulseConditions]


Maximumpulsepeakcurrentwhichcan be outputvariesdepending on the type
of weldingmachineor arc load.Whenthe pulsepeakcurrentfinely
(capability)
adjustedexceedsthe maximumpulsepeak current,the presetpulsepeak
currentis not output.
10. OPERATION( continued)

NOTE:When the unit pulse conditionschangesignificantly,there may be


a possibility of difference between the preset current value and the
output current and an impossibility of appropriate synergic fine
adjustment.

(13-1)Fineadjustment of PulsePeakCurrent F13*


The fine adjustmentof pulsepeak currentcan be achievedby activatingF13
usingthe F key [8] The valuewhichis substrusted or addedthe fine adlusting
value from the standardvalue of the pulse peak currentis output.At the wave
pulsewelding,the highpulsecondition(H. pulse)is ad.yusted

(13-2)FineAdjustment of the PulsePeakTime:F14*


The fineadjustment of pulse peaktime can be achievedby activating
F'14using
the F key [B] The valuewhichis substructed or addedthe fine adlustingvatue
form the standardvalue of the pulse peak time is output At the wave pulse
welding,the highpulsecondition(H pulse)is adlusted

(13-3)FineAdlustment of the BaseCurrentF15"


Frneadlustmentof basecurrentcan be achievedby activating F15 usrngthe F
key [8] The valuewhich is substrusted or addedthe fine ad.1usting
valuefrom
the standardvalueof the basecurrentis output

(13-4)Fine Adjustmentof L Pulse Peak Current:F16* (avaitabte


in optionat
wave
p u l s em o d eo n l y )
The frneadjustmentof low pulsecondition(L pulse)peakcurrentat wave pulse
weldrngcan be achievedby activatingF16 usingthe F key [B].The valuewhich
is substrusted
or addedthe ftneadjustingvaluefrom the standardvalueof the L
pulsepeakcurrentis outputas L pulsepeakcurrent

(13-5)FineAdjustmentof L PulsePeak Time FlT* @vaitable waveputse


in optronat
mode only)
The frneadjustment of L pulsepeaktime of the secondpulseconditionat wave
pulseweldingcan be achievedby activating F17 usingthe F key [8] The value
whtchts substrusted or addedthe fine adlustingvaluefrom the standardvalue
of the L pulsepeaktime is outputas L pulsepeaktime

(13-6)Fine Adjustmentof L Pulse Base Current FlS* (availabte


in optionat
wave
pulsemode only)
The fine adjustmentof the pulsebase currentof the secondpulseconditionat
wave pulseweldingcan be achievedby activating F18 usingthe F key [8] The
valuewhichis substrusted or addedthe fine adlustingvaluefrom the standard
valueof the L pulsepeakcurrentis outputas L pulsepeakcurrent.

I l.Jh p(ilse dnd[ron t ow Inils.-'


qrrdnroh I nglr P!ls.r
qrr.ltroir

\]V'yrl,;,,il\]L\.,
Example of current wave at wave pulse welding
10 . OP E R A TION( continued)

(14)TurboStartON/OFFSelectronF 19
The weldrngpowersourcehas TurboStartfuncttonby capaotordrscharge
whrchenableyou to obtarngood weldingstart At poor weldrngstart wrth
burnback settrngF'19to oFF" deactivates the Turbo Startfunction The
functionis presetto on tvalid)at factory

( 1 5 )K e y p a dt o n eO N / O F FS e l e c t r o n
F20
-lhe
SettrngF20 to oFF deactivates key pad tone functron volumeof thi.
key pad tonecan not be adlusted

1i)22 KeyLor.k
K e y l o c ki s a t u n c t t o Ii ro p r e v e nltf t t :w e i C t ' t : i ; n C r t t o tf-rtosn rt e t t r gu n a n g e db y : l i : r ; t d e n t a i i t
o p e r a t t n g k g v s a n c Ji . l r ; f , : : i , l ' 1 ! r : .l .r i . r r : t . r , ' r i a iO l r i , , l h e k e v * s; : j n r tp a r , - r n r e l eai d j , , : . ' t ; r ; r r ) l,
v . i l - i l C iht f e U S e i i f r j i ' i i n a l g i i t ( ; i : j . r ( . i li r l , ' r l t r t e i e r > : r ' r ' - lr r l L - r . . 1C
8 9; - r l ih t : D r O i e C l el. i l i . r w e v i ? r l f i
"r,,,
s 0 t t r n g s i : ; r n b e c i r c c i . r : Ci r r , , t r r r i , r r ' r r . , 1r. '1r L i : r i ; ! i' r rf { ; i ) l S i r l , i i ' a r i A N L i F L i , i i 5 a r r :
SjPOTIlMt i.evl11l

l J 6 r l ' J 1 1- 11 o. 1, , ^t ,t n^ t li t h e F f l l l k e v : : n o F N I T R K e y I ; l1 l
.-;t
t'r r;lt.-rrtcrti i SIV

l i o k j r n qd o w nb o t ht h e F k e y [ 1 2 ]a n d E N T E Rk e y [ 1 8 ]
s r m u l t a n e o r rfsel1ya ' , r h i l eb r t n g st h e k e v - l o c ck o n C r t r o l
W h r l ek e v sa r e l o c k e Cl h e F I a r n pi l o c a t e da t t h e u p p e r
l e f t o i t i , r . :t : I g y r I l i r : f , : , (ev llck can be cancelled by
holdrng b o t ht h e F k e v a n d t - N T E Rk e y s r m u l t a n e o u s l y
for a whrleagarn Key lock cannot be cancelledbv
s t a r t r n:gh e m a c h r n e
u0agarn

Whtlekevsare locked the F larnptt'rrrr,s

E v e nw h e nt h e k e y sa r t ,l o c k e dG A : ; a i J L u - Kl N t ) HN G , , : n ,Jl r - ) BN l E M O R \
functionscan be actrvated

1 02 3 J O B M E M O R YF u n c t r o n
The JOB MEMORYfunctionenablesweldinqcorrdrtions to be reproducrble by storrngthe
weldrngconditrons In memoryrnsrdepowersourceand by readingout the storeddataat anV
f e l d r n cg o r r d i t i o nt hsa ic a r rb e i r e l dr n m e f f i o r rys u p t o 1 0 0
t r m eT h en u m b e r ow

! CAUTION
The welding conditions(electronicinformation)stored by this function are susceptible
to occurrenceof static electricity,impact,repair,etc..and there is a possibilitythat the
sstorage contents
torage c may
ontents m be
ay b e cchanged orr llost.
hangeclo BE
ost. E SURE
lt S U R E TO MAKE
l() M COPY
AKb A G o P Y lFOR
-Of< :
IMPORTANT INFORMATION. I
We shall not assumeany responsibilityfor any change or loss of electronicinformationi
from qLqe,
!L\il! tgryg!_s hqUo_rlqle,Lng9_y
Once the machineentersthe memorymode and read-outmode all the key operations are
deniedexceptthe SAVE LOAD and ENTERkeys To exrtthe mode,pressthe LOAD key
[19] if it is in the memorymode,and the SAVEkey [20]if in the read-outmode Memorycan
be copiedto a differentconditionnumberafterreadingthe weldingconditions to be copred

NOTE:Even when welding conditionsare read out while the analog remotecontrol is
connectedto the welding power source,the setting values presetwith the analog
remote control are valid.
10. OPERATION( continued)

SAVEFunctron
Weldrngcondrtions
beingcurrentlyin use are storedrnthe memoryinsidethe
weidingpowersource
o Holding t h ew e l d r n gc o n d i t i o ni sn m e m o r y
(1) When pressrng the SAVEkey [20] the machineentersmemorymoclethe
SAVElamp(locatedat the upperleftof the SAVEkey)lightsup See the
f o l l o w r npgi c t u r eI n t h e r i g h td r s p l a yt h e c o n d r t i onnu m b e r' ' l b l i n k sa n d
t h e L E Dl a m po f t h ew e l d i n gc o n d i t i onnu m b e rl i q h t su p l n t h e l e f td r s p l a y
"
the settrngvaiueof weldrngcurrentpresetto the condrtion nrrmber"''1
a p p e a r sU n d e rt h r sc o n d t t t o tat c o n d r t r onnu n r b ecr a n b e s e tw h r l et L l r n r n q
t h ep a r a m e t eard l u s t r nkgn o b[ 5 ]

Welding
Current
setting
valueheldin memory Condrtron
nurnber
blinks

In the eventthatany memorydatais alreadypresetto the condition


numberyou selectedthe CRATERlamp the WELDINGMET|IODlar''rp
etc.alsolightup lf no memorydatais presetto the conditionnumberyou
s e l e c t e r i ' - b l r n k si n t h e l e f t - s i dder s p l a yI n t h r sc a s e t h e s y s t e ms k i p s
t h e p a r a m e t ecrn e c kc o n d r t r oonf S t e p1 2 )a n dl u r n p st o S t e p( 3 t

(2) When pressingthe ENTERkey l21l aftersettingthe condrtron number the


E N T E Rl a m pb l i n k s( l o c a t e a
d t t h e u p p e rl e f to f t h e k e y ) U n d e rt h r s
condrtronyouare allowedto confirmthe settingvalueof the parameter'
presetto the conditionnumberby usrngthe DISPLAYCHANGEkey [B]
The settrngvalueof the parameter you selectedblrnks

NOTE:In the save mode,you can not changethe welding condition


numberor selectany memory/readoutmode.To resetthe condition
number,press the SAVEkey [20],then returnto the step (1).To quit
the settingand exit from the memory mode, press the LOAD key [19].

