I

,
MANUAL NO.C0025-6
DAII-ENc""",,<JIal
OWNER'S MANUAL
FOR
ACCUTIG 300P
MODEL: AEP-300 C0025
100 NOT DESTROY I
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual , before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safely operation of welding
equipment. Do not allow untrained persons to install , operate 0
maintain this equipment. Contact your distributor if you do not
fully understand this manual .
Mudanjiang OTe Welding Machines Corporation WELDING PRODUCTS DIVISION
December 9. 2008
IAt your contact, tell MODEL and MANUAL NO.
I. SAFETY INFORMATION
No.C0025
P. 1/63
The following safety alert symbols and signal words are used throughout thi s manual to
identi fy variolls hazards and special instructions.




Lh WARNING
CAUTION
WARNING gives infonnati on regarding possible personal
injury or loss of life.
CAUTION refers to minor personal injury or possible
equipment damage.
2. ARC WELDfNG SAFETY PRECAUTIONS
Lh WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS fNJURY OR
DEATH.
Be sure to:
. Keep children away_
. Keep pacemaker wearers away until consulting a doctor.
Read and understand the summari zed safety information given below and the
origi nal principal infonnati on that will be found in the PRINCIPAL SAFETY
STANDARDS.
Have only trained and experienced persons perfonn installation, operation, and
maintenance of this equipment.
Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDfNG is safe when precautions are taken.
No.C0025
P. 2 / 63
ELECTRIC SHOCK can kill.
Jive electrical parts can cause fatal shocks or severe bums. The electrode and work
ICI"cullilsare electricall y live whenever the output is on. The power line and internal circuits
equipment are also li ve when the line disconnect switch is on. When arc wel ding all
Im"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 di sconnect switch before installing, changing torch parts or
maintaining thi s equipment .
Properly install and ground thi s equipment according to its Owner' s Manual and
national, state, and local codes.
Keep all panels and covers of this equipment securely in place.
Do not use worn, damaged, unders ized, or poorly spliced cables.
Do not touch electrode and any metal obj ect if POWER switch is ON.
Do not wrap cables around your body.
~ 4 f )
ARC RAYS can bum eyes and skin: FL YrNG SPARKS AND HOT
METAL can cause injury. NOISE can damage hearing.
" ".
~
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can
burn eyes and skin.
Noise from some arc welding can damage hearing.
I. Wear face shield with a proper shade of filter (See ANSI Z 49. 1 li sted in PRrNCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a
welder 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 clothi ng made from durable, flame-resistant materi al (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs ifnoise level is high.
Chipping and grinding can cause !l ying metal. As welds cool. they can throw orr slag.
6. Wear approved face shi eld or safety goggles. Si de shi elds recommended.
7. Wear proper body protection to protect skin.
WELDING can cause fire and explosion.
No.C0025
P. 3/63
Sparks and spatter fly oft' from the welding arc. The flying sparks and hot metal. spatter. hot base
metal, and hot equipment can cause fi re and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
I. Protect yourself and olhers from flying sparks and hot metals.
2. Do not weld where flying sparks can strike fl ammable material.
3. Remove all flammabl es within 10m (35ft.) orthe weldi ng 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 and
openings 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 partiti on can ignite a hidden fire.
7. Do not weld on closed containers such as tanks or drums.
8. Connect base metal side cable as close to the welding area as possible to prevent the welding
current from traveling along unknown paths and causing electric shock and fire hazards.
9. Remove stick electrode from holder or cut ofT 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 cable connections.
FUMES AND GASES can be hazardous 10 your heahh.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
I. Keep your head out 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 respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturers instruct ions on
metal s, consumabl es. coatings. and cleaners.
5. Do not weld or cut in locations near dcgreasing. cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to fonn highly toxic and irritating gases.
6. Work in a con lined space only if it is well or while weari ng an air-supplied
respirator. Shieldi ng gases lIsed for wclding can air c;]using injury or (kath.
Dc sure breathing air is stile.
No.C0025
P. 4 / 63
ITJI
;;;; CYLI NDER can expl ode ir dmnagcd .
. , J .
" ,.
: ..
A shielding gas cylinder contains high-pressure gas. I r damaged, a cylinder C3J;! explode.
Since gas cyli nders are nonnally part of the wel ding process, be sure to trcat them carefully_
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 the
CGA publication P-I listed in PRINCIPAL SAFETY STANDARDS.
7. Tum face away from valve outlet when openi ng 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 experienced
operators must perfonn the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, hair or clothes near the rotating fans or wire feed roll.
~
This equi pment uses high frequency for arc starting.
No.C0025
P. 5/63
Hi gh-frequency may enter ncarby uni ts as shown below, causing electromagneti c trouble.
Input cables, signal cables, telephone cables
Radio sets, TV sets
Computers and other control equipment
Industrial detectors and safety units
,
Pacemakers, hearing-aid sets
For preventing electromagnetic trouble;
I. Make the cable as shortest as possible.
2. Install cables along the fl oor 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 common base metal ground with other machines.
5. Tight ly close all 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 thi s instruction
manual until trouble is corrected.
Please contact OTC-DAIHEN , when necessary.
8. Pacemaker wearers must not come near this equipment during operation until consulting
a doctor.
Operation of the pacemakers will be affected badly by high frequency.
ARC WELDING work areas are potentially 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.
No.C0025
P.6 / 63
PRI NCIPAL SAFETY STANDARDS
Arc welding equipment - Install ation and usc, Technical Specificat ion
l Ee 62081. from Internat ional Elect rOlcchnical Commi ssion
Safety in Welding and Cutt ing, ANSI Standard 249. 1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superi ntendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Pl asma Arc Cuning, American Welding Society Standard A WS
C5.2, from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutt ing of Containers That
Have Held Hazardous Substances, American Welding Society Standard A WS F4.1 , from
American Welding Society.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphl et Pl , from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard WI17.2, from Canadian Standards
Association, Standards Sales.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard
Z87.1, from American National Standards Institute.
Cutting And Welding Processes, NFPA Standard 51 S, from National Fire Protection
Association.
J.GENERAL NOTICE AT OPERATION
3. 1 Rated duty cycle
& CAUTION
No.C0025
P. 7/63
. Use al the rated dUly cycle or under. Ife)(ceeding the rated dUl Y cycle. the welding power
source may be deteriorated and burned.
I) Rated dutY cycle: 40%
& CAUTI ON
. When you set to AC BALANCE is " MAX. PENETRATION" si de al AC TIG welding, lise it
wi th rated duty cycle is less than 30%. If duty cycle is over 30%, the welding power source
may be deteriorated and burned.
(2)The duty cycle is percentage of a ten mi nutes period that welding power source can be operated
at rated output wit hout causi ng overheating and damage of the welding power source. This
welding power source can be operated for four consecutive minutes. but it must operate al no
load for 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 weldmg power source and torch exceed the
allowable value, and it causes to burn the equipment.
(4) The fol[owing figure indicates the combinat ion of welding current and dUlY cycle.
Observe the duty cycle according to welding current.
(S)The duty cycle is limited by other machines (welding lorch CIC.). Therefore, observe the lowest
rated duty cycle in the combination machines.
(Less Ihan I64A)
100 _ __ . _ __ l.!Lessthan I90A
\ \ AC BALANCE
DUlY
cycle SO
(%).
o
\ Alowllble duty cycle .t
\ AG BAlANCE ...
\ wMAX.PENETRA n ONN
,
,
,
Usable range ", 40%
,
100 200
Welding CUlTclIl{A)
.. . (30%)
I
I
300
No.C002S
P. 8 / 6J
4. CHECK OF STANDARD COMPOSITI ON AND ACCESSORIES
4.1 Standard composition
. 1 I part s are standard compositi ons. The other parts shall be prepared at yOllr side.
Remote control box, extension cable and hose are available as a optional accessory.
Single phase
380V
Shielding gas cylinder
!
-1 Argon gas regulator with flowmeter I
[nput
cables Grounding ":"
4.2 Standard accessories
Cooling water hose for water cooled torch
Remote control box
(Optional accessory)
00 I Welding torch
Base metal
Grounding cable
Welding power source
Ch k h h ec the quantity w en you receive I e
Description Speci fication Quantity Remarks
Q)Glass enclosed fuse 5A 250Y I
Glass enclosed fuse IDA 250V 2
@Bolt MIO x 25 I
For torch connection
Nut . washer MIO I set
Bolt M8 X20 I For connection of base metal side cable
@Bolt M6 x l 6 2
For input tenninal connection
CVN ut washer M6 2 set
Cartridge fuse RLI1 5 IDA I
4.3 Accessori es whi ch you shoul d prepare
(I) Argon gas: Only when TIG welding (Gas; Tungsten Arc Welding)
Use argon gas for wcld ing.( Purity should be more than 99.9%),
(2) Filler wire : Onl y when TIG welding
Use a proper fi ller wire according to materi al and thickness of base metal.
(3) Electrode: Only when stick welding (Shi elded Metal Arc Welding)
No.C0025
P. 9/63
Use proper electrode according to material of base metal, welding position and joint shape.
(4) Electrode holder
Use an insulated electrode holder to ensure operator safety.
(5) Input cables and grounding cable
Input cables Thicker than 14 mm
2
X2
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 .
,

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5.2 Welding torch (Refer to owner's manual of each welding lorch for detai ls)
Torch switch
Water
Power cabl e ho:se[= b3CCC:r'/ L
i
Torch
Tungsten electrode
5.3 Argon gas regulator
Gas hos<: I=):e:===i
_To". \' switch
.&. WARNING
No.C002S
i'. 11/ 63
{
. An argon gas regulator is designed specifical ly for argon gas. Use the regulator only for
high pressure argon gas .
0 0 not di sassemble the regulator, and never touch the screw of safcty valve, and the
pressure controll ing mechanism inside of the regulator. Disassembli ng and touching may
cause seri ous ini urv or death. Refer to the owner' s manual of the rce. ul ator.
Flowmeter
Pressure gauge
o
o
\ Flu" k"uh
(l ull e! i.;Pll pl 1t1! ,
Fixi ng nut

