tig mig plasma ok

8/4/2019 Tig Mig Plasma Ok

1/83

MANUAL NO .C0025-6

DAII-EN c""",,


2/83

I. SAFETY INFORMATION

No.C0025P. 1/63

The following safety alert sym bo lsand signal words are used throughout thismanua l toidenti fy var iolls hazards and special instructions.

Lh WARNING

CAUTION

WARNING gives infonnation regarding possible personalinjury or loss of life.CAUTION refers to minor personal injury or poss ibleequipment damage.

2. ARC WELDfNG SAFETY PRECAUTIONSLh WARN ING

ARC WELDING can be hazardous.PROTECT YOURS ELF AND OTHERS FROM POSSIBLE SERIOUS fNJURY ORDEATH.Be sure to:. Keep children away_. Ke ep pacemaker wearers away until consulting a doctor .Read and understand the summ ari zed safety information g iven below and theoriginal principal infonnation that will be found in the PRINC IPAL SAFETYSTANDARDS.

Have only trained and experienced persons perfonn installation , ope ration , andmaintenance of this equipment.Use only well maintained equipment. Repair or replace damaged parts at once.

ARC WELDfNG is safe when precautions are taken.

2


3/83

No .C0025P. 2 / 63

ELECTRIC S HOCK can kill.

Jive electrical parts can cause fatal shocks or severe bums. The electrode and workIC I"cu llilsa re electrically live whenever the output is on. The power line and internal circuits

equipment are also live when the line di sconnect switch is on. When arc welding allIm"tal components in the torch and work circuits are electrically live.

o.

Do not touch live electrical parts.Wear dry insulating gloves and other body protection that are free of holes.Insulate yourself from work and ground using dry insulating mats or covers.Be sure to tum off the line disconnect sw itch before installing, changing torch parts ormaintaining this equipment.Properly install and ground this equipment accord ing to its Owner' s Manual andnational, state, and local codes.Keep all panels and covers of this eq uipment securely in place .Do not use worn, dam aged, undersized , or poorly spliced cables.Do not touch electrode and any metal object if POWER switch is ON.Do not wrap cables around your body.

ARC RAYS can bum eyes and skin: FLYrNG SPARKS AND HOTMETAL can cause injury. NO ISE can damage hearing." ".

Arc rays from the welding process produce intense heat and strong ultraviolet rays that canburn eyes and skin.Noise from some arc welding can damage hearing.I. Wear face shie ld with a proper shade of filter (See ANS I Z 49 .1 listed in PRrNCIPAL

SAFETY STANDARDS) to protect your face and eyes when welding o r watching awelder work.

2. Wear approved safety goggles. Side shields recommended.3. Use protective screens or barriers to protect others from fl ash and glare: warn others not

to look at the arc .4. Wear protective clothing made from durable, flame-resistant materi al (wool and leather)

and foot protection.5. Use approved earplugs or earmuffs ifno ise leve l is high.Chipping and gr ind ing can cause !lying meta l. As we lds cool. they can throw orr slag.6. Wear approved face shi eld or safety goggles. Side shi eld s recommended.7. Wear proper body protection to protect skin.

3


4/83

WELDING can cause fire and explosion .

No.C0025P. 3/63

Sparks and spatter fly oft' from the we lding arc. The flying sparks and hot metal. spatter. hot basemetal, and hot equipment can cause fi re and explosion. Accidental contact of electrode orwelding wire to metal object can cause sparks, overheating, or fire .I. Protect you rse lf and olhers from flying sparks and hot metals.2. Do not weld where flying sparks can strike fl am mable material.3. Remove all flammables within 10m (35ft.) orthe welding arc . If this is not possible, tightly,

cover them with approved covers.4. Be alert that welding sparks and hot metals from welding can easi ly pass through cracks andopenings into adjacent areas .5. Watch for fire , and keep a fire extinguisher nearby.6. Be aware that welding on a cei ling, floor, bulkhead, or partition can ignite a hidden fire.7. Do not weld on closed containers such as tanks or drums.8. Connect base metal side cable as close to the welding area as possible to prevent the weld ing

current from traveling along unknown paths and causing e lectric shock and fire hazards.9. Remove stick electrode from holder or cut o fT welding wire at contact tip when not in use.10. Do not use the welding power source for other than arc welding.\ 1. Wear oil-free protecti ve garments such as leather gloves, a heavy shirt, cuffiess trousers,

boots, and a cap.12. A loose cable connection can cause sparks and excessive heating.13. Tighten all cab le connections.

FUMES AND GASES can be hazardous 10 your heahh.

Arc welding produce fu mes and gases. Breathing these fumes and gases can be hazardous toyour health.I. Keep your head ou t of the fumes. Do not breathe the fumes.2. Ventilate the area and I or use exhaust at the 8rc to remove welding fumes and gases.3. lf ventilation is poor. use an approved air-suppl ied re spirator.4. Read the Material Safety Data Sheets (MSDS) and the manufacturer s instruct ions on

metals, consumables. coatings. and cleaners.5. Do not weld or cut in loca tions near dcgreasing. cleaning, or spraying opera tions.

The heat and rays o f the arc can react with vapors to fo nn highly toxic and irritating gases.6. Work in a con lined space only if it is well c n t i l a t ~ d or while wearing an air-supplied

re spirator. Shielding gases lIsed for wclding can p l a c ~ air c;]u s ing inju ry or(kath.Dc sure breathing air is stile.

4


5/83

No.C0025P. 4 / 63

ITJI;;; ~ : . - CYLI NDER can expl ode ir dmnagcd . . , J ." ,.: .A shielding gas cylinder contains high-pressure gas. Irdamaged, a cy linder C3J;! explode.Since gas cyli nders are nonnally part of the wel ding process, be su re to trcat them carefu lly_I. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the

specific application; maintain them in good condition.2. PrOlect compressed gas cylinders from excessive heat, mechanical shock, and arcs.3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent

falling or tipping.4. Keep cylinders away from any welding or other electrical circuit.5. Never touch cylinder with welding electrode.6. Read and fo llow instructions on compressed gas cylinders, associated equipment, and theCGA pub lication P-I listed in PRINCIPAL SAFETY STANDARDS.

7. Tum face away from valve outlet when opening cylinder valve.8. Keep protective cap in place over valve except when gas cylinder is in use or connected for

use

Rotating parts may cause injuries. Be sure to observe the following.

If hands, fingers , hair or clothes are put near the fan's rotating parts or wire feeder's feed roll,. .InJunes may occur.I. Do not use this equipment if the case and the cover are removed.2. When the case is removed for maintenance/inspection and repair, cert ified or experiencedoperators must perfonn the work. Erect a fence, etc. around this equipment to keep others

away from it.3. Do not put hands, f i n g ~ r s hair or clothes near the rotating fans or wire feed roll.

5


6/83

This equipment uses h igh frequency for arc sta rting.

No.C0025P. 5/63

Hi gh-frequency may ente r ncarby uni ts as shown below, causing electromagnetic trouble. Input cables , signal cab les, telephone cables Radio sets, TV sets Computers and other contro l equipment Industrial detectors and safety units , Pacemakers, hearing-aid sets

For preventing electromagnetic trouble;I. Make the cable as shortest as possible.2. Insta ll cables along the floor or the ground as close as possible.3. Put the base metal side cable together with the torch side cable.4. Do not use a co mmon base metal ground with other machines.5. Tight ly close a ll of the doors and covers of thi s equipment, and secure them.6. Do not press the torch switch other than when ready to start the arc.7. When electromagnetic trouble occurs, take the measures shown in this in struction

manual until trouble is corrected.Please contact OTC-DAIHEN , when necessary.

8. Pacemaker wearers must not come near this equipment during operation until consultinga doctor.Operation of the pacemakers will be affected badly by high frequency.

ARC WELDING work areas are potentia lly hazardous.

FALLlNG or MOVrNG machine can cause serious injury. Use both eyebolts, if instal led, to lift the welding power source. Put this equipment solidly on a flat surface. Do not pull this equipment across a floor laid with cables and hoses.

6


7/83

No.C0025P.6 / 63

PRINCIPAL SAFETY STANDARDS

Arc welding equipment - Installation and usc, Technical Specificat ionlEe 62081. from In ternat ional Elect rOlcchnica l Commiss ionSafety in Welding and Cutt ing, ANSI Standard 2 49. 1, from American Welding Soc iety.Safety and Health Standards, OSHA 29 CFR 1910, fro m Superi ntendent of Docum ents, U.S.Government Printing Office.Recommended Practices for Pl asma Arc Cuning, American Welding Society Standard A WSC5.2, from American Welding Society.Recommended Sa fe Practices for the Preparation for Welding and Cutt ing ofContainers ThatHave Held Hazardous Substances, American Welding Society Standard A WS F4.1 , fromAmerican Welding Society.Nationa l Electrical Code, NFPA Standard 70, from National Fire Protection Association.Safe Handling ofCompressed Gases in Cylinders, CGA Pamphlet Pl , from Compressed GasAssociation .Code for Safety in Welding and Cutting, CSA Standard WI17 .2, from Canadian StandardsAssociat ion, Standards Sales.Safe Practices For Occupation And Educa tional Eye And Face Protection, ANSI StandardZ87.1, from American National Standard s Institute.Cutting And Welding Processes, NFPA Standard 51 S, from National Fire ProtectionAssociation.

7


8/83

J.GENERAL NOTICE AT OPERATION3. 1 Rated duty cycle & CAUTION

No.C0025P. 7/63

. Use al the rated dU ly cycle or under. Ife)(ceeding the rated dUlYcycle. the welding powersource may be deteriorated and burned.

I) Rated dutY cycl e: 40 % & CAUTION. Wh en you set to AC BALANCE is "MAX. PE NETRATION" si de al AC TIG welding, lise it

wi th rated duty cyc le is less than 30%. If duty cycle is over 30%, the welding power sourcemay be deteriorated and burned.

(2)The duty cycle is percentage of a ten mi nutes period that we lding power source can be operatedat rated ou tput without causing ove rh eating and damage of the welding power source . Thi swelding power source can be operated for four consecutive minutes. but it must operate al noload fo r the remaining six minutes to allow proper COOling.

ON I orr I

I:4 min ' l 6 min.

:1..

IOmin.(3) If exceeding the rated duty cycle, temperature rise of weldm g power source and torch exceed thea llowa ble va lue, and it causes to burn the equipment.(4) The fo l[owing figure indicates the combinat ion of welding current and dUlY cycle.

Observe the duty cyc le according to welding current.(S)The duty cyc le is limited by other machines (we lding lorch CIC .). Therefore, observe the lowest

rated duty cycle in the combination machines .(Less Ihan I64A)

100 _ __ _ __ . !Less than I90A\ \ AC BALANCE

DUlYcycle SO(%).

o

\ Alowllble duty cycle . t\ AG BAlANCE ...\ wMAX.PENETRAn ONN,,,

Usable range ", 40%

100 200We lding CUlTclIl{A)

.. . (30%)II300

8


9/83

No.C002SP. 8 / 6J4. CHE CK OF STANDARD CO MPOS ITION AND ACCESSORIES4.1 Standard composition. 1 Ipart s are standard compositions. The other parts sha ll be prepared at yOllr side.