(3) Pressingthe ENTERkey l21l agarnholdsthe datain memoryand allowyou


to exitfromthe memorvmode
10 . OP E R A TION( continued)
A
LOADFunction
The weldingconditionsstoredin memoryare readout from the memoryinside
welding powersource

NOTE:The welding conditionscurrentlyused can be overwrittenwith the


welding conditionsread out. When you wan to save the welding conditions
that have been used until now, presetthe welding conditionsto any
condition number,then carry out readout.

o Readingout the presetweldingconditions


(1) When pressingthe LOADkey [19], the machineentersthe readoutmode,
LOAD lamp (locatedat the upperleftof the LOAD key) lightsup. See the
figurebelow The conditionnumber"'1" in the right-side
displayblinksand the
JOB No LED lamplightsup. ln the left-sidedisplay,the settingof welding
currentpresetto conditionnumber"1" lightsup Underthiscondition, a
conditionnumbercan be set whileturningthe parameter adjustingknob[6]

WeldinoCurrentheldin memory Condition


blinks

In the eventthatany memorydatais presetto the conditionnumberyou


selected,the CRATERlamp the WELDINGMETHODlamp,etc.also
lightup When no memorydatais presetto the conditionnumber,"- - -"
displayblinks See the figurebelow
rnthe left-side

( 2 ) When pressingthe ENTERkey l21l aftersettingthe conditionnumber,the


ENTERlamp(locatedat the upperleftof the key)blinks Underthiscondition
you are allowedto confirmthe settingof each parameteryou want to read out
by usingthe DISPLAYCHANGEkey [8] The settingof the parameter you
selectedblinks.

NOTE:You are not allowedto changecondition number or selecta


welding method,etc. To resetthe condition number,press the SAVE
key [20], then return to the step (1). To quit the setting and exit from the
readout mode, press the SAVE key [20].

( 3 ) When pressingthe SAVE key [20]again,you can readout the presetwelding


and exitfromthe readoutmode.
conditions
10. OPERATION( continued)

o Operationflow in the memorymode

Pressthe MEMORYkey.

Set the vueldingmndition numberwhi


tumingthe parameter
adjustingknob.

Pressthe MEMORYkey

Pressthe DISPLAYCFIANGEkey
to checkthe oarametervalue. Resettheweldinqcondition
number

uleldingmndrtionsare presetto the numberyou seleded

the LOADkey

o Operationflow in the readoutmode

Pressthe LOADkey.

Set the ureldingcondition number whi


turningthe pararneter
adjustingknob.

Pressthe LOADkey

Pressthe DISPLAYCMNGE key


to checkthe parametervalue. Resettheweldingmnditionnumber

are presetto the numberyou selecled


Theu,eldingconditions

modequits.
The readourt
10 . OP E R A TION( continued)

Erasingthe WeldrngConditrons
When you erasethe weldrngconditions storedin memory,you can selecteither'
e r a s i n ga l lo r e r a s r n o
gne

. Erasingthe weldrngconditrons
(1) Turnoff the powerswitchand turnon the powerswitchwrthboththe LOAD
key [19]and SAVEkey [20]pressedReleasethe keysaftertunrng on the
powerswitch.and then"dEL"appearrnthe left-srdedrsplaySeethe prctllre
below

ff
R
sw.

d E L ' r sd r s p l a y e w
d h r c hr n d i c a t e s C o n d i t r onnu m t r etro b e d e l e t e db l r n k s
the machrneis rndeletionmode

(2) Set the conditionnumberto be deletedwhrleturnrngthe parameter adlustrng


knob[6] Whenturningthe knobcounterclockwrse "ALL'
appearsin the rrght-
belowand you can eraseall the weldrngcondrtrons
sidedisplayas rllustrated

' d E L "r s 'ALL"


drsplayed bltnks

NOTE: When the welding conditions are deleted by selecting "ALL",


welding conditions currently in use are also deleted.Consequently,all
the parametersreturnto the initialsettings.

( 3 ) P r e s s r ntgh e E N T E Rk e y[ 2 1 ]b l r n k sd E L ' C o n f i r mt h e c o n d i t r onnu m b e r


agatnand if youwantto canceierasrngof the condrtron number pressany
keyotherthanthe ENTERkey [21]to returnto step(2) To qurtthe delete
mode,turnoff the weldrngpowersource

(4) Pressingthe ENTERkeyl21l agarndeletethe weldrngconditionpresetto the


"End"
conditionnumber When is drsplayed turnoff
afterend of datadeletion.
the powerswitch.thenstartup the weldrngmachine

NOTE:lf you pressthe ENTERkey twice in the deletionmode,you can


not recoverthe erasedwelding conditions.When you attemptto deletea
welding condition held in memory,make sure that the condition number
you want to eraseis surely selected.
' 10. OPERATION( continued)

10 2 4 Resetttng to Initral
Values
The weldtngconditions thatare currentlyused(rncludrngthe weldrngconditroncurrently
used)are all resetto tnitral values,turnoff the powerswitchand
values To resetto rnitral
thenturnon the powerswitchwithboththe F key [12]and GAS CHECKkey [14]helddown
When"End"sappearin the displaysafterturningon the powerswitch,releasethe keys turn
off the powerswitch thenturnit on again See the picturebelow

"SPECIFICATIONS'
See f o r t n i t t avla l u e so f e a c hp a r a m e t earn df u n c t i o n

10 2 5 Confirmrngsoftwareverston
The versionof softwaretncorporated
in the weldrngpowersourcecan be verifredfollowrng
thesesteps Turnon the powerswitchwithonlythe F key [12]helddown Afterpoweringthe
weldingpowersource,the versionnumberappearsrnthe display

(Example)
R r g h at n d l e f td i s p l a y s" P 1 0 3 5 2 " < - S o f t w a rn
e u m b e (r P 1 0 3 5 2i)s d i s p l a y e d .
.; Pressthe F key [12]
Leftdrsplay "001" + Main softwareversion (Ver 001) is
drsplayed
R r g h dt r s p l a y" 0 0 0 ' e Sub softwareversionrs displayed
. Press the F key ['12]
Leftdrsplay "- - -"
R i g h td i s p l a y " 0 0 2 ' < Combinatron is displayed
, Pressthe F key [12]
The weldtngpowersourcestartsup as usualand getsreadyto performwelding

10 2 6 AutomaticStopof Fan
The coolingfan automatrcally
stopsin 10 minutesafterweldrngis finishedand automatically
startsturningwhenweldrngis startedWhen poweringthe weldingpowersource,the cooling
fan is alsoturningbut automatrcally 'l
stopsin 0 minuteswhenno operationis carriedout

1 0 . 2 7 R e d u c t i oonf F a nN o i s e
Whenthe weldtngpowersourceis nottemporarily rn use,the rateof fan rotationdecreases
so thatfan noisecan reduceThisfunctionworksonlyfor 250 A or lessoutputcurrent
1 1 .A P P L I E DF U N C T I O N

11.1 Howto Solvean Error

! WARNING
Observethe following to prevent electricalshock.

I
When touching chargingparts,criticalelectricshock and burn may occur.
O Do not touch chargingparts inside or outsidethe welding machine.
O Groundingto the case of the welding power source should be performedby persons qualified
electricwork and accordingto the laws and regulationsin your area.
O When touching the parts inside the welding power source,wait more than three minutes after
poweringoff all input power supplv bV turninq off the line disconnectswitch in the switch box.

lf an erroroccursduringuse,an errorcode shownin the displayson the frontpanelblinks,then the


weldingpowersourcestopsautomatically In thiscase,checkthe errorsin the following
table.

Displayson the frontpanel


No Classrfication
of errors
Left i Right
1 dA l H E n Torchswitchoff statewaitinq
E
L - 000 OperationStop
-
L - 1 0 0 Controlpowersupplyerror

4 E ', 2oo Primary/ secondarycurrent detection


error
5 E- r 210 Errorin the voltagedetectionwire
o E- 300 Thermaloverload
7 E- 510 Abnormalwater oressure*
8 E- 600 Replacementof batteries(warning)
v E- 7 0 0 Outputovercurrent
10 E- 7 1 0 Lackof phase
11 E- ' 800 Encoderin the wire feeder
Thermal overload in the oovernor
12 E- 8 1 0
circuit
13 820 Motorover currentwarnino
14 - 830 Motorover currenterror
tc
- 900 Microcomouter error
*Wheninputrelaysignalto12Pterminalblock(TM12P) only
:ll.l-al,
(continued)
1 1 .A P P L I E DF U N C T I O N
1 ) d A l H E nD i s p l a y

lf "dAl"and "HEn"in the displaysblink,it indicates


the
"Torch
switchoff statewaiting"
When turningon the powerswitch,the displayson the frontpanelshows"dAl"and "Hen"for one
second,then the weldingpowersourcebecomesoperable.But,if the torchswitchremainson, the
safetycircuitwillfunction,the weldingpowersourcewill holda haltcondition, thenthe WARNING
lampand "dAl"and "HEn"shownin the displayswill blink.In this case,turnoff the torchswitchto
resetthe safetycircuitand make the weldingpowersourceoperable.

