DW 300 (P10537 8)

MANUAL NO:P10537-8
OWNER'S
FOR
MAG/MIG
MANUAL
DIGITAL INVERTER DW300

MODEL: DW-300 P10537
INVERTER CONTROLLED WELDING POWER SOURCE
DO
NOT
DESTROY
IMPORTANT: Read and understand the entire contents of this manual, with special emphasis on the safety material throughout the manual, before installing, operating, or maintaining this equipment. This equipment and this manual are for use only by persons trained and experienced in the safety operation of welding equipment. Do not allow untrained persons to install, operate or maintain this equipment. Contact your distributor if you do not fully understand this manual.
DAIHEN Corporation
WELDING PRODUCTS DIVISION September 26, 2008
Upon contact, advise MODEL and MANUAL NO.
No. P10537
CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9.
SAFETY INFORMATION 2 ARC WELDING SAFETY PRECAUTIONS 2 GENERAL NOTICE OF OPERATION 7 STANDARD COMPOSITION AND ACCESSORIES 8 FUNCTION OF EQUIPMENT 10 NECESSARY POWER SOURCE EQUIPMENT 11 TRANSPORT AND INSTALLATION 12 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE 14 WELDING PREPARATION 17
10. OPERATION 25 11. APPLIED FUNCTION 70 12. MAINTENANCE AND TROUBLESHOOTING 76 13. PARTS LIST 89 14. SPECIFICATIONS 92 15. SERVICE AND SUPPORT 97
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No. P10537
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to identify various hazards and special instructions. WARNING WARNING gives information regarding possible personal injury or loss of life. CAUTION refers to minor personal injury or possible equipment damage.
CAUTION
2. ARC WELDING SAFETY PRECAUTIONS

WARNING ARC WELDING can be hazardous. 1. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. Be sure to: Keep children away. Keep pacemaker wearers away until consulting a doctor. 2. Read and understand the summarized safety information given below and the original principal information that will be found in the PRINCIPAL SAFETY STANDARDS. 3. Have only trained and experienced persons perform installation, operation, and maintenance of this equipment. 4. Use only well-maintained equipment. Repair or replace damaged parts at once. ARC WELDING is safe when precautions are taken. ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuits are electrically live whenever the output is on. The power line and internal circuits of this equipment are also live when the line disconnect switch is on. When arc welding all metal components in the torch and work circuits are electrically live. Leaving accretive dust in the welding machine may cause an insulation deterioration and result in electrical shock and fire. 1. Do not touch live electrical parts. 2. Wear dry insulating gloves and other body protection that are free of holes. 3. Insulate yourself from work and ground using dry insulating mats or covers. 4. Be sure to disconnect the line disconnect switch before installing, changing torch parts or maintaining this equipment. 5. Properly install and ground this equipment according to its Owners Manual and national, state, and local codes. 6. Keep all panels and covers of this equipment securely in place. 7. Do not use worn, damaged, undersized, or poorly spliced cables. 8. Do not touch electrodes or any metal object if POWER switch is ON. 9. Do not wrap cables around your body. 10. Turn off POWER switch when not in use. 11. Remove dust by blowing moisture-free compressed air on each part periodically.
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No. P10537
2. ARC WELDING SAFETY PRECAUTIONS (continued)

ARC RAYS can burn eyes and skin: FLYING 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. 1. Wear face shield with a proper shade of filter (See ANSI Z 49.1 listed in PRINCIPAL SAFETY STANDARDS) to protect your face and eyes when welding or watching a welder work. 2. Wear approved face shields or safety goggles. Side shields recommended. 3. Use protective screens or barriers to protect others from flash and glare: warn others not to look at the arc. 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. 5. Use approved earplugs or earmuffs if noise level is high. Chipping and grinding can cause flying metal. As welds cool, they can throw off slag. 6. Wear proper body protection to protect skin. WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks, hot metal, spatter, hot base metal and hot equipment can cause fire and explosion. Accidental contact of electrode or welding wire to metal object can cause sparks, overheating, or fire. Leaving accretive dust in the welding machine may cause an insulation deterioration and result in electrical shock and fire. 1. Protect yourself and others from flying sparks and hot metals. 2. Do not weld where flying sparks can strike flammable material. 3. Remove all flammables within 10m (33ft) of the welding arc. If this is not possible, tightly, cover them with approved covers. 4. Be alert that welding sparks and hot metals from welding can easily pass through cracks and openings into adjacent areas. 5. Watch for fire, and keep a fire extinguisher nearby. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire. 7. Do not weld on closed containers such as tanks or drums. 8. Connect power cable for base metal as close to the welding area as possible to prevent the welding current from traveling along unknown paths and causing electric shock and fire hazards. 9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. 10. Do not use the welding power source for anything other than arc welding. 11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers, boots, and a cap. 12. A loose cable connection can cause sparks and excessive heating. 13. Tighten all cable connections. 14. When there is an electrical connection between a work piece and the frame of wire feeder or the wire reel stand, arc may be generated and cause damage by a fire if the wire contacts the frame or the work piece. 15. Remove dust by blowing moisture-free compressed air on each part periodically.
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No. P10537

FUMES AND GASES can be hazardous to your health.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to your health. 1. Keep your head out of the fumes. Do not breathe the fumes. 2. Ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 3. If ventilation is poor, use an approved air-supplied respirator. 4. Read the Material Safety Data Sheets (MSDS) and the manufacturers instructions on metals, consumables, coatings, and cleaners. 5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations. The heat and arc rays can react with vapors to form highly toxic and irritating gases. 6. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe. CYLINDER can explode if damaged.
A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to handle them carefully. 1. Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the specific application; maintain them in good condition. 2. Protect 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 follow instructions on compressed gas cylinders, associated equipment, and the CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS. 7. Turn face away from the valve outlet when opening cylinder valve. 8. Keep protective cap in place over valve except when a gas cylinder is in use or connected for use. 9. Do not disassemble or repair the gas regulator except if you are authorized by the manufacturer. ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machines can cause serious injury. 1. When hanging the welding power source by a crane, do not use the carrying handle. 2. Put the welding power source and wire feeder solidly on a flat surface. 3. Do not pull the welding power source across a floor laid with cables and hoses. 4. Do not put wire feeder on the welding power source. 5. Do not put the welding power source or wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds. 1. Do not press the gun trigger until instructed to do so. 2. Do not point the gun toward any part of the body, other people, or any metal when threading welding wire.
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No. P10537

WARNING Be sure to observe the followings for preventing physical injuries, a fire and electric shock. Handling of plastic parts Front panel and the likes on this power source are made of polycarbonate. Make sure to observe the following notice. 1. Do not apply external force and a shock to front panel and the likes. Otherwise it maybe broken and in trouble. 2. Polycarbonate can endure wiping off with water and alcohol in general but using at a sticking place with an organic solvent, chemicals, cutting oil and atmosphere such as composition oil, it gives bad influence to polycarbonate and it causes a crack (breaking) and a strength down. If abnormality was discovered such as crack on the front panel, stop operating immediately and ask to repair and change. Rotating parts may cause injuries. Be sure to observe the following.
If hands, fingers, hair or clothes are put near the fans rotating parts or wire feeders feed roll, injuries may occur. 1. Do not use this equipment if the case and the cover are removed. 2. When the case is removed for maintenance/inspection and repair, certified or experienced operators must perform the work. Erect a fence, etc. around this equipment to keep others away from it. 3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
HF
To prevent electromagnetic troubles, read the following. Also, if electromagnetic troubles occur, check the following again.
Before installing arc welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: 1. other supply cables, control cables, signalling and telephone cables, above, below and adjacent to the arc welding equipment; 2. radio and television transmitters and receivers; 3. computer and other control equipment; 4. safety critical equipment, for example guarding of industrial equipment; 5. the health of the people around, for example the use of pacemakers and hearing aids; 6. equipment used for calibration or measurement; 7. The user shall ensure that other equipment being used in the environment is compatible; 8. the time of day that welding or other activities are to be carried out; Methods of reducing EMC: z Public supply system Add a noise filter to the input cables. z Maintenance of the arc welding equipment Close and fix all doors and covers of the welding machine. z Welding cables Do not use an unnecessarily long cable. Place a base metal cable and a torch side cable as closely as possible. z Equipotential bonding Bonding of all metallic objects in the surrounding area should be considered. z Earthing of the workpiece The connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations. z Screening and shielding It is selective screening and shielding of other cables and equipment in the surrounding area.
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No. P10537
PRINCIPAL SAFETY STANDARDS

Arc welding equipment Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro technical Commission Arc welding equipment Part 10: Electromagnetic compatibility (EMC) requirements IEC 60974-10, from International Electro technical Commission Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office. Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, from American Welding Society. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society. National Electrical Code, NFPA Standard 70, from National Fire Protection Association. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association. NOTE: The codes listed above may be improved or eliminated. Always refer to the updated codes.
M080904
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No. P10537 3. GENERAL NOTICE OF OPERATION 3.1 Rated duty cycle CAUTION Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle limitation may result in damage to the welding machine. The rated duty cycle of the welding power source is 80% at 300A 29V: NOTE: When using the dust filter, perform 65% or less duty-cycle operation (without clogging). Otherwise, the welding machine may be damaged. Refer to Section 3.1, Rated Duty Cycle. The rated duty cycle of 80% means the machine must be rested for 2 minutes after 8 minutes of continuous welding at the rated current.
ON OFF
8 min.
2 min. 10 min.
Operation cycle of 80% duty cycle
Failure to observe duty cycle limitations may cause the temperature inside the welding
machine to exceed tolerance levels. This may cause to premature welding machine failure or product damage.
The
figure shown right indicates the relation between welding current and duty cycle. Use the welding machine within its usable range, based on the appropriate duty cycle for the welding current.
The duty cycle of the welding power source is

also limited by the duty cycles of accessories combined with it, such as welding torches. Use the welding machine within the lowest rated duty cycle of the accessories.
For use of exceeds rated voltage, duty cycle is

60% at 300A, 36V.
3.2 Applicable welding process and wire diameter Refer to Section 10.1.1, Setting of Welding Mode for details of applicable welding method and wire diameter.
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No. P10537 4. STANDARD COMPOSITION AND ACCESSORIES 4.1 Standard composition
The part names indicated in the boxes are standard parts. Preparation of the other parts is required to use the welding power source. Input cable and grounding cable For a switch box, the 2m input and grounding cables are from the back panel of welding power source. Input cable Grounding cable AWG10 5mm with 10mm terminal x 3 AWG10 5mm with 10mm terminal x 1
For air cooling torch
Gas regulator
3 phase 400V
2m Input cable
with grounding
Digital remote control Optionally available
Gas hose 3m Control cable for wire feeder 2m

Shield gas
Power cable for wire feeder 2m
Welding torch
Wire feeder
Welding power source
Base metal
Power cable for base metal 2m Analog remote control with 3m control cable Optionally available
Ground a work piece if a local law requires.
Gas regulator
3 phase 400V
2m Input cable
Water cooler
Gas hose 3m Control cable for wire feeder 2m
Shield gas
with grounding
Power cable for wire feeder 2m
Welding torch
Wire feeder
Base metal
Power cable for base metal 2m Analog remote control with 3m control cable Optionally available Digital remote control Optionally available
*Extension cables / hoses (5m, 10m, 15m and 20m) are available.
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No. P10537 4. STANDARD COMPOSITION AND ACCESSORIES (continued) 4.2 Accessory Make sure you have the item below before you start using the welding power source. Description Dust filter Specification 109-1000M13 Qty 2 Part number 4519-031 Remarks For the fan on the rear panel of welding power source
NOTE: When using the dust filter, perform 65% or less duty-cycle operation (without clogging). Otherwise, the welding machine may be damaged. Refer to Section 3.1, Rated Duty Cycle. 4.3 Accessory (not supplied) (1) Shield Gas Use a suitable gas for welding method.
Carbon dioxide gas (CO2 gas)

For welding (purity: 99.9% or more, moisture content: 0.002% or less)
MAG gas MIG gas for stainless steel, MIG gas for mild steel with AC pulse MIG gas for Aluminum
Pure argon (Ar) 98% argon (Ar) + 2% carbon dioxide gas (CO2 gas) 80% argon (Ar) + 20% carbon dioxide gas (CO2 gas)
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No. P10537
Carrying handle Parameter adjusting knob
Grommets with film (for pulling out external connection cables)
Eye bolt
5.1 Welding power source
Front panel
Main power lamp
5. FUNCTION OF EQUIPMENT
- 10 Power switch Input cable
Socket for wire feeder
Socket for analog remote controller
Cap Cooling fan

Output terminal (connect to wire feeder)
Cap
Output terminal (connect to the base metal)
Caster Caster
No. P10537 6. REQUIREMENT OF INPUT POWER 6.1 Welding power source equipment (for commercial use) WARNING When the welding machine is used in a humid environment such as a construction site, on a steel plate, or on a steel structure, install a leakage breaker. CAUTION Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each welding machine. Capacity of necessary power source utility MODEL Power supply voltage Tolerance range of fluctuation of power supply voltage Installed capacity Capacity of switch/circuit breaker
DW-300 400V, Three phase 400V15% 18kVA or more 30 A
6.2 Precautions for use of the engine generator CAUTION Use the auxiliary power of engine welder with an improved voltage waveform. Some engine welders have poor electricity, which may cause product damage. Contact an engine welder manufacturer for improvement of voltage waveform. To prevent the engine generator or auxiliary power from being damaged, follow the instructions below.
Set the output voltage of the engine generator to the voltage range between 400 and 410V at no-load welding operation. Setting to extremely high output voltage may result in product damage. Use the engine generator with a damper winding that has a capacity of more than twice that of the rated input of the welding machine. Generally, the recovery time of the engine generators voltage for load change is slower than that of the commercial input power source, and if the engine generator does not have sufficient capacity, sudden current change such as arc start will occur. This may result in abnormal decrease in output current or arc loss. Ask an engine generator manufacturer for a damper winding. Do not combine more than two welding machines with an engine generator. The effect of each welding machine may cause easy loss of arc.
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No. P10537 7. TRANSPORTATION AND INSTALLATION 7.1 Transportation WARNING Follow the instructions below to avoid trouble and product damage when carrying the welding machine. Do not touch the live electrical parts inside or outside the welding machine. Be sure to disconnect the line disconnect switch when carrying the welding machine. When carrying the welding power source by a crane, do not use the handle and hang the welding power source with the eyebolt surely. Do not hang welding power source without eyebolt by a crane.
7.2 Installation WARNING When installing the welding machine, follow the instructions below to avoid a fire caused by welding and physical injury from gas fumes. Do not place the welding machine near combustible materials and flammable gas. Remove combustible materials to prevent dross coming into contact with combustible objects. If that not possible, cover them with noncombustible covers. To avoid gas poisoning and risk of suffocation, wear a gas mask or adequately ventilate when the welding machine is used in the place regulated by a local law. To prevent injury or poisoning caused by fume, wear a gas mask or weld at a partial exhaust facility approved by the local regulation. Adequately ventilate or wear a gas mask when using the welding machine in a tank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide or argon gases are drifting there. When using the welding machine at a narrow space, comply with a trained supervisors directions. And be sure to wear a gas mask. Do not operate the welding machine near the place where degreasing, cleansing, and spraying are performed. Otherwise, poisonous gas may be generated. Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate. (Poisonous gas and fume may be generated.)
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No. P10537 7. TRANSPORTATION AND INSTALLATION (continued)
CAUTION To prevent electromagnetic troubles, read the following. Also, if electromagnetic troubles occur, check the following again.
Change the installation place of the welding machine. Mount an input cable in the grounded metallic conduit. Shield the whole welding places from electromagnetic trouble. CAUTION Follow the instructions below when selecting an installation place of the welding power source. Do not put heavy things on the welding power source. Do not cover the ventilation port of the welding machine. Do not install the welding power source in the place subject to direct sunlight and rain. Place the welding machine on a strong and stable surface. Install the welding machine in the place where the ambient temperature is between -10 C and +40 C (+14 F and +104 F). Do not install the welding machine in the place where metal material such as spatter enters the welding power source. Keep the install distance of 30 cm between the welding power source and the wall or other welding power. Install a wind shield to protect arc from wind. Fix the gas cylinder to the stand only for gas cylinder.
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No. P10537 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE WARNING Follow the instructions below to avoid electric shock.
Do not touch the live electrical parts, as this will result in fatal shock and severe burn. Do not touch the live electrical parts of the welding machine. Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected, following a local low. With the line disconnect switch inside the switch box all turned off, ground and connect the welding machine. Do not use a cable with lack of capacity or a damaged cable. Tighten and insulate the connections of cables. Surely attach the cover of the welding machine after connection of the cables.
8.1 Connecting of the Welding Power Source When using the air-cooled torch
Gas regulator
Power cable for wire feeder
Control cable for wire feeder

Shield gas
Gas hose
Wire feeder
Welding torch
Base metal
Power cable for base metal Analog remote control Control cable for remote control
Optionally available
M10 terminal
When using the water-cooled torch

Gas regulator Water hose Water cooler
Shield gas For feeding water
Surely insert the connector plugs into the sockets for wire feeder and for analog remote control up to the stop by turning them clockwise.
Gas hose Control cable for wire feeder Power cable for wire feeder

Welding torch
Wire feeder Control cable for remote control Power cable for base metal Base metal Analog remote control Optionally available) M10 terminal
NOTE: In case of putting the Abnormal water pressure signal into the welding power source, see 11.2.
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No. P10537 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) Follow the steps below to attach the cables to the output connectors of the welding power source referring to the illustrations of Connection of the Welding Power Sourceon the previous page. 1. Connect between the base metal - terminal and the base metal using the power cable for base metal. 2. Attach the power cable for wire feeder to the torch + output terminal. 3. Remove the right-side plate of the wire feeder, and then attach the power cable for wire feeder to the M10 terminal. Surely fix the power cable in position not to contact with the bottom of the frame and the terminal board. Put around the terminals with insulating tape. 4. Insert the control cable for wire feeder into the socket for wire feeder. 5. Attach the gas hose to the gas inlet on the wire feeder. 6. Connect the welding torch to the wire feeder. 7. Connect the hoses for water-out and for water-in to the water cooler. (When using a water-cooled torch.) 8.2 Connecting of the Gas Hose WARNING There is a danger of suffocation caused by lack of oxygen when shield gas keeps drifting in a closed place. Be sure to turn off the shield gas at the main when the welding power source is not in use.
CAUTION Be sure to connect the gas hose after fixing to the stand, as physical injuries may result from falling down of gas cylinder. Attach a proper gas flow regulator to a gas cylinder. Failure to observe the demand may result in physical injuries. The gas flow regulator for high pressure gas must be used. Securely attach the gas hose to the gas inlet located on the rear side of the wire feeder with a monkey wrench, etc. Fix the nut for attaching the gas cylinder to the gas cylinder with a monkey wrench, etc. Securely attach the gas hose to the gas outlet with a monkey wrench, etc.
Gas regulator
Nut for attaching gas cylinder

Gas outlet Gas cylinder
Wire feeder
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No. P10537 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) 8.3 Grounding and connection of input power WARNING Follow the instructions below to avoid electric shock.
Touching the live electrical parts may result in fatal electric shock and severe burn. Do not touch the live electrical parts of the welding machine. Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected in accordance with a local low. With the line disconnect switch in the switch box all touched off, ground and connect the welding machine. Attach the case properly after connecting the cable. When the welding machine is used in a humid environment such as a construction site, on a steel plate, or on a steel structure, install a leakage breaker.
CAUTION Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each welding machine.
Mount a switch with fuse or a circuit breaker on each welding machine.