No.C0025
P. 12 / 63
6. REQUIREMENT OF IN PUT POWER
6. 1 Commercial input power
Lb. WARNING
. Provide a leakage circuit breaker when the weldi ng power source is used at place with high
humidity such as work site, the stcctpl alc or the steel structure,.
Lb. CAUTION
e Se sure to provide a switch(with fuse) or circuit breaker at input side of each welding
power source.
ec :apaclty 0 commercia f d mput power an amperage 0 ffi eak use or CirCUit br er
TIG Stick
DC AC DC
I
AC
InDut voltage and phase 380 V Single-phase
Input voltage range
380V+ 1O%
Input power (KVA) More than More than More than More than
19.9kVA 22.3kVA 21.2kVA 22.0kVA
Amperage of fuse or
80A
circuit breaker
6.2 Precautions for use on an engine generator
Lb. CAUTION
Observe the following to prevent troubles of the welding machine in using auxiliary power
supply of engine generator and engine welder.
e Set the voltage of engine generator to 380 ......... 399V during no- load running.
If output voltage is set too high, failure of welding machine results .
Unlike commercial power source, engine generator is slow in recovering voltage when load
variations occur. Therefore, output voltage drops excessively when current varies
suddenly due to arc start, and that may cause loss of arc.(However. a welding power source
will not fai l due to such conditions.) To prevent this, the capacity of engine generator
must
be more than twice the rated input (KV A) of a weldi ng power SOUl"e. Especially, engine
generator with a damper winding is recommended. Contact the manufacture of engine
generator whether the engine generator is provided with a damper winding .
If one engi ne generator is used for two or more welding power sources, loss of arc is likely
to occur due to the influence of recepti ve welding power source .
When use the auxiliary power source of engine welder, use only the auxiliary power source
which voltage wave form is improved.(Contact the manufacture of engine welder for
delai ls. )
.
No.C0025
P.20 / 63
9 WELDING PREPARATION
Lh CAUTION
To prevent electromagnetic troubles. examine the followings. Also, when
if
electromagnetic troubles actually occur. examine the foll owings again .
Close and fix securely of all doors and covers of welding power source .
Install the welding cable along the floor or the ground as close as possible .
Pl ace the cable of the base metal side and (orch side as close as possi ble .
Keep fl owing rate ofshiclding gas proper. If it is not proper, high freq uency noise will
Increase.
9 I P . f Ii rcparallon 0 sa ety protective eqUIpment
Lh CAUTION
~ 4 f )
ARC RAYS can bum eyes and skin: FLYING SPARKS AND HOT METAL
can cause of injury. NOISE can damage hearing .
. '.
-
Arc rays from the welding produce intense heat and strong ultraviolet rays that can bum eyes
and skin. Noise from some arc welding can damage hearing .
Wear a face protection with a proper shade of filter ( See ANSI Z 49. I listed in
PRrNCIPAL SAFETY STANDARDS. ) to protect your face and eyes when welding or
watching .
Wear approved safety goggles .
Use protective screens or barriers to protect others from fl ash and glare: warn others not to
watch the arc .
Wear protecti ve clothing made from durabl e, fl ame-resistant material (wool 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 Ing
Welding current Less than 100A 100-300A 300-500A
More than.500A
Shielding No. 9 or 10 11 or 12 13 or 14 150rl6
,e JOg or we mg
Welding current Less than 30A 35- 75A 75- 200A 200- 400A
More than 400A
Shielding No. S or 6 7 or 8 9 or II 12 or 13 15 or 16
No.C0025
P.2 1/ 63
9.1 s.'X\\cn tll)eT"ation and gas fl ow 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 out let port .
High-pressure ~ a s may blow out, causing physical ini uries.
Preparation in order of the numbers,CD (2) ....
CDSet the line di sconnect
switch for single-
hase 380V to ON.
o
o
@Pl ace
CONTROL
POWER swi tch
in "ON"
positi on.
I""'''''''' check
the flow
adjust ing
handle is
placed in
"SHUT' side,
open the
of main
@Adjust the gas @PlaceGAS
switch in
"CHECK"
sition.
Flow usting flowing by turning
After adj usting
gas fl ow, pl ace
GAS swi tch in
"WELD"
sition.
handle. gas fl ow adjusting
handle to "OPEN".
9.3 Cooling method of welding torch
Lt. CAUTION
. Using water cooled torch when "TORCH" switch on front panel in "AIR-COOLED"
_position may cause burning the torch.
AIR COOLED
n
WATt : \{ COOI.EI)
I ORCI I
. Select ..... proper cooling method .... ccording 10
the sorl of welding la rch.
No.C0025
P.22 / 63
10 WELDING OPERATION
& WARNING
It
Observe the followings to prevent the electri cal shock.
.In touching the live electrical parts, cri tical electric shock and bum may occur .
Do not touch live electrical parts inside and outside of weldi ng power source.
e Se sure to turn off the line di sconnect switch before connecting .
Securely anach the case and cover after connect ing cables .
Wear dry clothes and gloves when weldi ng.
& CAUTI ON
. This weldi ng machine must be operated by operators understanding contents of this
owner's manual and having knowledge and ski ll s for handling the weldi ng machine safely .
Use at the rated duty cycle or under. If exceeding the rated duty cycle, the welding machine
may be deteriorated and burned .
Close panel cover of the fro nt panel duri ng weldi ng.
&
CAUTI ON
~
Observe the fo llowi ngs to perform TIG welding safely .
Use "GAS" switch when adjusting shielding gas fl ow. If using torch switch to adj ust the gas
fl ow, useless high frequency generates .
Using improper electrode may cause fail ure of arc stan, and generate useless high
frequency .
Improper shielding gas fl ow may cause failure of arc start, and generate useless high
frequency.
10. I TI G welding (Gas Tungsten Arc Welding)
10. 1. 1 Operation of TIG weldi ng
STICK
TIGC
TIG SPOT
WELDING MODE
Set the WELDING MODE
change-over switch to TIG welding.
DC
.....
A C
1-
Set the mode
change-over switch.
& WARNING
No.C002S
1' .23 / 63
WELDING CURRo
Set the welding
current.
If change-over thi s switch at welding, sparks will generate,
and it mi ght be a cause of buming .
10.1.2 Pulse (ON/OFF)
. Never change-over this switch at weldi ng .
. Sct the switch surel y.
Pulse function can be used at DC TIG weldi ng and AC TIG welding. It can not be used at
stick welding.
( I) What is pulse?
Pulse is the function which change the welding current periodically to stabilize arc, control
penetrations, and control heating.
ON
(2) Setting of pulse
For pulse operation, set the pulse change-over switch on front panel.
lJ
Pulse switch Main applications
Tack welding
Repeating of short
welding.
OFF
Thin plate welding
. Preventing weldi ng bead
hnnging down on thin
platl..! welding
ON
,
Torch switch
Welding current
Torch switch
OFF
PULSE
Timing chart
ON
~
~
ON
~
L
L
L
Welding "n.,."nl ~ ~
J'Il "": ":Uffl"111 11;1-''': e llrr':111
No.C0025
P. 24 / 63
(3) cHi ng the condition of pul se
ON
iA\'
VI ..
OFF
PULSE PULSE WELDING! PULSE TIME ($!,.'(;.) BASE TlME( Sct:. }
CURR.(A) BASE
SCI PULSE
change-over switch
loON.
PULSECURR.
!
CURR.(A)
Sel PULSE CURR., WELDfNG/ BASE
CURR., PULSE TIME and BASE TIME.
BASECURR.
--!n,----------,---n,--
h -I- t 1
Pulse time Base time
. Pulse li me can be set for 1.4 seconds maxi mum. and base time can be set for 2.5 seconds
maxImum.
10. 1.3 Craler-fi ller (ON/OFF/REPEAT)
( I) Whal is craler-fill er?
Crater
JL
Bcad
" . .
,
The hollow call ed "crntcr" is generated when
fini shi ng the weldi ng. That hollow distort ion may
cause cracks or weld ing defects and should be as
small as poss ible. The function of fi lling the hollow
is called "crater-fi ller",
(2) Cratcrti ll er setting
No.C0025
P. 25 / 63
REPEAT
. This welding power source has three ki nd welding operation by
sett ing af eRA TER-FILLER switch on front panel.
OFF
Setting of
CRATER-
FILLER
switch
OFF
ON
REPEAT
Main applications
Tack welding
Repeat of short welding
Thin plate welding
Thick plate welding
. Preventing welding bead
hangi ng down on thin
plate welding
Torch switch
(TS)
Wel ding
current
Gas now
Timing chart
ON
ON
ON
f
I 1
--' .
i<E7; Pre- now !!nIt
ON
CRATER
FILLER

i LOFF
POSt now ti ntti oE-'i
Keep torch switch on during welding.
Torch switch
(TS)
Welding
current
Gas flow
ON ON
Init iol cum:n!
\,
I !
--I ;
,.1
I OFF I
Main
;

; ,
!
; !

Crater filler
c rent
,
Prenow time ilo l
Up i i
slope !E-+l
time
time
POSI now
lime
Welding power source is not deenergizcd even if lorch
switch is oIT during main welding.
ON ON ON ON
Torch switch
OFF OFF OF
(TS) Initial Main welding current Crall::f-
CUrretlt
Welding -Hi '-1
i JL, "OP< .J! oj L
Prc-fl ow time .... nslope ti Rle 7 M <f- time
Welding power source is not deenergizcd even if torch
switch is ofT. For fini shing the welding. pull up the
torch from base metal and then turn the torch swit ch
oITO").
No.C0025
P.26 / 63
(3) Sett ing tile conditi on of crater-fi ller
REPEAT
OFf [0]
ON
CRATER
-FILLER
Set the crater-filler
switch to ON or
REPEAT oosition.
100(i) 'f) " 200 25' 100(i) 'f) " 200 '50 \i)f) ' " (i) ' "
50 3011 50 300 I I
,
INITIAL
CURR
CRATER UP SLOPE
-FILLER TIME
CURR
Set the INITIAL CURR., CRA TER-
FILLER CURR., UP SLOPE TIME
and DOWN SLOPE TIME.
DOWN SLOPE
TIME
Usually crater-fi ller current is 60 ......... 70%
of welding current
10. 1. 4 Crater-fi ller and pul se
By combining crater- fill er and pul se. foll owing weldi ng operat ion can be possible.
_
fONl, ~ __ JONl,
Torch switch I ~ OFF I L

Welding current
~ .
Ini tial Up slope time Pul se
current current
)
r
Base current Down slope time Crater-filler
current
10.1.5 Initial current
Initial current can be selected "ON" or "Or'T' by change-over switch (SW3)on
P. C.B. P6887T.
Refer to 11 .1.2 for detai ls .
Initial current can be sct from SA to JOOA with adjusting knob on front panel.
(Minimum val ue is 20A at AC TIG welding.)
10.1 .6 Post fl ow time
Post fl ow ti me can be adjusted from 1 to 20(sec.)
by set electrode diameter from 1.6 to 4.8(mm <!
with adjusting kllOb on front panel.
10. 1. 7 AC TIG welding
(I) Notice of using AC TIG mode
INTIAL CURR.(A)
No.C0025
P.27 / 63
When using AC TIG mode, observe the followings not to damage the welding power
source
I. Use proper length cable and use as short cable as possible.
2. When usi ng the extension cable, refer [0 f0r:-I"lo':w"i:.:n"g.:.fi"l g"' u"'re"'.--:---:-c--:-:-_:-:-___ "
Bind the torch side cable and base metal
side cable each other with tape .
o
/'
. Strai ghten the cables as much as possible.
Ifcable sett ing mentioned above cannot
be perfonned by all means, lay the torch
side cable on the base metal.
IGood exampl e I
No.C0025
P. 28 / 6J
3. IflOo long torch side cable is lIsed reluctantly, wind it according to following fi gure of
" Good exam Ie",
Bad exam Ie Good exam Ie
Do not wind the excess part of cable in the
same direction.
Refer to the figure below " How to coil a
exira cable", and make two windings in
opposi te direction each other and pile up
one on another.