2) E-000Display

lf " E-"and "000"in the displaysblink,it indicates


the
"Operation
Stop"
When disconnecting the wiringof the STOP terminals(OperationStop terminals:wiringnumber
143)on the 12P externalconnectionterminalblock,"E-" and "000"in the displaysblinkand the
weldingpower source stops In this case, after turningoff the power switchand eliminatingthe
possiblecauses of the stoppageof the weldingpower source,short-circuitthe STOP terminals
and turn on the powerswitchto cancelthe error

NOTE:When cancelingOperationStop, it is also possibleto solve the error only by short-


circuitingthe OperationStop terminalsagainwithout start the welding power source up
again. Referto Section 10.2.1l4l, "Selecting Auto/Semi-auto".

3) E-l00Display

l f " E - " a n d "1 0 0 ' t h e d i s p l a y s b l i n ki ti n


i n d i c a t e s t h e " C o n tpr o w
l ersupplyerror"
lf thereis an errorin the controlpowersource,the warninglampwill lightup and "E-"and "100"in
the displayswill blink then the weldingpowersourcewill automatically stop To cancelthe error,
startthe machineup again

4) E-200Display

lf "E-"and "200"in the displaysblink,it indicatesthe " Primary/Secondary currentdetection error"


lf an erroris detectedin the currentdetecting "E-" "200'in
area, and the displayswill blinkand the
weldingpowersourcewillstopautomatically. In thiscase,turnoff the powerswitch,thenturn it on
again after making sure that CN8 and CN9 on the printedcircuitboard P10264Uare surely
connected.

5 ) E - 2 1 0D i s p l a y

lf "E-'and "210"in the drsplays blink it indicates the " Errorin the voltagedetection wire"
lf there is an error in the plus voltagedetectionline (+;, the warninglamp will lightup, "E-" and
"210"
in the displayswill blink thenthe weldingpowersourcewill stopautomatically In this case,
a f t e r c h e c k i n g t o m a k e s u r e t thhaet w i r e f e e d e r c o n t r o l c a b l e ( 1i s0nPo)t d a m a g e d a n d t h a t C N O
and CN10 on the printedcircuitboardP10264T, CN23 and CN 24 on the printedcircuitboard
P10264U,and CN 1 on the printedcircuitboardP10264Xare surelyconnected, startthe machine
upagarn

6) E-300Display

lf "E-' and "300"in the displaysblink,it indicates the "Thermaloverload"


lf the actualduty cycle exceedsthe rated duty cycle of or temperatureinsidethe weldingpower
sourceincreases, "E-"and "300"will
blinkand the weldingpowersourcewillstopautomatically At
this time,the temperature lamp also will be lit. In this case,wait more than 10 minuteswith the
power switch pressedand the fan turned.When restartwelding,turn off the power switch and
restorethe systemafter loweringthe duty cycle and the weldingcurrent.Such actionwill cancel
the error. Repetitiouswelding without more than ten-minuterest may lead to damage to the
weldingmachine.Referto Section3.1, "RatedDutyCycle"forthe rateddutycycleof the welding
powersource.
(continued)
1 1 .A P P L I E DF U N C T I O N

7) E-510Display connectorCON4
In the caseof connecting

l f " E - ' a n d " 5 ' l 0 " r n t h e d i s p l a y s b rl it ni nkd i c a t e s t h e " A b n o r m a l w a t e r p r e s s u r e "


Thenthe weldingmachinewillautomatically stop In thiscase,checkto make surethatthe water-
cooledhosedoesnot leakwaterand thatadequatecoolingwateris goingthroughthe hose
"Water"and connectedthe relaycontactof water pressure
When set the switchof the front panel
b e f w e e nC O N 4 I - : , c o n t a c t b e t w e eCnO N I - : l s " O p e n "m a k e sE - 5 1 0 l t g h t u p .
When usingan air-cooled torch,makesurethatthe TORCHlampon the frontpanelis OFF (AlR)

8) E-600Display
"600" "Replacement
lf "E-"and in the drsplays blrnk,rt indrcates
the of battertes(warntng)"
This weldingpowersourceuses batteriesso that rt can hold the weldtngconditionsin memory
"E-'and "600 in the dtsplaysbltnkwhen the
evenwhen no operationrs carriedout for longtime
get low "E-" and "600"
batterres are dlsplayedonly when the front paneland the weldtngpower
sourceare temporarrly not in use To cancelthe drsplayof the error, pressany key Evenwhen
"E-" "600"
and appearrn the drsplaysweldrngcan contrnuedto be performed,but when the
batteriesrun down, the preset welding condition functions and the settings of functions
are all erased.The last welding conditions before power is appliedto the welding machine
can not be stored. Each time power is applied to the equipment,all the parametersare
" of batteriesfor details
resetto initialvalues.Referto Section12 4, Replacement

9) E-700Display
"700' in the d isplaysbltnk, tt indicates ' '
lf "E-" and the Outputovercurrent
lf an overcurrent or short circuiton the secondaryoutputconttnuesfor more than one second
" E - ' a n d" 7 0 0 "i n t h e d t s p l a b
y l t n k st h e nt h ew e l d i n g
d u r i n gw e l d i n gt ,h e W A R N I N Gl a m pl i g h t su p
powersourcestops automaticallyIn thrs case turn off the control power switchand check to
make sure that the weldrng current does not exceed the rated output value, or that there is no
short circuit on the output side such as a contact between the tip and the base metal,or a short
circuitof the outputcables

10) E-710Display
"E-" "710 in the displaysblink.it indicates the Lackof phase
lf and "E-"and"710'tn
lf alackof p h a s e i s d e t e c t e d a t t h e p r i m a r y ti hn ep w l i igl lh t u p
u ta r n i n g l a m p w
the displayswill blink,and then the weldrngpowersourcewtll stop automaticallyIn this case.
makesurethatthereis no lackof phasein prtmaryinputvoltage

11 ) E - 8 0 0D r s p l a y
"800"in the drsplays "Encoderin the wtrefeeder'
lf "E-"and blink rt rndicates the
lf thereis an errorin an encoderfeedbacksignalfor detectrng the feedingrateof wirefeeder.the
" E - ' a n d ' B 0 0 "r n t h e d r s p l a yw
s i l l b l i n k a n d t h e nt h e w e l d l n gm a c h t n e
w a r n i n gl a m pw i l l l i g h t
up.
willstop automatically In thrscase.make surethat thereis no damagein the encoderconnector
(4P)on the top of the motorinsidethe wirefeeder,the controlcablefor the wtrefeeder('l0P;,and
the printedcircuitboardP'10261Q

12) E-810Display
"E-" "810'in " T h e r m a l o v e r l o iandt h eg o v e r n ocr i r c u i t '
lf and t h ed i s p l a y bs l i n k r, ti n d r c a t et sh e
lf thermaloverloadin governorcircuit(prrnted circuitboardP10261Q)is detectedthe WARNING
"E-" "B10
l a m pw i l ll i g h tu p . and i n t h e d i s p l a yw s i l lb l r n ka. n d t h e nt h e w e l d t n gm a c h i n ew i l ls t o p
automatically In this case,checkfor defectiveprintedcircuitboardP10261Q,shortcircuiton the
motorpowersupplylines roughfeedrngof wire,and errorin the torchor the wirefeeder
(continued)
1 1 .A P P L I E DF U N C T I O N
1 3 )E - 8 2 0D i s p l a y
"E-" '820 "Motor
lf and blrnkin the displaysit indicatesthe overcurrent warning"
Contactresistanceto the feedingparts causesmotor currentto increase.lf the motor current
"E-" "820 in
exceeds70o/oof the rated duty cycle and the displayswill blink only while no
'E
operationat the front panelrs carriedout. When pressingany key or startingweldingagain
and 820"rn the displayswrlldisappear(, but weldrngpowersourcedoes not stop automatically)
In thiscase,checkfor shortcircuitin the motorpower
transmission line, roughfeedingof wire, and an error in the torch or the wire feeder Referto
"Setting
Section10.2.1(10) of FeedMotorLoadCurrentErrorDetection Level".

1 4 )E - 8 3 0D i s p l a y
"830" "Motor
lf 'E-" and rnthe displaysblrnk it indicates
the overcurrent"
"E-" "B30'rn
lf shortcircurtin the powerline to the motoror motoroverloadhappens. and the
displayswill blinkand the weldrngmachinewill automatically stop In thrscase,checkfor short
circuitin the powersupplyline,roughfeedingof the wire,and an errorin the torchor the wire
feeder.