Rem ote con trol box, ex tension cab le and hose are available as a optional accessory.

Single phase380V

Shielding gas cylinder! -1 Argon gas regulator with flowmeter I[nputcables Grounding ":"

4.2 Standard accessories

Coo ling water hose forwatercooled torchRemote control box(Optional accessory)

00 IWelding torchBase metal

Grou nding cableWelding power source

Ch k h hc the quantity w en you receive I e ~ q U l p m c n t . Description Specification Quantity Remarks

Q)Glass enclosed fu se 5A 250Y IG las s enclosed fuse IDA 250V 2@ Bolt MIO x 25 I For torch connection Nut . washer MIO I set Bolt M8 X 20 I For connection of base metal side cab le@ Bolt M6 x l6 2 For input tenninal connec tionCVNut washer M6 2 se tCartridge fuse RLI1 5 IDA I

9


10/83

4 .3 Accesso ries whi ch you should prepare(I) Argon gas: Only when TIG we ld ing (Gas; Tungsten Arc Welding)

Use argon gas for wcld ing.(Purity shou ld be more than 99.9%),(2) Filler wire : Onl y when TIG weld ing

Use a proper fi ller wire according to mate rial and thickness of base meta l.(3) Electrode: Only when stick we lding (S hi elded Metal Arc Welding)

No.C0025P. 9/63

Use proper electrode according to material of base metal, welding pos ition and joint shape.(4) Electrode holderUse an insulated electrode holder to ensure operator safety.

(5) Input cables and grounding cableInput cables Thicker than 14 mm2 X 2

Grounding cable Same in ut cable X 1* Be sure to make a grounding to avoid electric shock.The resistance of grounding should be less than 10 9 .

10


11/83

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-


12/83

5.2 Welding torch (Refer to owner's manual of each welding lorch for detai ls)Torch sw itch

Water p : : r : = = = = J - - . r - - ~Power cabl e ho:se[= b 3CCC:r'/ L i

Torch

Tungsten electrode5.3 Argon gas regulator

Gas hos


13/83

No.C0025P. 12 / 63

6. REQUIREMENT OF IN PUT POWER6. 1 Commercial input powerLb. WARNING

. Provide a leakage circuit breaker when the welding power source is used at place with highhumidity such as work s ite, the stcc tp lalc or the steel structu re,.Lb. CAUTION

e Se sure to provide a swi tch(with fuse) or circu it breaker at input side of eac h weldingpower source.ecapaclty 0 commercia dput power an amperage 0 ffi eakse or CirCUit br er

TIG StickDC AC DC I AC

InDut voltage and phase 380 V Single-phaseInput voltage range 380V + 1O%Input power (KVA) More than More than More than More than

19.9kVA 22.3kVA 21.2kVA 22 .0kVAAmperage of fuse or 80Acircuit breaker

6.2 Precautions for use on an engine generatorLb. CAUTION

Observe the following to prevent troubles of the welding machine in using auxiliary powersupply of engine generator and engine welder.e Set the voltage of engine generator to 380 ........399V during no- load running.

If output vo ltage is set too high, failure of we lding machine results. Unlike co mmercial power source, engine ge nerator is slow in recovering vo ltage when load

variations occur. Therefore, output voltage drops excessively when current variessuddenly due to arc start, and that may cause loss of arc.(Howeve r. a welding power sourcewill not fai l due to such conditions.) To prevent this, the capacity of engine generator

mustbe more than twice the rated input (KVA) of a welding power SOUl"e. Especially, enginegenerator with a damper winding is recommended. Co ntact the manufacture of enginegenerator whether the engine generator is prov ided with a damper winding

If one engine generator is used for two or more welding power sources, loss of arc is likelyto occur due to the influence of receptive welding power source.

When use the auxiliary power source of engine welder, use only the auxiliary power sourcewhich voltage wave form is improved.(Contact the manufacture of engine welder fordelai ls.)

13


14/83

.No.C0025P.20 / 63

9 WELD ING PREPARAT ION Lh CA UTIONTo prevent electromagnetic troubles. examine the fo llowings. Also, when

i f lectromagnetic troubles actually occur. examine the fo llowings again Close and fix sec urely of all doors and covers of welding power source Install the welding cable along the floor or the ground as close as poss ible . Pl ace the cable of the base meta l side and (orch side as close as possible . Keep flow ing rate ofshiclding gas proper. If it is not proper, high freq uenc y noise willIncrease.9 I P f Iicparallon 0 sa ety protective eqUIpmentLh CAUTION~ 4 f ) ARC RAYS can bum eyes and skin: FLYING SPARKS AND HOT METALcan cause of injury. NO ISE can damage hearing. .-Arc rays from the welding produce intense heat and strong ultraviolet ray s that can bum eyes

and skin. No ise from some arc welding can damage hearing Wear a face protection with a proper shade of filter ( See ANS I Z 49 . I listed in

PRrNCIPAL SAFETY STANDARDS. ) to protect your face and eyes when welding orwatching

Wear approved safety goggles Use protective screens or barriers to protect others from flash and glare: warn o thers not to

watch the arc. Wear protecti ve clothing made from durable, flame-resistant mater ial (woo l and leather)

and foot protection. Use approved ear plugs or ear muffs if noise level is high.,Shielding at TIG I STICK welding( I) Sh Id Ii T G Id e mg or I we IngWelding current Less than 100A 100-3 00A 300-500A More than.500AShield ing No. 9 or 10 11 or 12 13 or 14 150rl6

,e JOg or we mgWelding current Less than 30A 35- 75A 75- 200A 200- 400A More than 400AShielding No. S or 6 7 or 8 9 or II 12 or 13 15 or 16

14


15/83

No.C0025P.2 1 / 639.1 s.'X\\cn tll)eT"ation and gas flow control

Lt. CAUTION. 00 not put your hands, hair, and cloths near the rOlating parts of the fan motor.. When operating the main plug of the gas cylinder. do not put your face near the outlet port .High-pressure ~ may blow out, causing physical ini uries.

Preparation in order of the numbers,CD (2)....

CDSet the line di sconnectswitch for singlehase 380V to ON.

o o@ Pl aceCONTROLPOWER swi tchin "ON"position.

I"" ' ' ''' '' ' checkthe flowadjust inghandle isplaced in"SHUT' side,open theof ma in

@ Adjust the gasPlaceGASswitch in"CHECK"

sition.Flow usting flowing by turning

After adj ustinggas flow, pl aceGAS switch in"WELD"

sition.

handle. gas flow adjustinghandle to "OPEN".

9.3 Cooling method ofweld ing torchLt. CAUTION

. Using water cooled torch when "TORCH" sw itch on front panel in "A IR-COOLED"_position may cause burning the torch.

AIR COOLEDnWA Tt: \{ COOI.EI)

I ORCI I

. Select ..... proper coo ling method ....ccording 10the so rl of welding la rch.

15


16/83

No.C0025P.22 / 63

10 WELD ING OPERATION & WARNING

ItObserve the followings to prevent the elec tri cal shock.

. In touching the live electrica l parts, cri tical e lectric shock and bum may occur Do not to uch live electrical parts inside and outs ide of weldi ng power source.e Se sure to turn off the line di sconnect sw itch before connecting Securely anach the case and cover after connect ing cables Wear dry clothes and gloves when weldi ng.

& CAUTION. This weldi ng machi ne must be operated by operators understanding co ntents of thisowner's manua l and having know ledge and ski lls for handling the welding machine safely Use at the rated duty cycle or under. If exceeding th e rated duty cycle, the welding machine

may be deteriorated and burned. Close panel cover of the fro nt panel duri ng weldi ng.

& CAUTIONObserve the fo llowings to perform TIG welding sa fely

Use "GAS" sw itch when adjusting shielding gas flow. If using torch sw itch to adj ust the gasflow, useless high frequency generates

Using improper electrode may cause fail ure of arc stan, and generate use less hi ghfrequency .

Improper shielding gas flow may cause failure of arc start, and generate use less hi ghfrequency.

16


17/83

10 . I TIG welding (Gas Tungsten Arc Weld ing)10.1.1 Operation of T IG weldi ng

STICKTGCTIG SPOTWELDING MODE

Set the WELDING MODEchange-over switch to TIG welding.

DC.....

A C1-Set the modechange-over switch.

& WARNING

No.C002S1' .23 / 63

WELDINGCURRoSet the weldingcurrent.

If change-over this switch at we ld ing, sparks will generate,and it mi ght be a cause of buming

10.1.2 Pulse (ON/OFF )

. Never change-over this sw itch at weldi ng

. Sct the switch surely.

Pulse function can be used at DC TIG weldi ng and AC TIG welding. It can not be used atstick welding.

( I) What is pulse?Pulse is the fu nction which change the welding current periodica lly to stabilize arc, controlpenetrations, and control heating . ON

(2) Setting of pulseFor pulse operation, set the pulse chan ge-over switch on front pane l. lJPulse switch Main applications

Tack welding Repeating of short

welding.OFF Thin plate welding

. Preventing weldi ng beadhnnging down on th inplat l..! weldingON

,

Torch switch

Welding current

Torch sw itch

OFFPULSE

Timing chartON

ON

LLL

Welding "n.,."n lJ'Il "" : ":Uffl"111 11;1-''': e llrr':111

17


18/83

No.C0025P. 24 / 63(3) cHing the condition o f pulse

ON" " iA \'VI ~ o ) ] o o . I ..OFF

PULSE PULSE WELDING! PULSE TIME ($!,.(;.) BASE TlME(Sct:.}CURR.(A) BASE

SC I PULSEchange-over switchloON.

PULSECURR.!

CU RR .(A)Sel PULSE CURR., WE LD fNG / BASECURR ., PULSE TIME and BASE TIME .

BASECURR .

--!n,----------,---n,--h I- t 1Pulse time Base time. Pulse lime can be set fo r 1.4 seconds maximum. and base time can be set for 2.5 secondsmax Imum .10.1.3 Craler-fi ller (ON /OFF/REPEAT)( I) Whal is craler-filler?

CraterJL Bcad" . ' . ~ .,

The ho llow ca lled "crntcr" is genera ted whenfinishing the weldi ng. That ho llow distort ion maycause cracks or weld ing defects and shou ld be assmall as poss ib le . The function of fi lling the hollowis called "cra ter- fi ller",

18


19/83

(2) Cratcrti ller setting

No.C0025P. 25 / 63REPEAT

. This welding power source has three ki nd welding operation bysett ing af eRATER-FILLER sw itch on front panel. OFF

Setting ofCRATER

FILLERswitch

OFF

ON

REPEAT

Main app lications

Tack welding Repeat of short welding Thin plate welding

Thick plate welding

. Preventing welding beadhangi ng down on thinplate welding

Torch switch(TS)

WeldingcurrentGas now

Timing chart

ON

ONONfI 1- - ' .i


20/83

No.C0025P.26 / 63

(3) Sett ing tile condition of crate r-fi llerREPEAT

OFf [0]ONCRATER-FILL ER

Set the crater-fillerswitch to ON orREPEAT oosition.