Top view
Side view
Explanation
x
A B
the extra cable
A and B.
I them respectively as
Same coiling dirt:ction.
Same turns or..:oiling.
SaHlI.: di:tlll l'll..'r ( If
2
A B
over A in the
lo,."".s; Ie di rcelion.
o
J
10. 1.8 Cleaning width
No.COOlS
P.29 / 63
The cleaning power of arc which is necessary for AC TIG welding (Aluminum, etc.) is
adjustable by the AC BALANCE setting knob.
The relation between the setting position of the AC BALANCE setting knob and weld ing
result s is as follows.
Cleaning width
Penetration
Electrode
consumption
It
Nmow ""pSm.II 30% CJ 40% Lo'''Sh.II, w Wid,
Ma:c .. pcntrat ion Max. cteaning
,
ACBALANCE
Example of cleaning action
wide "f--- standard --.. . narrow
it. CAUTION
.The rated duty cycl e is 40%, but in case of sett ing AC BALANCE knob " Max. penetration"
at AC TIG welding, the rated duty cycle should be less than 30%. If exceedi ng 30%, the
welding power source might burned.
No.C0025
P.30 / 63
10. 1.9 TIG welding conditi ons for reference
(I) General TI G welding conditi ons for DC without pulse welding
Plate Electrode Filler wire Welding Ar. gas
Material thickness diameter Diameter current now rate
(mm) (mill cP) (mm ~ ) (A) (C Imin.)
0.6 1.0, 1.6 - 1.6 20- 40 4
1.0 1.0, 1.6 - 1.6 30- 60 4
Stainless 1.6 1.6,2.4 - 1.6 60-90 4
steel 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 5
Electrode 4.0 2.4, 3.2 2.4- 3.2 130- 180 5
Negative) 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 5
0.6 1.0, 1.6 - 1.6 50-70 3-4
Deoxidized 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 4
Electrode 3.2 3.2, 4.0 3.2- 4.8 140- 200 4-5
Negative) 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- 6
6.4 4.0.4.8. 6.4 4.8-6.4 300-400 5- 6
1.0 1.6 - 1.6 50-60 5-6
1.6 1.6,2.4 - 1.6 60- 90 5- 6
2.4 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- 8
4.8 3.2,4.0.4.8
4.0- 6.4 170- 220 7- 8
6.4 4.0, 4.8
4.0- 6.4 200-270 8-12
1.0 1.6 - 1.6 30- 40 3-4
1.6
1.6, 2.4 1.6-2.4 40-70 4-5
2.4 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- 6
4.8 3.2, 4.0
3.2- 4.8 110- 150 5- 6
6.4 3.2, 4.0
4.0- 4.8 130- 170 6- 7
I ~
I
c:f=3E
I I
C ~ t 1 3
( :I ) ( II ) (c)
Groove
Layers 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)
(2) Welding condit ions for DC pul se welding
In case of nat position bUll welding .
Oap
Material Joint geometry

Pul se
current
(mm) (A)
Mild steel 0 200
,
.
(SPC)
, -
1.2 150
1.2
1.6 130
_ '"I G I..
Stainless 0 150
,
' ~
steel
I.2t.
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
'1 G-
1. 6 280
Titanium
L
(Tp- I)
,
0 200 2.0
I
JOe
Shi elding gas: Argon (10C Imin.)
Filler wire : 1.2mm <b
,
Pulse conditi on
Base Pulse
current freq.
(A) ( Hz)
50 2.5
20 1. 5
20 1
50
,
J
20 I
20 0.8
20 0. 8
50 3
50 2
30 1.5
100 I
Pul se
Ratio
(%)
50
45
50
50
35
30
30
50
50
40
30
Welding
Speed.
NO.C002S
P. 31 163
Fi ller wire
feeding
speed
(emlmi n.) (emlmin.)
60 60
30 60
15 40
80 0
17 40
10 40
83 40
80 0
50 75
25 75
25 0
Electrode : Ceri ared tungsten (3.2mm cp)
Arc length: 2mm
No.C0025
P.34 / 63
(4) Appli cable tungsten electrode
Since electrode consumpti on degree in AC welding vari es depending upon setting posi ti onor
AC BALANCE knob, determine diameter of electrode to be used frol11 the next electrode
diameter chart.
I . Electrode diameter chart
,
,
...;,
,
,
,
,
,
/
,
3.2
--- - ...
150
250
300
\ - .
\ .-' I
~ > ' Y ( " i ~ '
ODC AC BALANCE Q
Setting position
For ceriated and thoriated tungsten electrode
,
,
/
--
,
,
,
,
\
For pun: tungsten l'k't; lrodc
2. How to lise electrode diameter finder chart
At AC TIG welding
\


,
"'0;. '--" J; j' \
1fj "0
f)
DC
AC
Ma;<. penetratIOn
AC BALANCE
Setting position
No.C0025
P.35 / 63
( 1) Draw a line from the dial center(point P) to welding current graduation (point Q) and
extend the line.
(2) Read electrode diameter at the positi on of". " (on circle--) cleani ng width (point R).
(3) If cleaning width sett ing is not at "e" (on ci rcl e---), determine diameter of electrode to be
used dependi ng upon the dial setting position.
(E I ) xamplc
Cleaning width setting
Welding 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 <!>
tungsten
At DC TlG weldi ng
Find crossing poi nt of extension line of PQ and DC ci rcl e (point T).
(Exampk)
WcldinJ,1 current Electrode Electrode diameter
120A Ceri um
Mon: Ilmil 1.6 Q
No.C0025
P.36 163
10.2 TIG arc spot welding
10.2. 1 What is arc spot welding?
Tungsten ele<:trde
I
Argon gas
Noule
Weld"'g ii i"(:
Gas removing _.......:gtJ-V UL.
TIG arc spot welding is a kind arTIG welding.
Using thi s method. two thin plates overlapped can be
jointed partiall y from one side of the plate by arc heat.
To perform the TIG arc spot welding, it is necessary
insulting bush and nozzle.
-.----I" --"---
Example) In case of A W-IS TIG welding torch
Insulating bush: H21 B70
Nozzle: H2 1 B71
Welding part
10.2.2 Sett ing and operation orTiO arc spot welding
:t,i):,
STICK
[01
TrG
TIG SPOT
WELOING MODE SPOT TIME WELDING CURRo DOWN SLOPE TIME CRATER FILLER. CURR.
Set the WELDING MODE
change-over switch to TIG
SPOT DOsi tion.
Torch switch

Set the SPOT TIME, DOWN SLOPE TIME,
WELDING CURR. and CRATER-FILL. CURR.
Timing chart
ON (ON)
1 -- OfF -------l
i Down sllope time 1
. ..!.. II i
! .

Output
current
Welding current
!
,,----_.--.. ---
t Crater-filler current
10.3 Slick wdding (Shielded Metal Arc Welding)
.& CAUTI ON
. Keep the welding rod in a place wi th low humidity.
e Ory the rod sufficiently before using .
No.C0025
1' .37 / 63
When the gas burner is used for prehcating or removing moi sture of the base mewl. be sure
to heat to l OOt or above .
Slag and fume generated when lack welding will cause wetting the part of base metal to be
welded. Remove slag and fume after tack welding .
When welding is performed olltdoors and wind velocity exceeds 3m/ sec, lise a wind shi eld.
10.3. 1 Sett ing and operation of stick weldi ng
STICK
TIG
TIG SPOT
WELDING MODE
Sel WELDING MODE
change-over swi tch to
STICK position.
10.3.2 Stick welding conditions
R f Id' (D ange 0 we mg current d) [AJ ownwar
~
(mm $)
2.6 3.2
Characteri stic
of electrode
lImenite type 50- 85 80- 130
Lime titania type 50- 100 90-130
Low hydrogen type 55-85 100- 140
" o ~ "
~ \ V I ) ~ o
WELDING CURRo
Sel Ihe WELDING
CURRo
4.0 4.5
120- 180 145-200
140- 180 160- 210
140- 190
-
Range of welding current (Vertical Upward) [A] ,
~
(mm )
2.6 3.2 4.0 4.5
Characteri sti c
Of electrode
Ilmenite type
40- 70 60- 110 100- 150 120- 180
Lime titani a type
50- 90 80- 130 110-170 125-190
Low hydrogen Iype
50- 80 90- 130 120- 180
-
5.0
170-250
190- 250
190- 250
5.0
130- 200
140- 210
160- 210
No.C0025
P. 38 / 63
II APPLIED FUNCTI ON
.
&, WARNING
~
Observe the followings to prevent the electrical shock.
In touching the li ve elect ri cal parts, critical electric shock and burn may occur.
. 00 not touch live electri cal parts inside and outside of the welding power samec .
Grounding to the case of the welding power source should be perfonned by persons
quali fied in electrical work and according to the laws and regulations.
e Be sure to tum off the line disconnect switch before touching insi de of welding power
source.
6 CAUTION
. When changeover the switch on P.c.s., wait for three minutes or more after turning
off the control power switch on the front panel. Also, be sure to turn off the li ne
di sconnect switch .
Never touch the potentiometer on P.C. s. with white painting.
11 .1 Built in function and change-over switch
qff :0 Be sure to turn off the li ne di sconnect switch
~ before perfonning .
Change-over switch(bui lted on P. C. B.P6887T)
Switch function(A side/ B side)
SWI Pre-flow ON I OFF
SW2 Current control PANEL 1 REMOTE
SW3 Initial current ON I OFF
All sWItches are A sIde on the shipment.
.[ftaking off the upper cover, change-o""r switch(SWI ~ 3 ) on P.C.B. P6887T can be found
on chassis.
Pre-flow
\
'\
P6S87S
~ W I
P6SS7T
=
51"2
SW:I
n
v=
/
/ I
Illi ti :d curn.: nt
11. 1.1 Change of gas pre- now time
Gas pre-now time function is to let gas now before arc start.
then it protects the tungsten electrode and welding zone from
oxidation. Gas pre-flow time has been set to approximate
0.3 second on delivery. When restart ing during post flow,
gas pre-flow time is zero automaticall y. Gas pre- flow
time can be changed to zero second when switch SWI is set
to B side.
1 L 1.2 Init ial current
This function has been set to ON side on delivery. If
change-over switch SW3 is set to B side, thi s function is set
to OFF.
11 .1.3 Panel/ remote change-over switch for current control
Thi s funct ion has been set to A (PANEL) side on deli very.
When using the remote control box (opti onal accessory), set
change-over switch SW2 to B (REMOTE) side. When SW2
is set to B side, current control is not available at adjusting
knob on front paneL When SW2 is sct to A side, current
control is not available at remote control box.
11.2 WARNING and OVER HEAT lamps
No. C0025
P. 39/ 63
elf WARNING and OVER HEAT lamps on front panel come on in red and yell ow during
use, the welding power source stops automaticall y.
Check foll owing items and refer to 12.6.
( I) THERMAL OVERLOAD
The rated duty cycle of this' welding power source is 40%. If actual duty cycle exceeds
the rated val ue, WARNING (red) and OVER HEAT (yellow) lamps come on, and the
welding power source stops automatically. In thi s case, keep CONTROL POWER
swi tch on and wait for about 15 minutes under the condition of the cooling fan rOlated.
When resuming welding, make sure to decrease the duty cycle or welding current to
prevent from turning on OVER HEAT lamp and stopping the welding power source.
The welding power source may be damaged if welding operation is resumed immediately
after WARNING lamp is put out.
(2) SHORTAGE OF WATER PRESSURE
i f cooli ng water is not flowing or the water pressure is lower than proper level when
TORCH selection switch on fronl panel is WATER COOLED side. welding power source
stops I1 lJl ol11micl1ll y. In thi s case. check cooling water fl owing without knkagc.
e lf thl: torch switch is aln:ady ON when CONTROL POWER switch is ON. WARNI NG
lamp (n:d) COll h.'S (ll1 <lml welding pOWl.'r kl.!l: ps off state.
Turn I hl.: l(In.:h s\\ it ch orr and turn it (Ill ilgain !"{Ir starl ing thl: \\dding IIp .. -rali(ln.
No.C0025
P.40/63
11 .3 Optional accessori es
11. 3. 1 Welding torch accessories
CD Air-cooled torch
4m
120A AW(P)-9
150A AW(P)- 17
Sm
120A AW(P)-9
150A A W(P)- 17
! 4m I 200A I AW-26
Extension cabl e and bose
4m BAWH- 1504
11m BAWH-1 511
16m BAWH-1 516
4m BAWH- 1504
11 m BAWH- 1511
4m BAWH-2004
11m BAWH-2011
16m BAWH-20 16