GREEN cable for Grouding cable
Base metal/JIG
Input cable Surely connect the input and grounding cables AWG10 (5mm2) to the circuit breaker .
CAUTION Be sure to ground the case of the welding power source. Use a grounding cable 14mm2 or more in thickness. If the welding power source which is not grounded is used, voltage will be generated in the case through the capacitor between the welding power source input circuit and the case or floating capacity (electrostatic capacity naturally generated between the input conductor and the case metal). If you touch the case or the base metal, you may suffer from electric shock. Be sure to ground the case of the welding power source.
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No. P10537 9. WELDING PREPERATION 9.1 Preparing the protective equipment To protect you from gas generated from welding, fume, and lack of oxygen, wear protective equipment.
To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately ventilate when the welding machine is used in the place regulated by a local law. To prevent disorder or poisoning caused by fume, wear a gas mask or weld at a partial exhaust facility approved by the local regulation. Adequately ventilate or wear a gas mask when using the welding machine in a tank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide or argon gases are drifting. When using the welding machine at a narrow space, comply with a trained supervisors directions. And be sure to wear a gas mask. Do not operate the welding machine near the places where degreasing, cleansing, and spraying are performed. Otherwise, poisonous gas may be generated. Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate. (Poisonous gas and fume may be generated.) NOTE: Install a windshield to protect arc from wind when using an electric fan for ventilation or when welding outdoors. Failure to observe the demand may result in poor welding. CAUTION Use the protective equipment to protect you and other workers from arc rays, spattering dross, and noise from welding operation.
When performing or monitoring welding operation, wear an eye protector with a good light blocking effect or face shield. Wear protective glasses to protect your eyes from the spattering dross. Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, and leather apron. Install protective screens or barriers to protect the eyes of others in the work area from arc ray. Wear an ear protector when noise level is high.
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No. P10537 9. WELDING PREPARATION (continued) 9.2 Operating the switches and controlling the gas regulators for gas cylinders CAUTION Do not put your hands, fingers, hair, clothes and metal near the fan rotating. Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as burst of high-pressure gas may result in physical injuries. NOTE: Gas checking automatically stops in two minutes. Turn on the line disconnect switch.
Set the gas regulators for gas cylinders to SHUT , then turn on gas at the main. Set the gas flow rate adjusting knob to OPEN to adjust the gas flow rate.
Place the power switch in the I (ON) position.
J OB W ARN IN G M EM O RY
A
D CN O -LO A DV O L T A G E
Press the GAS CHECK key. (The GAS CHECK lamp lights up.)
LO AD
m /m in S e c H z
%
J O BN O .
SAVE
A
m /m in
M AIN CO NDITIO N
ARC CO N TRO L
T2
EN TER
T1
INITIAL CO ND ITIO N O N
DISPLAY CH AN G E
SYNERG .
SYNER G . IND IV.
CRATER -FILL. CO ND ITIO N W ATER
f
W A VE FR E Q .
G A S C H EC K
O FF
IN ITIA L C O N D .
0. 8 0. 9
W E LD M O NIT O R
(O PTIO N)

VO LT. CO NTRO L TO R C H AL/PU RE

MI G
EN R ATIO
AC PU LSE AC W A VE P ULSE D CP ULS E D CW AVE PU LSE O P1 O P2

W E L D IN G M ETHO D
AL/MG C uSi C uAl
Press the GAS CHECK key again. (The GAS CHECK lamp goes out.)
O N
1. 0 1. 2 1. 4 1. 6
IN C H IN G
R EPEAT
MI G
STAINLESSSTEEL M ILDSTEEL
SPO T
M AG
M ILDSTEEL
S PO T TIM E
CRATER FILL.
W IRE DIA.
m Refer to m m anual for
recom m ended shieldinggases
9.3 Inching Operation WARNING Do not look into the tip hole to check for the rate of wire feeding while inching. The wire might fly out and hit the face or eyes, and you may get injured. Do not bring the tip of the welding torch close to the face, eyes, or bodies. You may get injured. CAUTION Keep away your hands, fingers, hair or clothes from the rotating parts of the feed roll, etc. to prevent you from being caught into the rotating parts while inching.
After straightening the welding torch, feed the wire while pressing the inching button. (INCHING lamp lights up). When the wire appears from the end of the torch, release the INCHING key. Cut the wire at about 10 mm from the end of the torch. When adjusting wire feed rate, use the parameter adjusting knob. Inching operation can be controlled by using the INCHING button on the analog remote control (optional accessory). When controlling inching operation with the remote control, the INCHING key on the front panel does not function. INCHING key
Parameter adjusting knob

J OB W ARN ING M EM O RY
A
LO AD
m /m in S e c H z
%
J O BN O .
SAVE
A
m /m in
M AIN CO NDIT ION
ARC
CO NTRO L
T2
ENTER
T1
INITIAL CO ND ITIO N O N
DISPLAY C HAN G E
SYN ER G .
SYN ERG . INDIV.
CRATER -FILL. CO NDITIO N W ATER
f
W AVE FREQ .
G AS C HECK
O FF
INITIA L CO ND .
0. 8 0. 9
W E LD M O NIT O R
(O PTIO N)

VO LT . CO NTRO L TO RCH AL/PURE

MI G
EN RATIO
AC PU LSE AC W AVE PULSE D C PULSE D CW AVE PU LSE O P1 O P2

AL/MG C uSi C uAl
ON
1. 0 1. 2 1. 4 1. 6
INC HIN G
R E PEA T
MI G
ST AIN LESSSTEEL M ILDSTEEL M ILDSTEEL
SPO T
M AG
SPO T TIM E
CRATER FILL.
W IRE DIA.
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No. P10537 9. 9.4 Welding Conditions When setting to the improper welding conditions, the following troubles will occur. Cause Wire extension is too long. Trouble Long Arc length Wide bead width Poor shield Short arc length Easy generation of spatter Long arc length Wide bead width Shallow penetration and flat bead Stick to base metal and easy generation of spatter Narrow bead width Deep penetration and low excess metal Wide bead width Deep penetration and high excess metal Narrow bead width Shallow penetration and low excess metal WELDING PREPARATION (continued)
Wire extension is too short. Welding voltage is too high.
Welding voltage is too low.
Welding current is too high. Travel speed is too fast.
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No. P10537 9. WELDING PREPARATION (continued) The data in the tables below is only for reference. Please find the optimum welding conditions for weldment shape and welding position. 9.4.1 Example Aluminum AC pulsed MIG Welding Conditions (reference) Wire: A5183 Wire diameter: 1.2mm Base metal: A5052 Gas: Ar gas (20 liter/min)
(1) Lap fillet welding condition example Plate thickness (mm) 0.8 Gap (mm) 0 1.0 0 1.0 1.5 2.0 0 1.0 1.5 2.0 0 1.0 1.5 2.0 Welding current *1 (A) 33 31 45 46 40 39 46 45 48 45 53 53 56 55 Welding Travel Wire feeding Aim EN ratio voltage *1 speed speed position *2 adjustment (V) (cm/min) (cm/min) 14.2 60 A 275 5 14.7 60 A 275 10 13.8 50 A 330 0 14.0 50 A 330 0 15.4 60 A 363 5 16.8 60 A 363 10 13.4 50 B 330 0 13.6 50 A 330 0 14.0 50 A 385 0 14.1 50 A 385 5 14.0 50 B 385 0 14.0 50 A 385 0 14.5 50 A 407 0 14.6 50 A 407 5 *1 Welding current and Welding voltage are measured value. *2 Aim position A: Upper plate angle aim B: Lower plate aim
1.0
1.2
1.5
(2) Butt Lap fillet welding condition example Plate thickness (mm) 0.8 1.0 1.2 1.5 Welding current *1 (A) 39 39 40 40 Welding Travel Wire feeding EN ratio voltage *1 speed speed adjustment (V) (cm/min) (cm/min) 15.2 150 330 5 14.0 70 275 0 13.8 70 300 0 13.9 70 300 0 *1 Welding current and Welding voltage are measured value.
- 20 -
No. P10537 9. WELDING PREPARATION (continued) 9.4.2 Example aluminum pulsed MIG welding conditions
(1) I shape butt joint welding condition example (reference) Welding Travel Plate Welding Wire voltage speed thickness current diameter (A) (V) (cm/min) (mm) (mm) 1.5 1.2 60-80 16-18 60-80 2.0 1.2 70-80 17-18 40-50 3.0 1.2 80-100 17-20 40-50 4.0 1.2 90-120 18-21 40-50 1.21.6 6.0 150-180 20-23 40-50 (2) Flat fillet welding condition example (reference) Welding Plate Welding Wire voltage thickness current diameter (A) (V) (mm) (mm) 1.5 1.2 60-80 16-18 3.0 1.2 100-120 19-21 1.21.6 6.0 150-180 20-23
Wire extension 12-15 15 15 15 15-18
Gas flow rate (liter/min) 20 20 20 20 20
Travel speed (cm/min) 60 60 50-60
Wire extension 15 15 15
Gas flow rate (liter/min) 15-20 15-20 20
9.4.3 Example pulsed MAG welding conditions (1) Example Welding Conditions of Horizontal Fillet Welding Plate Leg Aim angle Number thickness length and of (mm) (mm) position layers 3.2 4.5 6.0 34 5.0 6.0
30-40
Welding current (A) 150 170 200
Welding voltage (V) 26-27 26-27 27-28
Travel speed (cm/min) 60 40 40
1 1 1
Focus here.
Angle of advance: 10
8.0
8.0
1 mm2 - 3 mm
30-40
250
29-30
35
12.0
10.0
3 1
1 2 3
2
180-200 180-200 180-200 220-230 220-230 210-230
25-27 25-28 25-28 25-28 25-28 25-28
45 45 45 45 45 45
16.0
12.0
1 2 3
(2) Example welding conditions of downward welding Welding Welding Travel Plate Shape of current voltage speed thickness joint weld (A) (V) (cm/min) (mm) 2.3 butt 100 22-23 70 3.2 fillet 100 21-22 70
Remarks Back bead appearance is good. Leg length: 4 - 5mm, Throat depth: 2.5mm
- 21 -
No. P10537 9. WELDING PREPARATION (continued) (3) Example welding conditions of upward welding Plate Welding thickness Shape of joint weld current (mm) (A)
Stop at both ends
Welding voltage (V)
Remarks
12
100-110
20-21
Weaving Leg length: 10.0mm
(4) Both side welding conditions of (Semi-automatic) Plate Number of Groove shape thickness layers (mm) 1 6.0 2 1 9.0 2
Welding current (A) 170 180 270 290
Welding voltage (V) 25-26 26-27 29-30 30-31
Travel speed (mm/min) 30 30 30 30
1 12.0 2
280 330
30-31 33-34
40 40
19.0
Front 1 Front 2 Rear 1 Rear 2
300 300 340 280
31-32 31-32 32-33 30-31
45 45 45 45
25.0
Front 1 Front 2 Front 3 Rear 1 Rear 2 Rear 3
300 320 320 340 320 320
31-32 32-33 32-33 32-33 32-33 32-33
45 45 45 45 45 45
- 22 -
No. P10537 9. WELDING PREPARATION (continued) (5) Example welding conditions of single side welding conditions (Automatic) Plate Welding Number of Groove shape thickness current layers (mm) (A)
Welding voltage (V)
Travel speed (cm/min)
3.2
140
24-25
50
1 6.0 2
130 150
23-24 25-26
25 25
1 12.0 2
180 290
24-25 30-32
25 25
12.0
1 2 3
180-190 200 200
24-25 25-26 26-27
25 25 25
19.0
1 2 3
180 300 300
24-25 29-30 29-30
25 25 25
Oscillation width: 2 mm Oscillation times: 120 times/min.
- 23 -
No. P10537 9. WELDING PREPARATION (continued) (6) Single bevel groove penetration welding conditions (Semi-automatic) Welding Number of Groove shape current layers (A) Flat position 1 100 45 2 280 3 280 4 280 5 280 6 280 Unit: mm 3.2 7 280 Vertical position 1 100 45 2 130 3 130 4 130 5 130 6 120
32
32
Welding voltage (V) 20-21 26-27 26-27 26-27 26-27 26-27 26-27 20-21 21-22 21-22 21-22 21-22 19-20
Remark
Oscillation
Oscillation
3.2
Unit: mm
3.2 32
Unit: mm
1 100-200 20-22 2 200 24-25 3 200 24-25 4 200 24-25 5 200 24-25 No 6 200 24-25 oscillation 7 200 24-25 8 200 24-25 9 180 24-25 10 180 24-25 11 180 24-25 12 180 24-25 Wire diameter: 1.2 mmGas: 20% CO2 + Ar
45
- 24 -
No. P10537 10. WELDING OPERATION 10. Front Panel
[21] [20]
[19]
[4]
[13]
[8]
[5]
[6]
[9]
[10]
J OB W AR N IN G M EM O RY
LO AD
A m /m in S e c H z
%
J O BN O .
SAVE
A
m /m in
M AIN C O N D ITIO N
ARC C O N TRO L
T2
EN TER
T1
INITIAL CO N D ITIO N O N
DISPLAY C H AN G E
SYN ER G .
SYN ER G . IN D IV.
CRATER -FILL. C O N D ITIO N W ATER
f
W AVE FR EQ .
G AS C H EC K
O FF
IN ITIAL C O N D .
0. 8 0. 9
W ELD M O N IT O R
(O PTIO N)