100( i )f) 200 25' 100( i )f) 200 '50 \ i ) f ) " (i)"50 3011 50 300 I I ,

INITIALCURR CRATER UP SLOPE-FILLER TIME

CU RRSet the IN ITIAL CU RR ., CRA TER-FILL ER CU RR ., UP SLOPE TIMEand DOWN SLOPE TIME .

DOWN SLOPETIME

Usually crater -fi ller cu rrent is 60 ........ 70%of we ldin g current

10. 1.4 Crater-fi ller and pul seBy com bin ing crater- fill er and pulse. following we lding operat ion can be possible.

_ fONl, _ _ ONl,Torch sw itch I OFF I LWeld ing current

Initial Up slope time Pul securrenturrent

) rBase current Down slope time Crater-fillercu rrent

20


21/83

10.1.5 Initial currentInitial current can be selected "ON" or "Or'T ' by change-over switch (S W3)onP.C.B. P6887T.Re fer to 11 .1.2 for detai ls

Initial current can be sc t from SA to JOOA with adjusting knob on front panel.(M in imum value is 20A at AC TIG welding.)

10.1 .6 Post flow time Post flow time can be adjusted from 1 to 20(sec.)

by set electrode diameter from 1.6 to 4.8(mm

10. 1.7 AC TIG welding(I ) Notice of using AC TIG mode

INT IAL CURR.(A)

No.C0025P.27 / 63

When using AC TIG mode, observe the followings not to damage the we lding powerso urce

I. Use proper length cab le and use as short cable as poss ible.2. When using the extension cable, refer [0 f0r:-I"lo':w"i:.:n"g.:.fi"lg"'"'re'.--:---:-c--:-:-_:-:-___

Bind the torch side cable and base metalside cable each other with tape

o/'

. Straighten the cables as much as poss ible.Ifcable sett ing mentioned above cannotbe perfo nned by a ll means, lay the torc hside cable on the base metal.

IGood exampl e I

21


22/83

No.C0025P. 28 / 6J3. IflOo long to rch side cable is lIsed reluctan tly, wind it according to following figure of

" Good exam Ie",Bad exam Ie Good exam Ie

Do not wind the excess part of cable in thesame direction . Refer to the figure below " How to co il aexira cable", and make two windings inopposite direction each other and pile upone on another.

Top view

Side view

Explanation

xA B

the extra cableA and B.

I them respectively as Same coiling dirt:ction. Same turns or..:oiling. SaHlI.: di:tlll l'll..'r ( If

2A B

over A in thelo,."".s; e di rcelion.

oJ

22


23/83

10.1.8 Clea ning w idth

No.COOlSP.29 / 63

The cleaning powe r of arc whic h is necessary for AC TIG welding (A luminum, etc .) isadjustable by the AC BALANCE sett ing knob.The relation between the setting position of the AC BALANCE setting knob and we ld ingresult s is as follows.

Cleaning widthPenetrationElectrodeconsumptionIt D u t ~ C c

Nmow ""pSm.II 30% CJ 40% Lo' ' 'Sh.II, w Wid ,Ma:c . pcntration Max. ctean ing,ACBALANCEExample of cleaning action

wide "f - - - standard --. . narrowit. CAUTION

.T he rated duty cycle is 40%, but in case of sett ing AC BALANCE knob "Max. penetration"at AC TIG welding, the ra ted duty cycle should be less than 30%. If exceeding 30%, thewelding power source might burned.

23


24/83

No .C0025P.30 / 63

10 .1.9 TIG welding conditions for reference( I) General TIG welding conditions for DC without pu lse welding

Plate Elec trode Filler wire Weldin g Ar. gasMaterial thickness diameter Diameter current now rate

(mm ) (mill cP) (mm (A) (C Imin.)0.6 1.0 , 1.6 - 1.6 20 - 40 41.0 1.0, 1.6 - 1.6 30- 60 4

Sta inless 1.6 1.6,2.4 - 1.6 60-90 4steel 2.4 1.6,2.4 1.6 - 2.4 80 - 120 4

(DC , 3.2 2.4,3.2 2.4 - 3.2 110- 150 5Electrode 4.0 2.4, 3.2 2.4- 3.2 130- 180 5Negative) 4.8 2.4, 3.2,4.0 2.4 -4 .0 150- 220 5

6.4 3.2, 4.0, 4.8 3.2- 4.8 180 - 250 50.6 1.0 , 1.6 - 1.6 50-70 3 -4Deoxidized 1.0 1.6 - 1.6 60-90 3 -4

Copper 1.6 2.4 1.6- 2.4 80 - 120 3 -4(DC. 2.4 2.4,3 .2 2.4 - 3.2 110 - 150 4Electrode 3.2 3.2, 4.0 3.2 - 4.8 140 - 200 4- 5Negative) 4.0 3.2, 4.0, 4.8 4.0-4.8 180 - 250 4- 5

4.8 4.0,4.8 4.8 - 6 .4 250- 300 5- 66.4 4.0 .4 .8. 6.4 4.8-6.4 300-400 5- 61.0 1.6 - 1.6 50-60 5 -61.6 1.6,2.4 - 1.6 60- 90 5- 62.4 1.6, 2.4 1.6-2 .4 80 - 100 6 -7

Aluminum 3.2 2.4 , 3.2 2.4 - 4.0 100- 140 6- 7(AC) 4.0 3.2 , 4.0 3.2- 4.8 140 - 180 7- 84.8 3.2,4.0.4 .8 4.0- 6.4 170 - 220 7- 86.4 4.0, 4.8 4.0- 6.4 200-270 8-121.0 1.6 - 1.6 30 - 40 3 -41.6 1.6 , 2.4 1.6-2.4 40-70 4- 52.4 1.6, 2.4 1.6-2 .4 60-90 4- 5

Magnesium 3.2 1.6, 2.4 2.4 - 3.2 75- 110 5 -6(AC) 4.0 2.4, 3.2 3.2-4.0 90 - 120 5- 64.8 3.2, 4.0 3.2 - 4.8 110- 150 5- 66.4 3.2 , 4.0 4.0- 4.8 130- 170 6- 7

I I c:f=3E I It 1 3

( : I ) ( II ) (c )

Gro oveLaye rs shape

I (a). (b)I (a), (b)I (b)I (h)I (b)I (e), (d)I (e), (d)

1- 2 (a), (e)I (a), (b)I (a), (b)I (b)I (b)I (e)I (e), (d)I (e), (d)

1- 2 (e), (d)I (a), (b)I (a), (b)I (h)I (b)I (b)I (b)

1- 2 (e), (d)I (a)I (h)I (b)I (b)I (e), (d)I (e), (d)

1- 2 (e), (d)

y !/Oy\ /

( cl )

24


25/83

(2 ) Welding condit ions for DC pul se we lding In case of na t position bUll welding

OapMaterial Joint geometry

Pulsecurrent(mm ) (A)

Mild steel 0 200, .(SPC) , - 1.2 1501.2 1.6 130_ '"IG I..

Stainless 0 150teel I.2 t. 1.2 150

(SUS304) I 1.6 130-0 - 2.0 130

Copper '.I' 0 280(Teup-I) (4 --' J 1.2 280--I. - J'1G- 1.6 280

Ti tanium L(Tp- I)

,0 200.0 I

JOe

Shielding gas: Argon (10C min .)Filler wire : 1.2mm


26/83

26


27/8327


28/83

No.C0025P.34 / 63(4) Applicab le tungsten electrodeSince electrode consumption degree in AC weld ing vari es depending upon setting posi tionorAC BALANCE knob, determine diameterof electrode to be used frol11 the next electrodediameter chart .

I . Electrode diameter chart

,,...;,,,,

,

, /,3.2--- - ...

150

250300

\ - .. - ' I> ' Y ( " i ~ ' ODC AC BALANCE QSett ing pos ition

For ceriated and thoriated tungsten electrode

,,/

--, ,,,

\

For pun: tungs ten l'k't; lrodc

28


29/83

2. How to lise electrode diameter finder chart

At AC TIG welding

\,"'0;. '--" J; j ' " " 1fj I a n d a r d "0

f)DC

ACMa;< . penetratIOnAC BALANCESetting position

No.C0025P.35 / 63

(1) Draw a line from the dial center(point P) to welding current graduation (point Q) andextend the line.

(2) Read electrode diameter at the position of" . " (on circle--) cleaning width (point R).(3) If cleaning width se tt ing is not at "e" on circl e---), dete rmine diameter of electrode to be

used dependi ng upon the dial se tting posit ion .(E I )amplc

Cleaning width se ttingWelding current Electrode MAX .CLEANING MAX .PENETRA TION(Standard) to . to .

120A Cerium More than 3.2 More than 3.2 tb More than 2.4 tungs ten At DC TlG we ldi ngFind crossing point of ex tension line o f PQ and DC circl e (point T) .(Exampk)

WcldinJ,1 current Electrode Electrode diameter120A Ceri um l u n g t ~ n Mon: Ilm il 1.6 Q

29


30/83

No.C0025P.36 163

10.2 T IG arc spot welding10.2. 1 What is arc spot welding?

Tu ngsten ele


31/83

10.3 Slick wdding (Shielded Metal Arc We lding).& CAUTI ON. Keep the weld ing rod in a place with low humidity.e Ory the rod sufficien tly before using

No .C00251'.37 / 63

When the gas burner is used for prehcating or removing moi sture of the base mewl. be sureto heat to lOOt or above .

Slag and fume generated when lack welding will cause wetting the part of base me tal to bewelded. Remove slag and fume after tack welding.

When we lding is performed olltdoors and wind velocity exceeds 3m/sec, lise a wind shi eld.10.3. 1 Sett ing and operationof stick weldi ng

STICK

TIGT IG SPOT

WELDING MODESel WELDING MODEchange-over swi tch toSTICK position.

10.3.2 Stick welding conditions R f Id ' (Dnge 0 we mg current d) [AJwnwar

mm $ ) 2.6 3.2Characte risticof electrodelImenite type 50- 85 80 - 130Lime titania type 50- 100 90-130Low hydrogen type 55-85 100 - 140

" V WELDING CURRo

Sel Ihe WELDINGCURRo

4.0 4.5120 - 180 145 - 2 00140 - 180 160 - 210140 - 190 -

Range of welding current (Vertical Upward) [A]mm ) 2.6 3.2 4.0 4.5Characteristic

Of electrodeIlmenite ty pe 40 - 70 60- 110 100- 150 120 - 180Lime titania type 50 - 90 80 - 130 110-170 125-190Low hydrogen Iype 50- 80 90 - 130 120 - 180 -

5.0170-250190 - 250190- 250

5.0130 - 200140 - 210160 - 210

31


32/83

No.C0025P. 38 / 63II APPLIED FUNCTION

&, WARNINGObserve the fo llowings to prevent the electrical shock.