-+ 15m
--+ 20m



--+ 15m
--+ 20m
Li _ Sm_ ...... _ 2_0_0_A--' __ -i1: 1 :!: 1
@ Water-cooled torch
210A
AW-20
AW-25
4m AW-IS
300A AWG-S
(for arc spot)
210A
AW-20
AW-25
Sm AW- IS
300A AWG-S
Y
(for arc spot)
Extension cable and hose Length
4m BAWS-3004
11m BAWS-3011
16m BAWS-3016

--+ 15m
--+ 20ql
4m I
BAWS-3004 I 12m
19m
11m
I
BAWS-301 1
I
11 .3.2 Other opti onal accessori es ,
Description
Remote corll ral box
FOOl current controller
FOOl switch
Torch switch
(Push butlan type)
Part No.
P6699Z00
KI I04FOO
4259-004
K5091l00
K509COO
Remarks
wi th cable (4m)
with cable (4m)
wi lh cable (5111 ) (1V-34092)
with cable (4m)
with cable (8m)
No. C0025
P.41 / 63
No.C002S
1'.42 / 63
11. 3.3 Cables and hoses
( 1) For torch
Model
Description
Gas hose
Base mctal s ide cable
Part No.
PI042KOO
PI042POO
(2) For water cooled torch(Cooled by city water)
-
Model
Description Part No.
Gas hose PI042KOO
Base metal side cable PI 042POO
Water hose PI042LOO
Feed watcr place
PI042MOI
(for watcr hose)
Connecting metal
PI042M02
for water hose
Rubber hose (for city water)
BMRHP-l OOI
Q' ty Remarks
I 3m. nut s at both sides
I 38 mm", 3m
BAB-lSOI
Q' ty Remarks
I 3m, nuts al both sides
I 38 mm!X3m
I Sm, nut al one side
I
I
I 30 C(1l
(J) For water-cooled torch(Cooled by watcr cooler PU 30 I)
-
Model BMRHP-]OOI
Description Part No. Q'ty Remarks
Gas hose PI042KOO I ) m, nuts at both sides
Base metal side cable PI0421'00 I 38mm!X3m
\ \ :; 5 EXlension cables and hoses .
Descripti on
< I1I\WII 1501 > Extension torch sid.: cabl.:
For extending 1\'loJd Exh.:nsion cubic lor n:mOlc control
1\ WI 1' )-9 or A WI 1' )_ 17
Extension cable for torch swit ch
(cabl c length is 4 111 ) to 8 In
Adapter
Connection cover
< I3AWH15[ I > Extension torch side cable
For cxtcnding Model A W(P)-9 or Extension cable for remote control
A WIP)- 17{cablc length is 4m) Extension cable for torch switch
to 15 m Adapter
Connection cover
< BAWH1516 > Extension torch side cable
For extending Model A W(P)-9 or Extension cable for remole control
A W(P)-17 (cable length is 401) Extension cable for torch switch
t020m Adapter
Conncction cover
< I3A WJ-I-2004 > Extension torch side cabl e
For extending Model Extension cabl e for remote control
AW-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 control
AW-26(cable length is 4 m) to 15 m Extension cable for torch switch
Conncction cover
< BAWH-2016 > Extcnsion torch side cable
for extending Model Extension cable for remote control
AW-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 hose
AW-200rAW- 18 (For water supply)
(cable length is 4 m) to
Extension lorch side cable
8m Extension cable for remote control
Extension cable for torch switch
Connection cover
< SAWS-30 1 I >
Extension gas hose
For extending Model
Extension water hose
AW-200rAW-IS (For wata supply)
(cable length is 4 m) to I Sm Extension torch side cable
Extension cable for remote cOnlrol
Extension cable fur turch switdl
Cunnection covcr
< !lAWS-lOl l! >
Extensil\n hose
Fur ext..:nJin!,; Mudd
Extension wat.:r huse
A W-211 IIf i\ W I X
(Fur lI';nef supply)
l e:II,1.,: kn,gth is ", mil" :W III
E"tensilln tureh side callI.,:
J-; " t<"Il Si,1I1 \":lhl<" ti.r r.:nHlt e o.ntf,,1
<"" hk I,.,. I"feh ileh
(\'IIII<"<"li "lI e"h"(
I'll n No.
119541300
f>1 Q.l] ROO
PIO-USOO
1'1 600N02
115581'101
H955HOO
K 5 2 71-1 ()()
K527KOO
PI600N02
H558MOI
1-1956BOO
Kj27JQO
K527LOO
P1 600N02
H558MOI
H9571300
P l043ROO
PI 043Soo
H558MOI
H9581300
K5271-1 oo
K527Koo
1-1 558MOI
11959800
K527JOO
K527LOO
H:5 58MOI
PI04)KOO
"104)LOO
1-1 59) 1-1 00
PI 04) ROO
PI043Soo
H558MOI
K527BOO
K527DOO
I-I S93JOO
K5271IQO
KS27K()O
11 55KMUI
K517CUU
t.:: 527EUU
115'HKHIJ
" ."i :! 7JIICI
K."i27l.111J
11 55:-; \ j(l 1
No. C0025
P. 43 / 63
Q" ty
Remarks
I
4 m
I
4 111
I
4m
I
1ST
I
II m
I
11m
I
11 m
I
1ST
I
16m
I
16m
I
16 In
I
1ST
I
4m
I
4m
I
4m
1ST
I
11m
I
11 m
I
11m
1ST
I
16m
I
16m
I
16m
1ST
I
4m
I 4 m
I
4m
I
4m
I
4m
1ST
I
11m
I 11 m
I
11 m
I II m
I
II m
1ST
I
16m
I 16m
I
16 III
I
16m
I I fi III
l S I
No.C0025
P. 44 / 63
11.4 Connection of optional accessories
II A.1 Extension of torch side cables
I) For wat er-cooled torch
Connect optional extension cable and hose as shown in following fi gure.
Do not connect a hose for water supply to the olltl et of ft:lurncd water.
When using water cooler PU-30 I, please refer to the Owner's Manual for waler cooler
PU-301.
To front face of
Extens ion gas hose
Extension water hose
welding power source

Gas ou,l e' -[]"
-I

Water inlet -[J
:1
,,-
Torch ,erminal-cr=J!
/'
Extension torch side cable
(For condensed water)
2) For air cooled torch
/ (For fcedi ng water)
IT m1
7
I DtJ


-dO
.1
.I
inp at 3 noints
J
\
Connection cover
HSS8MOI
Extension lorch side cable
To waler-
- cooled torch
To front face of Taping al J points Connection cover
weld ing power source I
:l:Q@) (- 'occh
... , .............. ....
Power cable adapter
(torch accessori es)
Gas outlet-1: ",H 145EO I. HSOOD03
Adapter hose H 13000
(torch accessory)
Adapter P 1600N02 is necessary
in case of using model A W-9 torch
3) Extension of torch switch cable and remote control cable.
FrOll1 face o f .
\\"(.'l dill g

---'
2P Extension control cable
receptacle for torch switch
I' kF==([J\jll =c::P
Torch switch
QJl:D==:??==CdlP Q1tD==?F=( =[ 0 01
"'" \ II ' 1 ,1..:II ... j,'"l""lIlh.1 :tbl..:
,..:.!,l.Id..: 1.11 1 ... 111"(..: -:1'1111,,1 ! ""
[ 1.4.2 Optional remote control box
(I) TIG welding
Connection
Please refer to 8. 1. 1 for detail.
No. C0025
P. 45 / 63
Operation
II is same as "Welding current cont ror',
(Refcrto 5.1.)
(2) Stick welding
Connection Pl ease refer to 8. 1.2 for detail.
Operation It is same as "Welding current control", (Refer to 5. 1. )
Remote control 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 autommi c machine
Lh CAUTION
. Contro[ cable which is connected to internal tcmlinal block on chassis shall be separated as
far as possible from base metal side cable and torch side cablc .
Never connect the wiring to control circuit 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.R
on the chassis can be found. Function signals as shown in following fi gure which are
outputted to thi s ternlinal block can be used. Feed the wiring to terminal block through
bushing on rear panel of the welding power source.
When the upper cover is detached. wait for three minutes or more after turning ofT the control power
switch on the front panel. Also. be sure to tum ofTthc line di sconnect switch.
( 58)
o
Lj=-J
__ WCR
Used for detection of welding
current. Contact closes during
welding current fl owing. Contact
r a t i n ~ is less than O.3A at ACI lOY.
(78)
EiBEiB
EiBEiB
o
4P terminal block
Pluse synchronous oulput
During pulse welding. terminals
Will be closed.
Maximum allowable voltage: 24 Y DC
Maxi mlllll allowable current : lOrnA
No.C0025
P. 46 / 63
11 .6. Optional equipment ( Refer to respective owner's Ill anual for details.)
11.6.1 TIG welding with filler wire.
( I.) TIGUN
. TIGUN'S exclusive torch
Model
Rated output current
Duty cycle
Cooli ng method
Cable length
. Controller
Model
Rated input voltage
Rated input power
(2) TIG fiJl er wire feedi ng system
. Controller
Model
Rated input voltage
Rated input power
AWG - 1501
ISOA
40%
Ai r coolinl-'
8m
Adapter hook H528XOO is necessary when using HC-7 1 .
Wire guide assembly
Torch
AW - 18
AW - 26
AW -17
AW - 9
Model eM-27 1 wire feeder for TI G fi ll er
AWGW - 3001
30M
40%
Water cooling __
8m
HC - 81
200 V, single phase
200 VA
HC - 71
200 V, single phase
200VA.
Model of wire guide
BHC - 711 8
BHC - 7126
BHC-711 7
SHC - 7109
11 .6.2 Tungsten elect rode
Use ccrial cd tungsten or thoriated Hmgslcn elect rode.
No. C0025
P. 47/ 63
Select according to welding current. ( Refer to tabl es belO\v. EN: Electrode negative)
Ccriated tungsten electrode can be obtain consumpti on of elect rode come little. and good
arc start can be obtained.
Ceri aled tungsten
Part No.
Dimens ion (mOl ) Allowable welding current (A)
Diameter Lengt h DC EN AC (RMS value)
0870-016 1.6 150 150 130
0870-024 2.4 150 250 220
0870-032
' ?
>.- ISO 400 290
. Thori ated tungsten
Part No.
Dimension (rnm) All owable wel ding current (A)
Diameter Length DC EN AC (RMS value)
0831-005 0.5 150 20 10
083 1-01 0 1.0 150 80 40
0831-0 16 1.6 150 150 100
0831-316 1.6 75 150 100
-
083 1-020 2.0 150 200 120
0831 -024 2.4 150 250 135
0831-324 2.4 75 250 135
0831-032 3.2 150 400 175
083 1-332 3.2 75 400 175
083 1-040 4.0 150 - 300
Pure tungsten
Part No.
Dimensi on (mm) Allowable welding CUlTent (A)
Diameter Length AC ( RMS value)
0830-005 0.5 150 15
0830-010 1.0 150 50
0830-016 1.6 150 100
0830-024
2.4 150 130
0830-032 3.2 150 160
0830-040 4.0 150 240
0830-048 4.8 150
330
0830-064 6.4 150 430
Advanced Air Cooled COz/ MAG Welding Torch
BLUE TORCH II
OWNER'S MANUAL r Parts LisU
WT 35 10-Series
Technical Data
Rated 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 kg
Weight at Operating : 1. 2 kg 2:n
Cooling Method : Air Cooled
D.8m
3 - 1- 053 - 1
Standard Parts List
, ~ @ 14
tc:f---I 5
f1---@
Model: WT3510 - SZ ... 1U5327
WT351O-MZ ... l U5328
WT3510- LZ ... lU5329
. Front Side Components . Cable Components
No. I Part Descript ion Part No. No. Part Description Part No.
0) Nozzle (I.D.16mm) U4167GOI @ Cable Support (with Screw U5035KOO
i2l
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. 0 m 0 . 2mm) U4172HOI
@- 1 O Ring (S9) 3574- 001 @ Power Cable (Reinforcing Spring is included.)
(J) Cap U5341GOI 3. 0 m 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
<Ill
Spring U1 57E04
<lJi
Micro Switch (Dustproof Type) 4254- 137
Optional Parts List
A-Tip np !HI,h d L .. ' Loo. TiP ew-Tip a"" Lrr,) 1 H,avy



J'!