VO LT. C O N TR O L TO R C H AL/PU R E
MI G
EN R ATIO
AC PU LSE AC W AVE PU LSE D C PU LSE D CW AVE PU LSE O P1 O P2

W E LD IN G M ETHO D
AL/MG C uSi C uAl
O N
1. 0 1. 2 1. 4 1. 6
IN C H IN G
R EPEAT
MI G
STAIN LESSSTEEL M ILDSTEEL
SPO T
M AG
M ILDSTEEL
SPO T TIM E
CRATER FILL.
W IRE DIA.
[17] [18]
[11]
[7]
[12]
[3]
[14]
[15] [2]
[16]
[1]
[22]
[1] WELDING METHOD selector key [2] Wire material/gas selector keys [3] WIRE DIA (mm) selector key [4] Current setting display selector key [5] Voltage setting display selector key [6] Parameter adjusting knob [7] Crater selector key [8] DISPLAY CHANGE key
[9] Arc characteristic setting key [10] WAVE FREQ. setting key [11] Arc spot time setting key [12] F (FUNCTION) selector key [13] Initial condition selection key [14] Synergic/Individual selector key [15] Torch selector key [16] Weld monitor key (Option)
[17] GAS CHECK key [18] INCHING key [19] LOAD key [20] SAVE key [21] ENTER key [22] EN ratio setting key
- 25 -
No. P10537 10. WELDING OPERATION (continued) CAUTION This welding machine should be operated by persons only after reading and understanding contents of this owners manual and having knowledge and skills for handling the welding machine safely. Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle limitation may result in damage to the welding machine. When reading the operating instructions described below, unfold Page 91 so that you can read them confirming the location of the keys on the front panel. 10.1 Basic Settings 10.1.1 Setting of Welding Mode Choose the welding mode using WELDING METHOD selector key [1], the wire material/gas selector keys [2] and the WIRE DIA (mm) selector key [3] in accord with the welding method, material, gas and wire diameter used. The selectable welding modes are shown on the next page. When setting the welding mode, select the welding method using the WELDING METHOD selector key [1] first. Once the welding method is set, the available material and gas are automatically decided according to the welding method. Then, select wire/gas using the wire material/gas selector keys [2]. Finally, set the wire diameter with the WIRE DIA (mm) selector key [3]. Combination which is not in the tables below will cause abnormal indicator blink as welding method setting error, ---and --- in the displays to blink, and the welding power source to stop. Moreover, wire material/gas LED, and wire diameter LED which is the cause of abnormality, blink. For example, when selecting MILD STEEL MIG while setting "AC PULSE AL/MIG MIG 1.6" with the WELDING METHOD selector key [1], the "1.6" lamp blinks, which means the preset combination is incorrect. In that case, select material and gas again using the wire material/gas selector keys [2] or reset the welding method using the WELDING METHOD selector key [1]. Selecting the proper combination of material and gas can cancel the error and activate the welding power source. Wrong combination of welding mode and wire diameter will cause ---and --- in the displays to blink, the LED lamps to light, and the welding power source to stop. Table of the welding Welding method AC WAVE PULSE DC
AC PULSE DC
AC PULSE DC
Type of wire AL/MG (Hard Aluminum) AL/PURE (Soft Aluminum) AL/MG (Hard Aluminum) AL/PURE (Soft Aluminum) AL/MG (Hard Aluminum) AL/PURE (Soft Aluminum) Brazing CuSi Brazing CuAl AL/MG (Hard Aluminum) AL/PURE (Soft Aluminum) Brazing CuSi Brazing CuAl Stainless Mild Steel Solid Stainless Mild Steel Solid
Gas
MIG (Ar)
MIG (97.5%Ar+2.5%CO2 ) MAG
Wire diameter (mm) 1.0, 1.2, 1.6 1.2, 1.6 1.0, 1.2, 1.6 1.2, 1.6 1.0, 1.2, 1.6 1.2, 1.6 0.8, 0.9, 1.0, 1.2 0.8, 0.9, 1.0, 1.2 1.0, 1.2, 1.6 1.2, 1.6 0.8, 0.9, 1.0, 1.2 0.8, 0.9, 1.0, 1.2 0.8, 0.9, 1.0, 1.2 0.8, 0.9, 1.0, 1.2 0.8, 0.9, 1.0, 1.2 0.8, 0.9, 1.0, 1.2
MAG gas Argon (Ar) 80% / Carbon dioxide (CO2) 20% MIG gas (Stainless / Mild steel solid) Argon (Ar) 97.5% / Oxygen (O2) 2.5% - 26 -
No. P10537 10. WELDING OPERATION (continued) 10.1.2 Setting the Parameter Pressing the key while the A/m/min lamp (located at the upper left of the A/m/min selector key) is lit changes over displays of current setting and wire feed rate. Pressing the A/m/min selector key while the A/m/min lamp is not lit causes the A/m/min lamp to light. While the A/m/min lamp is lit, current can be adjusted using the parameter adjusting knob [6]. Pressing the key while the V/ lamp (located at the upper left of the V/ selector key) is lit changes voltage setting and fine adjustment from the center of the one knob adjustment. (Only for one knob adjustment) Pressing the V/ selector key while the V/ lamp is not lit causes the V/ lamp to light. While the V/ lamp is lit, current can be adjusted using the parameter adjusting knob [6].
Select a parameter using this key.
A
m /m in
T1 INITIAL C O N D ITIO N
T2
DISPLAY C H AN G E
CRATER -FILL C O N D ITIO N
[Parameter selector] Choose a desired parameter using the DISPLAY CHANGE key [8]. Display in the displays are changed according to the parameters you select and the UNIT lamp of the parameter lights up. UNIT lamps
WARNING
m/ m in
Sec
H z
%
JOB No .
Digital Meter [Parameter displays] z When the wire feed speed is displayed, you can not set to the maximum feed speed using the parameter adjusting knob [6] depending on the welding mode settings (especially for large diameter). You are only allowed to set the wire feed rate to the value that can achieve the current setting determined by the rated output current. The values shown in the displays are not the actual data but the setting values of voltage, current, and wire feed speed. Use the values in the displays as approximates.
- 27 -
No. P10537 10. WELDING OPERATION (continued) 10.1.2 Setting the parameter (continued) (1) Pre-flow time setting Once the pre-flow time is chosen, the setting value is displayed in the left display and the "sec." lamp lights. At this condition, you can set pre-flow time while turning the parameter adjusting knob [6]. The setting range of pre-flow time covers 0 second to 10 seconds. (2) Setting of the initial conditions The initial conditions can be chosen only when initial current is set to ON. Once the initial conditions are chosen, the setting values of initial conditions are displayed in the displays. (3) Setting of the main conditions Once the main conditions are chosen, the setting values of the main conditions are displayed in the displays. (4) Setting of the crater conditions Only for ON or REPEAT, the crater conditions can be selected. Once crater conditions are chosen, the setting values of the crater conditions are displayed in the display. (5) Setting of the post-flow time Once the post-flow time is selected, the setting value is displayed in the left display and the "sec." lamp lights up. At this conditions, the post-flow time can be set while turning the parameter adjusting knob [6]. The setting range of post-flow time covers 0 second to 10 seconds.
- 28 -
No. P10537 10. WELDING OPERATION (continued) 10.1.3 Setting of the CRATER-FILL functions Crater Bead Crater is a depression left at the termination of the weld. As it may cause cracks and poor welding, a crater treatment called crater-filler is used to fill in the depression.
Pool
When giving a crater treatment, set the crater selector key [7] to "ON" or "REPEAT". Each press of the crater selector key [7] changes the crater-fill mode in order.
"OFF" "ON" "REPEAT" "SPOT"
Crater
Initial Current
Timing Chart
ON OFF
Torch Switch Gas Flow
Pre-flow time No-load voltage Anti-stick (Burnback) time Post-flow time
OFF
Welding Voltage Wire Feed Speed

Slow-down speed
Welding Current
MAIN WELDING Keep the torch switch pressed and held during welding.
- 29 -
No. P10537 10. WELDING OPERATION (continued) Crater Initial Current

ON
Timing Chart
ON OFF OFF
Torch Switch
Pre-flow time No-load voltage
Anti-stick (Burnback) time
OFF
Gas Flow Post-flow time Welding voltage Wire Feed Speed Slow-down speed Welding current Crater current
ON
Welding Current MAIN WELDING

CRATER
ON Torch Switch
OFF
ON OFF
Pre-flow time No-load voltage Gas Flow
Anti-stick (Burnback) time
ON
Welding Voltage Wire Feed Speed Slow-down speed Initial current Welding current
Post-flow time
Crater current Welding Current

INITIAL
MAIN WELDING
CRATER
Even if the torch switch is switched off during welding, start signal will be self-hold. The torch switch should be kept pressed and held during the INITIAL and CRATER period.
- 30 -
No. P10537 10. WELDING OPERATION (continued) Crater Initial Current Timing Chart
OFF
ON (REPEAT)
ON
Even if the torch switch is switched off during welding, start signal will be self-hold. The torch switch should be kept pressed during the INITIAL and CRATER period. When turning on the torch switch again within about 2 seconds after arc disappears, welding condition starts with CRATER condition. The condition will continue until the torch switch is turned off. Repetition of the same operation enables you to have crater treatment as many times as you need.
- 31 -
No. P10537
10. WELDING OPERATION (continued) 10.1.4 Setting of Arc Spot Time When performing arc spot treatment, set to "SPOT" using the crater selector key [7]. Then, when pressing the arc spot time setting key [11], the SPOT TIME lamp (located at the upper left of the CRATER-FILL key) lights up, the setting value is displayed in the leftt display, then the "sec." lamp lights up. At that condition, the ARC SPOT time can be set while turning the Parameter adjusting knob. The ARC SPOT time between 0.1 second and 10 seconds can be set. Press the arc spot time setting key [11] again or press the DISPLAY CHANGE key [8] to return to the last parameter item. It is also possible to change the display to a current-related parameter using the current setting display selector key [4] and to a voltage-related parameter using the voltage setting display selector key [5]. The SPOT TIME key functions only during Arc Spot time.
ON Torch Switch OFF
ARC SPOT time
Output Current
Welding Current
Keep the torch switch pressed and held during the Arc Spot time. (When the torch switch is turned off during arc spot, the output is stopped.)
- 32 -
No. P10537 10. WELDING OPERATION (continued) 10.1.5 Adjusting welding voltage Using the synergic/individual selector key [14] allows you to select one of the following voltage adjustment methods. (1) Making the INDIVIDUAL adjustment The INDIVIDUAL adjustment can be achieved when the VOLT.CONTROL lamp (located at the upper left of the synergic/individual selector key [14]) is off. In the case of the INDIVIDUAL adjustment, welding current and welding voltage must be adjusted individually. When you want to set welding voltage, make sure that the VOLT. CONTROL lamp is lit, then adjust the welding voltage while turning the Parameter adjusting knob. When you want to set welding voltage, make sure that the VOLT. CONTROL lamp is lit, then set welding voltage while turning the Parameter adjusting knob. NOTE: When selecting only DC PULSE MILD STEEL solid or STAINLESS STEEL solid, the INDIVIDUAL adjustment can be achieved. For other welding method the SYNERGIG adjustment function is automatically activated. (2) Making the SYNERGIC adjustment The SYNERGIC adjustment can be achieved when the VOLT. CONTROL lamp (located at the upper left of synergic/individual selector key [14]) is on. For the SYNERGIC adjustment, the proper welding voltage for the current setting is automatically set. When the VOLT. CONTROL lamp is lit, welding voltage can be finely adjusted using the Parameter adjusting knob. In addition, it is also possible to change over the display setting in the right display using the voltage setting display selector key [5]. The selectable display settings are the INDIVIDUAL mode (V) and the SYNERGIC mode ( adjustment) . In the SYNERGIC display mode, the standard value is 0. The setting range of welding voltage is 0 to 30 . NOTE: Use of mixture gas other than the mixture ratio of the following gas may not properly adjust welding voltage at Synergic control, etc. MAG gas 80% argon (Ar) + 20% carbon dioxide gas (CO2 gas) MIG gas for stainless steel and mild steel solid 98% argon (Ar) + 2% carbon dioxide gas (CO2 gas)
10.1.6 Arc characteristics function When pressing the arc characteristic setting key [9] while the INITIAL CONDITION, MAIN CONDITION, or CRATER-FILL CONDITION is selected the ARC CONTROL lamp (located at the upper left of the arc characteristic setting key [9]) lights up, the setting value is displayed in the right display, and the V/ lamp lights up. At that condition, it is possible to set arc characteristics by using the Parameter adjusting knob. The setting range is 0 to 10. Pressing the arc characteristic setting key [9] again or pressing the DISPLAY CHANGE key [8] returns to the previous parameter setting. In addition, it is also possible to change over the display to a current-related parameter by using the current setting display selector key [4] and to a voltage-related parameter by using the voltage setting display selector key [5]. The standard setting value of arc characteristic is 0. As the setting value of the arc characteristic is set in the negative direction (up to -10), arc condition becomes harder. As the setting value of the arc characteristic is set in the positive direction, arc condition becomes softer (up to 10). When you use the welding power source in the low current range, set the setting value of the arc characteristic in the negative direction to obtain good welding results. When you use the welding machine in the high current range, set the setting value of the arc characteristic in the positive direction to obtain good welding results. If you can not obtain optimum arc condition due to use of the extension cables, set the setting value of the arc characteristic in the negative direction.
- 33 -
No. P10537
10. WELDING OPERATION (continued) 10.1.7 WAVE PULSE function In wave pulse welding, the ripple bead appearance can be obtained by applying two separate pulses cyclically at low frequency. This feature will also assist for aluminum welding or in welding joints that have some poor fit up or gaps. Although, the wave mode is usually most applicable for fully automatic welding, benefits are also achieved even in semi-automatic applications. Good bead appearances are obtained by setting the wave frequency to 5Hz or more even for semi-automatic. When setting wave pulse frequency, select DC WAVE PULSE or AC WAVE PULSE with the WELDING METHOD selector key [1]. When DC pulse or AC pulse is selected, wave pulse frequency setting is invalid. When the WAVE PULSE key is pressed while INITIAL CONDITION/ MAIN CONDITION/ CRATER-FILL. CONDITION is selected, the WAVE PULSE lamp (located at the upper left of the WAVE PULSE key) lights up, the setting value appears in the left display, the Hz LED lamp lights up. Under these conditions, wave pulse frequency can be adjusted while turning the Parameter adjusting knob. The setting range of wave pulse frequency is 0.5 Hz to 32 Hz. Adjust wave pulse frequency until you can obtain the desired bead appearance. When pressing the WAVE FREQ. key or DISPLAY CHANGE key again, return to the last parameter that you have set. When changing the display to a current-related parameter, press the current setting display selector key [4]. When changing the display to a volt-related parameter, press the voltage setting display selector key [5].
low frequency
high frequency
NOTE: - Wave pattern of the welding bead may not appear clearly depending on the heat input during welding. - When using soft aluminum, bead surface may blacken somewhat if shorting occurs frequently during the welding operation.
- 34 -
No. P10537 10. WELDING OPERATION (continued) 10.1.8 EN ratio ( )
In the AC pulse welding, the EP current (the torch is + polarity) and the EN current (the torch is - polarity) output alternately, and the heat input to the base metal (penetration) can be controlled according to the EP and EN ratio. As a result, a high-quality welding can be obtained for very thin plate or the work which has gap. For EN ratio setting, select AC PULSE or AC WAVE PULSE by WELDING METHOD selector key [1]. When DC pulse is selected, EN ratio setting is invalid. When pressing the EN ratio setting key [22] while the INITIAL CONDITION, MAIN CONDITION, or CRATERFILL CONDITION is selected the EN RATIO lamp (located at the upper left of the EN ratio setting key [22]) lights up, the setting value is displayed in the right display, and the LED lamp lights up. At that condition, it is possible to set EN ratio by using the parameter adjusting knob [6]. The setting range is 0 to 30. Pressing the EN ratio setting key [22] again or pressing the DISPLAY CHANGE key [8] returns to the previous parameter setting. In addition, it is also possible to change over the display to a current-related parameter by using the current setting display selector key [4] and to a voltage-related parameter by using the voltage setting display selector key [5]. The average EN ratio (%) during welding is displayed in the left display. The standard setting value of EN ratio is 0. As the setting value of the EN ratio is set in the negative direction, EN ratio becomes smaller (down to -30). As the setting value of the EN ratio is set in the positive direction, EN ratio becomes larger (up to +30) The relation between EN ratio setting and welding result are shown in the table below. Negative direction EN ratio setting Positive direction Decreasing EN ratio Increasing Slow Wire melting speed Quick Small Gap tolerance Large *It is substantially constant penetration.
EN means the period which the base metal is positive (+) and the torch is negative (-), and EP means the period which the base metal is negative (-) and the torch is positive (+). EN ratio means the current ratio of the EN polarities (ratio of the areas) at one AC cycle, and it was shown by percent. It is defined by the next expression. Ien EN ratio = Iep + Ien Ien 100%
Iep EP
EN
The EN ratio changes about 1% by adjustment amount 1 of the operation. A standard value of the EN ratio (value at center position '0') and the maximum value of the EN ratio are different at the welding process and each current setting. Minimum value of the EN ratio is 0%. Lost of the EN period and becomes direct current. Note: The EN ratio is as a guide, and it may become different result according to an actual welding condition and the working environment.
- 35 -
No. P10537 10. WELDING OPERATION (continued) 10.1.9 Notice of using AC pulse mode When using AC pulse mode, observe the followings not to damage the welding power source 1. Use proper extension cable and use as short cable as possible. 2. When using the extension cable, refer to following figure.
Bind the torch cable and base metal cable each other with tape. Straighten the cables as much as possible.
If cable setting mentioned above

cannot be performed by all means, lay the torch cable on the base metal.
- 36 -
No. P10537
10. WELDING OPERATION (continued) 3. If overlong power cable is used reluctantly, wind it according to following figure of Good example. Bad example Good example Do not wind the excess part of cable in the Refer to the figure below winding method of excess cable, and make two windings in opposite same direction. direction each other and pile up one on another.
Winding method of excess cable 1
Top view
Side view
Explanation Separate the excess cable into A and B. Wind it respectively as Explanation followings. Same winding direction. Same turns of winding. Same diameter of Windings.
Place B over A in the opposite direction.
After placing B over A, bind the winding cable not to be loose.
- 37 -
No. P10537 10. WELDING OPERATION (continued) 10.1.10 GAS CHECK function (with gas save function) S This function isGA used when opening the discharge valve of the shield gas and when adjusting the gas flow rate. When pressing the GAS CHECK key [17] once, the GAS CHECK lamp (located at the upper left of the GAS CHECK key) lights up and allows gas to flow. Pressing the GAS CHECK key again turns off the GAS CHECK lamp and stops discharging gas. In more than two minutes after the GAS CHECK key is pressed, gas discharge automatically stops and the GAS CHECK lamp goes out. In the event that the machine is started while gas is being checked, gas stops flowing after welding is completed (upon completion of post-flow) and gas does not continue to flow during down period. 10.1.11 INCHING function
When pressing the INCHING key [18], the INCHING lamp (located at the upper left of the INCHING key) lights up and begins feeding wire. Releasing the key stops wire feeding and causes the INCHING lamp to go out. When changing the wire feed rate by turning the parameter adjusting knob [6], make sure that the A/m/min selector lamp lights up. When connecting to the analog remote control (optionally available), the INCHING key on the front panel can not be used for inching operation. When connecting to the analog remote control, use the inching switch on the remote control to activate the INCHING function. 10.1.12 TORCH WATER/AIR selection When an abnormal signal of water cooling unit is connected with connector CON4, select WATER/AIR according to your torch by using the torch selector key [15]. When using a water-cooled torch, select WATER by pressing the TORCH key once. When WATER is selected, the TORCH lamp (located at the upper left of the TORCH key) lights up. When using an air-cooling torch, make sure that the TORCH lamp goes out. When water cooling unit abnormal occurs while WATER is selected, abnormal code E-510 blinks on the front panel digital meter
- 38 -
No. P10537 10. WELDING OPERATION (continued) 10.1.13 Verifying the parameters in the displays The displays on the front panel provides the following functions: 1. Display of parameter setting value When setting to parameter setting values display mode during down period (excluding the result display period right after the completion of welding) and during welding, values of parameters under adjustment are displayed. 2. Display of output current during welding The parameters shown in the displays automatically change to average values of output current and output voltage according to the output conditions every about 0.5 second. When you want to change the parameters during welding, switch to the parameter setting values display mode by using the DISPLAY CHANGE key [8]. When no welding operation is carried out for about 5 seconds or the DISPLAY CHANGE key [8] is held down, the display mode automatically returns to the average values display mode. When the TORCH key is pressed, the LED lamps of the sequence parameters go on sequentially according to the welding operations. When the display setting is switched to the "parameter setting values display" mode, each LED lamps (located at the sequence parameter setting section) of the sequence that is currently outputting begin blinking. Refer to Section 10.1.14, Using the Parameter Adjusting Knob for the parameters that can be adjusted using the parameter adjusting knob [6] during welding. 3. Display of welding results after completion of welding Upon completion of welding, the average output current and voltage for last one second blink for about 20 seconds (however, the output conditions of crater fill are ignored). Therefore, the operators can verify the welding conditions right after the completion of welding and can use them as approximates when adjusting the welding conditions. This display is cancelled by starting the next welding or by pressing any key on the front panel without waiting 20 seconds after the completion of welding. The result display time can be preset to F8 by using the F (FUNCTION) selector key [12]. The setting value is displayed in the left digital and the "sec" lamp lights up. The setting range of the result display time is 5 seconds to 60 seconds. NOTE: In the case where the less than one-second welding such as tack welding, etc. is performed, the correct results of the welding are not displayed. 4. Display of error message If an error is detected in the welding power source, an error number indicating error messages blinks. See Section 12.5, "Troubleshooting". NOTE: The average output values shown in the displays are processed by software and are not guaranteed as control data of measuring instruments. Display accuracy: Class 2.5 or equivalent). 10.1.14 Using the Parameter adjusting knob When adjusting parameters using the parameter adjusting knob [6] during welding, change over the display mode to the parameter setting value display mode by pressing the DISPLAY CHANGE key [8]. The initial conditions, the main conditions, and the fill crater conditions can be changed during the INITIAL welding, MAIN welding, and CRATER welding respectively. After changing to the parameter setting value display mode, pressing the arc characteristic setting key [9] adjusts the arc characteristics. Pressing the WAVE PULSE key adjusts the wave frequency. Pressing the EN RATIO key adjusts the EN ratio. In the average parameter value display mode, you can not adjust the parameter.
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No. P10537 10. WELDING OPERATION (continued) 10.1.15 Using the analog remote control K5416U (optional accessory) The welding machine automatically recognizes the analog remote control when the power switch is turned on. When the analog remote control is connected to the welding power source, the analog remote control is recognized first. Therefore, even when selecting welding current/voltage, the welding current/voltage can not be adjusted by using the parameter adjusting knob [6] on the front panel. When the analog remote control is connected, adjust the parameter while turning the WELDING CURRENT/VOLTAGE knobs on the analog remote control. It is possible to verify the parameter setting values which are preset with the analog remote control, in the displays of the front panel. Once the analog remote control is disconnected, the setting values preset with the remote control are erased. NOTE: With the power switch turned off, connect or disconnect the analog remote control. Scale of the analog remote control is up to 350A, but maximum output of this welding power source is 300A.
350
150 100 50 200 250
LO OS E
O2/ MAG/ M I G
22 24 26 28