In touching the live elect rical parts, critical electric shock and burn may occur.. 00 not touch live electrical parts inside and outside of the welding power samec Grounding to the case of the welding power source should be perfonned by persons

qua li fied in electrical work and according to the laws and regulations.e Be sure to tum of f the line disconn ect switch before touching in side of welding power

source.6 CAUTION

. When changeover the switch on Pc.s.,wait for three minutes or more after turningoff the control power switch on the front panel. Also, be sure to turn off the linedi sconnect switch.

Never touch the potentiometer on P.C.s . with wh ite painting.11 .1 Built in fu nction and change-ove r switchqf :0 Be sure to turn off the line di sconnect switchbefore perfonning Change-over switch(builted on P.C. B.P6887T)Switch function(A side/B side)

SW I Pre-flow ON I OFFSW2 Current contro l PANEL 1REMOTESW3 Initial current ON I OFFAll sWItches are A sIde on the shipment.

.[ftaking off the upper cover, change-o""r switch(SWI on P.C.B. P6887T can be foundon chass is.

Pre-flow\ ' \P6 S87S P6SS7T= 51"2SW:I nv=/ IIlli ti :d curn.: nt

32


33/83

11. 1.1 Change of gas pre- now timeGas pre-now time fun ction is to let gas now before arc start.then it protects the tungsten electrode and weld ing zone fromoxidation. Gas pre-flow time ha s been set to approximate0.3 second on delivery. When restart ing during post flow,gas pre-flow time is zero automatica lly. Gas pre- flowtime can be changed to zero second when switch SWI is setto B side.

1 L1.2 Init ial currentThis function has been set to ON side on delivery. Ifchange-over sw itch SW3 is set to B side, thi s functio n is setto OFF.

11 .1.3 Panel/remote change-over switch for current controlThi s funct ion has been set to A (PA NEL) side on deli very.When using the remote control box (op tional accessory), setchange-over sw itch SW2 to B (REMOTE) side. When SW2is set to B side, current control is not available at adjustingknob on front paneL When SW2 is sct to A side, currentcontrol is not available at remote control box.

11.2 WA RNING and OVER HEAT lamps

No. C0025P. 39/ 63

e l f WARNING and OVER HEAT lamps on front panel come on in red and ye llow dur inguse, the welding power source stops automatically.Check fo llowing items and refer to 12.6.

( I) THERMAL OVERLOADThe rated duty cycle of this' welding power source is 40%. If actual duty cycle exceedsthe rated value, WARNING (red) and OVER HEAT (yellow) lamps come on, and thewelding power source stops automatically. In this case, keep CONTROL POWERswi tch on and wait fo r about 15 minutes under the condition of the cooling fan rOlated.When resuming welding, make sure to decrease the duty cycle or welding current toprevent from turning on OVER HEAT lamp and stopping the welding power source.The welding power source may be damaged if welding operation is resumed immediatelyafter WARNING lamp is put out.

(2) SHORTAGE OF WATER PRESSUREi f coo ling water is not flowing or the water pressure is lower than proper level whenTORCH selec tion switch on fronl panel is WATER COOLED s ide. weld ing power sourcestops I1 lJlo l11micl1lly. In thi s case. check coo ling water flow ing without kn kagc.

e lf thl: torch sw itch is aln:ady ON when CONTROL POWER sw itch is ON. WARNI NGlamp (n:d) CO ll h.'S (ll1


34/83

No.C0025P.40/63

11 .3 Optional accesso ries11. 3. 1 Welding torch accessoriesCD Air-cooled torch

4m 120A AW(P)-9150A AW(P)-17

Sm 120A AW(P)-9150A A W(P)- 17

! 4m I 200A I AW-26

Ex tension cable and bose

4m BAWH- 150411m BAWH-1 51116m BAWH-1 516

4m BAWH- 150411m BAWH- 1511

4m BAWH-200411m BAWH-201116m BAWH-20 16

m -+ 15m-- + 20m

~ r n --+ 15m--+ 20m

L i_ Sm......_ 20_0_A--'__ _ - - - ' ~ f - - 1 4 ~ : : . . ~ 4 -i1: 1 :!: 1@ Water-cooled torch

210A AW-20AW-254m AW-IS

300A AWG-S(for arc spot)

210A AW-20AW-25Sm AW- IS

300A AWG-S Y(for arc spot)

Extension cable and hose Length

4m BAWS-300411m BAWS-30 1116m BAWS-3016

b m --+ 15m--+ 20ql

4m I BAWS-3004 I 12m19m1m I BAWS-301 1 I

34


35/83

11 .3.2 Other optional accessori esDescription

Remote cor ll ral boxFOOl current controllerFOO l switchTorch sw itch(Push butlan type)

Part No.P6699Z00KI I04FOO4259-004K5091l00K509COO

Remarkswi th cable (4m)with ca ble (4m)wi lh cable (5 111 ) (1V-34092)w ith cable (4m)with cab le (8m)

No. C0025P.41 / 63

35


36/83

No.C002S1'.42 / 63

11. 3.3 Cab les and hoses(1) For a i r ~ c o o l e d torch

ModelDescription

Gas hoseBase mcta l s ide cable

Part No.PI042KOOPI042POO

(2) For water cooled torch(Cooled by city water)Model

Desc ription Part No.Gas hose PI042KOOBase metal side cable PI 042POOWater hose PI042LOOFeed watcr place PI042MOI(fo r watcr hose)Con necting metal PI042M02for water hoseRubber hose (for c ity water)

BMRHP-lOOIQ'ty Remarks

I 3m. nuts at both side sI 38 mm ", 3m

BAB-lSOIQ' ty Remarks

I 3m, nuts al both sidesI 38 mm!X 3mI Sm, nut al one sideIII 30 C(1l

(J ) For water-cooled torch(Coo led by watcr cooler PU 30 I)Model BMRHP-]OOI

Description Part No. Q' ty RemarksGas hose PI042KOO I ) m, nuts at both sidesBase metal side cable PI0421'00 I 38 mm!X 3m

36


37/83

\ \ :; 5 EXlens ion cables and hosesDescription

< I1I\WII 1501 > Extension torch sid.: cabl.:For extend ing 1\'loJd Exh.:nsion cubic lor n:mOlc control1\WI1')-9 or AWI1' )_ 17 Extension cable for torch switch(cablc len gth is 4 111 ) to 8 In Ada pter

Conn ection cover< I3AWH15[ I > Extension torch side cable

For cxtcnding Model AW(P)-9 or Extension cable for remote controlA WIP)- 17{cablc length is 4m) Extension cable for torch switchto 15 m Adapter

Connection cover< BAWH1516 > Exten sion torch side cable

For extending Model AW(P )-9 or Extension cable for remole controlA W(P )-17 (cable length is 401) Extension cable for torch swit cht020m AdapterConncction cover

< I3A WJ-I-2004 > Extension torch s id e cabl eFor extending Model Extension cable for remote controlAW-26(cable length is 4 m) to 8 m Extension cable for torch switch

Conneclion cover< SAWH-20 11 > Extension torch side cable

For extending Model Extension cable for remote controlAW -26(cable length is 4 m) to 15 m Extension cable for torch switch

Conncction cover< BAWH-2016 > Extcnsion torch side cable

fo r ex tending Model Extension cable for remote controlAW -26(cablc length is 4 m) to 20 m Extension cable for torch switch

Connection cover< BA WS-3004 > Extension gas hose

For extending Model Extension water hoseAW -200rAW- 18 (For water su pply)(cable length is 4 m) to Extension lorch side cable8m Extension cab le for remote control

Extension cable for torch switchConnection cover

< SA WS-30 1I > Extension gas hoseFor extending Model Extens ion water hoseAW-200rAW-IS (For wata supply)(cable length is 4 m) to I Sm Extension torch side cable

Extension cable for remote cOnlrolExtension cable fur turch switdlCunnection covcr

< !lAWS-lOl l! > Extensil\n g a ~ hoseFur ext..:nJin!,; Mudd Extension wat.:r huseAW-211 II f i\ W IX (Fur lI';nef supply )l e:II,1.,: kn,gth is ", mil" :W II E"tensilln tureh side callI.,:

J-; " t1 Q.l] ROOPIO-USOO1'1 600N02115581'101H955 HOOK5271-1 ()()K527KOOPI600N02H558MOI1-1956BOOKj27JQOK527LOO

P1 600N02H55 8MOIH957 1300P l043ROOPI 043SooH558MOIH9581300K527 1-1 ooK527Koo1-1 558MOI1195 9800K527JOOK527LOOH:5 58MOIPI04)KOO"104)LOO1-1 59 ) 1-100PI 04) ROOPI043SooH558MO IK527BOOK527DOOI-IS93JOOK5271IQOKS27 K()O11 55KMUIK517CUUt.:: 527EUU115'HKHIJ" ."i :! 7JIIC IK."i27 l.111J11 55:-; \ j(l 1

No. C0025P. 43 / 63Q" ty Remarks

I 4 mI 4 111I 4mI

1STI II mI 11mI 11 mI

1STI 16mI 16mI 16 InI1STI 4mI 4mI 4m

1STI 11mI 11 mI 11m

1STI 16mI 16mI 16m

1STI 4mI 4 mI 4mI 4mI 4m1STI 11mI 11 mI 11 mI I I mI I I m

1STI 16mI 16mI 16 II II 16mI I i II I

l S I

37


38/83

No.C0025P. 44 / 6311.4 Con nection of optional accessories

II A.1 Ex tension of torch side cablesI) For water-cooled torch

Connect optional extension cable and hose as shown in following figure.Do not connect a hose for water supply to the o lltl et of ft:lurncd water.When using water cooler PU-30 I, please refer to the Owner's Manual for waler coolerPU-301.

To front fa ce of Extens ion gas hose Ex tension water hosewelding power sourceGas ou,l e' -[]" -I

Water inlet -[J :1 ,,-Torch ,erminal - c r=J !

/'Extension torch side cable(For condensed water)

2) Fo r air cooled torch

/ (For fcedi ng water)IT m17I DtJ-dO

.1

.Iinp at 3 noints

J\Connection coverHSS8MO IExtension lorch side cable

To waler-- cooled torch

To front face of Taping al J points Connection coverwe ld ing power sou rce ) - _ - . J : c a ~ t m ~ : : : ; : : : J ~ ~ : . . . . H _ I

T : c ~ ' : " ~ : ; ; ; ; ; : C j ~ l f 1 ~ :l:Q@) (- ~ ~ o ~ ~ ~ 'occh...,...... .... ......Power cable adapter

~ : : r ~ (torch accesso ries)Gas outlet -1 : ",H 145EO I.HSOOD03

Adapter hose H13000(torch accessory)

Adapte r P1600N02 is necessaryin case of using model AW-9 torch3) Ex tension of torch switch cable and remote control cable.

FrOll1 face o f .\\"(.'ldillgO l ~ ~---'

2P Extension control cab lereceptacle for torch switchIkF==([J\jll ~ ~ F = ( =c::PTorch sw itch

QJl:D==:??==CdlP Q1tD==?F=(=[0 01"'" \I ' 1 ,1..:II .. j , '" l"" l I lh.1 :tbl..:,..:.!,l.Id..: 1.11 1.. 111"(..: -:1'1111,,1 ! ""

38


39/83

[ 1.4.2 Optional remote contro l box(I) TIG welding Conn ection Please refer to 8.1.1 for detail.