1 5 )E - 9 0 0D i s p l a y
"E-" "900' "Microcomputer
lf and in the displaysblink it indicated
the error"
Therecouldbe an error in the burlt-inmicrocomputer, Pleasecontactyour dealerimmedtately
When contactingyour dealer,you are requiredto providethe detailsof the problemyou are
facing
(continued)
1 1 .A P P L I E DF U N C T I O N

! WARNING
Observe the following to prevent electricalshock.
tl
D Do not touch chargingparts insideor outsidethe welding machinq.
I Grounding to the case of the welding power source should be performed by persons
qualifiedelectricwork and accordingto the laws and regulationsin your area.
D When touching the parts inside the welding power source, wait more than three minutes
after powering off all input power supply by turning off the line disconnect switch in the
switch box.

! CAUTION
Try to move the control cable which is pulled out from the automaticconnectionterminal
on the chassisfather away from the welding power cable or the torch cable when making
an externalconnection.Otherwise,equipmentfailuremay be caused by noise,etc.,during
welding operation.
the on the printedcircuit board to outside.

11 2 ExternalConnection
of InsideTerminalBlockof AutomaticMachine

When takingoff the upper cover of the weldingpower source,you will find there is a 12P
terminalblock(TM12P)and a 6P terminalblock(TMGP)on the chassis Use the 12p terminal
"Parts
blockto connectwithan automaticmachineRefertoSection12 lavout"forthe locations
of the terminalblocks

NOTE:Wait more than three minutes after turning off the line disconnectswitch or no-
fuse breakerand the power switch on the front panel to remove the cover.

NOTE:Break the grommet with filter locatedon the rear side of the welding machineto
lead in the externalconnectingwires.When leadingin the externalconnectionwires, do
not touch the parts on the printedcircuit board and the edges of the steel plate.

o @ 3) a8) (9 (d) C) 6A
f-l
+ -
i- i f-T
READY STOP WCR

[12Pterminalblock]

c n a a\ lo,
LT
o
I
+6 a )-
\9 DIREC

[6P terminalblock]
(continued)
1 1 .A P P L I E DF U N C T I O N
2P termina ) l o c 1
P i nN o S i q n anl a m e Function
o a READY
(o u T P U T )
The terminalsused for ready power for prep relay When
there is not any error such as open phase, OperationStop
.1

ReadyPower outputovercurrent,and thermaloverload,the terminalswork,


etc. whilethe powerswitchis on, the terminalsfunction.
GAS ( T N P U T )The terminalsused for controlling the gas solenoidvalve by *2
-ll) .!t_,r
Solenoid Valve externalsignals (lf the terminalsare short-circuited, the gas
Control v a l v ew i l l o o e n)
*2
rC (0 E X T I ( t N P U T ) The terminalsusedfor specialspecifications
Extra
Theseterminals
Input shouldnot be usedfor normaluse.
S i g n a 1l
*2
(s) .O E X T 2( T N P U T ) The terminalsusedfor specialspecifications. Theseterminals
Extra Input shouldnot be usedfor normaluse.
S r o n a2l
Q) .,3 s T o P ( T N P U T ) To stop weldingexternally Releasethe wiring betweentwo *2
Operation Stop terminalsto run OperationStop.Weldingmachineis stopped
by runningOperationStop Closethe terminalsafter turning
off the torch switch to restartwelding To avoid accidental
restart,use of a PushlockTurn resetswitc! q5gggeqle!!
(ltr ltrcn(ou-rpurl ContactOutputof weldrngcurrentreia@
t0 Current weldingcurrent The contactsclose whileweldinqcurrentis
Detection flowino

6 P e r m r n abl lock(TM 6P
P i nN o at name Function
I A M M ETER Terminalsfor connecting an ammeter.
4) Use the ammeter(400AJ60mV, oart number.4403-057
VOLTMETER Terminalsfor connecting a voltmeter "4
..:')
:l _l)
Usethe voltmeter(fullscale100V,partnumber:4401-016
r5) Unused
Negatrve When using a power cable that is more than 30 m long,direct
[]/
Terminal for connectionof a direct detectionwire of the base metal (-) to the
Direct wirefeederis recommendedbut it is imoossible to connectto the
Detection of wire feederdue to jig use the terminalblockinsidethis welding
Voltage power source Refer to Section 10 2 I (12) "Arc Voltage Direct
DetectionON/OFFSelection"for detailsof directdetection.

Precaution for connection


withterminalson the terminalblock
The wires from the terminalblocksshouldbe twistedfor each signalsto avoid accidentaloperation
Take care thatthe wiresform the terminalblocksdo not crossothersionalwiresfrom otherweldino
oowersource.
*1 Equivalent circuitis as the figureshown right Maximumcapacityof TR is B0V, 100mA When
connectingsuch as relay to two terminals,do not exceed 80% of the maximum capacityof TR.
( F i g u r e1 )
"2 Equivalent
circuitis as the figureshownright.Connectallowablecontacts(10mAor more)to two
(Figure2)
terminals.
*3 Ratingof the providedrelaycontactsis '125VAC, 0 5A 30V DC, 14. Do not exceed 80% of the
ratingof the providedrelaycontacts.
*4 Be carefulthatno-loadvoltage(100Vor less)is appliedto betweenthe terminalsduringwelding

TR
+
h-
r--O -
Figure'1
(continued)
1 1 .A P P L I E DF U N C T I O N
11 3 Combining
withan AutomaticMachine

When combining withan automaticmachine,use the 12Pl6Pterminalblockinsidethe welding


powersource,the 10Pterminalblockinsrdethe wire feeder,and the receptacle
for the remote
controlor for the wire feeder Refer to Section1'1.2,"ExternalConnectionof the lnside
TerminalBlock of the AutomaticMachine'for the detailsof the terminalblock insidethe
weldingpowersource.

(1) CurrenWoltage Settingsand InchingSignal


When the analogremotecontrol(optionally supplied)is not in use, resistorR23 for current
setting,resistorR24 for voltagesetting,and switch PB for inchrng,which are all listedin
Section13 1 "PartsList",shouldbe used For settingcurrenUvoltageon externalvoltage.refer
"Selection
to Section10.2.1(4\, of Auto/Semi-automatic"
Analogremotecontrol
Current settang Voltage setting
rK t4
r R23 r R24
5<-,, J<- -
!t.r ! ):1

PB
I
!r/ C O+ 1)a
Inching

(2) StartSignal
When removingthe right-srdeplateof the wire feeder,you willfind a 10P terminalblock See
the figurebelow Weldlngis carriedout by the startsignalwhen wiringnumbers306 and 307
are contactinputand when the terminalsare closed.Weldingstopswhen the terminalsare
ooen.

( 3 ) DirectDetectionSignal
When usinga powercablethat is more than 30 m long,connectthe base metal(-) and the
connectorfor voltagedetectionof wirefeeder(wiringnumber 310)withvoltagedetection cable
K5416G00When usingthe equipment whichemploysa brush,etc , as the feedingpartslikea
positioner
or a turntable,attachment of the voltagedetection
cableto the terminalfor the base
metalpowercableis recommended
"
Referto Section10.2.1(12), Arc voltagedetectionON/OFFselection"for detailsof direct
detection
*Outgoinglinesof startsignal
and directdetectionsignalare locatednext to the 10P control
cable Breakthe grommetwithfilm

J)- rn

__--
--E_

Terminalsfor
startsignal
<r Terminals
forvoltage
detection
(continued)
1 1 A P P L I E DF U N C T I O N
1 1 . 4OotionalAccessories

1 14 1 Other al Accessories
Remarks
4nqlog_iq11ele_eglt_tlg! With a 3-metercable
Digitalremotecontrol A CAN communication moduleand cableare
needed
CAN communication
module
CAN communrcatronBKCAN-O4XX XX= 05 (for 1 0 ( f o r1 0 m )
cable
Wheelkit K 5 4 16 8 0 0
detectioncable K5416G00 30 m with a terminal

11.42 Extension (Extension


Cable/Hose of Work Space)
! CAUTION

O When using an extensioncable,roll it out. Failureto observethe demand may result


in unstablearc.

Choosea propertorchcable(separately
sold)for work space.When extendingthe work space,
(separatelysold ) that matchthe work space
use otherextensioncables/hoses

) i I -nlrol .ah. tor wre fe1e.