IWI" 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 Shield
Low Current High Current Arc Spot DHp and Narrow Spaee U2075J Ol
U41 67HOl U4167H16 U4170HOI U4167H04
Welding T arch
i!!E
'l31--B - ""3
I!f
I
I

". j
I ,00. I
,-
L ,-
J
Combine with
Long Tip.
Torch Body
R77, 4 So R 1 1 5, 4 5 R77. 55 Al l 5, 5 5 St raight Flexible Long Neck
U5339BOO U5339COO U5347BOO U5350BQO U5339HOO U5339LOO U5339NOO




<Ji 1211

1111_

Rn.
'If.1. .'/
... Rn.
Rn_
Rlls..
RIls..
Standard
n... ..... ,_..s.
Liner
r
"'
Inner Li ner
Wire Size Length Part No. Wire Size Pert No. The$6 are available

t-:_
Om U4173G04 0.8- 1.2I11III _ U5()03L82 for the torch bodies
1.2 ...... 1.6nn 4.Sm U4537GOl
\..
1.2-1.1; .. above.
1.2-1.6mm 6.0m U4175G04
= .,
I
lIs..
- I
. Oirect Plugs
. Volt age Detecting Cable
For using this torch with ot her brand's welding
Part No. : U 5 3 6 5 H 0 0
machine, change connection part of blue torch [I
( Wire Feeder: C MV - 7 4 01 )
with Direct Plugs shown below.
Wel ding Power Source: 0 L - 3 5 0
I I I
ii
';- For using this torch combining with equipment

above, build voltage detecti ng cable in the welding
-
Coy.;, Black T arch
torch. For detaiL see owner's manual of the weld- Panesonic
jng power source and wi r e feeder.
Euro (Binzal)
-
Miller
Miller (Separate Gas Hose)
Hobart
Lincoln
it
DArDEN FS Series
DArDEN MOVE Series
I
Torch Type
WT351 0
-SD
Direct Plugs
I
Rated Current
( 350A )
CO,/MAG
Blue T arch [J Series
S
-r
eries No.
T arch Length
S (Standard) 3. Om
M (Middle) 4 .5 m
L (Long) 6. Om
D :
DB : C c::> Black T arch ' I
P Panasonic
E Euro (Binzal)
M Miller
MS Miller (Separate Gas Hose)
H Hobart (Tweco)
L lincoln
FS DAIDEN FS Series
"I OTC black l orch Power ceble 8dIlPI8<", (,IlIld
not attached. The perl S thllt YOU usa now
new Pllrts ef. required. order parIs below
e Dulle' guide 8te
DM : DAIDEN MOVE Series
or new parts ere reqUIred. If
HT Hitachi
MPeretely.
Power Cable Adapter U2853GOO Z : No Direct Plug
Guide 8dlll)l" U785C13
Outlet Gl.licle lo.g-1.2) U69BJ.4
Outlet Guide 0 .2- 1.6) U69B35
Product Line of OTe Blue Torch n Series
Model WT 1 BOO WT2000 WT 3500
Rated Current lBOA(CO,)/130A (MAG) 200A(CO,) / 160A (MAG) 350A(CO,) / 200A(MAG)
Duty Cycle 40% (CO,) /30% (MAG) 50% (CO,) /30% (MAG) 30% (CO,)/30% (MAG)

Wire Size
(0.6) , O.B
(O.B)' 0.9 (O.B) , 0.9
(0.9), 1.2t 1.2
( .. ) ,,' (1.0), (1.2) (1.0), (1.2)
1.2
T arch Length 3.0m
4.0m
3.0m 4.5m 6.0m
Net Weight 1.7kg 2.0kg 2. 4kg 2.3kg 3.0kg 3.Bkg
Cooling Method Air Cooled Air Cooled Air Cooled
Model WT 3 5 1 0 WT 3520 WT 5000
Rated Current 350A (CO,) / 300A(MAG) 350A(CO,) / 350A(MAG) 500A (CQ,) /450A(MAG)
Duty Cvcle 60% (MAG)
BO% (CO,) /30% (MAG) /30% (MAG)
--
Wire Size
(0.9).(1.0) (1.0), l t
2
, (1.4)
1.2 1.2 1.2
(1.2), 1.4 {1.2) , 1.4 (1.2). 1.4
(mm) :;' 1.2, (1.4) (1.4)
0.4), 0.6l 4), (1 .6r .4), (1. 6)
(1.6) (1.6) (1.6)
Torch Length
3.0m 6.0m
3.0m 4.5m 6.0m 3.0m 4.5m 6.0m
Net Weight 2.7kg 3.6k9 . 4.5kg 3.0kg 4.1 kg 5.1 kg 3.4kg 4.6kg 5.7kg
Cooling Method Air Cooled Air Cooled Air Cooled
-:. Optional l iner IS reqUired for usmg the wire Size shown m ( J.
DAIHEN, INC. OTC (Taiwan) Co.,Ltd.
DAYTON OFFICE No. 63-4. Nan Yuan 2 Ad ..
OTC Industrial (Shanghai)
Co., ltd.
DAIHEN Corporat ion
5-1. Minamisenrioka.
Sensu-shi. Osaka 566-0021.
Japan
Phone: +81 -6-6317-2506.
Fal\: +81-6-6317-2583
1400 Blauser Drive Chung U, Taoyuan Hsien,
Tipp City. Ohio 45371. USA Taiwan R.O.C.
Phone: +1-937667-0800. Phone: +886-3-461 3962,
Fal\: +1 -937667-0885 Fal\: +886-34342394
7G Mlljesty Building. 138 Pu
Dong 011 Oao Shang hil i The
People's RePt.lblic of Chinll
Post Code: 200120
OTC DAIHEN EUROPE
GmbH.
Phone: +86-21-58828633.
OTC OAIHEN Asia Co., Lt d. Fel\: +86-21 -58828846
60/86 Moo 19. Navanakorn
Krefelder SIr. 677. 0 41066
Monchengladbach, F .R.
GERMANY
Phone: +49-2 161 -69-49710.
Fal\: +49-2161 -69-49711
Industrial Estate Phase 3.
Klang Nueng, Klang luang.
Pathumthani 12120
Phone: +662-90941 63,
Fax: +66-2-909-4166
I
. ,
ACCESSORY KIT AK-3
CA8l . Wc-a.22
EXTENSION KIT NOT AVAILABLE
ttOOK-UP KIT HK2, HK-3 .
OHK2: (OCS) .
auto( COHNECT ADD 0 IN FAONT
OF TORCH PACKAGE OR CA.BLE "
, 1
lA
,
,

5

7

,.
11
"
"
" 15
" 17
WP26
1H
.no,
."'"
"CG
"'N63
",N'"
18CG2O

. " .
200 AMPS . AIR ,',
21
26 6

18
19

"
- nozzle (See' chan 8 )
"
-
nozzle (See chart 8) .
20 45Vsi cable adapter
"

- 1 plecl rubber
1 ft . (3.8m)
25 ft . (7.6m)
22 - 2: pilei Gil IwM only
12'h ft . (3,8m)
. 4CN7SR
2S It (7,6m) . 41VlOR
"
WP-2fN torch body. includes 'cup gil.keI and
(70")
" "'"'
98WT7 Q-nng
"
H,2OOA . (ribbed . tandard)
"
HZOO (:smooch. option.r) chart 8)
Cabll Rlpalr Kltl .
ZCRK26
-, ,
rep.ilr kit
ZCRK2...2 ; . cable rIPII. kit
CH ART A. '\I ..... I CHAR:T HOZZLES HPN HIGH PERFORMANCE NOlnEs AVAILABLE


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W'U'9"'FT PR"D,IF" \ ' !NC. CA 91502. USA (800) 752-7620 FAX (818)
COP'fRIGIO" " M3 WElOCRAFT PAOOUCni, IHC
:
- -
,
-
-
.-
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-
I
I\EV. M5
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MANUAL NO;P250002
DAIHENcapor""'"
OWNER'S MANUAL
FOR
DYNAAUTO
~ [ Q ) 3 5 0 ~
MODEL: CPXDS-350 P25000
100 NOT DESTROY 1
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install , operate or
maintain this equipment. Contact your distributor if you do not
full understand this manual.
DAIHEN Cor oration WELDING I'RODUCTS DI VISION
July 1,2007
IUpon contact, advise MODEL and MANUAL NO. I
No.P25000
3. SPECIFICATIONS
3.1
3.2 Standard accessories (welding power source)
i i
Fuse
s -
No.P25000
6. LOCATION AND FUNCTION OF CONTROL
6. 1 Front panel
Lf1 CAUTION
. With the welding st opped, use the switches or knobs on thi s front panel .
A
,
T AUTO PROGRAM SWitch
To select a welding process and a wire diameter
while pressing + or - button. Set to only the
numbers listed on the next page. Refer to the
table of program switch on the next page.
(j! CRATER FILLER CURRENT(A)NOLTAGE(V)
control knobs
To set current and voHage when filling in a crater.
Set to optimum crater-filler conditions.
1.,1 CRATER FILLER switch (ON/OFF)
Switch this swi tch to ON when filting In a crater.
Refer to section 8.2, Crater-filler" for details.
1 PENETRATION CONTROL switch
To control penelration. Set to ON for penetration
control. (Refer to section 8.3.)
<i> VOLT. CURR. CONTROL switch
Refer 10 section 6.2, "Remote control" for details
of Ihis switch.
I; SHIELDING GAS switch
To controllhe amount of gas flow. Switch this
switch to WELD when welding. The TORCH
switch is nol available as long as the GAS swi tch
is set to CHECK.
@