20 18 16 14
300 350
30 32 34 36
WELDING CURRENT knob To set welding current. INCHING button Pressing this switch feeds wire only. The wire feed rate changes by turning the WELDING CURRENT knob on the left. VOLTAGE knob / SYNERG.ADJ. knob < INDIVIDUAL adjustment> Set welding voltage. < SYNERGIC adjustment > Aligning to mark achieves the standard setting. Turn the knob in the "HIGH" direction to increase voltage and in the "LOW" direction to decrease voltage.
When making the INDIVIDUAL adjustment:

Selecting the "INDIVIDUAL" adjustment allows you to set welding current and welding voltage individually.
When making the SYNERGIC adjustment:

When selecting the "SYNERGIC" adjustment, welding voltage is automatically adjusted only by turning the WELDING CURRENT knob. To finely adjust welding voltage, use the VOLTAGE. knob. NOTE: It is possible to adjust low-current region, where a small-diameter wire is used for weld, and to finely adjust welding current by replacing with the full-scale 200A plate (supplied). To replace the scale plate, press the F (FUNCTION) selector key [12] and change the initial value of F9 to 200. Refer to Section 10.2.1(9), Selection of scale plate of analog remote control.
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No. P10537 10. WELDING OPERATION (continued) 10.2 10.2.1 Applied settings Using internal function How to use internal functions When holding down the F (FUNCTION) selector key [12] for a few seconds, the function number in the left-side display blinks, and the status of function assigned to the function number lights up and is displayed in the right-side display. Under this condition, a function number can be preset by using the parameter adjusting knob [6].
W ARNNING
/min sec
H z
%
JO BN o.
The number of function blinks. The conditions of function lights. A function number can be preset with the parameter adjusting knob [6] The above example indicates that F19 is set to on. When pressing the F (FUNCTION) selector key [12] again after presetting the desired function number, the function number lights and the function conditions blinks. Under this condition, functions can be preset by using the parameter adjusting knob [6].
W ARNNING
/min sec
H z
%
JO BN o.
The condition of function blinks. Conditions can be set while turning the parameter adjusting knob. The above example indicates that F4 is set to off. Pressing the F (FUNCTION) selector key [12] again causes the function number to light up and returns to the step . To cancel the function mode, hold down the F (FUNCTION) selector key [12] for a few seconds. NOTE: In the function mode, no confirmation of the function is carried out when it is changed. Upon change of the setting by using the parameter adjusting knob [6], the change becomes valid. Therefore, before changing a function setting, carefully check to make sure that the correct function number is selected and that the proper setting value for the function number is set.
The number of function lights.
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No. P10537 10. WELDING OPERATION (continued) The following welding conditions can be adjusted by using the F (FUNCTION) selector key [12] and the parameter adjusting knob [6], but only the welding conditions with* next to the function numbers can be preset to the welding condition numbers. (1) Fine adjustment of anti-stick (burnback) time: F1* Anti-stick (burnback) time means the processing time to prevent electrode wire from fusing to base metal when welding is completed. Anti-stick (burnback) time is preset to proper conditions according to welding methods and wire diameters at shipment, but it can be finely adjusted by activating F1. The standard antistick (burnback) time is preset to "0", time decreases in the negative direction and increases in the positive direction. The fine adjustment range is 0 to 50 and the unit is 0.01 seconds. Ex. 1) Ex. 2) When the setting value of anti-stick (burnback) time is 25, add 0.25 second to the standard antistick (burnback) time. When the setting value of anti-stick (burnback) time is -10, subtract 0.1 second from the standard anti-stick (burnback) time.
(2) Fine adjustment of anti-stick (burnback) voltage: F2* Anti-stick (Burnback) voltage means the voltage which is output when processing is carried out to prevent electrode wire from fusing to base metal at the end of welding. Anti-stick (Burnback) voltage is preset to proper conditions according to welding methods and wire diameters at shipment, but it can be finely adjusted by activating F2. The standard anti-stick (burnback) voltage is preset to 0. When the voltage is set in the negative direction, it decreases. When the voltage is set in the positive direction, it increases. The fine adjustment range is 0 V to 9.9V. (3) Fine adjustment of slow-down speed: F3* Slowdown speed means the speed to feed wire that is slower than the feed rate at normal welding during the period from startup to arc start. The slowdown speed is preset to proper conditions according to welding methods and wire diameters at shipment, but it can be finely adjusted by activating F3. 0 is standard. When the slowdown speed is set in the negative direction, it decreases. When the slowdown speed is set in the positive direction, it increases. The fine adjustment range is 0 m/min to 1.0 m/min. When poor arc start occurred, lower the slowdown speed. Even when arc start is good, the slow-down speed can be increased to shorten tact time. NOTE: The minimum slow-down speed is 0.4 m/min.
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No. P10537 10. WELDING OPERATION (continued) (4) Selection of auto/semi-automatic:F4 "Automatic machine mode" and "Semiautomatic mode" can be switched by function number '4'. And there are two kinds for automatic machine mode. The relation between the setting method and the function of each mode is tables below. Function No. 4 0 (factory setting) 1 2 Mode Semi-automatic Automatic 1 Automatic 2 By power source By short-circuit of the operation stop terminal Return from operation stop returning on again After the anti-stick completion, it impresses about Stuck wire removal voltage Do not impress 0.2 seconds. By panel or analog Welding current and By panel or analog By external voltage (*1) remote control voltage setting remote control Retract function (*2) Out of use Possible to use Inching from interface (*3) Out of use Possible to use *1: The current and the voltage of main condition cannot be set with the parameter adjusting knob [6] of the front panel. *2: Wire feed direction will be reversed by short-circuit between 4 and 6 of the 12 P terminal block (TM2) in the welding power source; and turning on the inching signal (retract function).] Refer to "11.2 External connection with an automatic machine by power source internal terminal" for details. *3: This is a case for short-circuited between 5 and 6 of CON2 without using analog remote control. About automatic machine 1 mode For combination with the robot etc., this is used when the current and the voltage setting are input by using an external voltage. And connection is shown in the figure below. For connection, current capacity of an external power source must be 0.5mA or more.
Remote control receptacle
MAX 0.5mA
MAX 0.5mA 0V15V
CON2 Welding Voltage Welding Current
Acceptable plug Spec. Part No.
DPC25-6A 4730-009
PROHIBITION Supply 0 - +15 voltage to E1 and E2. Exceeding +15V may result in damage to the control circuit of the welding power source. CAUTION Be sure to finish setting of and inputting to E1 and E2 within 100 milliseconds before starting signals are input. Inputting after 100 milliseconds or at start signals may result in affecting start.
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No. P10537
10. WELDING OPERATION (continued) NOTE: - At the "Semiautomatic" mode, even if an external voltage is supplied to the remote control outlet, a set value of the front panel becomes effective. - Regardless of automatic or semi-automatic, when analog remote control is connected, a set value of remote control is prioritized. Please combine with the welding condition memory fine adjustment function when the welding condition memory function is used. Please refer to "Setting of fine-tuning 10.2.1(11) welding condition memory" for details. About automatic machine 2 mode Use this mode though this welding power source is used with automatic machine, you want to set all setting by front panel or welding condition memory function. Moreover, use this when you combine digital remote control with an automatic machine.
(5) For external setting voltage ranges between 0 and 10V: F5 When the welding machine is used by combining with a robot or an automatic machine and when the maximum command voltage from the robot or an automatic machine is output up to 10V, set F5 using the F (FUNCTION) selector key [12]. This function is preset to OFF for factory setting. Set F5 to "on" to activate the function using the F (FUNCTION) selector key [12]. NOTE: It is necessary to set '4' of the function to "Automatic machine 1" mode '1' to make this function effective. The relationship between current/voltage command voltage from outside and welding current and welding voltage is shown as follows. The welding current and welding voltage corresponding to welding conditions setting voltage may differ from the indications in the graphs due to wire extension length and dragging of output cable. These graphs are only for reference.
350 Welding current (V) 300 250 200 150 100 50 0 0 5 10 15 Command voltage (V)
External voltage 1 External voltage 2
40 35 30 25 20 15 10 5 0 0 5 10
Welding voltage (V)
External voltage 1 External voltage 2
15
Command voltade (V)
External Voltage 1: When command voltage is externally supplied in the range from 0V to 15V under the standard settings. External Voltage 2: When command voltage is externally supplied in the range from 0V to 10V with F 5 set to "on" NOTE: The current and voltage indicated in the graphs above are not measured after fine adjustment of unit pulse conditions. You may not obtain such the results as the graphs show depending on finely adjustable range of pulse unit conditions.
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No. P10537 10. WELDING OPERATION (continued) (6) Setting of upslope time: F6* Upslope time means the time for increasing welding conditions stepwise when initial current is changed to final current. The upslope time at shipment is set to 0 second, but can be adjusted by using F6. The setting range is 0 second to 10 second. This function is used when wire burns up while conditions are changed over due to the great difference of setting between initial current and main current. (7) Setting of down-slope time: F7* Down-slope time means the time for decreasing welding conditions stepwise when main current is changed to crater current. The down-slope time at the time of product shipment is set to 0 second, but can be adjusted by using F7. The setting range covers 0 second to 10 second. This function is used when wire crashes into the base metal while the conditions are changed over due to the great difference of setting between main current and crater current. (8) Setting of result display holding time: F8 After completion of welding, the average value of output current and output voltage for last one second blinks for about 20 seconds, but the result display holding time can be set by F8 using F (FUNCTION) selector key [12]. The setting range of result display holding time is 0 seconds to 60 seconds. (9) Selection of scale plate of analog remote control: F9 When the analog remote control (optional accessory) is used, it is possible to finely adjust a low-current region where a small-diameter wire is used for weld by replacing the full-scale 350A scale plate with the full-scale 200A scale plate (supplied). The analog remote control scale is changed over by using the F (FUNCTION) selector key [12]. Set to "200" by using F9. (10) Setting of feed motor load current error detection level: F10 In the event that contact resistance is applied to the wire feed line section due to worn liners, defective tips, etc., the current supplied to the motor increases (when feed roll lacks smooth movement). Monitoring current of this motor can detect defective feed. The motor load current detection level at shipment is 70% (2.0A) of the rated motor current 2.8A (continuous), and if the current exceeds the setting value, "E-" and "820" in the displays are displayed after welding operation is stopped. But, in this case, the welding machine stops operation automatically, then it self-restores by re-welding. (Welding can be stopped by abnormal signal, refer to 10.2.1(16) setting switch of warning for detail.) This detection level can be changed by changing the setting of F10 using F (FUNCTION) selector key [12]. The setting range of motor load current trouble detection level is 20% to 150%. NOTE: Adjust the detection level optionally and use it in the best detection level, because the application environment and judgment criteria vary depending on wires and torches and customers respectively.
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No. P10537 10. WELDING OPERATION (continued) (11) Setting of job memory fine adjustment: F11 Under the welding conditions already stored in JOB MEMORY, current can be finely adjusted with the WELDING CURRNET knob located on the optional analog remote control and voltage with the VOLTAGE knob. The initial setting of F11 is oFF. When activating the function, set F11 to on. Setting both CURRENT and VOLTAGE knobs to the center of the scales allows the machine to work under the conditions already stored in the welding conditions memories. To increase welding current slightly, turn the knob clockwise and to decrease slightly, turn it counter-clockwise. Welding voltage can be adjusted in the same manner. The fine adjustment range is 20%. NOTE: -When no data is stored in the JOB MEMORY, the function cannot be activated. -When using this welding power source in "Automatic machine 1" mode, center voltage is as below. External setting voltage 0V-15V 0V-10V Center setting voltage 7.5V 5V
Place these knobs in the center positions.
350
150 100 50 200 250 300 350
LO OS E
O2/ MAG/ M I G
22 24 26 28