No. C0025P. 45 / 63

Operation II is same as "Welding current contror',(Refc r to 5.1.)(2) Stick welding Connection Please refer to 8. 1.2 for detail. Operation It is sa me as "Welding current control", (Refer to 5. 1.)

Remote co ntrol is available when swi tch SW2 on P,C .R P6887T is changed over.Refer to 11 .1.3 for detai l.

11 .5 Connection with autommic machineLh CAUTIO N. Contro[ cable which is conn ected to internal tcmlinal block on chassis sha ll be separated as

far as possible from base metal side cable and torch side cablc Never connect the wiring to control circu it except for intemalterminal block.

It cause trouble and malfunction.When the upper cover is detached from the welding power source, 4P terminal block on P C.Ron the chassis can be found. Function signals as shown in following figure wh ich areoutputted to this ternlinal block can be used. Feed the wiring to terminal bloc k throughbushing o n rear panel of the welding power source.

When the upper cover is detached. wa it fo r three minu tes or more after turn ing ofT the control powerswitch on the front panel. Also. be sure to tum ofTthc line discon nect sw itch.

(58)

oLj=-J__ WCRUsed for detection of welding

current. Contact closes duringwelding curre nt flowing. Contacta t i n ~ is less than O3A at AC I lOY .

(78)

EiBEiBEiBEiB o

4P terminal block

Pluse synchronous oulputDuring pu lse welding. terminalsWill be closed.Maximum allowable voltage: 24 Y DCMaximlllll allowable current: lOrnA

39


40/83

No.C0025P. 46 / 63

11 .6. Optional eq uipm ent (Refe r to respective owner's Ill anua l for details.)11.6.1 TIG welding with filler wire.( I.) TIGUN. TIG UN'S exclusive torchModelRated out put currentDuty cycleCoo ling methodCable length. ControllerModelRat ed input vo ltageRated input powe r

(2) TIG fiJl er wire feedi ng system. ControllerModelRated input vo ltageRated input power

AWG - 1501ISOA40%

Air coo lin l-'8m

Adapter hook H528XOO is necessary when using HC-7 1 Wire guide assembly

TorchAW - 18AW - 26AW -17AW - 9

Model eM -27 1wire feeder for TIG fi ll er

AWGW - 300130M40%

Water cooling_8m

HC - 81200 V, single phase

200 VA

HC - 71200 V, s ingle phase

200 VA.

Mode l ofwire guideBHC - 711 8BH C - 7126BHC-7 11 7SHC - 7109

40


41/83

11 .6.2 Tungsten elect rodeUse ccrialcd tun gsten or thoriated Hmgslcn elect rode.

No. C0025P. 47/ 63

Selec t accord ing to welding current. (Refer to tables be lO\v. EN: Elec trode negative)Ccriated tun gsten e lectrode can be o btain consum pti on of electrode come little. and goodarc start can be obtained . Ce rialed tungsten

Part No. Dimens ion (mOl ) Allowable welding current (A)Diameter Length DC EN AC (RMS va lue)0870-016 1.6 150 150 1300870-024 2.4 150 250 2200870-032 ' ?>.- ISO 400 290

. Thoriated tungstenPart No. Dimension (rnm) Allowable wel ding current (A)Diameter Length DC EN AC (RMS va lue)

0831-005 0.5 150 20 10083 1-01 0 1.0 150 80 400831-0 16 1.6 150 150 1000831-316 1.6 75 150 100-083 1-020 2.0 150 200 1200831 -024 2.4 150 250 1350831-324 2.4 75 250 1350831-032 3.2 150 400 175083 1-332 3.2 75 400 175083 1-040 4.0 150 - 300

Pure tungstenPart No. Dim ension (mm ) A llowable welding CU lTent (A)Diameter Len gth AC (RM S value)

0830-005 0.5 150 150830-010 1.0 150 500830-016 1.6 150 1000830-024 2.4 150 1300830-032 3.2 150 1600830-040 4.0 150 2400830-048 4.8 150 3300830-064 6.4 150 430

41


42/83

Advanced Air Cooled COz / MAG Welding Torch

BLUE TORCH I IOWNER'S MANUAL r Parts LisU

WT 3 5 10 -Se r i e s

Technical DataRated Current: 350A (C 0 ,) I 300A (M A G)

Dutv Cvcle : 60% ( C 0 ,) I 30% (M A G)Wire Size : O. 9 mm, 1. 0 mm, 1. 2 mm, 1. 4 mm

(1.2mm Tip is standard.)Torch Length : 3. 0 m 4. 5 m 6. 0 m

Net Weight : 2. 7 kg 3. 6 kg 4. 5 kgWeight at Operating : 1. 2 kg 2:nCooling Method : Air Cooled D8m

3 - 1- 053 - 142


43/83

Standard Parts List

, 14tc:f---I 5

f1---@Model: WT3510 - SZ ... 1U5327

WT351O -MZ... lU5328WT3510 - LZ ... lU5329

. Front Side Components . Cable ComponentsNo. I Part Desc ript ion Part No . No. Part Descr iption Part No.0) Nozzle ( I.D.16mm ) U4167GOI @ Cab le Support (with Screw U5035KOOi2l Insulator U4167LOO @- 1 Smal l Screw (M4 x 16)@ Contact Tip (1.2mmJ K980C26 Liner@ Tip Bodv U4167G03 3.0 m (0. 9 - 1. 2mm ) U4170H02@ Orifice U4167G02 4. 5 m (1. 0 - 1.2 mm ) U4535GOI@ Torch Body U5347BOO 6. 0m 0 . 2mm ) U4172HOI@- 1 ORing (S9) 3574 - 001 @ Power Cable (Reinforcing Spring is included .)(J) Cap U5341GOI 3. 0m U5347DOO@ Flat Pin U5035G03 4.5 m U5348DOO@ Handle (with Screw) U5035GOO 6. 0 m U5349DOO@- 1 Small Screw (M4 x 20) @-1 Bolt wi th hole (M5X 14)@- 2 Small Screw (M4 x 16)

> Trigger U5035EOI


44/83

Optional Parts List

A-Tip n p !HI,h d L . Loo. TiP ew-Tip a"" Lrr,) 1H,avyJ'!

WI" I 1 I [ ; 1... ... ...O 91M! K980C03 - _u"" n"1. 0 1M!I. 2 mm

K980C;/CY{K980C19 K980C05 U4167H05 K990E12 U4167H12- I- - l - f-I. 4 nun , Few: K98OC20 K980C06 - K990E1 4 U4167Hll

NOlzle Heat ShieldLow Current High Current Arc Spot DHp and Narrow Spaee U2075JOlU41 67HO l U4167H 16 U4170HOI U4167H04 Welding Tarchi!!E 'l3 1-- B - ""3 I!f~ t l I ". j I ,00. I- L ,- J Combine withLong Tip.

Torch BodyR77 , 4 So R 1 1 5, 4 5 R77 . 55 A l l 5, 5 5 St raight Flexible Long Nec kU5339BOO U533 9COO U5347BOO U5350BQO U5339HOO U5339LOO U5339NOO


45/83

Torch Type

WT35 1 0 -SD Direct PlugsIRated Current

( 350A )

CO , /MA GBlue Tarch [J Series

S

-r

eries No.

Tarch LengthS (Standard ) 3. OmM (Midd le) 4 .5 mL (Long) 6. Om

D : o k i n DB : C c:> Black Tarch ' IP PanasonicE Euro (Binzal)M MillerMS Miller (Separate Gas Hose)H Hobart (Tweco)L lincolnFS DAIDEN FS Series

"I OTC black lorch Power ceble 8dIlPI8


46/83I

.ACCESSORY KIT AK-3CA8 l C O V ~ . ~ l o . Wc-a.22 EXTENSION KIT NOT AVA ILABLEttOOK-UP KIT HK2, HK-3 .

OHK2: (OCS) . auto( COHNECT ADD 0 IN FAONTOF TORCH PACKAGE OR CA.BLE "

, 1lA,,57.11"""5"7

WP261H.no,."'"CG

"'N63

",N'"

18CG2O

. " .200 AMPS . AIR C Q O L E D ,' ,

2126 6 : : : : . r ~ 1

} ' ~ " !1819

' ~ " - ? ' U ~ a J u m i n ~ nozzle (See' chan 8 )" - l ~ i ' nozzle (See chart 8) .20 45Vsi cable adapter" I ~ ~ ~ e & b t e - 1 plecl rubber1~ 6 \ O O R ~ ' h ft . (3.8m)25 ft . (7.6m)22 - 2: p i l e i G il IwM only

12'h ft . (3,8m) . 4CN7SR2S It (7,6m) . 41VlOR" WP-2fN I ~ ~ ~ torch body. includes 'cup gil.keI and(70")" "'"' 1 ~ ~ ~ " l n c U d " 98WT7 Q-nng" H,2OOA . (ribbed. andard)"

HZOO (:smooch. option.r)hart 8)Cabll Rlpalr Kltl .

ZCRK26 -, , ~ b l e rep.ilr kitZCRK2...2 ; . cable rIPII. kitCH ART A . '\ I ..... I CHAR:T HOZZLES HPN HIGH PERFORMANCE NOlnEs AVAILABLE

1 = ~ I " j : . ' I ~ ~ ' ~ ~ , to : u -- - -, - - , ,- -!ooI",' "." .. !ooI",. - -I=- - I - I " - i"t _ ::. ::;" f--f--f-:::::-1I-I-f-:::I-I-I--,-J'-.--"-J51"15 ~ 1 " 1 ' , 501"": .- - _.,

- - "- 11


47/83

MANUAL NO;P250002

DAIHENcapor""'"

OWNER'S MANUALFORDYNAAUTO

~ [ Q )MODEL: CPXDS-350 P25000

100 NOT DESTROY1IMPORTANT: Read and understand the entire contents of thismanual, with special emphasis on the safety material throughoutthe manual, before installing, operating , or maintaining thisequipment. This equipment and this manual are fo r use only bypersons trained and experienced in the safety operation of weldingequipment. Do not allow untrained persons to install , operate ormaintain this equipment. Contact your distributor if you do notfull understand this manual.

DAIHEN Cor oration WELDING I'RODUCTS DIVISIONJuly 1,2007

IUpon contact, advise MODEL and MANUAL NO . I47


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No.P25000

3. SPECIFICATIONS3.1

3.2 Standard accessories (weldi ng power source)i i

Fuse

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No.P250006. LOCATION AND FUN CTION OF CONTROL

6. 1 Front panelLf1 CAUTION

. With the welding stopped, use the switches or knobs on th is front panel.

A ,

T AUTO PROGRAM SWitchTo select a welding process and a wire diameterwhile pressing + or - button. Set to only thenumbers listed on the next page. Refer to thetable of program switch on the next page.

(j ! CRATER FILLER CURRENT(A)NOLTAGE(V)control knobsTo set current and voHage when filling in a cra ter.Set to optimum crater-filler conditions.