c_ ~ . . __ I ...
------y '" I.
$IIIEiJ,1Ii liAS tli(
...
u ' .
.. ,
4


0II1dr"
~ 1 1 J 1
~ ,
.-
-
-
--
9
1-
'7J

. , ~
1''':;:'
, ~
n
@
~
@
II
',7 WARNING lamp
When an error is detected, this lamp lights or
flashes, then output stops. Refer to section 10.3.
"When an error occurs' for details and
cancellation of the error.
.'I POWER lamp
Ughts when the line disconnect switch of input
power box is connected. Be sure to disconnect
the line disconnect switch, and make sure this
indicator goes out when inspecting external
connections.
.9 CONTROL POWER switch
When this switch is turned on, all indicators
instantly come on and fan starts rotating.
If this welding machine is rested for more than 6
min. while the CONTROL POWER switch is
turned on, the fan automatically stops rotating.
II AMMETER
II VOLTMETER
,J( FUSE{s)
No.P25000
6.LOCATION AND FUNCTION OF CONTROL (conlinued)
6.1 Front panel (continued)
. MODE switch (C0
2
/ MAG)
MODE No. Wektlng process Type of wire Wire diameter. ( m m ~ )
I CO,
2 MAG
O.
3 CO,
SOLID 1.0
4 MAG
5 CO,
12
6 MAG
- -
7 CO, 1.2
8 CO,
FLUX CORED
1.4
9, 0 No programs
I. set a mode number to 1 8.
CAUTION
6.2 Remote control
CURRENT adjusting knob
To set welding current
Set the welding current by
the scale of using wire
diameter.
. SEPARATE adjustment
INCHING button
To feed a wife.
Turn the welding
current adjusting knob
to change a wire
feeding speed.
VOLTAGE knob
SEPARATE adjustment
To set welding voltage.
ONE KNOB adjustment
- Sel Ihis knob In the position mar1<ed
for standard welding voltage. Turn
Ihis knob clockwise for higher voltage
and counterclockwise for lower voltage.
(Decide an optimum setting by
expenmentally generating arc.)
Welding currentlvoltage can be set Individually when the VOLT CURR. CONTROL knob is set to
SEPARATE .
ONE KNOB adjustment
When the CURR VOLT. CONTROL switch on the front panel is set to ONE KNOB. welding voltage is
automatically set ooly by turning the CURRENT knob. To make a fine adjustment of welding voltage.
tum the VOLTAGE knob
NOTE: When any wire feeders other than CMXl2302 are used, actual current and voltage may be
different from the scales of current and voltage control.
- 15
NO.P25000
8 WELDING OPERATION
Ll',
WARNING

Follow the instructions below to avoid electric shock.
Do not touch charging parts inside or outside the welding machine.
Only certified operators or the person who knows welding machi ne well , should change
wiring of the welding machine or changing switch.
Turn off all of the line disconnect switches and wait more than three minutes before
touching the parts inside t he welding machine.
8.1 Sett ing of the built-In changeover switch
it CAUTION
Be sure to turn off all of the line disconnect switches when switching the dip switch 0
adjusting vari abl e resistor.
Never touch the variable resistor painted white .
Variable resistors and dip switches are located on K5374P(Microcompuler COO53X on peBl). inside the
welding power source A desirable function can be selected by changing the settings or resistOfS and dip
I
sWitcheSLJ
I DODD
peBl 0 0



o
o
OFF
NOTE: 00 not touch other resistance or dip switch.
- 17 -
o
o
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 g
I 345678
1 Switch S 1 #2 to ON 10 use ini tial 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 swi tch is
set to OFF. initial current function does not work.
Initial current ON
Torch switch
(TS)
Wire feeding
Gas flow
Welding
current
8.1.2 Preheating function

:J-L....!
J ; ; L
II I I I
J: I I :L

--.J :: L
Inot"'_ M.ln folie'
" .. ,fIR
Initial current OFF


.'

.J: ,: L
r:----L

('.'f' 1,11f.
weld,ng ...... Id'ng
. Preheallng function has been set to OFF prior to the shipment of the welding power source. Switch the
function to ON to use 100V receptacle.
(When the preheating function is set to ON. 100V AC is always applied to the receptacle. But when the
function is OFF. l OOV AC is sporadically applied according to settings of the switches. No control of the
switches 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 regul ator
with a heater. Failure t o do so may cause damage of gas flow regulator. Refer to an
operation manual supplied with a Qas now reQulator .
Switch S 1 #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
18 -
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 OFF
I When use wire feeder CMXL2302
ON
- 19 -
No.P25000
NO.P25000
8. WELDING OPERATION (COnlinued)
8.2 Craterfiller setting
e Three types of welding operation, craterfiller off, craterfiller on, and craterfiller repetition, can be
performed by switching the CRA TERFILLER switch on the front panel
ONIOFF Main purposes Timing chart
ON
Torch swilch (TS)
-.J
10FF
Output voltage
J
"--,
, Tack welding
J
penod
, Repetition of short
Wire feeding
OFF weldings
..do ... n i!"od
Welding a thin
Welding current
-.J
"-
plate
Gas now
-.J L
",cld,n

.
.. f\o'" pnlOll
1'rc: .. 1\u ... pnlOd
eOo nol turn off the torch SWitch during main welding.
ON ON
Torch switch (TS)
.J I
QEF
n
OFF
Output voltage
---
.,..,.
.. Filling In a

--
depression
Wire feeding
(crater) left at the

ON termination of the
Welding current
Jcnller ..,..
weld
.. Welding an
-.J Mllm we4dOI\g )I L
average plate Gas flow
Post .. 1'Iow penod
< <
,
Pn! .. 1'Iow perIOd Cr-,er .. hUe1 perIOd
e Welding power source is sel f .. held when torch SWi tch is turned off
during the crater-filler period
e Set crater-filler conditions by switch the CRATER-FILLER switch
on the front panel..
8 .. 3 Controlling penetration
For typical C02l'MAG welding, penetration of base metal or bead Width as well as welding current varies
depending on wire extension. The wire feeding speed is automatically adjusted by lurning on the
PENETRATION CONTROL switch on the front panel , which causes small change of penetration depth
of a base metal or bead width Turn on the PENETRATION CONTROL switch for constant penetration
depth.
20
8. WELDING OPERATION (conlinued)
8.4 Change of Del (Reference)
Tap 01 Del can be changed according to a use. Del is on the inside of the front cover.
Middle tap
the shipment Maximum tap
17T 24T
28T
When use wire of O.9.1,Orp or extension cable, change to Middle lap
according 10 welding condition .
Change to MSlCimum lap when use more soft arc.
8.5 Connection with automatic machine
8.5.1 Parts of necessary
Name
Wire assy for automatic
machine
ConSlllulion:
Parts No.
P25000WOO
Wire with terminal board' , . . .
Plale' . . 1
M3screw' .... , .... . . 2
M4 screw'
8.5.2 Selling of sWi tches inside the welding power source
I Switch 51 #310 ON to change Wife feeder.
S1 Fgg[rnbl [j bl
5 678
When connect with automatic machine, il is ' ON",
Change ' CN1A" and 'CN3A" of PCB3 to ' eN1S" and ' CN3B",
PCB3
CJ
CN4
21
Quantity
No P25000
NO.P25000
8. WELDING OPERATION (continued)
8.5.2 SettJl"lg of internal 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
/
PCB1

=
o
iell core by screw
Attach terminal Ix>ard with plate by screw
Plate
Detaell and insert
connector indicated "CN1 T'to CN1 7 of PCB2
Terminal board
22
8. WELDING OPERATION (continued)
8.5.3 Connection of external
co Tear the grommet of back board and connect to 8P terminal board.
Start
+
SOL
( : '" "':, f W ~ R : 11 OV less than O.03A
~ Operation stop
tiD
'+'
CD When open il. operation IS sttoped
No.P2S000
<;2) Insert opti onal remote control to CON2 of output termi nal or input signal that customer prepared.
CON2
5)1-- ------,
4).
3 ~
Max O.SmA
Voltage Current
setting setting
(O-15V) (O-15V)
- 23 -
~ Inching switch
NO.P25000
8. WELDING OPERATI ON (continued)
B.6 When errors occur
,1':,
WARNING

Follow the Instructi ons below to avoid elect ric shock .
Do not touch chargi ng parts insi de or out side the wel ding machine.
e Have a quali fi ed engineer or a person who is familiar with this welding power source change wiring
inside the welding machi ne or change over the switches.
e Turn off all of the line disconnect switches and wait more than three minutes before touching the
parts inside the welding machi ne.
e When an error occurs. warning lamps (yellow light) on the front panel and LE01 (red light) or l ED2 (green
light) on PCBlturns on or flashes. then the welding power source automatically stops. In this case, check
the errors in the table below and "9. I Troubleshooting" in this manual
o (ON)
(OFF)
@ (Flicker 1)
6. (Flicker 2)
Error
*------------------

?-------------------------
WARNING lamp PCBI
Error
No.
on the front panel
LED 1 (red light) LED 2 (green light:
(yellow liQhtl
I 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 @


r:tJ
Gas check @

0

Output overcurrenl
0

0
t1!
Microcomputer /',
0

"
Output voltage /',

0
'II" Current detection /',


Power supply frequency
When the POWER CONTROL swi tch 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. turn
off 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 lamp
fl ashes and the welding power source stops automatically. (Refer to 3.2 for details of duty cycle.) In this
case, wal t until the fan stops. wi th the CONTROL POWER SWitch turned on. When starting the wekling
operation again. use the welding machine lower the duty cycle or the welding current.
2 1 -
8. WELDING OPERATION (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 SlOPS
automallCally Dtsconnect the CONTORL POWER switch and meaSUfe the input voltage With such a
measunng '"'trument as a tester to check to make sore if excesslVety high voltage is not output To
eliminate the error tum on the CONTORl POWER SWItch agatn after r8fT'lOWlg 8 cause of the error
above
I Shortage of Input voltage error
When Input voltage falls below 304V. the warning lamp lights. then the Welding power source
automatically slop operation In thiS case dlsconned the SWitch and oonfirm there nI no failure. then tum
00 the switch again
.,' WELDING MODE sWitch error
When unavallabte mode numbers are set while presSing the MODE SWit ch on the front panel , the
WARNING lamp nashes and the welding power source keep stopping
In this case, seiling back to the normat setllng remove abnormal
Ii.' Error before starling welding machine
When the CONTROL POWER sWitch is turned on while the TORCH SWitch Is on, the warning lamp
nashes (Flash 1) and the welding power source keep stopping Turn off the TORCH sWitch to cancel the
error
'1' Gas check error
When more than two minutes has passed while the GAS CHECK SWitch IS turned to the CHECK side, the
warning lamp ftaShes (Flash 1), then the welding power source stops automallcally To cancel Gas check
error, set the GAS CHECK SWitch 10 WELD
10{ Error in output over current
When more than two-seconds over current or shor1-ctrClllt IS oontlnoed, the warning lamp hghts up and
weldtng machine aulomallcally stoPs In thiS case, tum off the CONTROl POWER swrtch and make sure
to see If welding current does not exceed the rated output current or contact between tip and base metal
or short-orcult of output (cables) To cancel this error, sotve the cause of error, !hen tum on the
CONTROL POWER SWitch again,
'I Error m microcomputer
When an error Is detected in microcomputer, the warning lamp nashes (Flash 2) After the warning lamp
Hashes, the welding machine automatically stops.
J(l Trouble 01 oulput volt age
When the TORCH switch Is turned off and voltage on the output l ermlnals presents, the WARNING
lamps nashes (Flash 2) and the welding machine automatically stop welding In case of welcllng same
work piece wi th several welding mact1lnes, tum off the power switch and check whether wire or torch
cable contact With base metat or output cable of other wekllng machine II there are some contacts,
make sure removi ng them and turn the swrtch 0f1 If abnormal sti1l eXist, Chec\( to make sore if main
thyristor or an electromagnetIC contactor IS not broken by using a tester, after turning off the POWER
SWItch To cancel this error, tum on the main power SWitch again after solving the cause of the efl'Of'
J r Current detection error
loose or breaklf'lg Wlnl'lQ between a halt element (CT) and a pnnted CIrCUit board (P C B 1). warning lamp
lights up and wekhng powet" source automatically stops In thiS case, tum off the POWER swrtch and
check fOf the trouble of Wiring After solving the cause of trouble, turn on the CONTROl POWER switch
again to cancel the error
- 25
No.P25000
B. WELDING OPERATION (continued)
8 7 Seiling of variable resistors inside the welchng power source
8.7.1 Changing pre-flow perIOd (For
Pre-flow period is factory-set to 0.05 see. Turn the variable
resistor R 13 clockwise to adjust the pre-flow period. The relation
between setting positions of the variable resistor and pre-flow
period is almost as the figure shown right.
8.7.2 Changing post-flow period
Default settmg of post-flow period IS 0.4 see. TurOing the vanable
resistor R14 in the dockwlse directlOfl to adjust the post -flow
period. The relation between setting positioos of the variable
resistor and post-flow period is almost as the figure shown righl
8.7.3 Changing anti-stick period
0.21see.
0.05see.
(STO)
1.2 sec.
0.4 sec.
(STO)
0.37see.

