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TABLE OF CONTENTS 

1. SAFETY 

INFORMATION…………………………………………………………… 2

2.  ARC WELDING SAFETY PRECAUTIONS………………………………………

2

3.  GENERAL NOTICE OF OPERATION…………………………………………….. 8

4.  STANDARD COMPOSITION AND ACCESSORIES……………………………

9

5.  FUNCTION OF EQUIPMENT……………………………………………………… 10

6.  NECESSARY POWER SOURCE EQUIPMENT………………………………… 12

7.  TRANSPORT AND INSTALLATION……………………………………………… 13

8.  CONNECTION PROCEDURE AND GROUND FOR SAFETY USE………….. 15

9. WELDING 

PREPARATION………………………………………………………… 21

10. OPERATION…………………………………………………………………………. 27

11. APPLIED FUNCTION……………………………………………………………….. 58

12.  MAINTENANCE AND TROUBLESHOOTING…………………………………… 67

13. PARTS LIST…………………………………………………………………………. 74

14. SPECIFICATIONS…………………………………………………………………... 77

15. SERVICE AND SUPPORT………………………………………………………… 82

 

Summary of Contents for DA300P

Page 1: ...hout 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 equipmen...

Page 2: ...AND ACCESSORIES 9 5 FUNCTION OF EQUIPMENT 10 6 NECESSARY POWER SOURCE EQUIPMENT 12 7 TRANSPORT AND INSTALLATION 13 8 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE 15 9 WELDING PREPARATION 21 10 OPER...

Page 3: ...al 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...

Page 4: ...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 Remov...

Page 5: ...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...

Page 6: ...RE 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 This equi...

Page 7: ...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 Public supply syste...

Page 8: ...ety 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 St...

Page 9: ...ycle limitations may cause the temperature inside the welding power source to excess tolerance levels This may cause to premature welding power source failure or product damage The figure shown right...

Page 10: ...connector DIX SK 50 1 4734 016 For base metal and holder cable 4 3 Other Equipment 1 TIG Welding Use argon gas for welding with 99 9 or more purity Use the proper filler wire for material plate thick...

Page 11: ...m et with film For pulling out external connection cables Rubber feet t f C R AT ER F I L L SPO T TIM E G A S CH EC K OF F O N REPEAT SPOT WELDING METHOD ON O N O N ON WATE R TOR CH SLO PE INITIAL CU...

Page 12: ...1 5 FUNCTION OF EQUIPMENT continued 5 2 Welding Torch Torch switch 2P Water in hose 5 8 18UNF Gas hose 9 16 18UNF Water out hose 5 8 18UNF Power cable connector Cap Torch body Nozzle Tungsten electrod...

Page 13: ...use product damage Contact an engine welder manufacturer for improvement of voltage waveform To prevent the welding power source from being damaged because of engine generator follow the instructions...

Page 14: ...ding machine follow the instructions below to avoid a fire caused by welding or physical injury from gas fumes Do not place the welding machine near combustible materials or flammable gas Remove combu...

Page 15: ...o not install the welding power source in the place subject to direct sunlight or rain Do not place the welding power source wire feeder torch control unit conduit and control cable including the exte...

Page 16: ...chine with all the line disconnect switches inside the switch box turned off Do not use a cable with lack of capacity or a damaged cable Tighten and insulate the connections of cables Attach the case...

Page 17: ...5 Connect the gas hose to the gas connection 6 Connect the torch switch or foot switch to the socket for torch switch 7 Make drainage treatment when using tap water When using the circulation system...

Page 18: ...l laws or codes 2 Connect the base metal cable to the negative output terminal on the welding power source 3 Connect the holder to the positive output terminal on the welding power source 8 2 Connecti...

Page 19: ...er to the gas cylinder with a monkey wrench etc 3 Securely attach the gas hose to the gas outlet with a monkey wrench etc 8 4 Grounding and Connecting of Input Power Source WARNING Observe the followi...

Page 20: ...s CAUTION Be sure to install a switch with fuse or a circuit breaker for motor to the input sides of each welding machine The following figure shows the cable connections When using the air cooled tor...

Page 21: ...meter water supply hose P1042L00 Tap water kit BBDW 3001 2 Hose connector P1042M02 3 Rubber hose for tap water None 4 Feed water port for water supply hose P1042M01 5 Nipple 1 2 None Not supplied a In...

Page 22: ...c start and unnecessary high frequency CAUTION Use the protective equipment to protect you and other workers from arc rays spattering dross and noise from welding operation When performing or monitori...

Page 23: ...pplied directly to the torch with the welding power source bypassed and the water cooled torch is used with the torch selector key set at air side it cannot be detected whether cooling water is flowin...