1.,1 CRATER FILLER switch (ON/OFF)Switch this switch to ON when filting In a crater.Refer to section 8.2, Crater-filler" for details.1PEN ETRATION CONTROL switchTo control penelration. Se t to ON for penetrationcontrol. (Refer to section 8.3.)

VOLT. CURR. CONTROL switchRefer 10 section 6.2, "Remote control" for detailsof Ihis switch.I; SHIELDING GAS switchTo controllhe amount of gas flow. Switch thisswitch to WELD when welding. The TORCH

switch is nol available as long as the GAS switchis set to CHECK.

@c_ __ I .. .------y '" I.$IIIEiJ,1Ii liAS t l i (...

u ... ,40II1dr" ~ 1 1 J 1 .- --

--1-

'7J

. 1''':;:'n@ @

I I

',7 WARNING lampWhen an error is detected, this lamp lights orflashes, then output stops. Refer to section 10.3."When an error occurs' for details andcancellation of the error.

.'I POWER lampUghts when the line disconnect switch of inputpower box is connected. Be sure to disconnectthe line disconnect switch, and make sure thisindicator goes out when inspecting externalconnections ..9 CONTROL POWER switch

When this switch is turned on, all indicatorsinstantly come on and fan starts rotating.If this welding machine is rested for more than 6min. while the CONTROL POWER switch isturned on, the fan automatically stops rotating.II AMMETER

II VOLTMETER,J(FUSE{s)

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No.P250006.LOCATION AND FUNCTION OF CONTROL (conlinued)6.1 Front panel (continued)

. MODE switch (C02/ MAG)MODE No. Wektlng process Type of wire Wire diameter. ( m m ~ )

I CO,2 MAG O.3 CO, SOLID 1.04 MAG5 CO, 126 MAG - -7 CO, 1.28 CO, FLUX CORED 1.49, 0 No programs

I. set a mode number to 1 8.CAUTION

6.2 Remote control

CURRENT adjusting knob To set welding currentSet the welding current bythe scale of using wirediameter.

. SEPARATE adjustment

INCHING button To feed a wife.Turn the weldingcurrent adjusting knobto change a wirefeeding speed.

VOLTAGE knob SEPARATE adjustment To set welding voltage. ONE KNOB adjustment- Sel Ihis knob In the position mar1


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NO.P25000

8 WELDING OPERATIONLl', WARNING

Follow the instructions below to avoid electric shock. Do not touch charging parts inside or ou tside the welding machine. Only certified operators or the person who knows welding mach ine well, should changewiring of the welding machine or changing switch. Turn off all of the line disconnect switches and wait more than three minu tes beforetouch ing th e parts ins ide the welding machine.

8 .1 Setting of the built-In changeover switchi t CAUTION

Be sure to turn of f all of the line disconnect sw itches when swi tching the dip switch 0adjustin g va riable resistor. Never touch the variable resistor painted white Variable resistors and dip switches are located on K5374P(Microcompuler COO53X on peBl) . inside thewelding power source A desirable function can be se lected by changing the settings or resistOfS and dip

I W itcheSLJI DODDpeBl 0~ 0~

P C ~ ~ s ~ oo

OFF

NOTE: 00 not touch ot her resistance or dip switch .

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oo

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No.P25000

8. WELDING OPERATION (continued)8.1 Setting of the buil t-in changeover switch (continued)8.1.1 Initial current function(1) Initial cunent function. Welding starts. following the same conditions as crater filler Initlal currents are factory-set to OFF. Set Sl #2 on P C.B. 1 to ON to use initial current.

51 P"g g bH:H.l g gI 3456781 Switch S1 #2 to ON 10 use initial current function. and to OFF when the initial current is not used Set the CRATER-FILLER switch on the front panel to ON to use initial current function. When the switch is

set to OFF. initial current function does not work.Initial current ON

Torch switch(TS)Wire feeding

Gas flowWeldingcurrent

8.1.2 Preheating function

J-L....!J ; ; LI I I I IJ: I :L

-.J :: LInot"'_ M.ln . , ~ , folie'" .. fIR w e l d ; n ~ I d , n g

Initial current OFF

'.J : , : Lr:----L~ J n ('.'f' 1,11f.weld,ng ......Id'ng

. Preheallng function has been set to OFF prior to the shipment of the welding power source. Switch thefunction to ON to use 100V receptacle.(When the preheating function is set to ON. 100V AC is always applied to the receptacle . But when thefunction is OFF. l OOV AC is sporadically applied according to settings of the switches. No control of theswitches for six minutes while the preheating function is off makes a fan stop automatically.)

.&.. CAUTION Warm up for more than 5 minutes before welding operation when using a gas flow regu latorw ith a heater. Failure to do so may cause damage of gas flow regulator. Refer to an

operation manual supp lied with a Qas now reQulator Switch S1 #4 10 ON to make use of preheating function.

SWitch #4 to ON when using l00V AC for heater. and to OFF when not using. I

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8. WELDING OPERATION (continued)8.1 Setllng of the buillin changeover switch (continued)8.1.3 Changing wire feeder function

Switch S 1 #5 to OFF to change wire feeder.

2 3 '1. 6 7 8+I When use wire feeder CMX 2302 OFFI When use wire feeder CMXL2302 ON

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No.P25000

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NO.P250008. WELDING OPERATION (CO nlinued)

8.2 Craterfiller settinge Three types of welding operation, craterfiller off, craterfiller on, and craterfiller repetition, can beperformed by switching the CRA TERFILLER switch on the front panel

ONIOFF Main purposes Timing chartON

Torch swilch (TS) -.J 10FFOutput voltage J "--,

, Tack welding J ~ d - S l i d r : penod, Repetition of short Wire feedingOFF weldings ~ I " " , ..do ..n i!"odWeld ing a thin Welding current - .J "-plate

Gas now -.J L~ b ' n ",cld,n

..f\o'" pnlOll'rc: .1u .. pnlOdeOo nol turn off the torch SWitch during main welding.

ON ONTorch switch (TS) .J I QEF n OFFOutput voltage --- .,..,... Filling In a --epression Wire feed ing(crater) left at the - ~ " ' " N termination of the Welding current Jcnller .,..eld

.. Welding an -.J Mllm we4dOI\g )I Lverage plate Gas flow Post .1'Iow penod< < ,Pn! .1'Iow perIOd Cr-,er .hUe1 perIOd

e Welding power source is self .held when torch SWitch is turned offduring the crater-filler periode Set crater-filler conditions by switch the CRATER-FILLER switchon the front panel..

8 .3 Controlling penetrationFor typical C02l'MAG welding, penetration of base metal or bead Wid th as well as welding current variesdepending on wire extension. The wire feeding speed is automatically adjusted by lurning on thePENETRATION CONTROL switch on the front panel, which causes small change of penetration depthof a base metal or bead width Turn on the PENETRATION CONTROL switch for constant penetrationdepth.

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8. WELDING OPERATION (conlinued)8.4 Change of Del (Reference)

Tap 01 Del can be changed according to a use. De l is on the inside of the front cover.Middle tap r : : : : T ~ a ! e p the shipment Maximum tap17T 24T 28T

When use wire of O.9 .1,Orp or extension cable, change to Middle lapaccording 10 welding condition Change to MSlCimum lap when use more soft arc .

8.5 Connection with automatic machine8.5.1 Parts of necessaryNameWire assy for automatic

machineConSlllulion:

Parts No .P25000WOO

Wi re with terminal board' , . . .Plale' . . 1M3screw' . . . . , . . . . . . 2M4 screw'

8.5.2 Selling of sWitches inside the welding power sourceI Switch 51 #310 ON to change Wife feeder.

S1 Fgg [rnbl [j bl~ 2 L t J 4 5 678When connect with automatic machine, il is 'ON",

Change ' CN1A" and 'CN3A" of PCB3 to ' eN1S" and ' CN3B",

PCB3 CJCN4

21

Quantity

No P25000

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NO .P25000

8. WELDING OPERATION (continued)8.5.2 SettJl"lg of in ternal welding power source (cootmued):1 Attach and connect cover fOf automatic machine P2SOOOWOO like following below.

PCB3

PCB2

Insert connector indicated "CN4" to CN4 of PCB3/

PCB 1

=

o

iell core by screw

Attach terminal Ix>ard with plate by screw

Plate

Detaell ' n s e r t ' ~ and insertconnector indicated "CN1 T'to CN1 7 of PCB2

Terminal board

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8. WELDING OPERATION (continued)8.5.3 Connection of ex ternal

co Tear the grommet of back board and connect to 8P terminal board.

Start+SOL

( " "':,f W ~ R : 11OV less than O.03AOperation stoptiD+'CD When open il. operat ion IS sttoped

No.P2S000


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NO.P25000

8. WELDING OPERATION (continued)B.6 When errors occur

,1':, WARNING

Follow th e Instru cti ons below to avo id electric shock Do not touch charging parts insi de or o utside th e weld ing machine.e Have a q uali fied eng ineer or a person wh o is familiar with th is weld ing power source c hange wiringinside the welding machine or change over the switches.e Turn off all of th e line disconnec t sw itches and wait more than three minutes before touching theparts inside the welding machine.e When an error occurs. warn ing lamps (yellow light) on the front panel and LE01 (red light) or l ED2 (greenligh t) on PCBlturns on or flashes. then the welding power source automatically stops. In this case, checkthe errors in the table below and "9. I Troubleshooting" in this manualo (ON) (OFF)@ (Flicker 1)6. (Flicker 2)

Error

*------------------?-------------------------

WARNING lamp PCBIErroro. on the front panel LED 1 (red light) LED 2 (green light:(yellow liQhtlI Power supply frequency .., Temperature 0 Input overvollage 0 0, Shortage of input voltage 0 \..}., AUTO PROGRAM setttng @ 0 0:tv Error before start ing welding @ :tJ Gas check @ 0 Output overcurrenl 0 0t1! Microcomputer /' , 0 " Outpu t voltage /' , 0'II" Current detection /' , Power supply frequency

When the POWER CONTROL switch on the front panel is turn on at unstable power supply frequency,the warmng tamp comes on and the welding power source continues 10 stop operation In this case. turnoff the power switch and tum on again to cancel the error.;t Temperature error

When the duty cyde exceeds the rated duty cycle or the temperature exceeds 40 C. the WARNING lampflashes and the welding power source stops automatically. (Refer to 3.2 for details of duty cycle.) In thiscase, wal t until the fan stops. wi th the CONTROL POWER SWitch turned on. When starting the weklingoperation again. use the welding machine lower the duty cycle or the welding current.

