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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
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
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.
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.
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
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.
Recommended Practices
for PlasmaArc Cutting,AmericanWeldingSocietyStandardAWS C5 2,
from AmericanWeldingSociety
SafeHandlingof Compressed
Gasesin CylindersCGA PamphletP-1,from Compressed
Gas
Association.
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
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
31OA or less)
s
LU
- DP-400
Usable range
l
o
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.
Vvblding torch l
Base retal
l .lelding pwer sour€
\AHer cooler
Gas hose 3m
V\,blding torch
Base metal
V\,eldino Diler souT€
*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
(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
O
=o
c
o
a
3
c
I
0
C
C 0
o P
o O
c o
FM
a o
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f
c
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c
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o
o l
- O O
c o
9 r
C'
a
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o
- .c
E
0 P
c ]o - I
o o =o
5 = o
o e
o o i G l
g O
L O O
in
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o-
o
9
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-
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o t ;
i -
o / i c \ o
1 9 \
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':
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- E
o
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; o o
O 9 o
o e c
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.
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.
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
[]ase rnetal
l-.->/),
, { ,) ,
.F-W
Ml U terDinal
rT- 1\
Wre feeder
base rrretal .l Base rretal
Control cable for rerncte control Analog rernote control
i Optionally available) M1O terminal
! 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
! 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.
! 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
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.
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.
"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.
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
(2) ExampleWeldingConditrons
of DownFillet
,9..
. f i\ , .
/L-_+_}.4 \ l l l | /
(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)
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
(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
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
1211t201
[1e] I4l telt10l
! 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. _ |
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)
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
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]
selector]
IParameter
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
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
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]
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
10 1.5AdjustingWeldingVoltage
Usingthe VOLT.CONTROLkey [14]allowsyou to selectone of the following
voltage
adjustmentmethods
( 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
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
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.
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 . 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
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".
.-"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
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
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 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.
( 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.
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]
,
,/ 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
NoTE:Thecurrentandvoltageindicatedinthegraphsabovearenot
measuredafterfineadjustmentofunitpu|seconditions'Youmaynot
adjustable
obtain such the resultsas the graphs show dependingon finely
range of Pulseunit conditions.
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)
(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
\]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
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
Pressthe MEMORYkey.
Pressthe MEMORYkey
Pressthe DISPLAYCFIANGEkey
to checkthe oarametervalue. Resettheweldinqcondition
number
the LOADkey
Pressthe LOADkey.
Pressthe LOADkey
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
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
! 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.
2) E-000Display
3) E-l00Display
4) E-200Display
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
7) E-510Display connectorCON4
In the caseof connecting
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
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.
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
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
Choosea propertorchcable(separately
sold)for work space.When extendingthe work space,
(separatelysold ) that matchthe work space
use otherextensioncables/hoses
2. Gas Hose
5m 10m 15m 20m
Model BKGG-0605 B K G G - 0 6 1 0 BKGG-0615 BKGG-0620
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
! 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.
! CAUTION
Do not touch the parts for the main circuit which are located inside the
! 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
! 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.
12 4 Replacement
of Batteries
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
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
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
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
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
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
&
[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
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
: 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:
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.
H F ; ' l . r \ 4 . , ' . i J
-l
I
'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
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
( (
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.
OTCDAIHENAsia Co.,Ltd.
60 / 86 Moo 19.NavanakomlndustrialEstatePhasci.
Klong Nueng,Klong Luang,Pathumthani12120
63. Fax: +66-2-909-4166
Phone:+66-2-909-41