0.69sec.
RJ3
2 sec.
2.8 sec.

. . . -
. .
. .
3.6 sec.
R J 4
. Anti-slick lime is the processing lime that prevents elec:trode
wire from depositing the base metal at the end of welding.
. Anti -stick time is factory-set to the correct condillOns to match
welding method or wire diameter. The anli-stick time can be
adjusted by turning vanable resistor R15 on P.C.B. 1 clockwise.
The relation between selting positions of variable resistor and
anti-stick time is almost as the figure shown right.
Shorter ,
,-
,.
. Simultaneous moving a torch with release of the torch SWitch
may result in failure of antl stld( treatment and protrusion of
wire caused by inertia of molor
8.7.4 Changing anti-stick voltage
Anti-stick voltage is output voltage that is produced when
preventing electrode wire from deposi ting the base metal.
Anti-stick voltage has been adjusted to proper welding
method and wire diameter prior to the shipment of the
wetding machine The voltage can atso be sel by turning the
vanable resistor R16 on P C.B. 1 The relation between
setting positions of vanable resistor and anti-stICk voltage IS
almost as the fIQure shown right.
26
5096
15096

R J 5
Shorter ...!:,onger
" OV
+4.5V
OV
R J 6
MANUAL NO: U5790
ct)TcJ:=>
DAlHENcorpo<_
OWNER'S MANUAL
FOR
WIRE FEEDER
MODEL: CMXL-2302 U5790
1
0
0
NOT DESTROY I
IMPORTANT: Read and understand the entire contents of this
manual , with special emphasis on the safety material throughout
the manual , before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
DAIHEN Corporation
WELDI NG PRODUCTS DIVISION
N()\cmbcr 15. 2007
IUpon contact, advise MODEL and MANUAL NO. I
No. U5790
P.12 / 22
7. WELDING PREPARATION
7.1 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 operation
with hanQinQ the wire feeder.
condition at
ewhen hanging the wire feeder ,
wire reel shaft should be turned
to 90 counterclockwise.
Commended tightening
torque: 12.4N-m
Wire reel shaft Jit)
Capknob
Hanging bracket
(Fabricated by user.
Use proper material to
withstand load.)
Attachment
ewhen performing welding with the wire
feeder hung, firmly tighten the cap knob to
prevent the wire reel from falling down.
No. U5790
P. 13 / 22
7. WELDING PREPARATION (continued)
7.2 Fitting of wire
C!.l Wire straightener
Pressure handle
Wing nut Hing
Pressure roll
holder
I Checking wire size of the feed roll
CD Check the groove of the feed roll and match
with the wing wire size.
Attach the feed roll 10 the wire feeder, with proper
groove facing out
[Fitting of wire I
@ Raise the stopper and bring it down.
@ Attach the wi re to the wire reel shaft .
@ Return the stopper to oriQlnal position.
&. CAUTION
Wire reel shaft
Stop
Be sure to return the stopper vertically as it was to
prevent dropping of the wire.
Wire

Bring down the pressure handle.
@ Raise the pressure roll holder.
(7) Pull out the wire to let it through the wire
straightener, 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 wi ng nut. adjust the hinge and fix it at an appropriate posi tion.
Wi re pressure adjusting Wire straightener adjusting
Wire size Pressure handle scale Straight hinge adjusting
Solid wire Flux cored wire
scale
4) 1.6
5- 6 4- 5 0- 2
4) 1.2. 1.4 5- 6 3- 4 1- 3
$ 1.0,0.9 3- 4
2-4
4. 0.8 2- 3 3- 5
.
No. U5790
P. 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 the
inching button, and release from the button
when the wire is projected from the welding
torch tip by about 10mm.
Inching button I
WARNING
Touching 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.
No. U5790
P. 22 / 22
10. SPECIFICATIONS
10 1 Specifications
Model CMXL-2302
Applicable wire diameter (O.B, 0.9, 1.0, 1.2, (1.4), (1 .6)
A p ~ licable wire Solid wire. flux cored wire
Wire feedin speed Max. 18m I min.
Shaft dia. Ql 50mm
Applicable wire reel Outer Max. (I) 300mm
dia.
Width 103mm
A p ~ licable wire mass Max. 25kQ
Approximate mass 14 kg
10 2 Standard accessories
Description Part No. Q' ty Remarks
Base metal cable U1997JOO 1
60mml x1 .Bm
Allen wrench 4739-2BO 1 NO. 6 (MB)
'\
MANUAL NO:C0087-3
DAIHENcorporation
OWNER'S MANUAL
FOR
AIR C70
PLASMA
MODEL: MRCT-?O C008?
100 NOT DESTROyl
IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safely operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
D A I HEN Cor p 0 rat io n WELDING PRODUCTS DIVI SION
February 29, 2008
IAt your contact, tell MODEL and MANUAL NO.
No. C0087
CD PLASMA ARC CUTTING SAFETY PRECAUTIONS
The following safety alert symbol and signal words are used throughout this manual to call
attention to and identi fy different levels 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
WARNING . - ~ ~
PLASMA ARC CUTTING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR
DEATH.
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, and
maintenance of this equipment.

Use only well-maintained equipment. Repair or replace damaged parts at once.
PLASMA ARC CUTTING is safe when precautions are taken.
- 1 -
No. C0087
CD PLASMA ARC CUTTING SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
Touchi g live electrical parts can cause fatal shocks or severe bums. The torch and work
circuit i electrically live whenever the output of the plasma cutting power source is on. The
power line and internal circuits of the plasma cutting power source are also live when line
disconn ct switch is on.
When " UTPUT HIGH VOLTAGE" indicator lamp is lighting, cutting machine generates
output 'V oltage(DC200"'-'400V). So when this indicator lamp is lighting, never touch torch
tip 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,
stat1e, 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 off POWER 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 burn
eyes 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.
- 2 -
No. C0087
CD PLASMA ARC CUTTING SAFETY PRECAUTIONS
FUMES AND GASES can be hazardous to your health.
Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes; do not breathe the fumes.
2. Ventilate the area and / or use exhaust at the arc to remove cutting fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacture's instruction for metals
to 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 off power 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 -
No. C0087
CD PLASMA ARC CUTTING SAFETY PRECAUTIONS
~
"
, .'J';>-
" ..... .. :.J.:a.
. is .: '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 solidly 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.
- 4 -
No. C0087
CD PLASMA ARC CUTTING SAFETY PRECAUTIONS
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from Welding Society, 550
N.W. Lejeune Rd, Miami FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C.20402.
Recommended Practices for Plasma Arc Cutting, American Welding Society Standard A WS
C5.2, from American Welding Society, 550 N.W.Lejeune Rd, Miami, FL 33126.
Recommended Safe Practices for the Preparation for Welding and cutting of containers That
Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from
American 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 of Compressed Gases in Cylinders, CGA Pamphlet P-1 , from Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety Welding and Cutting, CGA Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W lR3.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard
Z87.1 , from American National Standards Institute, 1430 Broadway, New York, NYI0018.
Cutting And Welding Processes, NFPA Standard SIB, from National Fire Protection
Association, Batterymarch Park, Quickly, MA 02269.
- 5 -
. No. C0087
~ C MPOSITION AND SPECIFICTION
2.1 Specification
2. C .
1.1 uttmg machine
Model MRCT-70
Rated input voltage
380V1O% 3c/>
KVA(KW) at rated output 20.0kVA 10.5kW
Frequency 50/60Hz
Rated output current 70A
Rated output voltage 108V
Max. no-load voltage 245V
Rated duty cycle 60%
Temp erature rise 160C
U sable temperature range - 10-40C
Mass 102kg
Exter al dimensions 360(W) x 560(D) x 550(H) mm
(WxOxH) (Without the input terminal cover and
bolts for hanging.)
2 C h . 1.2 uttmg tore
Model K5456B
Rated current 70A
Rated duty cycle 60%
Cooling system Air-cooled
Cable length 6m
Using gas Air
Mass(without cables) 250g
2.2 Standa d accessories
2 2 1F tf h' .. or ~ u mg mac me
Description Specification Q'ty
CD 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 ; ; .
-6-
NO. C0087
@ CUTTING OPERATION
5.1 Operation of front panel
Warning lamp
This lamp lights when the following abnormality
occurs.
1 )Over heat
2)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 thyri stor.
When this lamp is lighting, execute the checkN 0.3 in