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8. WELDING OPERAT ION (continued)8.6 When errors 0CClJ( (continued), Input over voltage error

No P25000

When Input YOItage goes beyond 437V, the WARNING lamp lights up and the wetdlng power source SlOPSautomallCally Dtsconnect the CONTORL POWER switch and meaSUfe the input voltage With such ameasunng '"'trument as a tester to check to make sore if excesslVety high voltage is not output Toeliminate the error tum on the CONTORl POWER SWItch agatn after r8fT'lOWlg 8 cause of the errorabove

I Shortage of Input voltage errorWhen Input voltage falls below 304V. the warning lamp lights. then the Welding power sourceautomatically slop operation In thiS case dlsconned the SWitch and oonfirm there nI no failure . then tum00 the switch again

.,' WELDING MODE sWitch errorWhen unavallabte mode numbers are set while presSing the MODE SWitch on the front panel, theWARNING lamp nashes and the welding power source keep stoppingIn this case, seiling back to the normat setllng remove abnormal

Ii.' Error be fore starling welding machineWhen the CONTROL POWER sWitch is turned on while the TORCH SWitch Is on, the warning lampnashes (Flash 1) and the welding power source keep stopping Turn of f the TORCH sWitch to cancel theerror

'1' Gas check errorWhen more than two minutes has passed while the GAS CHECK SWitch IS turned to the CHECK side, thewarning lamp ftaShes (Flash 1), then the welding power source stops automallcally To cancel Gas checkerror, set the GAS CHECK SWitch 10 WELD

10{ Error in output over currentWhen more than two-seconds over current or shor1-ctrClllt IS oontlnoed, the warning lamp hghts up andweldtng machine aulomallcally stoPs In thiS case, tum off the CONTROl POWER swrtch and make sureto see If welding current does not exceed the rated output current or contact between tip and base metalor short-orcult of output (cables) To cancel this error, sotve the cause of error, !hen tum on theCONTROL POWER SWitch again,

'I Error m microcomputerWhen an error Is de tected in microcomputer, the warning lamp nashes (Flash 2) After the warning lampHashes, the welding machine automatically stops.

J(l Trouble 01oulput vo ltageWhen the TORCH switch Is turned of f and voltage on the output lermlnals presents, the WARNINGlamps nashes (Flash 2) and the welding machine au tomatically stop welding In case of welcllng samework piece with several welding mact1lnes, tum off the power switch and check whe ther wire or torchcable contact With base metat or output cable of other wekllng machine II there are some contacts,make sure removing them and turn the swrtch 0f1 If abnormal sti1l eXist, Chec\( to make sore if mainthyristor or an electromagnetIC contactor IS not broken by using a tester, after turning of f the POWERSWItch To cancel this error, tum on the main power SWitch again after solving the cause of the efl'Of'

Jr Current detection errorloose or breaklf'lg Wlnl'lQ between a halt element (CT) and a pnnted CIrCUit board (P C B 1). warning lamplights up and wekhng powet" source automatically stops In thiS case, tum of f the POWER swrtch andcheck fOf the trouble of Wiring After solving the cause of trouble, turn on the CONTROl POWER switchagain to cancel the error

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No.P25000B. WELDING OPERATION (continued)

8 7 Seiling of variable resistors inside the welchng power source8.7.1 Changing pre-flow perIOd (For M A G ) Pre-flow period is factory-set to 0.05 see. Turn the variableresistor R13 clockwise to adjust the pre-flow period. The relation

between setting positions of the variable resistor and pre-flowperiod is almost as the figure shown right.

8.7.2 Changing post-flow periodDefault settmg of post-flow period IS 0.4 see. TurOing the vanableresistor R14 in the dockwlse directlOfl to adjust the post-flowperiod. The relation between setting positioos of the variableresistor and post-flow period is almost as the figure shown righ l

8.7.3 Changing anti-stick period

0.21see.

0.05see.(STO)

1.2 sec.

0.4 sec.(STO)

0.37see.

0.69sec.RJ32 sec.

2.8 sec.. . -. .. . 3.6 sec.R J 4

. Anti-slick lime is the processing lime that prevents elec:trodewire from depositing the base metal at the end of welding.

. Anti -stick time is factory-set to the correct condillOns to matchwelding method or wire diameter. The anli-stick time can beadjusted by turning vanable resistor R15 on P.C.B. 1 clockwise.The relation between selting positions of variable resistor andanti-stick time is almost as the figure shown right.

Shorter , l O O ~ n g e r ,- ,.

. Simultaneous moving a torch with release of the torch SWitchmay result in failure of antl stld( treatment and protrusion ofwire caused by inertia of molor

8.7.4 Changing anti-stick voltage Anti-stick voltage is output voltage that is produced whenpreventing electrode wire from depositing the base metal. Anti-stick voltage has been adjusted to proper welding

method and wire diameter prior to the shipment of thewetding machine The voltage can atso be sel by turning thevanable resistor R16 on P C.B. 1 The relation betweensetting positions of vanable resistor and anti-stICk voltage ISalmost as the fIQure shown right.

26

5096 15096

J 5

Shorter ...!:,onger" OV+4 .5V

OVR J 6

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MANUAL NO : U5790

ct)TcJ:=>DAlHEN corpo


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No. U5790P.12 / 22

7. WELDING PREPARATION7.1 Replace the wire reel shaft at lowering( When wire feeder is not lowering, this operation is nol necessary)& CAUTION

e To prevent the wire dropping, be sure to observe the following at welding operationwith hanQinQ the wire feeder.

" " T - , j I ~ e n t condition atewhen hanging the wire feeder ,wire reel shaft should be turnedto 90 counterclockwise.Commended tighteningtorque: 12.4N-m

Wire reel shaft Jit)

Capknob

Hanging bracket(Fabricated by user.Use proper material towithstand load.)

Attachment

ewhen performing welding with the wirefeeder hung , firmly tighten the cap knob toprevent the wire reel from falling down .

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No . U5790P. 13 / 22

7. WELDING PREPARATION (continued)7.2 Fitting of wireC!.l Wire straightener

Pressure handle

Wing nut Hing Pressure rollholder

I Checking wire size of the feed rollCD Check the groove of the feed roll and match

with the w i n g wire size.

Attach the feed roll 10 the wire feeder, with propergroove facing out

[Fitting of wire I@ Raise the stopper and bring it down.@ Attach the wire to the wire reel shaft .@ Return the stopper to oriQlna l position.&. CAUTION

Wire reel shaftStop Be sure to return the stopper vertically as it was toprevent dropping of the wire.Wire( @ j ) ~ - V r J ! ; C " F

Bring down the pressure handle.@ Raise the pressure roll holder.(7) Pull out the wire to let it through the wirestraightener, and insert it into the outlet guide. Return the pressure roll holder and the

pressure handle, in this holder.

IAdjusting of pressure and straightener Adjust the pressure handle to set pressure force matching the wire size.(@ Loosen the wing nut. adjust the hinge and fix it at an appropriate posi tion .

Wire pressure adjusting Wire straightener adjustingWire size Pressure handle scale Straight hinge adjustingSolid wire Flux cored wire scale

4)1.6 5- 6 4- 5 0- 24) 1.2. 1.4 5- 6 3- 4 1- 3$ 1.0,0.9 3- 4 2 -44.0.8 2- 3 3- 5

.

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No . U5790P. 14 / 22 7. WELDING PREPARATION (continued)73 W f d' b ' h're ee InQ Oy Inc Ing operation

L!:; WARNING- Do not look into the tip hole to check on feeding of the wire while inching.

L!:; CAUTION- Do not put your hands, fingers, hair or clothes near the rotating parts of the

feed roll , etc. while inching. Biting may occur, causing injuries.

Remote control box Feed the wire while stretching the

I

welding lorch straight and pressing theinching button, and release from the buttonwhen the wire is projected from the weldingtorch tip by about 10mm.

Inching button IWARNINGTouching the electrification parts may cause fatal electric shook and burn .

Never touch electrically hot parts of wire and wire feeder.1;;;;;;;;1 part is indicated to electrically hot part when welding.

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No. U5790P. 22 / 22

10. SPECIFICATIONS10 1 SpecificationsModel CMXL-2302Applicable wire diameter (O.B, 0.9 , 1.0, 1.2, (1.4), (1 .6)A p ~ licable wire Solid wire . flux cored wireWire feedin speed Max. 18m I min.

Shaft dia. Ql 50mmApplicable wire reel Outer Max . (I) 300mmdia .

Width 103mmA p ~ licable wire mass Max. 25kQApproximate mass 14 kg

10 2 Standard accessoriesDescription Part No . Q'ty Remarks

Ba se metal cable U1997JOO 1 60mml x1 .BmAllen wrench 4739-2BO 1 NO . 6 (MB)

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' \MANUAL NO:C0087-3

DAIHENcorporation

OWNER'S MANUALFOR

AIR C70LASMAMODEL: MRCT-?O C008?

100 NOT DESTROylIMPORTANT: Read and understand the enti re contents of thismanual, with special emphasis on the safety material throughoutthe manual, before installing, operating, or maintaining thisequipment. This equipment and this manual are fo r use only bypersons trained and experienced in the safely operation of weldingequipment. Do not allow untrained persons to install, operate ormaintain this equipment. Contact your distributor if you do notfully understand this manual.

D A I HEN C o r p 0 rat io n WELD ING PRODUCTS DIVISIONFebruary 29, 2008

IAt your contact, tell MODEL and MANUAL NO.

66


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No. C0087CD PLASMA ARC CUTTING SAFETY PRECAUTIONS

The following safety alert symbol and signal words are used throughout this manual to callattention to and identi fy different leve ls of hazard and special instructions.LJ . WARNING WARNING gives information regarding possible personal injury

or lose of life.LL CAUTION CAUTION refers to minor personal injury or possible equipment

damage.

if WARNINGPLASMA ARC CUTTING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY ORDEATH.

Especially: . Keep children away Pacemaker wearers keep away until consulting the doctor.

Read and understand. the summarized safety informations given in below. the original principal informations that will be found in the table SAFETY

STANDARDS.

Have only trained and experienced person perform installation, operation, andmaintenance of this equipment. Use only well-maintained equipment. Repair or replace damaged parts at once.PLASMA ARC CUTTING is safe when precautions are taken.

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ELECTRIC SHOCK can kill.

Touchi g live electrical parts can cause fatal shocks or severe bums. The torch and workcircuit i electrically live whenever the output of the plasma cutting power source is on. Thepower line and internal circuits of the plasma cutting power source are also live when linedisconn ct switch is on.When " UTPUT HIGH VOLTAGE" indicator lamp is lighting, cutting machine generatesoutput 'Voltage(DC200"'-'400V). So when this indicator lamp is lighting, never touch torchtip and electrode.I. Do not touch live electrical parts.2. We r dry, hole-free insulating gloves and body protection.3. Insulate yourself from work and ground using dry insulating mats or covers.4. Dis onnect line disconnect switch before installing, changing torch parts or maintaining

this equipment.5. Pro erly install and ground this equipment according to its Owner's Manual and national,

stat1, and local codes.6. Connect base metal with output terminal of cutting machine surely.7. Keep all panels and covers ofthis equipment securely in place.8. Do not use worn, damaged, undersized, or poorly spliced cables.9. Do ot touch electrode and any metal object if POWER switch is ON.10. Do ot wrap weld cables around your body.11. Tu of fPOWER switch when not in use.12 . Keep away from torch tip and pilot arc when trigger is pressed.