\.l,lP(rer cble for wre f€ler

\ ; i.1l Control cble for remote control :€)


\ // lf ^ ^ll
w-- 1\\- ll / Aralm rercte @nlrol
.:
V\blding porcr sour@ (Ophonally avarlable)

* A watercoolerand waterhosesare necessaryfor use of a water-cooled


torch
(continued)
1 1 .A P P L I E DF U N C T I O N
PowerCable(for torchand tor base metal
5m 10m 15m 20m
7
Model BKPDT-6007 B K P D T - 6 0 1 2 BKPDT-801 BKPDT-8022

2. Gas Hose
5m 10m 15m 20m
Model BKGG-0605 B K G G - 0 6 1 0 BKGG-0615 BKGG-0620

ontro Cablefor Wire Feeder


3. Control I E AAdAT (10 P
5m 10m 15m 20m
1O5 BKCPJ-l010
Model B K C P J -O BKCPJ-1015 BKCPJ-1020

ControlCablefor RemoteContro
5m 10m 15m 20m
Model BKCPJ-0605 B K C P J - 0 6 1 0 B K C P J . 0 6 1 5 BKCPJ-0620

water Hose(forteedrnqwaterand condensed water


5m 1 0 m 15m 20m
Model BKWR.06O5 B K W R - 0 6 1 0 B K W R-0615 BKWR-0620
12 . M A I N T E N A N CAEN D T R O U B L E S H O O T I N G

! WARNING
To avoid electric shock, follow the below instructions.
rl
O Do not touch live electricalparts inside or outsidethe welding machine.
O Turn off alt of the line disconnect switches before touching the parts inside the welding
machine.
O Perform the maintenance checks periodically. lf any damaged parts are found, only use the
welding machineafter troubleshootingor repairing.
O Only certifiedoperatorsshould maintain,inspect,or repairthe 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. Capacitormay be
dischargingeven after powering off all input power supply. Check to make sure that charging
voltagedoes not exist beforecarryingout the maintenance.
O This welding power source uses a high-frequencyinverter system, be careful of accidental
connectionof the line disconnectswitch at input side.
O Have qualifiedoperatorsor the personsfamiliarwith this welding power source test withstand
voltage.And install a protectivewall around the welding machineto keep away others from the
welding machine.

! CAUTION
Rotatingparts may cause injuries.Be sure to observethe following.

O Only certifiedoperatorsshould maintain,inspect,or repairthe welding machine.


O Installa fence around the welding machineto keep others away from it.
O Do not put your hands,fingers,hair and clothes near the fans and wire feed roll rotatinq.

! CAUTION
Do not touch the parts for the main circuit which are located inside the

d source, such as single-phase transformer, DC inductor, heat sink, etc.


immediately after welding is performed, as the parts are extremely hot. Wait
until the parts cool down, when touching. Failureto observe the demand may
result in burn.

! CAUTION
O The welding conditions(electronicinformation)stored using the JOB MEMORYkeys 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 recommendtaking notes of important data.
O We shall not assumeany responsibilityfor any changeor eraseof the electronicinformation
from repair.
' l2 . M A IN T E N A N CA ( continued)
EN D T R OUBLESHOOTING
on the WeldingPowerSource
121 Carryingout Maintenance

(1) Periodica ch
l ecking
(2)
Periodicallycheckthe weldingpowersourceto ensurethe safetyof the equipmentand the
efficiencyof work
o Dailycheckingthe followings:
- No strangevibration,buzzingnoise,and smell are generatedfrom the weldingpower
source
- No excessiveheat is generatedfrom the cableconnections
- Fan functionsproperlywhen the powerswitchis turnedon.
- The switchesproperlyfunction
- Connection of cablesare surelvmade.
and insulation
- Thereare no breakin cables.
- Fluctuation
of powersourcevoltageis not large.
- Case Earthis surely connected(Disconnection of the Case Earthmay resultin failureor
of the equipment)
malfunction
o Checkingthe followings
eachthreeto six months
- Thereis no damageinsidethe torch
- Thereare no looseconnections or no poorcontactscausedfrom rust.on inputstdeof the
weldingpowersourceand outputsideof the cables
- Thereis no troublewithtnsulatton
- The weldingpowersourceis properlygrounded
- Built-updust on the transistoror the cold plateon the rectifiermay affectthe equipments.
Take off the cover of the welding power source once a half year then remove dust by
blowingmoisture-free compressedair on each part.
- The dust protectivefilter locatedon the inlet of the fan does not clog which may resultin
damageto the weldingpowersource.Be sureto inspectit pertodically

12 2 Precautionfor Replacementof the PrintedCircuitBoard


o Makesurethatthe connectornumber
on the orintedcircuitboardmatches
inscribed
the numbermarkedon the connector
o Turn off the control power switch and line
disconnect switch before carrying out
maintenance on the weldingpowersource,and
wait three minutesuntilthe capacitorsinsidethe
weldingpowersourcedischarge NOTE:Match the number on the printedi
I
o Thisweldingpowersourceusesa high-frequency circuit board with that on the connector. i
inverter system, be careful of accidental
connectionof the line disconnectswitchat input
side
. Surelyconnectthe connectors clicks.Failureto do so may resultin
untilthe connector
damageto the printedcircuitboardand the welding
do not turn on the powerswitchon the front panel.
o With the connectorsdisconnected,
o Do not useorganicsolventsuchas thinner,trichloroethylene,
gasoline,
etc.,to cleanthe
and flawmay result
plasticcoverand carryinghandleof the weldingmachine.Deformation
from the adherenceof the organicsolvent
1 2 . MA IN T E N ANCE ( continued)
AND TROUBLESHOOTING
'12.3Insulation
Resistance
Test

! WARNING
Observethe following to prevent an electricalshock.

I
When touching chargingparts,a criticalelectricshock and burn may occur.
O Have qualifiedoperatorsor the persons familiarwith this welding power source measure
insulationresistanceand test withstand voltage . And install a protectivewall around the
welding machineto 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
measurementof insulationresistanceand withstandvoltaqetest.

When measuringinsulationresistanceand testingwithstandvoltage followthe steps below.


And, referto the schematicdiagram,partslayoutand partslistfor maintenance.

1. Disconnect the grounding cable(wiringnumber.80) fromthe earth


2. Short-circuit on AC sideand commutation sideof DR1.
3 . S h o r t - c i r c ubiet t w e e n
T R 1 ( C 1 )a n d ( E l ) , T R 2 ( C 2 ) a n d( E 2 ) ,T R 3 ( C 2a) n d ( E 2 ) .

Be sure to reconnectthe cables after carryingout measurementof insulationresistanceand


withstandvoltagetest

12 4 Replacement
of Batteries

Thisweldingpowersourceuseslithiumbatterres to holdweldingconditions in memory.The life


of the batteriesdiffersdependingon the environments"E-' and "600"shownin the displayson
the frontpanelblinkswhen the batteriesgets low. Replacementof the batteriesevery5 yearsor
so are recommended "E-" "600"
evenwhen and do not blink.Replacethe batteriesfollowrng
the
steos.

1 Turn off the line disconnectswitchin the switchbox or the no-fusebreakerand the oower
switchof the weldingpowersource
2. Aftermorethanthreeminutes,removesix screwsthat securethe frontpanel,and then pull
' the frontpanelout.Do not pullit forcibly.With the wiringinsidethe equipmentdisconnected,
do notturnon the powerswitch.Failureto do so may resultin damageto the weldingpower
source.
3 Removethe connectors on the P C 8.P10263Rto replacethe prrntedcircuitboard.Referto
the positionfor "Rearsideof the frontpanel"in Section12.7, " PartsLrst"
4 Insertthe disconnected connectors intothe P C.8.P10263R
5. Screwthe frontpanelin position
1 2 . MA IN T E N A N CA ( continued)
EN D T ROUBLESHOOTING
12 5 Troubleshooting

When an errorcodeis displayedreferto Section11.1,"HowTo Solvean Error"


o Checkthe troubleshootinq informationlistedbelowbeforecontactinq
o UT dealerfor servtce
vour
No rouble Cause Solution
The power Neverturnit on aqain.Contactvourdealer
switchon the
1
frontpanelis
triooed.
The main Whenturningon the Troublewith PL1 InspectPLI
powerlamp powerswitch the
P L 1w i l ln o t displavsliqht.
) light Whenturningon the The linedisconnect switchin the Inspectthe powerbox
powerswitch, switchbox is not turnedon
nothingappearsin The inputcablesare not surely Inspectthe inputcables
the display attached
Whenturning The main power Referto No 2 in thislist
on the power l a m pP L I w i l ln o t
switch nothing
appearsin the Shortageof the inputvoltage Checkfor properinput
display. voltage
tiounte witntne powercircuit Afterinspecting PCB
PLI lrghts
P10263Q a n dP 1 0 3 2 2 X ,
replacethem if
necessary
W h e nt u r n i n go rr the powerswitch the neferio Sectron t i t "Howto
4
W A R N I N Ga n d T E M P E R A T U R E Solvean Error"
lampslightup a rd an errorcode
aopearsin the d
Shieldgas is Gas is not generated The discharge valveof the gas Openthe valve
not generated whenthe GAS cylinders cl6sed
when the torch C H E C Kk e yi s Lbct<oi g-s pressureof t g unecKTorpropergas
switchis presseo cylinder pressure.
pressed. I
irouoie witn tne gr- Inspectthe gas
5 electromagnetic valveSOL electromagnetic valve
ea\l
-
Gas rs generat,ed Disconnectionot tne mrChatrtCh Checkthe wiringnumber
whenthe GAS cableor incompleteinsertionto 306 and 307
C H E C Kk e yi s reno nf an lo

presseo.
o Shieldgas doesnot stop. T h e G A SC H E C Kl a m pl i g h t su p Stopgas checkingby
pressrng
the GAS
qrqcl!-!sv-
Troublewiththe gas solenoid Cf'eck-toroperatron of
valveSOL the gas solenoidvalveof
wire feeder.
When the torch switchis oressed.no- Troublewith the invertermain Turn off the powerswitch,
loadvoltageis not outputbut shield circuit thencontactyourdealer.
7 gas is generated. . .
Trouble\Mnhthe contrd circut Aner Inspecung
PCBPl0264Por P10352
reolaceit if necessarv.
( continued)
AND TROUBLESHOOTING
1 2 .MA IN T E N A NCE