20 18 16 14
30 32 34 36
(12) Arc voltage direct detection ON/OFF selection: F12 When using an extension cable results in abnormal generation of spatter or when unstable welding is caused from malfunction of pulse weld, use a voltage detection cable (optional accessory K5416G00) for directly detecting arc voltage(-). When using an extension cable that is more than 30 m long, use an arc voltage direct detection cable. Connect between base metal and wire feeder or the direct voltage detection (-) terminal inside the welding power source. (Voltage detection cable K5416G00 is a 30 m single core cab tyre cable. Cut it as necessary.) After connecting the voltage detection cable, activate the function of voltage direct detection by setting F12 to on. The function is preset to oFF (invalid) at factory. NOTE: When using the equipment with such as brush for feeding parts like a positioner a turn table, connecting the voltage detection cable to the terminal for the base metal power cable after setting F12 to on is recommended.
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No. P10537 10. WELDING OPERATION (continued) (13) Fine adjustment of pulse peak current The unit pulse conditions (pulse peak current/time and base current) at pulse welding is set properly according to welding method and wire diameter, but you can make the fine adjustment to obtain the optimum conditions of unit pulse according to the wire brand or welding position.
The finely adjustable range of pulse peak current is 0 A to 150 A. The peak current is set by 1A. The finely adjustable range of pulse peak time is 0 ms to 1.5 ms. The pulse peak time is set by 0.1 ms. The fine adjustable range of base current is 0 A to 60A. The base current is set by 1 A.
In function mode, when pressing the DISPLAY CHANGE key [8] during the fine adjustment of pulse width, the DISPLAY CHANGE lamp lights up (located at the upper left of the DISPLAY CHANGE key). Under this condition, you can switch the fine adjustment value shown in the right display to the modulus (the value which is substrusted or added the fine adjustment value from the standard value). When pressing the DISPLAY CHANGE key, you can return to the fine adjustment value display mode. [Example of fine adjustment of the unit pulse conditions] When making a fine adjustment of the unit pulse conditions, adjust the pulse peak time first. Take longer fine adjustment time when large droplet and unstable arc (droplet transfer) occurs. Take shorter fine adjustment time when sharp tip of wire and extremely strong arc occurs. When only the adjustment of the pulse peak time is insufficient, adjust the pulse peak current following the same steps as pulse peak time adjustment. [Precaution for the fine adjustment of the unit pulse conditions] Maximum pulse peak current which can be output varies depending on the type (capability) of welding machine or arc load. When the pulse peak current finely adjusted exceeds the maximum pulse peak current, the preset pulse peak current is not output. NOTE: When the unit pulse conditions change significantly, there may be a possibility of difference between the preset current value and the output current and an impossibility of appropriate synergic fine adjustment.
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No. P10537 10. WELDING OPERATION (continued) (13-1) Fine adjustment of Pulse Peak Current : F13* The fine adjustment of pulse peak current can be achieved by activating F13 using the F (FUNCTION) selector key [12]. The value which is substrusted or added the fine adjusting value from the standard value of the pulse peak current is output. At the wave pulse welding, the high pulse condition (H. pulse) is adjusted.
(13-2) Fine Adjustment of the Pulse Peak Time: F14* The fine adjustment of pulse peak time can be achieved by activating F14 using the F (FUNCTION) selector key [12]. The value which is substructed or added the fine adjusting value form the standard value of the pulse peak time is output. At the wave pulse welding, the high pulse condition (H pulse) is adjusted. (13-3) Fine Adjustment of the Base Current: F15* Fine adjustment of base current can be achieved by activating F15 using the F (FUNCTION) selector key [12]. The value which is substrusted or added the fine adjusting value from the standard value of the base current is output. (13-4) Fine Adjustment of L Pulse Peak Current: F16* (available in optional wave pulse mode only) The fine adjustment of low pulse condition (L pulse) peak current at wave pulse welding can be achieved by activating F16 using the F (FUNCTION) selector key [12]. The value which is substrusted or added the fine adjusting value from the standard value of the L pulse peak current is output as L pulse peak current. (13-5) Fine Adjustment of L Pulse Peak Time: F17* (available in optional wave pulse mode only) The fine adjustment of L pulse peak time of the second pulse condition at wave pulse welding can be achieved by activating F17 using the F (FUNCTION) selector key [12]. The value which is substrusted or added the fine adjusting value from the standard value of the L pulse peak time is output as L pulse peak time. (13-6) Fine Adjustment of L Pulse Base Current: F18* (available in optional wave pulse mode only) The fine adjustment of the pulse base current of the second pulse condition at wave pulse welding can be achieved by activating F18 using the F (FUNCTION) selector key [12]. The value which is substrusted or added the fine adjusting value from the standard value of the L pulse peak current is output as L pulse peak current.
High pulse condition
Low pulse condition
High pulse condition
Example of current wave at wave pulse welding
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No. P10537 10. WELDING OPERATION (continued) (14) Turbo Start ON/OFF Selection: F19 The welding power source has Turbo Start function by capacitor discharge, which enable you to obtain good welding start. At poor welding start with burnback, setting F19 to oFF deactivates the Turbo Start function. The function is preset to on (valid) for factory setting. (15) Keypad tone ON/OFF Selection: F20 Setting F20 to oFF deactivates key pad tone function. The volume of the key pad tone can not be adjusted. (16) Setting change of warning: F21 When the motor over current (warning) (E-820) or the battery voltage decrease warning (E-600) are generated, it is possible to keep using this welding power source without stopping outputting though an abnormal code is displayed to a digital meter. Therefore, it is likely to not notice though the alarm display has gone out when a welding machine is set far. If the function No.21 is set to 'on', when warning is generated, it can be treated as abnormality. In this case, the welding machine stops automatically as well as other abnormalities. Moreover, because the returning on the power source is needed for re-start, it never keeps being used without noticing. The setting when the product is shipped is invalid in 'oFF'. (17) EN ratio setting by external signal: F22 By turning function '22' to 'on', the EN ratio in the AC pulse welding can be adjusted according to an external signal. The signal from the outside is input to "EN Ratio" of 8P terminal(TM1) in the welding power source within the range from 0 to 5V. If the external signal voltage decreases lower than 2.5V, EN ratio becomes smaller; and if the external signal voltage increases higher than 2.5V, EN ratio becomes larger. Note: - if input voltage exceeds 5V, the control circuit of the welding power source might be destroyed. - This function is effective only in the automatic machine mode 1. - When this function is effective, the EN ratio cannot be adjusted with the front panel. However, the value set by an external signal can be confirmed with the EN ratio key. - When this function is effective, make sure to input signals to EN ratio terminal. If this function is made effective without connecting anything, this causes the malfunction.
(18) Switch of AC start: F23 In the AC pulse welding, to obtain enough penetration of the welding starting part, DC welding is performed from the welding beginning for a certain period. To suppress the heat input in the welding beginning part, and to decrease penetration, the AC welding can performed from the welding start by turning function '23' to 'on'.
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No. P10537 10. WELDING OPERATION (continued) 10.2.2 Key lock Key lock is a function to prevent the welding conditions from being changed by accidentally operating keys and knobs on the front panel. Only the keys and parameter adjusting knob which are used for changing each parameters and modes can be protected. However, the settings can be checked and confirmed by using the DISPLAY CHANGE key [8] and the arc spot time setting key [11].
EN TER
T1
Holding down both the F (FUNCTION) selector key [12] and ENTER key [21] simultaneously Holding down both the F (FUNCTION) selector key [12] and ENTER key [21] simultaneously for a while brings the key-lock condition. While keys are locked, the F lamp (located at the upper left of the F key) blinks. Key lock can be cancelled by holding both the F key and ENTER key simultaneously for a while again. Key lock cannot be cancelled by starting the machine up again.
G AS
While keys are locked, the F lamp blinks
Even when the keys are locked, GAS CHECK, INCHING, and JOB MEMORY function can be activated.
Note: Initial process will be deactivate the key lock
10.2.3
Key lock with the password The primary purpose of Key lock is to avoid changing welding conditions accidentally. In other words, everybody can un-lock it easily. On the other hand, this Key Lock with the Password make possible to avoid any change by those who does not know the password. The basic operation is the same as the standard Key Lock. If the password was entered, the welding power source will ask the password to un-lock. Until you enter the correct password, the welding power source never un-lock itself. Note: If the Key Lock with the Password is activated, entering the correct password is the only way to un-lock the welding power source. Neither Initialize process nor power-on reset can un-lock it. If you want to enter a new password, you have to enter the current password first. Therefore, please manage the password well and never forget it. In the password setting and entering stage, the welding power source disregards for the torch switch (start signal).
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No. P10537 10. WELDING OPERATION (continued)
There are two (2) modes in the key lock with the password. Listed below is the description of each option: Option Mode 1 #1 (OP 1) Prohibit welding Description When OP1 is "on", the welding power source asks the password at every power-on. The welding power source can start welding after the correct password is entered. If the password is incorrect, the welding power source never starts welding. Note: If the password is not set (indicated "000"), this option does not mean anything. To activate this, please make sure to set the password except "000". When OP2 is "ON" during key lock, it is impossible that changing the welding condition by external setting voltage and job memories save or load. Note: Job change by EXT in can work even OP2 is on.
Mode #2 (OP2) Prohibit to change the welding conditions
OP1 Prohibit welding Welding start OP2 Prohibit to change the welding conditions Parameter adjusting knob, variety of welding setting External setting voltage including analog remote control Welding condition memory Inching Gas check
ON Impossible until entering the correct password at power-on. ON Invalid Invalid Invalid Valid Valid
OFF Valid
OFF Invalid Valid Valid Valid Valid
Note: Both OP1 and OP2 are activated at the same time. OP1 works even the standard Key Lock described in previous section is not activated. OP2 works only when the standard Key Lock is activated.
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No. P10537 10. WELDING OPERATION (continued) 1. Procedure to set the password and the lock option (1) Turn off the welding power source and back on with pressing "F (FUNCTION) selector" key [12] and "ENTER" key [21] together. After the power source are properly turned on, Digital Meters show "PAS PAS" as per below. If the password is not set or the password is "000", go to (2) which is the next step. If the password was already set, go to 2. (2) to clear the current password.
W AR N IN G
A m /m in S e c H z
D CN O -L O A DV O L T A G E
%
J O BN O .
(2) After digital meter shows "PAS PAS" in a few seconds, the power source enters the password setting mode and shows "Loc 000". Left digit (hundred's place) of right meter blinks as per below. Rotate the parameter adjusting knob [6] to set the hundred's place of the password. Following description sets the password "123" as an example.
W AR N IN G
D CN O -L O A DV O LT A G E
on
A m /m in S e c H z
blink
on
on
%
J O BN O .
The number of blinking place can be set by the parameter adjusting knob [6]. The range is from 0 to 9.
W AR N IN G
on
A m /m in S e c H z
blink
on
on
%
J O BN O .
(3) Move to next digit (place) by pressing DISPLAY CHANGE key [8]. Then the center digit (ten's place) can be set by the parameter adjusting knob [6].
W AR N IN G
on
A m /m in S e c H z
on
blink
on
%
J O BN O .
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No. P10537 10. WELDING OPERATION (continued) (4) Move to next digit (place) by pressing DISPLAY CHANGE key [8]. Then the right digit (one's place) can be set by the parameter adjusting knob [6]. If the DISPLAY CHANGE key [8] is pressed again, the digit to set will be back to left again.
W AR N IN G
on
A m /m in S e c H z
on
on
blink
%
J O BN O .
(5) Finish the password setting by pressing ENTER key [21]. To confirm the password, the Digital Display blinks "Loc" on the left meter and the password on the right meter alternately. If the password is NOT correct, press any key except ENTER [21]. It will be back to the previous stage to re-set the password. If the password is correct, press ENTER key again to activate the password. Blink alternately
W AR N IN G
blink
A m /m in S e c H z
blink
%
J O BN O .
(6) If there is no correction in the password, the password is fixed by pressing the ENTER key [21] again and the lock option setting mode is displayed. OP1 on left meter display and the condition on right meter display are displayed.
W AR N IN G
blink
(a)
A m /m in S e c H z
on
%
J O BN O .
Condition (a) or (b) can be selected by pressing DISPLAY CHANGE key [8]. The parameter of blinking side can be changed by the parameter adjusting knob [6].
W AR N IN G
on
(b)
A m /m in S e c H z
blink
%
J O BN O .
(7) To finish setting password, press ENTER key [21]. At this point, the condition is not locked. For locking, push F (FUNCTION) selector key [12] and ENTER key [21] at the same time for a while (if password is not set, it is key lock state), and upper left of the F selection key blinks.
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No. P10537 10. WELDING OPERATION (continued) 2. The way to input the password to clear the Key Lock with the password (1) When the lock is released by pushing F (FUNCTION) selector key [12] and ENTER key [21] at the same time for a while from the state of the lock with the password, when the power is turned on during lock option 1 is on, and when the password has already been set during the password setting; the welding power source becomes password input mode, 'PAS' 'PAS' is displayed in a digital meter as shown in the figure below.
W AR N IN G
A m /m in S e c H z
%
J O BN O .
(2) After Digital Meter shows "PAS PAS" in a few seconds, the power source enters the password request mode and shows "Loc 000". "Loc" on the left meter and the left digit (hundred's place) of right meter blinks as per below. Rotate the parameter adjusting knob [6] to set the hundred's place of the password. To change the digit, press DISPLAY CHANGE key [8]. The value of the blinking digit can be changed by the parameter adjust knob.
W AR N IN G
blink
A m /m in S e c H z
%
J O BN O .
(3) After entering the correct password, press ENTER key [21]. If the password is correct, the Digital Display shows "good" and the power source is unlocked. If the power source is in the password setting mode, go back to 1. (2).
W AR N IN G
A m /m in S e c H z
%
J O BN O .
If the password was incorrect, the Digital Display shows "bAd" and the power source is NOT unlocked.
W AR N IN G
A m /m in S e c H z
%
J O BN O .
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No. P10537 10. WELDING OPERATION (continued) 3. The way to cancel entering or setting the password - If the power source is in the password setting mode, just turn it off. In this case, the password can not be set. - If the power source is in the password setting mode, press F key [12]. In this case, the Key Lock with the password can not be cleared. - In case of the password option 1 (OP1) was activated, the power source can not work until entering the correct password.
- 55 -
The flow chart of the password setting

Turn on with pressing "F" and "ENTER"
Was a password already set? No Set the 1st digit of the password by the knob.
Yes
Goto Reset (unlock). Return here after Reset
Press "DISPLAY CHANGE"
Set the 2nd digit of the password by the knob.
Set the 3rd digit of the password by the knob.
Press "ENTER"
Press any key other than "ENTER"
Abort
Confirm the password OK
Set again
Turn off the power source
Press "ENTER"
Goto Options
- 56 -
The flow chart of the password option setting (continue from the password setting)
After setting the password
Set OPtion number by the knob
Set the function in the OPtion by the knob
Abort
Press "ENTER"
Turn off the power source
Finish to set the password
Activate key lock by pressing "F" and "ENTER" together in long time.
The flow chart when the power source is turned on in case of OP1 is on
Turn on the power source
Password requested
Enter password as per described before
Wrong password
Can NOT operate the power source until entering the correct password.
Correct password Can operate the power source
- 57 -
The flow chart of unlock

Press "F" and "ENTER" in long time
Set the 1st digit of the password by the knob.
Set the 2nd digit of the password by the knob.
Set the 3rd digit of the password by the knob.
Press "ENTER"
Display "bAd"
Abort
Wrong password Password check Correct password Came from Set password
Press "F"
Came from Set password Turn off the power source
End without unlock Display "good" and unlock Return to Set password
- 58 -
No. P10537 10. WELDING OPERATION (continued) 10.2.4 JOB MEMORY function The JOB MEMORY function enables welding conditions to be reproducible by storing the welding conditions in memory inside power source and by reading out the stored data at any time. The number of welding conditions that can be held in memory is up to100. CAUTION The welding conditions (electronic data) stored by this function are susceptible to occurrence of static electricity, impact, repair, etc., and there is a possibility that the storage contents may be changed or lost. BE SURE TO MAKE A COPY FOR IMPORTANT DATA. Please note that we shall not assume any responsibility for any change or loss of electronic data resulting from repair. Once the machine enters the memory mode and read-out mode, only the SAVE, LOAD, and ENTER keys can be operated. To exit the mode, press the LOAD key [19] if it is in the memory mode, and the SAVE key [20] if in the read-out mode. Memory can be copied to a different condition number after reading the welding conditions to be copied. NOTE: Even when welding conditions are read out while the analog remote control is connected to the welding power source, the setting values preset with the analog remote control are valid. If you want to read the welding condition when analog remote control is connected,; combine 10.2.1(11) Setting of job memory fine adjustment function.
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No. P10537 10. WELDING OPERATION (continued) 1. SAVE function Welding conditions being currently in use are stored in the memory inside the welding power source. Holding the welding conditions in memory (1) When pressing the SAVE key [20], the machine enters memory mode, the SAVE lamp (located at the upper left of the SAVE key) lights up. See the following picture. In the right display, the condition number 1 blinks and the LED lamp of the welding condition number lights up. In the left display, the setting value of welding current preset to the condition number "1" appears. Under this condition, a condition number can be set while turning the parameter adjusting knob [6].
W ARNNING
m/ m in . SE C H z
%
J OB No.
Welding Current setting value held in memory
Condition number blinks
In the event that any memory data is already preset to the condition number you selected, the CRATER lamp, the WELDING METHOD lamp, etc. also light up. If no memory data is preset to the condition number you selected, - - - blinks in the left-side display. In this case, the system skips the parameter check condition of Step (2) and jumps to Step (3).
W ARNNING
/min S EC . H z
%
J OB No.
(2) When pressing the ENTER key [21] after setting the condition number, the ENTER lamp blinks (located at the upper left of the key). Under this condition, you are allowed to confirm the setting value of the parameter preset to the condition number by using the DISPLAY CHANGE key [8]. The setting value of the parameter you selected blinks. NOTE: In the save mode, you can not change the welding condition number or select any memory/readout mode. To reset the condition number, press the SAVE key [20], then return to the step (1). To quit the setting and exit from the memory mode, press the LOAD key [19]. (3) Pressing the ENTER key [21] again holds the data in memory and allow you to exit from the memory mode.
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No. P10537 10. WELDING OPERATION (continued) 2. LOAD function The welding conditions stored in memory are read out from the memory inside welding power source. NOTE: The welding conditions currently used can be overwritten with the welding conditions read out. When you wan to save the welding conditions that have been used until now, preset the welding conditions to any condition number, then carry out readout. Reading out the preset welding conditions (1) When pressing the LOAD key [19], the machine enters the readout mode, LOAD lamp (located at the upper left of the LOAD key) lights up. See the figure below. The condition number "1" in the right-side display blinks and the JOB No. LED lamp lights up. In the leftside display, the setting of welding current preset to condition number "1" lights up. Under this condition, a condition number can be set while turning the parameter adjusting knob [6].
W ARNNING
m/min
SE C H z
%
J OB No.
Welding Current held in memory
Condition blinks
In the event that any memory data is preset to the condition number you selected, the CRATER lamp, the WELDING METHOD lamp, etc. also light up. When no memory data is preset to the condition number, "- - -" in the left-side display blinks. See the figure below.
W ARNNING
m/min
SEC H z
%
JO B N o.
(2) When pressing the ENTER key [21] after setting the condition number, the ENTER lamp (located at the upper left of the key) blinks. Under this condition, you are allowed to confirm the setting of each parameter you want to read out by using the DISPLAY CHANGE key [8]. The setting of the parameter you selected blinks. NOTE: You are not allowed to change condition number or select a welding method, etc. To reset the condition number, press the SAVE key [20], then return to the step (1). To quit the setting and exit from the readout mode, press the SAVE key [20]. (3) When pressing the ENTER key [21] again, you can read out the preset welding conditions and exit from the readout mode.
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No. P10537 10. WELDING OPERATION (continued) Operation flow in the memory mode
Press the MEMORY key.

Discontinue
Set the welding condition number while turning the parameter adjusting knob. Press the ENTER key.
Discontinue
Press the DISPLAY CHANGE key Reset the welding condition number. to check the parameter value.
The welding conditions are preset to the number you selected.
Press the LOAD key.
Press the ENTER key. The memory mode quits.
Operation flow in the readout mode
Press the LOAD key.