Section 7.2, "Troubleshooting table".
@
50
Control power switch
If this switch tripped, immediately turn off
the input side power-board switch.
Be sure to check No.1 0 in Section 7.2,
"Troubleshooting table".
Fuse
-E3- Fl (3A) POWER indi cator
~ WARNING
B D 9 _ /,--Ia_mp _ _ -----.
o on 0 This lamp li ghts when
V input power (380V) is
impressed to the input
AIR -e CCNTRCX.. POWER ! POWER
side.
Cutting current adj usting knob.
Set the optimum cutting current
for thickness and material of
base metal.
OUTPUT HIGH VOLTAGE
indicator lamp
This lamp lights when output voltage
is impressed to output terminal.
Please see Section 5.3 for the
standard cutting condition.
Air check switch
Air flows at "CHECK" position.
If this lamp is lighting before torch switch
is triggered, immediately turn off
the 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.
- 11 -
I
I
No. C0087
@ CUTTING OPERATION
!
WARNING
~
Observe the followings to prevent the electrical shock.
-Connect 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 burns
when 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.
Wear 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 disconnect
swi tch or circuit breaker.
Set "C NTROL POWER"
switch to "ON".
Set "AI " switch
to "CHECK".
~ The machine is energized, and the "MAIN LINE" indication
lamp lights.
. The control circuit is energized, and the fan is started.
"OUTPT HIGH VOLTAGE" indicator lamp is lighting before torch
~ switch is triggered, immediately turn off the input side power-board
switch, 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 the
machine from a cold location to a warm one, when you use the
machine in the places subject to humidity, water droplets may form
on the inside of the machine.
Regulate the output pressure of air Before using the torch, carry out air check and drain any water
droplets. uni t to 0. _ MPa.
~ A I R ' switch to "CUT".
!
Do not Li se the torch with condensation formed inside the equipment'.
Failure to do so may lead to seri ous damage to the torch.
- 12 -
NO. C0087
@ CUTTING OPERATION
Check operation of reducing
no-load voltage circuit.
Check whether no load voltage reducing circuit operates normall y
according to the foll owing procedure before cutting operation.
Do not tum torch to the person.
Do not look into inside of tip when checking it.
(This cutting machine has the ~ And pay attention to pil ot arc which is generated from tip.
circuit which stops outputting - Check procedure -
at once, when it will not shift
to the cutting arc within 0.3
sec. after pilot arc is
generated. )
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 1.5
sec. when torch swi tch is triggered with there no base metal,
"OUTPUT HIGH VOLTAGE" indicator lamp lights momentarily
(about 0.3 sec.), and it turns off at once.
2)The braking of the no load voltage reducing circuit when "OUTPUT
HIGH VOLTAGE" indication lamp keeps lighting while the torch
switch is triggered.
Stop operating immediately.
Do not carry out cutting operation until operation is restored normally
after replacing the printed circuit board PCB I.
Electrode and tip are contacted until air flows.
As about 60V is impressed to tip, never touch tip.
"OUTPUT HIGH VOLTAGE" indicator lamp keeps
turning off during start-up delay time.
I Start-up delay time. ( 1.5 sec.) I
No-load voltage is generated, and "OUTPUT HIGH
VOLTAGE" indicator lamp turns on.
-----i----- ---- ------------
. Air flows out, and pilot arc 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 terminal
or plasma arc is not generated within 0.3 sec.
And "OUTPUT HIGH VOLTAGE" indication lamp turns
off.
- 13 -
- ..
No. C0087
@ CUTTING OPERATION
I Release torch switch.
Operati n end
~
Tum 0 "CONTROL
POWE " switch.
Tum off the line
disconn ct switch.
(power hut oft)
I
. Output stops. (Cutting stop)
.. . "OUTPUT HIGH VOLTAGE" indicator lamp turns off.
. Air stops.
Air postflow for 5 sec.
[
When the plasma arc is not J
generated, postflow control is not
taken
During postflow control(within 5
sec. after releasing the torch
switch), trigger torch switch
again.
1
Postflow control is stopped, and
the machine returns to the state
that the torch switch is triggered.
~ . The control circuit is di-energized, and the fan stops.
... . Power suppl y to the machine is shut off, and
"POWER" indicator lamp turns off.
- 14 -
No. C0087
@ CUTTING OPERATION
5.3 Cutting conditions
To perform favorable cutting operation, it is important to follow the proper cutting conditions for materi al and
plate thickness of the plate to be cut.
(I) Cutting capacity
Thickness (mm) O. 1 5 10 15 20 25 30
Iron
Stainless steel
A1urnimun
Copper
(2) Cutting speed
Contactless
Contactless
Contact less
Contact l ess cutting
If the current is constant , the cutting speed slows as cut plate thickness becomes thick.
And the cutting speed differs depending on material.
Critical cutting speed
300
250
Iron
\
(em/min)
o
Stainless steel
-c
200
Q)
Q)
0.

150
u
100
o
Note) The graph shows the maximum
cutting speed. The optimum cutting speed
is 60"""'80% of the cutting speed shown
on the graph.
Aluminium
5
50


D
o
15 16 20 25
9 10 12
30
P] a t e thickne ss (mm)
- 15 -
NO.C0087
@ CUTTING OPERATION
(J) Cutti ng condition(Reference)
Thickness
Cutting Cutting Height
Material
(mm)
Current speed of tip Remarks
(A) (cm/min) (mm)
3.2 30 60'-""'" 120 2
-Cutting gas
(Compressed air)
4.5 40 60'-""'" 120 2 Air pressure :0.5MPa
6.0 50 60'-"""'120 2'-"""' 4
i1d steel 9.0 70 50'-""'" 100 2'-"""'3
St in less steel
12.0 70 40'-"""'80 2'-"""'3
16.0 70 30'-"""'50 3.-.......4
20.0 70 20.-.......30 3.-.......4
25.0 70 15'-"""'25 3.-.......4
30.0 70 10 or less 3.-.......4
4.0 40 60'-""'" 120 2
8.0 50 60'-""'" 120 2'-"""'3
,Aluminum 12.0 70 60'-""'" 120 2'"'-'3
20.0 70 30'-"""'50 3.-.......4
25.0 70 20 or less 3.-.......4
5 70 60'-"""' 100 2
Copper 8 70 30.-.......40 2'-"""'3
12 70 20 or less 2'-"""' 3
-
- 16 -
No. C0087
@ CUTTING OPERATION
5.4 Cutting operation
!
WARNING
It
Observe the following to prevent the electrical shock.
-Connect base metal with output terminal (base material side) of cutting machine surely.
High voltage might be impressed to base metal and cause fatal shocks or severe burns
when used with base metal is not connected with output terminal.
-Do not touch base metal by bare-handed carelessly while cutting operation.
Wear dry, hole-free insulating gloves and body protection.
-Operate by the contactless cutting.
Do not operate by contact cutting which tip contact to base metal.
- When operate following cutting by using a gauge, use a gauge made of the insulation material.
-Check the following items prior to start of cutting.
1. Have the torch parts set properly? 2. Is not the electrode consumed?
3. Is not the electrode damaged? 4. Is the cutting part is dirty?
5.4.1 Cutting operation
-Please operate cutting by the contactless start and contactless cutting which does not contact tip
with base metal.(2-4mm is the best for the distance between tip and base metal.)
-Do not remove standoff guide from torch, except when you use a gauge etc.
(The distance between tip and base metal can be automatically
maintained in 3mm by using the standoff guide.)
CDTorch switch turns on.
Bring the tip near to the cutting
start spot, and generate pilot
arc.
(Pilot arc is generated
momentari Iy.)
Standoff guide
cz,Start cutting. @Finish cutting. @Torch switch turns off.
Plasma arc is generated, and Slow down the cutting speed a After completion of
cutting starts. bit as the torch moves close to cutting operation,
the edge of the plate.
release the torch switch.
@Cutting.
Cut the plate with tip set afloat from
the base metal by 2 ~ 4 m m .
The distance can be kept constant by
using the standotf guide suppli ed with
the torch.
- 17 -
No. C0087
@ <:UTTING OPERATION
* (Things you should take care about )
I\Sl "\l
I
".
'II
Proper angle of the torch is 90
o
----- 5.
Direction of
cutting
The optimum cutting speed is the speed when plasma arc flows slightly
backward.
If the cutting speed is too fast, flow-up occurs; and if it is too slow, bum marks
on the plate surface increase.
Max. 5mm
Contact plate
(5-----7mm in thickness)
Cut the late with tip set afloat
from th , base metal by
As cutting is executed by tip along the contact plate, you can do that
with less movement of the torch, and the base metal looks neat.
Use an insul ating plate of 5-----7 mm in thickness for this contact
plate. If conductive material such as metallic plate is used for this
purpose, double arc is apt to result, and the hole of tip is deformed.
maxim m 5 mm.
- 18 -
NO. C0087
@ CUTTING TROUBLE AND REMEDY
7. 1 Cutting troubles
A t first check the external connection and the front panel operation.
Check also that the torch parts have been set as specified.
TROUBLE
~ _____ C_A_U __ SE ______ ~ I ' REMEDY
Pilot arc is not Air pressure is too high or too Set air pressure to O.SOMPa.
generated. low of air unit.
Shield cup loose , or dirt Thoroughly wipe off dirt , and tighten
- ~
adheres to it. the shield cup.
--1 Air switch is "CHECK". Switch to "CUT".
~ I Electrode and tip exhausted. Replace electrode and tip.
Y Electrode and tip is welded.
Transfer from pilo I Tip hole has been deformed. Replace electrode and tip.
arc to plasma arc is
not smooth. ~ I Electrode exhausted. Replace electrode and tip.
Discharge air regulator drain, and clean
H Air contains water or oil.
r-
the filter.
Base metal in contact with side If the base metal contacts the side
f-- -
surface of tip. surface of tip a strong arc is generated,
resulting in deformation of tip hole.
Avoid doing this.
Base metal cable is loose
f--
--1 Surely connect base metal cable.
connected.
~ l Torch angle is too large.
Set torch angle to +5 0
to _5 0.
- 19 -
No. C0087
@ CUTTING TROUBLE AND REMEDY
UBLE
CAUSE
Transfer from pilot f---+--i There is excessive distance
arc to p asma arc is
not smooth.
Transfe to plasma
arc is accompanied
by nois _.
Plasma rc is
interrupted.
Cut surface
became oblique.
t--
between tip and base metal.
Paint or other insulation
material cling to base metal.
The base metal is not
completely connected with the
output terminal(base metal).
Ele'ctrode has been exhausted.
Cutting speed is too low.
Distance between tip and base
metal is excessive.
H Dross exists on tip surface.
'--
Tip hole has been excessively
deformed.
Tip hole has been deformed.
Electrode and tip have been
r--
exhausted.
r--
Distance between tip and base
metal is too short.
Torch angle is too large.
--1 Cutting speed is too high.
Y Cutting current is too low.
- 20-

REMEDY
Adjust distance to the range between 2
and 4 mm.
Cut the start part with marking- off knife
to expose the base metal.
The base metal is surely connected with
output terminal(base metal side).
If the electrode has been exhausted by
more than 1.5 mm,
transfer is accompanied by noise.
Replace the electrode timely.
Increase cutting speed.
--1 Approach tip to base mm)
Clean tip surface with brush.
--1 Replace electrode and tip.
,
Replace electrode and tip.
--1 Replace electrode and tip.
H Approach tip to base metal. mm).
Set vertically the torch.
Decrease cutting speed.
I
I
I
I
I
Increase setting of cutting current.
I
No. C0087
@ CUTTING TROUBLE AND REMEDY
TROUBLE CAUSE REMEDY
If electrode has been exhausted by more
Ti p hole is easy to - --l Electrode exhausted.
r-
than 1.0 mm, tip hole is soon deformed
deforme.
after tip is repl aced.
Repl ace electrode.
When starting, tip si de IS In If base metal or backi ng plate
- -,--
contact with base metal.
,
(conductive) contacts tip side, double arc
,
Due care must be taken may occur.
-
When cutting, tip is in contact
-
when starting. Use backing plate made
I
with backing plate.
of material.
--1 Torch angle is too large.
r
If torch angle is too large, arc contacts
I tip, causing deformation.
, Set torch angle within 90 +5
0

Decrease cutting speed below allowable

Plasma arc fails to Cutting speed is too high.
r-
limit.
cut plate thoroughly
H Cutting current is too low. Increase cutting current.
and blows up.
Tip hole has been deformed
-
---j Replace electrode and tip.
excessively.
If torch angle is too large, cutting
rl Torch angl e is too large.
r-
capacity is reduced.
Set torch angle within 90
+5
A lattice exists under cut
Set base metal at a distance from lattice
-
material.
I-
si nce blow-up may occur at lattice.
--1 Backing plate is conductive.
r-
If tip is in contact with backing plate
made of conductive material
when cutting, double arc may occur.
Use backing plate made of insulation
material.
- 21 -