No. Trouble Cause Solution


Currentand voltage Troublewith the control After inspectingPCB P10264Por
can not be set. circuit P10264Uand replaceit if necessary
Troublewith the filtercircuit Afterinspecting PCB P10264T,replace
it if necessarv.
8 Troublewiththe remote After inspectingthe cable/plugfor
control remotecontrolor the remotecontrol,
replacethem if necessary
Errorin wire voltage lnspectconnections of CN23and CN
detection o r C N 1o n P C B
2 4 o n P C BP 1 0 3 5 2 U
P10264X
Wire is not fed Incomolete insertion
or Afterinspectingthe contactsof the plug
breakingof the contror and cable.reolacethem if necessary.
cablefor wire feeder
Troublewith the motor Afterinspecting PCB P10264Q,replace
v
controlcircuit it if necessary.
Troublewith the filtercircuit After inspectingPCB P10264f, replace
it if necessarv
WCR keepsworking Troublewiththe hole Insoectthe holecurrentdetectorCT2
currentdetectorCT2
10
Troublewiththe WCR Afterinspecting PCB P10264P,replace
circuit it if necessary
12 MAINTENANC
AEN DT R O U E
12.6SchematicDiagram

I
I

I
I

U
V
l{

oruoofl,,
TTT

PCB11

Bot----l---l
---t m t-+-

'*'ff---'-S
Qffi.,n
!i{e
PCE3(P102630)
l P o w e ns u p p t y )
ct{t
| | ffi
_ J r Y - n t _

PCB12
t STARTI
Iu?)
Pl 0264S

cli 7

PCB5 PCBT
t -
(Flltent
1 t I ( G o ve r n o n)
(P10264r\ (P10261Q)

cxt

+l < o
+ r + l 9 - @ o
:P
/-i\ ,4-\ D;
( A ) ( V ) , F
\-/ \-/ EG
Ie E E
o o
:J

;3 E
U
E
U
9o

R e m o t ec o n t n o l b o x
a
I
II
ROUBLESHOO
N TGI continued
( )
-- --- --
FcB6
ai;vent-eil-
(P10352M)
TR' rna i (P10264S)

r;*f .[li1 i
lt Rr r+ o{ i$'! l ,i u l l r tsLEl 1Z I

'F-:.Ir-.-lt

I li?1*
l l l l ' lT
L-l$rl/l i
,,6'j'F4fI ll .-
-----'lo
l l i l " l li l
ld 6 I I | |
-'f I llll

P C 8 4 t I G Bd T
nrvenJ PCB10(P'10264X)
(P10264V) I v ot t a g e d e t e c t)
ct{3

PCBl
l C o n t n oC
l incuitJ
(P10352U)

J-L-{t!t_-l

i ' n ' i
PCB9
t FP O n t H a n eI l
| 0... i
lleattenyll
(P10264R) 1(P10263R)1
t i
- - + - F +
i--r
I E
+ | - - - *
* - o i O t I a
=
O ( C X X ( J + l
o- t o W a t e rC o o [ n g
U o Untl (212\
F
TRO UB L ES H O O TNI G (co n ti n u e d )

C O N1

CON2
ii i'l

Rear Panel

Top Chassis FrontPanel

ffirrvrt
ffiF6
ffi
ffi
ffi
rvz
-trI
qs5 ffiF5
FgT FET
ffiF5 FFE
P 10 2 6 1Q $e5 ffi
ffiffi
ffi$ffi
IET IEI
1 2 .M A I N T E N A N C
AEN DT R O U
12.7PartsLayout

-"r r- P
c14
-JT L- t l
c 1 2 ,R 3 0
SCRl
F l
I 11
-l
i l L 4 ll [[ , ]1
f- t
P1o352M I
l
I mF-
I'1n*.*i rHP2 ir
R 1 8 .C 1 5
l
DR7 qR.l I f:r
t B"hrd"f
I FrontPane

CT1

R
I H-l
R2o_F I
nrgH

[t
l12 |
TR5

t t R6
f - '
I top
L pt 0322x R27a-d.R28
t-;
P 10 2 6 4 S

O O
P10264r '
P10263Q
LF1

P10264X
13.PARTSLIST

o Pleasecontactyourdealerto orderparts.(Seethe back coverfor telephoneand fax numbers,and


addresses.
Symbol Part No Description Specifications Q'tv Remarks
NF 4614-101 Circuitprotector cB3-X0-10-072-42D-C1
LF1 4519-022 Linefilter CF3O3OC-DJ 1
PL,1 4600-34 1 Pilotlamp NPA1O 2H WS I
DR1 4531-717 Diodemodule DFA15OAA160 1
DR2-7 4 5 3 1- 3 0 8 Highspeeddiodemodule DBA2OOUA6O 6
DRB 4 5 3 1- 5 0 5 Diode S2L6O 1
DR9 4531-710 Diode D1N6O 1
TR1-4 4534-528 I G B Tm o d u l e CM2OODY-12NF 4
TR5 4534-529 I G B Tm o d u l e SKM3OOGAL128D 1
SCRl 4530-412 Thyristor SG25AA2O 1
CTl 4810-030 lurrent transformer w-wO3029 1
wtz 4406-009 lole currentdetector HA4OO53EH 1
r1 P10264800 nvertertransformer P10264800 1
r2 4 8 10 - 3 5 1 Auxiliary
transformer w-w02921A 1

L,I P 10 3 5 2 8 0 0 DC reactor P10352800 I


L2,3,6,7,8,
'10 4739-497 Ferritecore E04RA4002701
50 o

L4 P10322L00 Inputreactor P10322L00 1


L5 P l 0 3 5 2 C 0 0Chokecoil Pl 0352C00A 1
L9 4739-497 Ferritecore E04RA4002701
50 Z

L111 2 4739-543 Ferritecore E 0 4 R A 30119 0 10 0 Z

THPl 4258-046 Thermostat US-6O2AXTTL 120C 1


T H P 23 4614-057 Thermostat 671080 Z

FM1.2 4805-074 Fan 4715S1-05W-860-D00 2


cR1 4341-139 Relay G2R-1-TDC24V 4
I

SH 4403-116 Metershunt KY4OOA4OOA/6OMV 1


TM1 4739-505 Terminalblock T B ' 1 0 - 0112 P 1
TM2 4739-504 Terminalblock T B 1 0 - 06 1P 1
Rl - 4 4516-119 Surgeabsorber E N C g 1 1 D1 4 4 4
R6 4509-81 9 Cementresistor 40sH2000J 1
R 8 1 3 , 1 7 4509-704 Carbonresistor R D 1 / 4 Wl K O J 7
o
R 1 4 , 1 5 4509-121 Metalfilmresistor RNP sOSC lOOF
R16 4509-916 Cementresistor T2OSH2.2OJA 1
R18 4509-107 Metaloxidefilm resistor R S 2 W 1 s O J 1
R1 9 , 2 0 4509-905 Cementresistor MHR2OA513JI z

R23,24 4 5 0 1- 0 3 9 Variableresistor RV24YN2OSB 5KO 2


R25,26 4509-883 Cementresistor 2 0 s H2 0 k o J 2
R27a d 4504-321 Wire woundresistor N C R F 2 2 V1 O O 4
R28 4504-322 Wire woundresistor NCRF22V2OO 1
R 2 9 , R 3 0 4509-704 Carbonresistor R D 1 / 4 Wl K O J Z

a
R 3 1 , R 3 2 4509-922 Cementresistor 2 O S Hl O O J A
C2 4518-530 Filmcapacitor US16X1 54JAASA 1
C4,C5 4518-519 Filmcapacitor MIC-ST3D182J z

vt,wtz 4518-402 Filmcapacitor 0.47ytF 50V z


1 3 . P A R T SLIST( continued)

Symbol PartNo. Description Specifications Qtv Remarks


c8,c9 4511-344 A l u m i n u me l e c t r o l v tcr ca p a o t o r w-w02212 2
c10 4 5 18 - 5 3 3 Filmcapacitor US2OX473JAASA 1
cl1 4518-528 Filmcapacitor U52OXlO3JAASA 1
4517-455 Ceramiccaoacitor 0.01pF 2kV 1
c14 4511-510 A l u m i n u me l e c t r o d cea p a c i t o r LWA2N6Ol MSMAZO 1
coNl 4730-421 Metalconsentreceptacle H 5 2 5 R - 01 1
I
CON2 4730-426 Metalconsentreceptacle 25-6BK I

coN3 P10352X02 Cablewith3P connecter P10352X02 1


coN4 P'10352X04 ablewith 6P connecter P10352X04
PCBl P 10 3 5 2 U 0 0Printedcircuitboard P 10 3 5 2 U 0 0 I