Discontinue
Press the LOAD key.
Discontinue
Press the SAVE key.
Press the ENTER key. The readout mode quits.
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No. P10537 10. WELDING OPERATION (continued) 3. Erasing the welding conditions When you erase the welding conditions stored in memory, you can select either erasing all or erasing one. Erasing the welding conditions (1) Turn off the power switch and turn on the power switch with both the LOAD key [19] and SAVE key [20] pressed. Release the keys after tuning on the power switch, and then "dEL" appear in the left-side display. See the picture below.
W ARNNING
m/min
SE C
H z
%
J OB No.
"dEL" is displayed, which indicates
Condition number to be deleted blinks
(2) Set the condition number to be deleted while turning the parameter adjusting knob [6]. When turning the knob counterclockwise, "ALL" appears in the right-side display as illustrated below and you can erase all the welding conditions. [The machine is in deletion mode]
W ARNNING
m/min
SE C
H z
%
J OB No.
"dEL" is displayed
"ALL" blinks
NOTE: When the welding conditions are deleted by selecting "ALL", welding conditions currently in use are also deleted. Consequently, all the parameters return to the initial settings. (3) Pressing the ENTER key [21] blinks "dEL". Confirm the condition number again and if you want to cancel erasing of the condition number, press any key other than the ENTER key [21] to return to step (2). To quit the delete mode, turn off the welding power source. (4) Pressing the ENTER key [21] again delete the welding condition preset to the condition number. When "End" is displayed after end of data deletion, turn off the power switch, then start up the welding machine. NOTE: If you press the ENTER key twice in the deletion mode, you can not recover the erased welding conditions. When you attempt to delete a welding condition held in memory, make sure that the condition number you want to erase is surely selected.
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No. P10537 10. WELDING OPERATION (continued) 10.2.5 Welding result management function In the welding result management function, "Welding point", "Total welding time", and "Wire consumption amount" can be observed. Moreover, the function to inform the attainment to the frequency and the amount set beforehand to the worker (alarm display) is provided, too. In addition, when the output current and the voltage are observed, and an output becomes outside the range set beforehand; the output will be stopped, and the alarm will be displayed. (1) Welding point The welded frequency is counted. It is measured from the torch switch is turned on (the current start flowing) to the torch switch is turned off (the output is stopped) as one count. The unit is 'times'. (2) Wire consumption The wire amount used by the welding is measured. The unit is 'kg'. NOTE: This welding power source memorizes unit amount data (g/m) beforehand which is calculated from specific gravity data (g/cm3) of the material by each wire material and each wire diameter in the welding power source as data shows in the next table. The wire consumption is calculated from this unit amount data and the wire sending amount during welding. Therefore, the error goes out by the wire element etc. in an actual use amount and the measurement value. So use it as a guide. Moreover, the amount used by Inching and the slow down of the wire is not included. The wire consumption about the special wire which is not shown in the table below is not measured.
Wire diameter (mm) 0.8 0.9 1.0 1.2 1.6
Unit amount data (g/m) Mild steel solid Stainless steel 3.9 4.0 5.0 5.1 6.2 6.3 8.9 9.0
Aluminum
2.1 3.0 5.4
(3) Total welding time The total welding time is measured. Time from the torch switch is turned on and the current flows, until the torch switch is turned off and the output is stopped; is assumed to be welding time, and it is added to the total welding time at each welding. Unit is minutes.
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No. P10537 10. WELDING OPERATION (continued) (4) Welding monitor Welding monitor watches the average current and the voltage in the tolerance that was set beforehand. Moreover, when the average current or the voltage under the welding exceeds set value, welding monitor informs the worker of that. (Example) If there were the following settings. Welding current (set value) Welding voltage (set value) Plus side current allowance error (P41) Minus side current allowance error (P42) Plus side voltage allowance error (P43) Minus side voltage allowance error (P44) Abnormal judgment time (P45) NOTE: (Pxx) means Weld Monitor numbers.
: 200A : 20V : 10% ( =200A ) : 20% ( =160A ) : 20% ( =24V ) : 10% ( =18V ) : 10 seconds
In this case, when the output under the welding (mean value every one second) for the current becomes 160A or less, or 220A or more; or for the voltage becomes 18V or less, or 24V or more; the welding monitor begins counting considering a welding condition abnormal. When the state is consecutive for ten seconds, the operation which is set by operation when welding condition abnormality is detected is done. In the alarm display the difference between a mean value and a set value when the ranges are exceeded most in the welding is displayed. 'P40' is displayed in a left meter, the unit A" LED lights for the current, the current difference is displayed in a right meter; the unit V" LED lights for the voltage, and the voltage difference is displayed in a right meter. The voltage is displayed by one digit below the decimal point. When the current exceeds the range, the current difference is confirmed in P40; and when the voltage exceeds the range, the voltage difference is confirmed in P40; and when both of the current and voltage differences are exceed the range, one with large width of excess can be confirmed in P40. When 0" is set for abnormal judgment time (P45), a welding abnormal condition is not detected. The relation between a weld monitor number and a right meter is tables below. Weld monitor Setting range number Weld monitor data (right meter (left meter display) display) P10 Welding point result (times) P11 Target value (times) 0-999 P12 Operation when target reaches (*1) 0-5 P20 Wire consumption result (kg) P21 Target value (kg) 0-999 P22 Operation when target reaches (*1) 0-5 P30 Total welding time result (min) P31 Target value (min) 0-999 P32 Operation when target reaches (*1) 0-5 Mean value monitor maximum value of fluctuations P40 P41 P42 P43 P44 P45 P46 Plus side current allowance error margin(%) Minus side current allowance error margin(%) Plus side voltage allowance error margin(%) Minus side voltage allowance error margin(%) abnormality judgment time (second) Operation when target reaches (*2) 0-100 0-100 0-100 0-100 0-100 0-2
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No. P10537 10. WELDING OPERATION (continued) *1: Relation between setting value of P12, P22 and P32, and operation content when target reaches Setting value Operation current 0 1 2 3 4 5 Counter clearness when the target value is Do Dont Do Dont Dont Dont reached (Note 1) Continuance operation when target value is Possible Possible Possible Possible Impossible Impossible reached (Note 2) When the power supply is turned on, it is counter Do Do Dont Don Do Dont clearness Note 1: The counter is cleared by pushing an arbitrary panel key when the alarm is being displayed. Note 2: In case of Impossible, the following welding cannot begin until an arbitrary panel key is pushed when the target is reached.
*2: Relation between P46 set value and operation content when welding condition abnormality is detected Set value Operation content 0 The continual operation is possible. The alarm display only. A present welding can be continued as it is. After the welding ends, the following welding cannot begin until an arbitrary panel key 1 is pushed. The output is stopped during welding immediately. 2 Afterwards, the following welding cannot begin until an arbitrary panel key is pushed.
About the alarm display when the target is reached or welding condition abnormality is detected The weld monitor data blinks. (example) When the wire consumption reaches a target value, 'P20' in the left meter and present measurement data in the right meter alternately.(alarm display) When an arbitrary panel key is pushed, it returns to a usual display. Moreover, in case continuance operation possible has been selected in the operation when the target is reached, every time the welding power source keeps displaying the alarm after the welding ends until an arbitrary panel key is pushed.
- 66 -
No. P10537 10. WELDING OPERATION (continued) How to use the weld monitor function. When weld monitor key (16) is pushed for a while, the weld monitor number blinks to a left meter, and allocated data in weld monitor number lights to a left meter. Under this condition, the weld monitor number can be set with the parameter adjusting knob.
W AR N IN G
blink
A m /m in S e c H z
on
%
J O BN O .
After a target weld monitor function number is set, If weld monitor key [16] is pushed again, display becomes as shown in the figure below. Under this state, the target value and the operation when the target is reached can be set with the parameter adjusting knob [6]. Cut the power on/off switch once, and turn it on again.
W AR N IN G
on
A m /m in S e c H z
blink
%
J O BN O .
The number advances by the weld monitor key [16].
This can be set by parameter adjusting knob [6].
W AR N IN G
on
A m /m in S e c H z
blink
%
J O BN O .
When the weld monitor key [16] is pushed again, the state goes back to {1}.
To come off the weld monitor mode, push the weld monitor key [16] for a while.
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No. P10537 10. WELDING OPERATION (continued) 10.2.6 Resetting to initial values The welding conditions that are currently used (including the welding condition currently used) are all reset to initial values. To reset to initial values, turn off the power switch and then turn on the power switch with both the F (FUNCTION) selector key [12] and GAS CHECK key [17] held down. When "End"s appear in the displays after turning on the power switch, release the keys, turn off the power switch, then turn it on again. See the picture below.
W AR N IN G
A m /m in S e c H z
%
J O BN O .
[ Indication of complete] Refer to SPECIFICATIONS for initial values of each parameter and function. 10.2.7 Confirming software version The version of software incorporated in the welding power source can be verified following these steps. Turn on the power switch with only the F (FUNCTION) selector key [12]held down. After powering the welding power source, the version number appears in the display. (Example) Left and right displays: [P10511] Software number (P10511) is displayed. Press the F key Left display: Right display: [001] [000]
Main software version (Ver. 001) is displayed. Minor software version is displayed.
Press the F key Left display: Right display: [- - -] [002]
Combination is displayed.
Press the F key The welding power source starts up as usual and gets ready to perform welding.
10.2.8 Automatic stop of fan The cooling fan automatically stops in 10 minutes after welding is finished and automatically starts turning when welding is started. When powering the welding power source, the cooling fan is also turning but automatically stops in 10 minutes when no operation is carried out. Low speed fan rotation will work for 3 minutes every 20 minutes without weld. 10.2.9 Reduction of fan noise When the welding power source is not temporarily in use, the rate of fan rotation decreases so that fan noise can reduce. This function works only for 250 A or less output current.
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No. P10537 11. APPLIED FUNCTION WARNING Observe the following to prevent electrical shock.
Do not touch the live electrical parts inside or outside the welding machine. Grounding to the case of the welding power source should be performed by persons qualified electric work and according to the laws and regulations in your area. When touching the parts inside the welding power source, wait more than three minutes after powering off all input power supply by turning off the line disconnect switch in the switch box. CAUTION Try to move the control cable which is pulled out from the automatic connection terminal on the chassis father away from the welding power cable or the torch cable when making an external connection. Otherwise, equipment failure may be caused by noise, etc., during welding operation. Pull out only the wiring on the printed circuit board to outside. 11.1 External connection of inside terminal block of automatic machine When taking off the upper cover of the welding power source, you will find there are a 12P terminal block (TM2) and a 8P terminal block (TM1) on the chassis like the figure below. Use them to connect with an automatic machine. Refer to Section 12, Parts layout for the locations of the terminal blocks. NOTE: Wait more than three minutes after turning off the line disconnect switch or nofuse breaker and the power switch on the front panel to remove the cover. NOTE: Break the grommet with film located on the rear side of the welding power source to lead in the external connecting wires. When leading in the external connection wires, do not touch the parts on the printed circuit board and the edges of the steel plate. [12P terminal block]
READY
EXT
EXT
[8P terminal block]
D I RECT EN Rati o
- 69 -
No. P10537 11. APPLIED FUNCTION (continued) 12P terminal block (TM 2) Pin No. Signal name READY (OUTPUT) + - Ready Power + - GAS (INPUT) Solenoid Valve Control EXT1 (INPUT) Extra Input Signal 1 EXT2 (INPUT) Extra Input Signal 2 STOP (INPUT) Operation Stop WCR (OUTPUT) Current Detection Unused
Function The terminals used for ready power for prep. relay. When there is not any error such as open phase, Operation Stop, output over current, and thermal overload, the terminals work, etc. while the power switch is on, the terminals function. The terminals used for controlling the gas solenoid valve by external signals. (If the terminals are short-circuited, the gas valve will open.) The terminals used for special specifications. Short between these terminals to reverse rotation (retract function) with inching signal on during 1 or 2 on function 4. Refer to section 10.2.1(4) selection of auto/semiautomatic. The terminals used for special specifications. These terminals should not be used for normal use.
*1
*2
*2
*2
+ - -
+ - ,
To stop welding externally. Release the wiring between two terminals to run Operation Stop. Welding machine is stopped by running Operation Stop. Close the terminals after turning off the torch switch to restart welding. To avoid accidental restart, use of a Pushlock Turn reset switch is suggested. Contact Output of welding current relay used for detection of welding current. The contacts close while welding current is flowing.
*2
*3
8P terminal block (TM1) Pin No. Signal name AMMETER + - VOLTMETER -

+ -
Function Terminals for connecting an ammeter. Use the ammeter (400A/60mV, part number: 4403-057). Terminals for connecting a voltmeter. Use the voltmeter (F.S. 75V, part number: 4401-016). When you use a voltmeter on the market, use the one whose full-scale is 100V or more. When using a power cable that is more than 30m long, direct connection of a direct detection wire of the base metal (-) to the wire feeder is recommended, but it is impossible to connect to the wire feeder due to jig, use the terminal block inside this welding power source. Refer to Section 10.2.1 (12) Arc Voltage Direct Detection ON/OFF Selection for details of direct detection. This is a terminal used when the EN ratio is adjusted by an external signal. Refer to "10.2.1(17) EN ratio setting according to external signal" for details.
*5 *4,5
Unused Terminal for Direct Detection of Voltage
EN ratio setting signal (input)
Precaution for connection with terminals on the terminal block. The wires from the terminal blocks should be twisted for each signals to avoid accidental operation. Take care that the wires form the terminal blocks do not cross other signal wires from other welding power source.
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No. P10537
11. APPLIED FUNCTION (continued) *1 Equivalent circuit is as the figure shown right. Maximum capacity of TR is 80V, 100mA. When connecting such as relay to two terminals, do not exceed 80% of the maximum capacity of TR. (Figure 1) *2 Equivalent circuit is as the figure shown right. Connect allowable contacts (10mA or more) to two terminals. (Figure 2) *3 Rating of the provided relay contacts is 125V AC, 0.5A, 30V DC, 1A. Do not exceed 80% of the rating of the provided relay contacts. *4 Be careful that no-load voltage (100V or less) is applied to between the terminals during welding. 24V TR PC
Figure 1 *5 External view of ammeter and voltmeter are shown as below.
4.7k
Figure 2
+ -
Ammeter: Parts number 4403-057 Voltmeter: Parts number 4401-016
(mm)
- 71 -
No. P10537 11. APPLIED FUNCTION (continued) 11. 2 Combining with an automatic machine When combining with an automatic machine, use the 12P/8P terminal block inside the welding power source, the 10P terminal block inside the wire feeder, and the receptacle for the remote control or for the wire feeder. Refer to Section 11.1, External connection of the Inside Terminal Block of the Automatic Machine for the details of the terminal block inside the welding power source. (1) Current/Voltage settings and inching signal When the analog remote control (optionally supplied) is not in use, resistor R1 for current setting, resistor R2 for voltage setting, and switch PB for inching, which are all listed in Section 13.1 Parts List, should be used. For setting current/voltage on external voltage, refer to Section 10.2.1(4), Selection of Auto/Semi-automatic.
Analog remote control

93 94 95 96 97 98 1 2 3 4 5 6
93 93
Current setting
94
Voltage setting
94
R1
95
R2
96
PB
97 98
Inching
(2) Start signal When removing the right-side plate of the wire feeder, you will find a 10P terminal block. See the figure below. Welding is carried out by the start signal when wiring numbers 306 and 307 are contact input and when the terminals are closed. Welding stops when the terminals are open.
Terminals for start signal

Terminals for voltage detection
*Outgoing lines of start signal and direct detection signal are located next to the 10P control cable. Break the grommet with film.
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No. P10537 11. APPLIED FUNCTION (continued) 11.3 Optional accessories 11.3.1 Other optional accessories Description Analog remote control Digital remote control CAN communication module CAN communication cable Voltage detection cable
Part No. K5416U00 E-2454 K5422C00 BKCAN-04XX K5416G00
Remarks With a 3-meter cable A CAN communication module and cable are needed. XX= 05 (for 5 m), 10 (for 10 m), 15 (for 15m), 20 (for 20m) 30 m, with a crimp-style terminal
11.3.2 Extension cable/hose (extension of work space) CAUTION Do not connect an unnecessarily long extension cable. When using an extension cable, roll it out. Failure to observe the demand may result in unstable arc. Choose a proper torch cable (separately sold) for work space. When extending the work space, use other extension cables/hoses (separately sold ) that match the work space.
Control cable for wire feeder
Gas hose
Power cable for wire feeder
Wire feeder
Control cable for remote control