At ) ARC RAYS can bum eyes and skin=\J "// NOISE can damage hearing. .. >j

Arc rays from the cutting process produce intense heat and strong ultraviolet rays that can burneyes an skin.Noise fr m some arc cutting applications can damage hearing.1. Wear face protection with a proper shade of filter (See ANSI Z 49.1 listed in table

SAFETY STANDARDS.) to protect your face and eyes when cutting or watching.2. Wear approved safety goggles.3. Us , protective screens or barriers to protect others from flash and glare: warn others not

to watch the arc.4. Wear protective clothing made from durable, flame-resistant material (wool and leather)

an foot protection.5. Use approved ear plugs or ear muffs if noise level is high.

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FUMES AND GASES can be hazardous to your health.

Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous toyour health.1. Ke ep yo ur head out of the fumes; do not breathe the fumes.2. Ventilate the area and / or use exhaust at the arc to remove cutting fumes and gases.3. If ventilation is poor, use an approved ai r-supplied respirator.4. Read the Material Safety Data Sheets (MSDSs) and the manufacture 's instruction for metalsto be cut, consumables, coatings, and cleaners.5. Do not cut in locations near degreasing, cleaning, or spraying operations.

The heat and rays of the arc can react with vapors to from highly toxic and irritating gases.

PLASMA ARC can cause injury

1. Keep away from the torch tip.2. Do not grip material near the cutting path.3. The pilot arc can cause burns. Keep away from tip when trigger is pressed.4. Wear proper flame-retardant clothing covering all exposed body areas.5. Point torch away from your body and toward work when pressing the torch trigger.6. Tum offpower source and disconnected input power before disassembling torch or changi g

torch parts.7. Use only torch(es) specified in the Owner 's Manual.

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.1. Wear approved face shield or safety goggles with side shields.2. Wear proper body protection to protect skin.3. Wear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears.

..,- .J -

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, .'J';>-" .... .. .J.:a.

. s .: 'l.'" . \I .

CYLINDER can explode if damaged.

Shielding gas cylinder contain high pressure gas. If damaged, a cylinder can explode.1. Use only correct gas cylinders, regulators, hoses, and fittings designed for the specific

ap lication; maintain them in good condition.2. Pr tect gas cylinder from excessive heat, mechanical shock, and arcs.3. Ke p cylinder in an upright position securely chained to stationary support or rack to prevent

falling or tipping.4. Ke p cylinders away from any cutting or other electrical circuit.5. Never touch cylinder with welding electrode.

Never allow electrical contact between a plasma arc torch and a cylinder.6. Read and follow instructions on compressed gas cylinders, associate equipment, and CGA

publication listed in table SAFETY STANDARDS.Si ce gas cylinders are normally part of the metal working process, be sure to treat carefully.

7. Turn face away from valve outlet when opening cylinder valve.8. Ke p protective cap in place over valve except when gas cylinder is in use or connected for

use .

Rotating parts may cause injuries. Be sure to observe the followings .If hand , fingers, hair and clothes are put near the rotating parts of fans , biting may occur,..causmg mJunes.1. Do not use the cutting machine in removing the case and the cover.2. W en the case is removed in maintenance/inspection and repair, certified operators or

op ,rators knowing the cutting machine well must perform the working.3. By providing a fence, etc. around the welder, do not let other persons come near the welder

car -"lessly.4. Do not put your hands, fingers , hair ad cloths near the fans rotating.

PLASMA ARC CUTTING WORKSHOP is potentially hazardous.FALLING, FALLING DOWN and MOVING machine can cause serious injury. Do not lift the cutting machine with one eyebolt.

Us two eyebolts to lift it. Put the cutting machine so lidly on a flat surface . Do not pull the cutting machine on floor laid with cables and hoses. Do not put the cutting machine where they will pit or fall.

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No . C0087CD PLASMA ARC CUTTING SAFETY PRECAUTIONS

PRINCIPAL SAFETY STANDARDSSafety in Welding and Cutting, ANSI Standard Z49.1, from A m ~ r i c a n Welding Society, 550N.W. Lejeune Rd, Miami FL 33126.Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent ofDocuments, U.S.Government Printing Office, Washington, D.C.20402.Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWSC5.2, from American Welding Society, 550 N.W.Lejeune Rd, Miami, FL 33126.Recommended Safe Practices for the Preparation for Welding and cutting of containers ThatHave Held Hazardous Substances, American Welding Society Standard AWS F4.1, fromAmerican Welding Society, 550 N.W.Lejeune Rd, Miami, FL 33126.National Electrical Code, NFPA Standard 70, from National Fire Protection Association,Batterymarch Park, Quickly, MA02269.Safe Handling ofCompressed Gases in Cylinders, CGA Pamphlet P-1 , from Compressed GasAssociation, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.Code for Safety Welding and Cutting, CGA Standard W117.2, from Canadian StandardsAssociation, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W lR3.Safe Practices For Occupation And Educational Eye And Face Protection, ANSI StandardZ87.1 , from American National Standards Institute, 1430 Broadway, New York, NYI0018.Cutting And Welding Processes, NFPA Standard SIB, from National Fire ProtectionAssociation, Batterymarch Park, Quickly, MA 02269.

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. No. C0087C MPOSITION AND SPECIFICTION

2.1 Specifica tion2. C ..1 uttmg machineModel MRCT-70Rated input voltage 380V1O% 3c/>KVA(KW) at rated output 20.0kVA 10.5kWFrequency 50/60HzRated output current 70ARated output voltage 108VMax . no-load voltage 245VRated duty cycle 60%Temp erature rise 160CUsable temperature range - 10-40CMass 102kgExter al dimensions 360(W) x 560(D) x 550(H) mm

(WxOxH) (Without the input terminal cover andbolts for hanging.)2 C h1.2 uttmg toreModel K5456BRated current 70ARated duty cycle 60%Cooling system Air-cooledCable length 6mUsinggas AirMass(without cables) 250g

2.2 Standa d accessories2 2 1F tf h'. or mg mac me

Description Specification Q'tyCD Air unit COO76U 1@ Hose band No.OOO 1@ Base metal cable 1.5m 1@ Glass enclosed fuse 250V 3A 1@ Cartridge fuse 380V 3A 1@ Screw M8-20 1

CD CV @) ~ , .

@ ~ 7 ; ; .

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NO . C0087@ CUTTING OPERATION5.1 Operation of front panel

Warning lampThis lamp lights when the following abnormalityoccurs.1 Over heat2)Lack input phase.3) Air pressure shortage.4) Short-circuit by welding oftip and electrode.5) Poor connection of the connector for current

detection.6) Trouble ofWCR's circuit.7) Trouble of main thyristor.When this lamp is lighting, execute the checkN0.3 in

Section 7.2, "Troubleshooting table".

@50

Control power switchIf this switch tripped, immediately turn offthe input side power-board switch.Be sure to check No.1 0 in Section 7.2,"Troubleshooting table".

Fuse

- E 3 - F l (3A) POWER indicatorWARNING BD 9 _ / ,--Ia_mp_ _ ----- .o on 0 This lamp lights whenV input power (380V) isimpressed to the inputAI R -e CCNTRCX.. POWER ! POWER side.

Cutting current adj usting knob.Set the optimum cutting currentfor thickness and material ofbase metal.

OUTPUT HIGH VOLTAGEindicator lampThis lamp lights when output voltageis impressed to output terminal.

Please see Section 5.3 for thestandard cutting condition.

Air check switchAir flows at "CHECK" position.

If this lamp is lighting before torch switchis triggered, immediately turn of fthe input side power-board switch.Be sure to check No.4 in Section 7.2,"Troubleshooting table".

Set to "CUT" position when cutting.Please use it when you adjust air pressure before cutting operation.Air pressure is O.5MPa.

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II

No. C0087

@ CUTTING OPERATION! WARNING

Observe the followings to prevent the electrical shock.

-C onnect base metal with output terminal (base material side) of cutting machine surely.High vol age might be impressed to base metal and cause fatal shocks or severe burnswhen used with base metal is not connected with output terminal.

-Check whether no load voltage reducing circuit operates normally before cutting operation.(refer to 13 pages)-Do not to ch base metal by bare-handed carelessly while cutting operation.

We ar dry. hole-free insulating gloves and body protection.eOo not to ch tip with torch switch is triggered.-Operate b, ,the contactless cutting.

Do not operate by contact cutting which tip contact to base metal.eTurn off "CONTROL POWER" switch and disconnect power line when you check torch or exchange

Earts.

5. Operat'on procedure

Turn on the line disconnectswi tch or circuit breaker.

Set "C NTROL POWER"switch to "ON".

Set "AI " switchto "CHECK".

The machine is energized, and the "MAIN LINE" indicationlamp lights.

. The control circuit is energized, and the fan is started."OUTPT HIGH VOLTAG E" indicator lamp is lighting before torchswitch is triggered, immediately turn off the input side power-boardswitch, and execute the check No.4 of$ection 7.2 .

Air flows out of tip of torch.Due to a sudden change in temperature, such as when you move themachine from a cold location to a warm one, when you use themachine in the places su bject to humidity, water droplets may formon the in side of the machine.

Regu late the output pressure of air Before us ing the torch, carry out air check and drain any waterdroplets.nit to 0._MPa.

switch to "CU T".!Do not Lise the torch with condensation form ed inside the equipment'.Failure to do so may lead to se rious damage to the torch .

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NO. C0087@ CUTTING OPERATION

Check operation of reducingno-load voltage circuit.

Check whether no load voltage reducing circuit operates normallyaccording to the foll owing procedure before cutting operation.Do not tum torch to th e person.Do not look into inside of tip when checking it.

(This cutting machine has the And pay attention to pilot arc which is generated from tip.circuit which stops outputting - Check procedure -at once, when it will not shiftto the cutting arc within 0.3sec. after pilot arc isgenerated. )

Operation starts I

Trigger torch switch. I '"~ - - - - - - ~ - - - - - - - - - - ~

Plasma arc is generated .(Cutting start)

I)Pilot arc is generated momentarily after the start-up delay time of 1.5sec. when torch switch is triggered with there no base metal,"OUTPUT HIGH VOLTAGE" indicator lamp lights momentarily(about 0.3 sec.), and it turns of f at once.

2)The braking of the no load voltage reducing circuit when "OUTPUTHIGH VOLTAGE" indication lamp keeps lighting while the torchswitch is triggered.Stop operating immediately.Do not carry out cutting operation until operation is restored normallyafter replacing the printed circuit board PCB I.

Electrode and tip are contacted until ai r flows.As about 60V is impressed to tip, never touch tip.

"OUTPUT HIGH VOLTAGE" indicator lamp keepsturning off during start-up delay time.

I tart-up delay time. ( 1.5 sec.) INo-load voltage is generated, and "OUTPUT HIGHVOLTAGE" indicator lamp turns on.-----i----- ---- ------------ . Air flows out, and pilot a rc generates.

(Pi lot arc generates only momentarily.)r-The no-load voltage is stopped 0.3 sec. later,

when base metal is not connected with output terminalor plasma arc is not generated within 0.3 sec.And "OUTPUT HIGH VOLTAGE" indication lamp turnsof f.

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No. C0087

@ CUTTING OPERATION

IRelease torch switch.

Operati n end

Tum 0 "CONTROLPOWE " switch.

Tum of f the linedisconn ct sw itch.(p