PC82- P10264P00 Printedcircuitboard P10264P00 1 Referto NOTE below

PCB3 P10263Q00 Printedcircuit board P10263Q00 1


PC84 P10264V00 Printedcircuitboard P10264V00 1
PCB5 P10264T00 Printedcircuitboard P10264T00 1
PC86 Pl 0352M00 Printedcircuitboard P 10 3 5 2 M 0 0 1
PCBT P 10 2 6 1Q 0 0 Printedcircu board P 10 2 6 1Q 0 0 1
PCBB P 10 2 6 3 R 0 0 Printedcircut board P 10 2 6 3 R 0 0 1
PC89 P10264R00 Printedcircuitboard Pl 0264R00 1
PCBlO Pl 0264X00 Prrntedcircuitboard P10264X00 1
P C B l1 P10322X00 Printedcircuitboard P10322X00 1
PCBl2 P10264S00 Printedcircuitboard Pl 0264500 1
l r 4739-474 Grommetwith film w-w02805 4
!, 4735-038 Knob K - 1 O O2 2 R S B 1
ustingknob
(:i 4735-039 cap K.lOO 22CSBL 1
i t'r 4739-475 Rubberfoot c-30-RK-3220 4
:) panelsheet
P 1 0 3 1 3 W 0Control
2 P10313W02 1
4739-476 cap w-w02814
P5801G03 CarryingHandle P5801G03 2
8 P10263G12 Bush P10263G12 4
{)l P10264J01 Frontcover P10264J01 1
il0 P10263J02 Controlpanelcover P'10263J02 1
ll. 4734-007 Machinesocket DIX BE 5OI7O 2 Outputterminal
Plugfor tt. 4734-025 Powercableconnector DIX SK 70 I F o r6 0 m m ' c a b l e
Plugfor iltr 4734-026 Powercableconnector DIX SK 95 1 F o r8 0 m m ' c a b l e

*NOTE:When orderinga printedcircuit board P10264P00, provide the softwareversion


on a label below a nameplateattachedto the rear side of the welding power source.

P 1 0 3 5V .tfttlt.ffi . 0 0 0
2 e r-I-
version,
theIttftt.tttt'ttwithsoftware
Replace
13.PARTSLIST(continued)
Parts listfor a remotecontrol(oDttonal
I accessor
accessories
Symbol Partno. Description Specifications Q'tv Remarks
.)
R23,24 4 5 0 1- 0 3 9 Variableresistor RV24YN2OSB 5KO
PB 4250-077 Pushbuttonswitch A2A-4R 1
4730-009 Metalsocketplug DPC25-64 1
4735-007 Knob K-2195(larqe) 2
K5416H02 350/5004scaleolate K5416H02 1

1 4 .S P E C I F I C A T I O N S
Specifications
\A/elrlinn nn\^/ar c^r rraa

--Mqdel
--
Specificaitons DioitalInverterDP400
-
Model DP-400

Numberof ohase
Ratedfrequency 50/60H2
Ratedinputvoltage 400v
Inputvoltagerange 400 v ! 15%
Ratedinputpower 2 2 . 0k v A . 2 1 . k5W 1 9 . 7 k V A1, 7 k W
Ratedinputcurrent
nateOoutoutcurrenf 4 0 0A
Ratedloadvoltaqe 34V
Ratedoutputcurrentrange 30-400A
Ratedoutputvoltagerange 12-38V
Maximumno-loadvoltage 80v
Rateddutycycle
Numberof weldingcondition 100
Temoeraturerise + ' 1 6 0' C ( + 3 2 0" F )
Usabletemperature range - ' 1 0- + 4 0 ' C ( * ' t +- + ' 1 0 4 " F )
Usablemoistureranoe 20 - 80%(withoutdew condensation)
Storagetemperaturerange - 1 0- + 6 0" C F l q - + 1 4 0' F )
Storagemoisturerange 20 - 80%(withoutdew condensation)
Externaldimensions(W x D x H) 250 mm x 640 mm x 544 mm (withoutthe carryinghandle)
Mass 45 kg

Theweldingpowersourcecomplieswiththe requirements
of 18C60974-1
( continued)
14 . S PECIFICATIONS

14.2 ExternalView

o
o
o
o
o

rir
ffi
ffi
ffi

ffix ffiffi
( continued)
14 . S P ECIFICATIONS
olnitialValuesand Setti R a e of Parameter

Pre-flowtime 0 - 10seconds
I n i t i acl o n d i t i o n 20-4004
M a i nc o n d i t i o n 10-45V
Craterfillercondition Fineadjustmentof voltage
Post-flowtime 0 -'l 0 seconds
Arc spottime 0 . 1- 1 0 s e c o n d s
Arc characteristic - 1 0- 1 0
Wave frequency 05-32Hz
J O B M E M O R Yn u m b e r s 1- 1 0 0
oFunction
I n i t i avl a l u e Settinqitem
O F F / O N w i t h o upt u l s e /) O N ( w i t hp u l s e ) /S P O T
method DC tse DC / DC wave
M I L DS T E E LC O : / M I L DS T E E LC O R E D
SOFT
C O , / S T A I N L E SCSO R E DC O 2 / M I L D
STEEL
Wire/Gas STEEL C O R E DM A G / S T A I N L E SSST E E LM I G /
MAG A L U M I N U IP \ 4U R EM I G /A L U M I N U MI V l I G

W i r ed i a m e t e r 0 8 t 09 t 1 . 0 t 1 . 2
Initialcurrent ON/OFF
A d j u s t m e not f w e l d i n gv o l t a g e SYNERGIC SYNERGIC/INDIVIDUAL
Penetration
control OFF ON/OFF
(Function) < R e f etro S e c t i o n1 0 2 . 1 ." U s i n oo f i n t e r n af ul n c t i o n>s
oInternalFunctions
I n i t i avl a l u e S e t t i n gr a n g e

F i n e a d j u s t m e n to f a n t r - s t i c k( b u r n b a c k ) - 5 0 ( 0 . 5 0s e c o n dd o w n )- 5 0 ( 05 0 s e c o n du p )
F1
time*
Fine adjustment of anti-stick(burnback) -9.9-99V
F2 00
F3 Fineadjustmentof slow-downspeed* 00 10-10m/min
F4 Selectionof automatic/semi-automatic
_oFF ]. _O_ olcr
t-5 Externalcommand1OVMAX oFF ON(VALTD)/OFF(TNVALTD)
F6 oo I o-lOoseconds
F7 Settingof down-slopetime* 0-l00seconds
F8 R e s u l td i s p l a yh o l d i n gt i m e 20 5 - 60 seconds
Selection of scale plate of analog remote
F9 200/350
control
Feed motor load current error detection
F10 20-150%
level
F i n e a d j u s t m e n to f J o b M e m o r y F i n e
F11 o N T V A L I D/ o) F F( I N V A L I D )
ustment
Arc voltage direct detection ON/OFF
F12 O N ( D I R E C T/)O F F( T E R M I N A L )
selection
t- tJ Fineadjustmentof pulsepeak current* -150A-150A
F14 Fineadjustmentof pulsepeaktime* - 1 5 ( m s )- 1 . 5( m s )
F15 Fineadjustmentof base current* -60A-60A
F16 Fineadjustmentof L pulsepeakcurrent* -150A-150A
F17 Fineadjustmentof L pulsepeaktime* - 1 . 5( m s )- 1 . 5( m s )
F18 Fineadjustmentof L pulsebasecurrent* -604-60A
F19 TurboStartON/OFFselection O N ( V A L I D/)O F F( I N V A L I D )
F20 Keypadtone ONiOFFselection O N ( V A L I D/)O F F( I N V A L I D )
'Welding
whichcan be presetto a JOB MEMORYnumber
conditions
FrontPanel
t 2 1 l l 2 0 l[ 1 e ]

J O B
N/El\CRf
&

[ 17 ] [ 1 8 ][ 11 ] l12l t3l l14l

[1]WELDING M E T H O Dk e y [ 9 ] A R CC O N T R O Lk e y [ 1 7 l G A SC H E C Kk e y
2lWlRE/GASselector [ 1 0 ] W A V EP U L S Ek e y( o p t i o n a l ) [ 1 8 ]I N C H I N Gk e y
W I R ED I A( m m 1 1 1S P O TT I M Ek e y LOADkev
t'191
4lAlm/minselector [ 1 2 ]F ( F U N C T I O Nk)e y [20]SAVEkey
5lV/t selectork [ 1 3 ]l N l T l A LC U R R .k e y [ 2 1 ]E N T E Rk e y
6l Parameter adiustinqknob [ 1 4 ] V O L TC . O N T R O Lk e y
[7] CRATER-FILL key [15] CONSTANTPENETRATION key
8I DISPLAYCHANGEK I I 6 l T O R C Hk e v
( continued)
14 . S PECIFICATIONS
ol
Q U I C KM A N U A L
Referto Section10.1,"BasicSettings"and "AppliedSettings".
Section10.2,

o 4. Settinqs
of Parameter P a r a m e t e ra d l u s tn g k n o b

1. Settinqsof Weldinq Method

Set a weldingmethod,
wire/ shield gas, then
wire diameterby using
t h eW E L D I N GM E T H O D
key, the WIR/GAS
selectorkeys, and the
WIRE DIA (mm) key
oF respectively. Use the DISPLAY CHANGE key to select the parameter
you want to set, then adjust it while turning the parameter
adjustingknob.
2. Settinqsof Crater/Arc
Spot W h e n c h a n g i n gt h e p a r a m e t e ru n i t i n t h e d i s p l a y ,u s e t h e
H o,H s6teltor
key
Use the CRATER-FILLkey to select
oFF/oN(-yoN( g P O TT I M E .p r e s st h e S P O T
W h e na d j u s t i nS
Jlll)/sPor T I M Ek e y ,t h e ns e t S P O TT I M Ew h i l et u r n i n g
the parameter adjusting knob.