Analog remote control
(Optionally available)
* A water cooler and water hoses are necessary for use of a water-cooled torch.
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No. P10537 11. APPLIED FUNCTION (continued) 1. Power cable (for torch and for base metal) 5m 10m Mode BKPDT-6007 BKPDT-6012 l 2. Gas hose Mode l 5m BKGG-0605 10m BKGG-0610 15m BKGG-0615 20m BKGG-0620
15m BKPDT-8017
20m BKPDT-8022
3. Control cable for wire feeder (10P) 5m 10m Mode BKCPP-1007 BKCPP-1012 l 4. Control cable for analog remote control (6P) 5m 10m 15m Model BKCPJ-0605 BKCPJ-0610 BKCPJ-0615
20m BKCPJ-0620
5. Water hose (for water-in and water-out) 5m 10m 15m 20m Model BKWR-0605 BKWR-0610 BKWR-0615 BKWR-0620 Note: When you use automatic machine or with the current that is near to a rated current, use a thick cable more than one rank.
- 74 -
No. P10537 12. MAINTENANCE AND TROUBLESHOOTING WARNING To avoid electric shock, follow the below instructions.
Do not touch live electrical parts inside or outside the welding machine. Turn off all of the line disconnect switches before touching the parts inside the welding machine. Perform the maintenance checks periodically. If any damaged parts are found, only use the welding machine after troubleshooting or repairing. Only certified operators should maintain, inspect, or repair the welding machine. When carrying out the maintenance, wait more than three minutes after powering off all input power supply by turning off the line disconnect switch in the switch box. Capacitor may be discharging even after powering off all input power supply. Check to make sure that charging voltage does not exist before carrying out the maintenance. This welding power source uses a high-frequency inverter system, be careful of accidental connection of the line disconnect switch at input side. Have qualified operators or the persons familiar with this welding power source test withstand voltage. And install a protective wall around the welding machine to keep away others from the welding machine. CAUTION Rotating parts may cause injuries. Be sure to observe the following.
Only certified operators should maintain, inspect, or repair the welding machine. Install a fence around the welding machine to keep others away from it. Do not put your hands, fingers, hair and clothes near the fans and wire feed roll rotating. CAUTION Do not touch the parts for the main circuit which are located inside the power source, such as single-phase transformer, DC inductor, heat sink, etc. immediately after welding is performed, as the parts are extremely hot. Wait until the parts cool down, when touching. Failure to observe the demand may result in burn. CAUTION The welding conditions (electronic data) stored using the JOB MEMORY keys are likely to be affected by occurrence of static electricity, and there is a possibility that the preset data contents may be changed or erased. We recommend taking notes of important data. We shall not assume any responsibility for any change or loss of the electronic data resulting from repair.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.1 Maintenance (1) Periodical checking (2) Periodically check the welding power source to ensure the safety of the equipment and the efficiency of work. Daily checking the followings:
No strange vibration, buzzing noise, and smell are generated from the welding power source. No excessive heat is generated from the cable connections. Fan functions properly when the power switch is turned on. The switches properly function. Connection and insulation of cables are surely made. There are no break in cables. Fluctuation of power source voltage is not large. Case Earth is surely connected. (Disconnection of the Case Earth may result in failure or malfunction of the equipment.) There is no trouble in crack and the like on the front panel.
Checking the followings each three to six months: There is no damage inside the torch. There are no loose connections or no poor contacts caused from rust, on input side of the welding power source and output side of the cables. There is no trouble with insulation. The welding power source is properly grounded. Built-up dust on the transistor or the cold plate on the rectifier may affect the equipments. Take off the cover of the welding power source once a half year, then remove dust by blowing moisture-free compressed air on each part. damage to the welding power source. Be sure to inspect it periodically. 12.2 Precaution for replacement of the printed circuit board -Make sure that the connector number inscribed on the printed circuit board matches the number marked on the connector. -Turn off the control power switch and line disconnect switch before carrying out maintenance on the welding power source, and wait three minutes until the capacitors inside the welding power source discharge.
- The dust protective filter located on the inlet of the fan does not clog, which may result in
C N1
-This welding power source uses a high-frequency inverter system, be careful of accidental connection of the line disconnect switch at input side.
NOTE: Match the number on the printed circuit board with that on the connector.
- Surely connect the connectors until the connector clicks. Failure to do so may result in damage to the printed circuit board and the welding . -With the connectors disconnected, do not turn on the power switch on the front panel. -Do not use organic solvent such as thinner, trichloroethylene, gasoline, etc., to clean the plastic cover and carrying handle of the welding machine. Deformation and flaw may result from the adherence of the organic solvent.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.3 Insulation Resistance Test WARNING Observe the following to prevent an electrical shock.
When touching live electrical parts, a critical electric shock and burn may occur. Have qualified operators or the persons familiar with this welding power source measure insulation resistance and test withstand voltage . And install a protective wall around the welding machine to keep away others from the welding machine. Check to make sure that charging voltage does not exist before carrying out the maintenance before carrying out measurement of insulation resistance and withstand voltage test. When measuring insulation resistance and testing withstand voltage, follow the steps below. And, refer to the schematic diagram, parts layout, and parts list for maintenance. 1. 2. 3. 4. Disconnect the grounding cable (wiring number: 80) from the earth. Short-circuit on AC side and commutation side of DR1. Short-circuit between TR1 (C1) and (E1), TR2(C2) and (E2), TR3(C2) and (E2). Short-circuit between TR5 (C1) and (E1), TR8(C2) and (E2).
Be sure to reconnect the cables after carrying out measurement of insulation resistance and withstand voltage test. 12.4 Replacement of Batteries This welding power source uses lithium batteries to hold welding conditions in memory. The life of the batteries differs depending on the environments. E- and 600 shown in the displays on the front panel blinks when the batteries gets low. Replacement of the batteries every 5 years or so are recommended even when E- and 600 do not blink. Replace the batteries following the steps: 1. 2. Turn off the line disconnect switch in the switch box or the no-fuse breaker and the power switch of the welding power source. After more than three minutes, remove six screws that secure the front panel, and then pull the front panel out. Do not pull it forcibly. With the wiring inside the equipment disconnected, do not turn on the power switch. Failure to do so may result in damage to the welding power source. Remove the connectors on the P.C.B.P10533R to replace the printed circuit board. Refer to the position for Rear side of the front panel in Section 12.8, Parts Layout. Insert the disconnected connectors into the P.C.B.P10533R. Screw the front panel in position.
3. 4. 5.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.5 How to Solve an Error WARNING Observe the following to prevent electrical shock.
When touching live electrical parts, critical electric shock and burn may occur. Do not touch live electrical parts inside or outside the welding machine. Grounding to the case of the welding power source should be performed by persons qualified electric work and according to the laws and regulations in your area. When touching the parts inside the welding power source, wait more than three minutes after powering off all input power supply by turning off the line disconnect switch in the switch box. If an error occurs during use, an error code shown in the displays on the front panel blinks, then the welding power source stops automatically. In this case, check the errors in the following table. When using this product with a robot of our company, refer to Application (arc welding) in owners manual of the robot. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Displays on the front panel Left Right dAI HEn E000 E100 E200 E210 E300 E510 E600 E700 E710 E751 E800 E810 E820 E830 E9xx Classification of errors Torch switch off state waiting Operation Stop Control power supply error Primary / secondary current detection error Error in the voltage detection Thermal overload Water cooling unit error Battery low (warning) Output over current Lack of phase Secondary side over voltage Encoder in the wire feeder error Thermal overload in the governor circuit Motor over current (warning) Motor over current (error) Microcomputer error
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 1) dAIHEn Display If dAI and HEn in the displays blink, it indicates the Torch switch off state waiting. When turning on the power switch, the displays on the front panel shows dAI and Hen for one second, then the welding power source becomes operable. But, if the torch switch remains on, the safety circuit will function, the welding power source will hold a halt condition, then the WARNING lamp and "dAI and HEn" shown in the displays will blink. In this case, turn off the torch switch to reset the safety circuit and make the welding power source operable. 2) E-000 Display If E- and 000 in the displays blink, it indicates the Operation Stop . When disconnecting the wiring of the STOP terminals (Operation Stop terminals: wiring number 143) on the 12P external connection terminal block, E- and 000 in the displays blink and the welding power source stops. In this case, after turning off the power switch and eliminating the possible causes of the stoppage of the welding power source, short-circuit the STOP terminals and turn on the power switch to cancel the error. NOTE: When canceling Operation Stop, it is also possible to solve the error only by shortcircuiting the Operation Stop terminals again without start the welding power source up again. Refer to Section 10.2.1 (4), Selecting Auto/Semi-auto. 3) E-100 Display If E- and 100 the displays blink in, it indicates the " Control power supply error ". If there is an error in the control power source, the warning lamp will light up and E- and 100 in the displays will blink, then the welding power source will automatically stop. To cancel the error, start the machine up again. 4) E-200 Display If E- and 200 in the displays blink, it indicates the " Primary/Secondary current detection error ". If an error is detected in the current detecting area, E- and 200 in the displays will blink and the welding power source will stop automatically. In this case, turn off the power switch, then turn it on again after making sure that CN8 and CN9 on the printed circuit board P10537U are surely connected. 5) E-210 Display If E- and 210 in the displays blink, it indicates the "Error in the voltage detection". If there is an error in the plus voltage detection line (+), the warning lamp will light up, E- and 210 in the displays will blink, then the welding power source will stop automatically. In this case, after checking to make sure that the wire feeder control cable (10P) is not damaged and that CN6 and CN10 on the printed circuit board P10537T, CN23 and CN 24 on the printed circuit board P10537U, and CN 1 on the printed circuit board P10537X are surely connected, start the machine up again. And check the no-load voltage at output terminal of welding power source. Moreover, check that the setting of F12 is off. 6) E-300 Display If E- and 300 in the displays blink, it indicates the "Thermal overload" If the actual duty cycle exceeds the rated duty cycle of or temperature inside the welding power source increases, "E- and 300" will blink and the welding power source will stop automatically. At this time, the temperature lamp also will be lit. In this case, wait more than 10 minutes with the power switch pressed and the fan turned. When restart welding, turn off the power switch and restore the system after lowering the duty cycle and the welding current. Such action will cancel the error. Repetitious welding without more than ten-minute rest may lead to damage to the welding machine. Refer to Section 3.1, Rated Duty Cycle for the rated duty cycle of the welding power source.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 7) E-510 Display In the case of connecting connector CON4
If E- and 510 in the displays blink, it indicates the Water cooling unit error. Then the welding machine will automatically stop. In this case, check to make sure that the watercooled hose does not leak water and that adequate cooling water is going through the hose. When set the switch of the front panel Water and connected the relay contact of water pressure between CON4 -, contact between CON4 - is Open makes E-510 light up. When using an air-cooled torch, make sure that the TORCH lamp on the front panel is OFF (AIR). 8) E-600 Display If "E- and 600" in the displays blink, it indicates the "Battery low (warning)". This welding power source uses batteries so that it can hold the welding conditions in memory even when no operation is carried out for long time. E- and 600 in the displays blink when the batteries get low. E- and 600 are displayed only when the front panel and the welding power source are temporarily not in use. To cancel the display of the error , press any key. Even when E- and 600 appear in the displays, welding can continued to be performed, but when the batteries run down, the preset welding condition functions and the settings of functions are all erased. The last welding conditions before power is applied to the welding machine can not be stored. Each time power is applied to the equipment, all the parameters are reset to initial values. Refer to Section 12.4, Replacement of batteries for details. 9) E-700 Display If E- and 700 in the displays blink, it indicates the Output over current. If an overcurrent or short circuit on the secondary output continues for more than one second during welding, the WARNING lamp lights up, E- and 700 in the display blinks, then the welding power source stops automatically. In this case, turn off the control power switch and check to make sure that the welding current does not exceed the rated output value, or that there is no short circuit on the output side such as a contact between the tip and the base metal, or a short circuit of the output cables. 10) E-710 Display If E- and 710 in the displays blink, it indicates the Lack of phase. If a lack of phase is detected at the primary input, the warning lamp will light up, E- and 710 in the displays will blink, and then the welding power source will stop automatically. In this case, make sure that there is no lack of phase in primary input voltage. 11) E-751 Display If E- and 751 in the displays blink, it indicates the Secondary side over voltage, restriking circuit temperature error. 1) When LED (PL1) of printed circuit board P10537S lights When the surge voltage of the secondary transistor rises abnormally because of the extension cable use etc.; the abnormal indicator lights, E- and 751 in the displays blink, and the welding power source stops automatically. In this case, after following the 10.1.9 Notice of using AC pulse mode, turn on the power switch again. 2) When LED (PL1) of printed circuit board P10510S does not light When the semiconductor temperature of the printed circuit board P10537S restriking circuit rises abnormally; the abnormal indicator lights and E- and 751 in the displays blink, and the welding power source stops automatically. In this case, confirm whether the fan of printed-circuit board P10537S rotates.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12) E-800 Display If E- and 800 in the displays blink, it indicates the Encoder in the wire feeder error. If there is an error in an encoder feedback signal for detecting the feeding rate of wire feeder, the warning lamp will light up, E- and 800 in the displays will blink, and then the welding machine will stop automatically. In this case, make sure that there is no damage in the encoder connector (4P) on the top of the motor inside the wire feeder, the control cable for the wire feeder (10P), and the printed circuit board P10533Q. 13) E-810 Display If E- and 810 in the displays blink, it indicates the Thermal overload in the governor circuit. If thermal overload in governor circuit (printed circuit board P10533Q) is detected, the WARNING lamp will light up, E- and 810 in the displays will blink, and then the welding machine will stop automatically. In this case, check for defective printed circuit board P10533Q, short circuit on the motor power supply lines, rough feeding of wire, and error in the torch or the wire feeder. 14) E-820 Display If E- and 820 blink in the displays, it indicates the Motor over current (warning). Contact resistance to the feeding parts causes motor current to increase. If the motor current exceeds 70% of the rated duty cycle, E- and 820 in the displays will blink only while no operation at the front panel is carried out. When pressing any key or starting welding again, E and 820 in the displays will disappear (, but welding power source does not stop automatically). In this case, check for short circuit in the motor power transmission line, rough feeding of wire, and an error in the torch or the wire feeder. Refer to Section 10.2.1(10) Setting of Feed Motor Load Current Error Detection Level. 15) E-830 Display If E- and 830 in the displays blink, it indicates the Motor over current (error). If short circuit in the power line to the motor or motor overload happens, E- and 830 in the displays will blink and the welding machine will automatically stop. In this case, check for short circuit in the power supply line, rough feeding of the wire, and an error in the torch or the wire feeder. 16) E-9XX Display If E- and 9XX in the displays blink, it indicated the Microcomputer error. There could be an error in the built-in microcomputer, Please contact your dealer immediately. When contacting your dealer, you are required to provide the details of the problem you are facing.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.6 Troubleshooting When an error code is displayed, refer to Section 11.1, How To Solve an Error. Check the troubleshooting information listed below before contacting your dealer for service. No. Trouble Cause Solution The power Never turn it on again. Contact your dealer. switch on 1 the front panel is tripped. When turning on Trouble with PL1. Inspect PL1. The main power lamp the power switch, the displays light. PL1 does not light. The line disconnect switch in Inspect the power When turning on 2 the switch box is not turned box. the power switch, on. nothing appears in the display. The input cables are not Inspect the input surely attached. cables. The main power Refer to No.2 in this list. When lamp PL1 does not turning on light. the power switch, Shortage of the input voltage Check for proper 3 nothing input voltage. appears in PL1 lights. Trouble with the power circuit. After inspecting, PCB the display. P10532Q, replace it if necessary. When turning on the power switch, Refer to Section 11.1, How the WARNING and To Solve an Error. 4 TEMPERATURE lamps light up and an error code appears in the display, Shield Gas is not generated The discharge valve of the Open the valve. gas is not when the GAS gas cylinder is closed. generated CHECK key is Lack of gas pressure of the Check for proper gas when the pressed. gas cylinder. pressure. torch Trouble with the gas Inspect the gas switch is 5 electromagnetic valve SOL. electromagnetic valve pressed. SOL. Gas is generated Disconnection of the torch Check the wiring when the GAS switch cable or incomplete number 306 and 307. CHECK key is insertion to receptacle. pressed. Shield gas does not stop. 6 The GAS CHECK lamp lights up. Trouble with the gas solenoid valve SOL When the torch switch is pressed, no-load voltage is not output but shield gas is generated. 7 Trouble with the inverter main circuit Trouble with the control circuit Stop gas checking by pressing the GAS CHECK key. Check for operation of the gas solenoid valve in wire feeder. Turn off the power switch, then contact your dealer. After inspecting PCBP10265P or P10537U replace it if necessary.
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No. P10537 12. MAINTENANCE AND TROUBLESHOOTING (continued) No. Trouble Current and voltage can not be set. Cause Trouble with the control circuit Trouble with the filter circuit 8 Trouble with the remote control Error in wire voltage detection Wire is not fed. Incomplete insertion or breaking of the control cable for wire feeder Trouble with the motor control circuit Trouble with the filter circuit WCR keeps working. 10 Trouble with the hole current detector CT2 Trouble with the WCR circuit Solution After inspecting PCB P10265P or P10537U and replace it if necessary. After inspecting PCB P10537T, replace it if necessary. After inspecting the cable/plug for remote control or the remote control, replace them if necessary. Inspect connections of CN23 and CN 24 on PCB P10537U or CN1 on PCB P10537X. After inspecting the contacts of the plug and cable, replace them if necessary. After inspecting PCB P10533Q, replace it if necessary. After inspecting PCB P10537T, replace it if necessary. Inspect the hole current detector CT2. After inspecting PCB P10532P, replace it if necessary.
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No. P10537
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No. P10537
12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.7 Schematic Diagram
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No. P10537
12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.7 Schematic Diagram
(P10265P)
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No. P10537
12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.8 Parts layout
Under Frame C15 CT2 Panel C11 DR10 R51a,b R52a,b R44,45
THP4
CON3,4 TR9 C10 TR8 TR10 R38 SH R39
TR7
Around TRLeft Side

TR7 TR8 TR10 SH
L2 T1
Front Panel
Heat sink Heat sink FM2
PCB9 DR11,12 R35 DR9 DR8 TR6 TR5 C14 TR1,2 THP3 DR11 Heat sink L1 Heat sink FM1 PCB6 DR1 DR25 CR1 R53 DR13 DR14 PCB4 R50 PCB10 DR12 PCB15
Bottom Chassis
C9 SCR1 R36 C8
TR3,4 R48
R49
PCB1
Around TRRight Side

TR6 TR5
PCB2
PCB13
Middle Chassis
TM1 TM2
PCB14
Front Side
THP2
Rear Side
R41,42
PCB11 PCB3
T2 LF1
Around
C12 R47 R29a,b C6 PL1
PCB8
PCB5 THP1 C13
NF1 FM1
Top Chassis
CON1, PCB7 PCB12 DR1 R30a,b DR25 C7
,
CON2, FM2
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No. P10537
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No. P10537 13. PARTS LIST Please contact your dealer to order parts. (See the back cover for telephone and fax numbers, and mailing addresses.) Symbol Part No. Description Specifications Qty Remarks NF LF1 PL1 DR1 DR25,8 DR9 DR1012 DR13 DR14 TR14 TR58,10 TR9 SCR1 CT1 CT2 T1 T2 L1 L2 L3,4,6,12 L5,8,9 L10,11,13,14 L7 L15,16,17 L18 L19,20,22 L21 L23 L24 THP1 THP2 THP3 THP4 FM12 SH CR1 4614-101 K5610B00 100-0171 4531-716 4531-308 100-0200 4531-308 100-0188 100-0172 100-0173 100-0174 4534-402 4530-137 4810-030 4406-009 P10537B00 100-0004 P10322L00 P10537C00 4739-497 4739-543 4739-497 4739-358 4739-497 4739-579 4739-543 4258-040 4614-057 4614-051 100-0123 P30016L00 4403-134 4341-139 Circuit protector Line filter Neon lamp DR and SCR complex module High speed diode module Diode High speed diode module Diode Bridge diode IGBT module IGBT module IGBT Thyristor Current transformer Hole current detector Inverter transformer Auxiliary transformer Input reactor DC reactor Ferrite core Missing number Ferrite core Ferrite core Missing number Ferrite core Missing number Ferrite core Clamp filter Ferrite core Thermostat Thermostat Thermostat Thermostat Fan Meter shunt Relay CB3-X0-10-072-42D-C K5610B00 N46010A7KW-01(RoHS) DFA100BA160 DBA200UA60 S2L60-5000 DBA200UA60 D1N60-5060 D5SB60-7000 CM150DU-24NFH-300G CM400DY-12NF-300G 1MBH50D-060 SG25AA60 W-W03029A HA400S3EH P10537B00 W-W03029A P10322L00 P1057C00 E04RA400270150 E04RA310190100 E04RA400270150 RI-17.5-28.5-10.7 E04RA400270150 ZCAT3035-1330 E04RA310190100 67L085 67L080 67L090 US-602SXTTAS 130C P30016L00 SH400A 400A/60mV G2R-1-T DC24V 1 1 1 1 5 1 3 1 1 4 5 1 1 1 1 1 1 1 4 4 3 1 1 1 1 1 1 1 2 1 1
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No. P10537 13. PARTS LIST (continued) Symbol R14 R5,6 R712 R1320,43 R2128 R2930 R3134 R35 R36,38 R37,40 R39 R41,42 R43 R44,45 R46 R47 R48 R49,50 R5152 R53 C15 C6, 7 C8 C9 C10 C11 C12 C13 C14 C15 CON1 CON2 CON3 CON4 TM1 TM2 Part No. 100-0175 4509-704 4508-317 100-0176 4509-916 4509-704 4504-944 4509-922 4508-317 4509-905 4509-704 4509-819 4509-825 4504-325 4509-109 4518-528 4518-402 100-0177 4518-497 100-0086 4518-402 4518-530 Description Surge absorber Missing number Carbon resistor Carbon resistor Missing number Metal film resistor Missing number Cement resistor Carbon resistor Missing number Wire wound resistor Cement resistor Carbon resistor Cement resistor Missing number Carbon resistor Cement resistor Cement resistor Wire wound resistor Metal oxide film resistor Missing number Film capacitor Film capacitor Aluminum electrolytic capacitor Film capacitor Film capacitor Specifications ENE911D14A RD1/4W 1kJ RD1/2W 3kJ RNP-50SCZ00 10F T20SH 2.2JA RD1/4W 1kJ KNP1W 10 20SH 10JA RD1/2W 3kJ MHR20A513JI RD1/4W 1kJ 40SH 200J 20SH 15kJ NCRF 24V 20J RS1B 51k US20X103JAASA 0.47F 50V LWA2N601MSEAZO DHS630V103JSL EM351200D0BA2HP 0.47F 50V US16X154JAASA W-W02212A CS17-F2GA103MYAS HS25R-10 (71) 25-6BK-Z P10511X02 P10542X04 TB10-01 8P TB10-01 12P Qty 4 6 9 4 1 2 1 2 1 2 1 1 2 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2200F 400V 20F 350VDC Remarks
Film capacitor Film capacitor Aluminum electrolytic 4511-251 capacitor 4517-401 Ceramic capacitor 100-0103 Metal consent receptacle 100-0178 Metal consent receptacle P10511X02 Cable with 3P connecter P10542X04 Cable with 6P connecter 4739-616 Terminal block 4739-505 Terminal block
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No. P10537 13. PARTS LIST (continued) Symbol PCB1 PCB2* PCB3 PCB4 PCB5 PCB6 PCB7 PCB8 PCB9 PCB10 PCB11 PCB12 PCB13 PCB14,15 Plug for Plug for Part No. Description P10537U00 Printed circuit board P10265P00 Printed circuit board P10532Q00 P10532V00 P10537T00 P10537M00 P10533Q00 P10533R00 P10537R00 P10537X00 P10532S00 P10537S00 P10537V00 P10487P00 4739-474 4739-604 4735-038 4735-039 100-0201 P10511W02 4739-476 P5801G03 P10263G12 P10261J01 P10263J02 4734-007 4734-025 4734-026 P10261G23 4519-030 4519-031 Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Printed circuit board Grommet with film Grommet with film Knob Cap Fixing caster Control panel sheet Cap Carrying Handle Bush Front cover Control panel cover Machine socket Power cable connector Power cable connector Bush Filter kit Dust filter Specifications P10537U00 P10265P00 Qty 1 1 Remarks Refer to NOTE below.
P10532Q00 1 P10532V00 1 P10537T00 1 P10537M00 1 P10533Q00 1 P10533R00 1 P10537R00 1 P10537X00 1 P10532S00 1 P10537S00 1 P10537V00 1 P10487P00 2 W-W02805 3 C-30-SG-32A 1 K-100 22RSB 1 For adjusting K-100 22CSBL 1 knob 420SR-RD50 CR3 4 P10511W02 1 W-W02814 2 P5801G03 2 P10263G12 4 P10261J01 1 P10263J02 1 DIX BE 50/70 2 Output terminal 2 DIX SKK 70 1 For 60mm cable 2 DIX SKK 95 1 For 80 mm cable P10261G23 1 109-1000F13 2 With fan guard 109-1000M13 2 Filter only G6B-1114P-FD-US Relay 4341-308 1 For PCB11 DC24V *NOTE: When ordering a printed circuit board P10265P00, provide the software version on a label below a nameplate attached to the rear side of the welding power source.
P10511 Ver. ###.###.000 Replace the ###.### with software version.
Parts list for analog remote control (optional accessories) Symbol Part no. Description Specifications R1,2 4501-039 Variable resistor RV24YN20SB 5K R3 100-0487 Register RD20STP-52 12 PB 4250-077 Push button switch A2A-4R 4730-009 Metal socket plug DPC25-6A 4735-007 Knob K-2195large
Qty 2 1 1 1 2
Remarks
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No. P10537
14. SPECIFICATIONS 14.1 Specifications 1Welding power source Model Specifications Model Number of phase Rated frequency Rated input voltage Input voltage range Rated input power Rated input current Rated output current Rated load voltage Rated output current range Rated output voltage range Maximum no-load voltage Rated duty cycle Number of welding condition Temperature rise Usable temperature range Usable moisture range Storage temperature range Storage moisture range External dimensions(W x D x H) Mass
Digital Inverter DW300 DW-300 3 50 / 60 Hz 400 V 400 V 15% 18kVA, 16 kW 19 A 300 A 29 V 30 - 300 A 12 36 V 81 V 80% 100 +160 C (+320 F) -10 +40 C (+14 - +104 F) 20 80% without dew condensation -10 +60 C (+14 - +140 F) 20 80% without dew condensation 300 mm x 705 mm x 595 mm without the carrying handle 66 kg
The welding power source complies with the requirements of IEC60974-1, IEC60974-10 and directive 2002/95/EC (RoHS).
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No. P10537 14. SPECIFICATIONS (continued) 14.2 External View
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No. P10537 This page is intentionally left blank.
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No. P10537 14. SPECIFICATIONS (continued) Initial Values and Setting Range of Parameter Pre-flow time Initial value 0.1 second 20 A 12 V 0 0.4 second 3 seconds 0 3 Hz 0 1 Initial value OFF AC pulse MIG AL/MG Setting range 0 10 seconds 20 400 A 10 45 V -30 30 0 10 seconds 0.1 10 seconds -10 10 0.5 32 Hz -30 - 30 1 100
Initial condition Main condition Crater filler condition