[ O N ] :S P O TT l t r 4 E
l a m pi s o n .
[ O F F ]S' P O I T I M El a m pi s o f f

3. Settinqsof Functions To adlust the desired arc characteristic


(HARD/SOFT),after turning on the ARC
C O N T R O L l a m p b y p r e s s i n gt h e A R C
ol CONTROLkey. set the level of the arc
characteristic.

: R CC O N T R O lLa m pi s o n
[ O N ]A
[OFF]:ARC C O N T R O lLa m pi s o f f
. For using lNlTlAL CURRENT, press the lNlTlAL
"ON".
CURR. key to set the functionto When the weldingmethodis wave pulse,to
obtain the desired bead appearanceafler
[ O N ] : l N l T l A LC U R R . l a m p i s o n turningon the WAVE PULSE lamp by
[ O F F ] :l N l T l A LC U R R . l a m p i s o f f . pressingthe WAVEPULSEkey,set the wave
pulse while turningthe parameteraojusting
. knob.
For controlling voltage in the SYNERG. way, select
"SYNERG.' pressing
by t h e V O L T . C O N T R O Lk e y .
[ O N ]W
: A V EP U L S El a m pi s o n
[OFF]:WAVE P U L S El a m pi s o f f .
[ S Y N E R G I C ]V: O L T . C O N T R O Ll a m p i s o n
I N D I V I D U A L ] V O L T . C O N T R O Ll a m p i s o f f
NOTE:

. o Turning the parameter adjusting knob clockwise


For activatinga CONSTANT PENETRATIONfunction,
"ON". increases the parameter. To decrease the
set the functionto
parameter, turn the parameter adjusting knob
lONl: CONTANT PENETRATIONlamp is on. counter-clockwise.
[OFF]: CONSTANT PENETRATIONlamp is off. o There may be unavailable parameters in some
crater settings and function settings. Refer to
''WATER"
. For using a water-cooled torch, select by S e c t i o n 1 0 , " O P E R A T I O N "f o r d e t a i l s
pressingthe TORCH key, then run coolingwater.
5. Checkinqthe Rate of Gas Flow
[WATER]:TORCH lamp is on.
[ A l R ] : T O R C Hl a m p i s o f f Openthe dischargevalveof the gas cylinder,
pressthe GAS CHECKkey to checkthe rate
of gas flow. After performingGAS CHECK,
stop the gas flow by pressingthe GAS
C H E C Kk e v .
6. I n c h i n qt h e W i r e i n ot h e Condil
il
After pressurizing the wire mountedon the 1 ) Pressing the LOAD key enter the load mode. The
wire feederusingthe pressureroll,feed the preset welding condition number is displayed in the
wireup to the end of the torchwhileusingthe right displayand the welding current is displayedin the
I N C H I N Gk e y W h e n p r e s s i n gt h e I N C H I N G left display.
keyagain,the wirefeedingstops. 2 ) Preset the welding conditionsto the desired numbers
'100
0 - while turning the parameter adjusting knob.
Now you have completed the preparationsthat are required When
"---"
is displayed in the left display, no welding
to start welding.Press the torch switchto start welding.
conditionsare presetto the number you selected.
5) Press the ENTER key to check for the parameter
I l,Frotecting
the Keys and Releasinqthe Kev Protectioni preset to the number.
. Protectingof the keys 4) When pressing the ENTER key agarn, the welding
conditionspreset to the welding conditionnumber are
Hold down the ENTER key + 169 F key at a
retrieved.
time for a few seconds. The F lamo starts
b l i n k i n g .B l i n k i n go f t h e F l a m p m e a n s t h e the LOAD key

welding machine is in the key protectionmode

I
Set the u,elding condition number
. Releasingthe key protection tJmrng lhe parameteradlLstrngknoo
Hold down the ENTER key + 16s F key at a
time for a few seconds. When the F lamp Pressthe ENTERkey IP;..,f* Loilt]
turns off, the key protection function rs
released. the DISPLAY
to cfrtr* the paraneter value Pefl lhe re|drng @rdton aLtmF.

re t h e W e l d i n qC o n d i lThe wcldrng @ndttons ae pre*t to the number yoLt scldcd

1) Pressingthe SAVEkey entersthe save the ENTERrSl


lPress
mode. The preset welding condition
numberis displayedin the rightdisplay The readoiJtrDde qurts
current
is dispraved
in
#J[i:;l;:s ai, of the (lnternal)F
Preset the welding conditions to the
d e s i r e dn u m b e r s0 - 1 0 0 w h i l e t u r n i n g 1) When holding down the F key for a few seconds, the
the parameteradjustingknob When "--- function mode is activated. The function numoer
" blinks in the left display, the function status is
is displayed in the left display, the
number you selectedis available.When displayedin the right display.
"---" 2\ Set the function number while turning the parameter
is not displayed in the left display,
the number you selected is unavailable. a d j u s t i n gk n o b .
In this case, select another number 3) When pressing the F key, the function number lights
Otherwise,the welding conditionspreset up, then the functionstatus blinks.
to the number are erased and 4) Set the function status while turning the parameter
overwrittenwith the welding conditions adlustingknob.
you newly set. 5) To cancel the function mode, hold down the F key for
3) Press the ENTER key to check the a few minutes.
parameterpresetto the number.
4 ) W h e n p r e s s i n gt h e E N T E R k e y a g a i n , L r:fli/: :n uri
t.I i r . . : : r : t r . r L: f t r : : t
the welding conditionsare set.
:1!h:

H F ; ' l . r \ 4 . , ' . i J

-l
I

Set the vr,elding condition number irhnrr :r.nrLrxr,,,.l ' jll


1:l:',"
turnrngthe parameter adjusting knob lllt " 1' -tot,'tl:"'tl ":

'111,l*:,,::
I:1,1" lll

to checkthe parameter
value Resetthe relding @nditionnurber
l : : : E rf. lri r, lli x !, fr! lel

The relding mnditionsare pres€tto the numberyou seieded I I l l l.rna-!v.1.rd !L thr q.' pDLrr !f!r1

l Ill.t r :v3r'!reht r'dnuLt

I lr!r : r?rtrri.rl irr,: I


1 5 .S E R V I CA
EN DS U P P O R T
Pleasecontactyourlocaldealerfor service.(Seethe backcoverfor telephonenumbers,fax numbers,
and mailingaddresses.)

NOTE:
1) See Section 12, "MAINTENANCE AND TROUBLESHOOTING" before contactingyour
dealerfor service.
2) When contactingyour dealer for service, you are required to provide the following
information:
o Address
o Name
. Telephonenumber
o Product model
o Manufactureyear
o Serialnumber
o Software version number
o Detailsof troubles

ooooo
MODEL:DP-400
'DATE: 20XX
. SERIAL
NO. PlO3s2YXXXXXXXXXXX

P10352Ver tllf# l#.000 I


C)TE
DAIHENcorporonorr

( (

DAIHEN Corporation
5-1, M i n a m i s c n r i o kS
a .e - t t s u - sO
h is. a k a5 6 6 - 0 0 2 1J,a p a n
Phone:+ll l-6-63I 7-1506.Fax: +ti l-6-63l7-2,sll3

DAIHEN,INC.
DAYTON OFFIC]E
lzl00BlauscrDrivc
T i p p C i t y .O h i o, 1 , 5 3 7U
1 ,S A
Phonc:+ l-931-667-0lJ(X). Far: *l-937-667-0118-5

OT CD A IHENEUROPE
GmbH.
Krel-elder F.R. GERMAN\
Str. 677. D-41066Mdnchcglaclbach,
Far: t 49-2161-69-497
Phorre:+49-2161-69-49110" ||

O T C I n d u s t r i a l ( S h a n g h a i )C o . , L t d .
7G Ma.jcstyBuilcling,l3lJ Pu [)ong [)a Dao Shanghai
The People'sRcptrblicof C'hina
PostClode:200120
Phone:+tt6-2I Fax: +[i6-2I -5t{t{2t{tt46
-5tt82tt633.

OTC (Taiwan) Co.,Ltd.


No. 63-4,Nan Yuan 2 Rd.. ChungLi.
TaoyuanHsicn,TaiwanR.O.C
l-3962.Fax: +tltl6-3-.1i'+-2i9.+
Phone:+886-3-46

OTCDAIHENAsia Co.,Ltd.
60 / 86 Moo 19.NavanakomlndustrialEstatePhasci.
Klong Nueng,Klong Luang,Pathumthani12120
63. Fax: +66-2-909-4166
Phone:+66-2-909-41

Uponcontact,adviseMODELand MANUAL NO.


t ) D .1 . 1 8 . F '