Post-flow time Arc spot time Arc characteristic Wave frequency EN ratio JOB MEMORY numbers Function Crater Welding method Wire/Gas Wire diameter Initial current Adjustment of
Current Voltage Fine adjustment of voltage
Front Panel
[21] [20]
[19]
[4]
[13]
[8]
[5]
[6]
[9]
[10]
J OB W AR N IN G M EM O RY
LO AD
A m /m in S e c H z
%
J O BN O .
Setting item OFF / ON / ONrepeat/ SPOT AC pulse / AC wave pulse DC pulse / DC wave pulse AL/PURE MIG / AL/MG MIG / CuSi MIG / CuAl MIG / STAINLESS STEEL MIG / MILD STEEL MIG / MILD STEEL MAG
SAVE
A
m /m in
ARC C O N TRO L
T2
EN TER
T1
INITIAL C O N D ITIO N O N
DISPLAY C H AN G E
SYN ER G .
SYN ER G . IN D IV.
CRATER -FILL. C O N D ITIO N W ATER
f
W AVE FR EQ .
1.2 0.8 / 0.9 / 1.0 / 1.2 / 1.6 OFF ON/OFF welding SYNERGIC SYNERGIC / INDIVIDUAL Internal Functions (Function <Refer to Section 10.2.1, Using of internal functions >
Memory* Initial value
G AS C H EC K
O FF
IN ITIAL C O N D .
0. 8 0. 9
W ELD M O N IT O R
(O PTIO N)

VO LT. C O N TR O L TO R C H AL/PU R E
MI G
EN R ATIO
Setting range
-50(0.50 second down) 50(0.50 second up) -9.9 9.9 V -1.0 1.0 m/min. 2 (Automatic mode 2) / 1 (Automatic mode 1) / 0 (Semi automatic mode) ON(VALID) / OFF(INVALID) 0 10.0 seconds
AC PU LSE AC W AVE PU LSE D C PU LSE D CW AVE PU LSE O P1 O P2

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Fine adjustment of anti-stick (burnback) time* Fine adjustment of anti-stick (burnback) voltage* Fine adjustment of slow-down speed* Selection of automatic/semi-automatic
0 0.0 0.0 0
AL/MG C uSi C uAl
O N
1. 0 1. 2 1. 4 1. 6
IN C H IN G
R EPEAT
MI G
STAIN LESSSTEEL M ILDSTEEL
SPO T
M AG
M ILDSTEEL
External command 10VMAX OFF Setting of up-slope time* 0.0 0 10.0 seconds Setting of down-slope time* 0.0 5 60 seconds Result display holding time 20 200/350 Selection of scale plate of analog remote control 350 20 150 % Feed motor load current error detection level 70 Fine adjustment of Job Memory Fine ON(VALID)/OFF(INVALID) F11 OFF Adjustment F12 Arc voltage direct detection ON/OFF selection OFF ON(DIRECT)/OFF(TERMINAL) -150 A 150 A F13 Fine adjustment of pulse peak current* 0 -1.5 (ms) 1.5 (ms) F14 Fine adjustment of pulse peak time* 0 -60 A 60 A F15 Fine adjustment of base current* 0 -150 A 150 A F16 Fine adjustment of L pulse peak current* 0 -1.5 (ms) 1.5 (ms) F17 Fine adjustment of L pulse peak time* 0 -60 A 60 A F18 Fine adjustment of L pulse base current* 0 ON(VALID)/OFF(INVALID) F19 Turbo Start ON/OFF selection ON F20 - F23 are also available and refer to section 10.2.1 Using internal function (15)-(18) *Welding conditions which can be preset to a JOB MEMORY number.
SPO T TIM E
CRATER FILL.
W IRE DIA.
m Refer tomanual for m
recom m ended shielding gases
[17] [18]
[11]
[7]
[12]
[3]
[14]
[15] [2]
[16]
[1]
[22]
[1] WELDING METHOD selector key [2] Wire material/gas selector keys [3] WIRE DIA (mm) selector key [4] Current setting display selector key [5] Voltage setting display selector key [6] Parameter adjusting knob [7] Crater selector key [8] DISPLAY CHANGE key
[9] Arc characteristic setting key [10] WAVE FREQ. setting key [11] Arc spot time setting key [12] F (FUNCTION) selector key [13] Initial condition selection key [14] Synergic/Individual selector key [15] Torch selector key [16] Weld monitor key (Option)
[17] GAS CHECK key [18] INCHING key [19] LOAD key [20] SAVE key [21] ENTER key [22] EN ratio setting key
- 95 -
No. P10537
14. SPECIFICATIONS (continued) QUICK MANUAL Refer to Section 10.1, Basic Settingsand Section 10.2, Applied Settings.
Discontinue
Press the LOAD key. Set the welding condition number while
Before Using the Welding Power Source

Settings of Welding Method Set a welding method, wire/ shield gas, then wire diameter by using the WELDING METHOD key, the WIR/GAS selector keys, and the WIRE W IRE DIA. diameter(mm) key respectively. 2. Settings of Crater/Arc Spot
0. 8
AL/P UR E C uSi

IN C H IN G
1.
SPO T TIM E
A C PU LS E
0. 9
MI G
A L/MG C uAl
1. 0 1. 2 1. 4 1. 6
A CW AV EP U LSE DC PULSE O P 1 O P 2
When adjusting SPOT TIME, press the SPOT TIME key, then set SPOT TIME while turning the parameter adjusting knob. [ON]: SPOT TIME lamp is on. [OFF]: SPOT TIME lamp is off. To adjust the desired arc characteristic (HARD/SOFT), after turning on the ARC CONTROL lamp by pressing the ARC CONTROL key, set the level of the arc characteristic. [ON]: ARC CONTROL lamp is on. [OFF]: ARC CONTROL lamp is off. When the welding method is wave pulse, to obtain the desired bead appearance after turning on the WAVE PULSE lamp by pressing the WAVE PULSE key, set the wave pulse while turning the parameter adjusting knob. [ON]: WAVE PULSE lamp is on. [OFF]: WAVE PULSE lamp is off.
turning the number parameter adjusting knob. condition are retrieved.
Releasing the key protection
Hold down the ENTER key + the F key at a time for a few seconds. When the F lamp turns off, the key protection function is released.
Discontinue
Press the ENTER key.
Press the LOAD key.
DC W A VE PU LS E
MI G
STAIN LESSSTEE L M ILDS TEE L M ILDS TEE L
M AG
m Refer tomanual for m
W E LD IN G M ETHO D
ARC CO NTROL
Presetting the Welding Conditions

1) Pressing the SAVE key enters the save J OB mode. The preset welding condition M EM O R Y number is displayed in the right display and the welding current is displayed in the left display. LO AD 2) Preset the welding conditions to the desired numbers 0 - 100 while turning the parameter adjusting knob. When --SAVE is displayed in the left display, the number you selected is available. When --- is not displayed in the left display, the number you selected is unavailable. In this case, select another number. EN TER Otherwise, the welding conditions preset to the number are erased and overwritten with the welding conditions you newly set. 3) Press the ENTER key to check the parameter preset to the number. 4) When pressing the ENTER key again, the welding conditions are set.
Press the SAVE key.
Press the ENTER key. The readout mode quits.
O FF
O N
Use the CRATER-FILL key to select ( ) )/ SPOT. OFF/ON(-)/ON(

f
W AVE FR EQ .
REPEAT
SPO T
Settings of the (Internal) Functions

1) When holding down the F key for a few seconds, the function mode is activated. The function number blinks in the left display, the function status is displayed in the right display. 2) Set the function number while turning the parameter adjusting knob. 3) When pressing the F key, the function number lights up, then the function status blinks. 4) Set the function status while turning the parameter adjusting knob. 5) To cancel the function mode, hold down the F key for a few minutes.
No. Displays on the front panel Left Right dAI HEn E000 E100 EEEEEEEEEEEEE200 210 300 510 600 700 710 751 800 810 820 830 9xx Classification of errors Torch switch off state waiting Operation Stop Control power supply error Primary / secondary current detection error Error in the voltage detection Thermal overload Water cooling unit error Battery low (warning) Output over current Lack of phase Secondary side over voltage Encoder in the wire feeder error Thermal overload in the governor circuit Motor over current (warning) Motor over current (error) Microcomputer error
CRATER FILL.
3.
Settings of Functions
O N SYNER G .
SYN ER G . IN D IV.
W ATER
IN ITIAL C O N D .
W ELD M O N IT O R
(O PTIO N)
VO LT. C O N TR O L TO R C H
NOTE:
For using INITIAL CURRENT, press the INITIAL CURR.

key to set the function to ON. [ON]: INITIAL CURR. lamp is on. [OFF]: INITIAL CURR. lamp is off.
Turning There
the parameter adjusting knob clockwise increases the parameter. To decrease the parameter, turn the parameter adjusting knob counter-clockwise. may be unavailable parameters in some crater settings and function settings. Refer to Section 10, OPERATION for details.
For
controlling voltage in the SYNERG. way, select SYNERG. by pressing the VOLT.CONTROL key. [SYNERGIC]: VOLT. CONTROL lamp is on. [INDIVIDUAL]: VOLT. CONTROL lamp is off. using a water-cooled torch, select WATER by pressing the TORCH key, then run cooling water. [WATER]: TORCH lamp is on. [AIR]: TORCH lamp is off. WELD
For For
4.
5. Checking the Rate of Gas Flow Open the discharge valve of the gas cylinder, press the GAS CHECK key to check the rate of gas flow. After performing GAS CHECK, G AS C H EC K stop the gas flow by pressing the GAS CHECK key. 6. Inching the Wire After pressurizing the wire mounted on the wire feeder using the pressure roll, feed the wire up to the end of the torch while IN C H IN G using the INCHING key. When pressing the INCHING key again, the wire feeding stops. Now you have completed the preparations that are required to start welding. Press the torch switch to start welding. Protecting the Keys and Releasing the Key Protection
Discontinue
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Discontinue
using weld monitor function, push the MONITOR key for a while. Settings of Parameter
W AR N IN G
A m /m in S e c H z
Press the LOAD key.
Press the ENTER key. The memory mode quits.
Loading the Welding Conditions

1) Pressing the LOAD key enter the load mode. The preset welding condition number is displayed in the right display and the welding current is displayed in the left display. 2) Preset the welding conditions to the desired numbers 0 100 while turning the parameter adjusting knob. When --- is displayed in the left display, no welding conditions are preset to the number you selected. 3) Press the ENTER key to check for the parameter preset to the number. 4) When pressing the ENTER key again, the welding conditions preset to the welding
%
J O BN O .
A
m /m in
T1 INITIAL C O N DITIO N
M AIN C O ND ITIO N
ARC C O N TRO L
T2
DISPLAY C H AN G E
CRATER -FILL. C O N D ITIO N
Use the DISPLAY CHANGE key to select the parameter you want to set, then adjust it while turning the parameter adjusting knob. When changing the parameter unit in the display, use the A or V selector key.
m /m in
Protecting of the keys

EN TER
Hold down the ENTER key + the F key at a time for a few seconds. The F lamp starts blinking. Blinking of the F lamp means the welding machine is in the key protection mode. - 96 -
When using this product with a robot of our company, refer to Application (arc welding) in owners manual of the robot.
No.P10537 15. SERVICE AND SUPPORT Please contact your local dealer for service. (See the back cover for telephone numbers, fax numbers, and mailing addresses.) NOTE: 1) See Section 12, MAINTENANCE AND TROUBLESHOOTING before contacting your dealer for service. 2) When contacting your dealer for service, you are required to provide the following information:
Address Name Telephone number Product model Manufacture year Serial number Software version number Details of troubles
MODEL: DW-300 DATE: 20XX SERIAL NO.: P10537YXXXXXXXXXXX P10511 Ver ###.###.000
- 97 -

DW 300 (P10537 8)

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MANUAL NO:P10537-8

DIGITAL INVERTER DW300

INVERTER CONTROLLED WELDING POWER SOURCE

WELDING PRODUCTS DIVISION September 26, 2008

Upon contact, advise MODEL and MANUAL NO.

2. ARC WELDING SAFETY PRECAUTIONS

2. ARC WELDING SAFETY PRECAUTIONS (continued)

2. ARC WELDING SAFETY PRECAUTIONS (continued)

2. ARC WELDING SAFETY PRECAUTIONS (continued)

PRINCIPAL SAFETY STANDARDS

Operation cycle of 80% duty cycle

The duty cycle of the welding power source is

For use of exceeds rated voltage, duty cycle is

No. P10537 4. STANDARD COMPOSITION AND ACCESSORIES 4.1 Standard composition

For air cooling torch

Digital remote control Optionally available

Gas hose 3m Control cable for wire feeder 2m

Power cable for wire feeder 2m

Welding power source

Ground a work piece if a local law requires.

Power cable for wire feeder 2m

Welding power source

Ground a work piece if a local law requires.

Carbon dioxide gas (CO2 gas)

Carrying handle Parameter adjusting knob

Grommets with film (for pulling out external connection cables)

5.1 Welding power source

Main power lamp

- 10 Power switch Input cable

Socket for wire feeder

Socket for analog remote controller

Cap Cooling fan

Output terminal (connect to the base metal)

DW-300 400V, Three phase 400V15% 18kVA or more 30 A

No. P10537 7. TRANSPORTATION AND INSTALLATION (continued)

Power cable for wire feeder

Control cable for wire feeder

Welding power source

Ground a work piece if a local law requires.

When using the water-cooled torch

Ground a work piece if a local law requires.

Nut for attaching gas cylinder

Mount a switch with fuse or a circuit breaker on each welding machine.

Place the power switch in the I (ON) position.

CRATER -FILL. CO ND ITIO N W ATER

VO LT. CO NTRO L TO R C H AL/PU RE

AC PU LSE AC W A VE P ULSE D CP ULS E D CW AVE PU LSE O P1 O P2

AL/MG C uSi C uAl

Parameter adjusting knob

M AIN CO NDIT ION

CRATER -FILL. CO NDITIO N W ATER

VO LT . CO NTRO L TO RCH AL/PURE

AC PU LSE AC W AVE PULSE D C PULSE D CW AVE PU LSE O P1 O P2

AL/MG C uSi C uAl

ST AIN LESSSTEEL M ILDSTEEL M ILDSTEEL

Wire extension is too short. Welding voltage is too high.

Welding voltage is too low.

Welding current is too high. Travel speed is too fast.

Wire extension 12-15 15 15 15 15-18

Gas flow rate (liter/min) 20 20 20 20 20

Travel speed (cm/min) 60 60 50-60

Gas flow rate (liter/min) 15-20 15-20 20