Page 24: ...0 3 4 1 a b 1 0 1 6 0 1 6 60 90 3 4 1 a b 1 6 2 4 1 6 2 4 80 120 3 4 1 b 2 4 2 4 3 2 2 4 3 2 110 150 4 1 b 3 2 3 2 4 3 2 4 8 140 200 4 5 1 c 4 0 3 2 4 4 8 4 0 4 8 180 250 4 5 1 d c 4 8 4 4 8 4 8 6 4 2...

Page 25: ...A Frequency Hz Pulse Width Mild Steel spcc 0 1 2 1 6 200 150 130 50 20 20 2 5 1 5 1 50 46 50 60 30 15 60 60 40 Stainless Steel SUS304 0 1 2 1 6 2 0 150 150 130 130 50 20 20 20 3 1 1 0 8 0 8 50 35 30 3...

Page 26: ...rent A Base Current A Pulse Freq Hz Pulse Width Feeding Speed cm min Copper Mild Steel 1 250 50 0 8 20 10 60 Cu Stainless Steel Mild Steel 1 170 60 2 5 50 50 60 SUS Mild Steel 1 120 50 2 50 20 30 Stai...

Page 27: ...1 5 3 2 3 0 6 0 70 80 90 85 170 170 220 25 40 25 25 25 25 25 1 1 1 1 1 1 1 50 50 50 50 50 50 50 1 6 1 6 1 6 1 2 1 2 1 6 1 6 75 95 75 95 290 170 250 6 0 180 25 1 50 1 6 250 3 2 6 0 170 220 25 25 1 1 5...

Page 28: ...key 14 SLOPE selection key 7 AC BALANCE key 15 TORCH change over key 8 AC DC change over frequency set up key 16 GAS CHECK key t f CRATER FILL SPO T TIM E G AS C H E C K O FF O N REPEAT SPO T W E LD I...

Page 29: ...operating instructions described below unfold page section 14 so that you can read them confirming the location of the keys on the front panel 10 1 TIG Welding 10 1 1 DC TIG Welding Set the welding p...

Page 30: ...of the parameter adjusting knob 4 3 Upslope time This parameter may be selected only if both initial current and slope settings are ON When this parameter is selected the set value appears on the righ...

Page 31: ...arameter adjusting knob 4 8 Crater current This parameter may be selected only if the crater setting is ON ON REPEAT or ARC SPOT When this parameter is selected the set value appears on the left digit...

Page 32: ...h cleaning action is obtained and the direct current period during which deep penetration is obtained are outputted alternately in a cyclical manner This type of welding is suitable mainly for automat...

Page 33: ...e below winding method of excess cable and make two windings in opposite direction each other and pile up one on another Winding method of excess cable 1 2 3 Top view Side view Explanation Separate th...

Page 34: ...ive for thin plate butt welding etc Also the arc sound level is low Maximum welding current is 200A CAUTION If the welding current exceeds 200A in the hard mode the bead width is larger than the AC ba...

Page 35: ...setup and welded results electrode consumption extent or degree is as shown in the table below EN refers to the period in which the base metal is positive in polarity and the torch is negative in pol...

Page 36: ...ency setup and filler wire insertion interval is as shown in the table below When frequency is low The insertion interval is long The ripple spacing becomes wide For low speed welding 1 Manual inserti...

Page 37: ...may be selected with the parameter selection key 3 And the welding current becomes the base current Further in case where the welding process used is AC DC TIG no pulse selection key can be selected...

Page 38: ...the SLOPE selection key 10 1 12 Crater setting At the end of welding there remains a dent called crater This dent that might cause cracking or other welding defects must be minimized in size this ope...

Page 39: ...h switch must be held turned ON If the torch switch is turned OFF during crater fill operation it is switched back to welding current again Those switching operation will be repeated cyclically It is...

Page 40: ...adjusted In the modes other than arc spot the arc spot time key may not be selected Torch Switch ON ON OFF Output Current Slope ON Possible adjustable parameters Arc spot time Down slope time Welding...

Page 41: ...or high voltage is generated at the start and no electromagnetic interference is caused Depress torch switch with electrode not contacted with base metal Bring electrode in touch with base metal It is...

Page 42: ...in two minutes after the GAS CHECK key is depressed If the welding started during gas check period the gas flow is to be automatically prevented when the welding is finished after the end of post flow...

Page 43: ...appears on the display the function No will light up while its status indication will start blinking In this state the desired status can be selected with the parameter adjusting knob 4 Function No ap...

Page 44: ...peration sequence so that arcing may discontinue even during arc spot process if the torch switch is turned OFF in ARC SPOT mode To change the sequence in such way the status of Function No 2 should b...

Page 45: ...ol receptacle with MANUAL mode selected When the analog remote control is connected the set values on the remote control have the highest priority regardless of AUTO or MANUAL mode To use Function No...

Page 46: ...function If the status of Function No 6 is set to ON the status of Function No 5 will be automatically set to OFF The following chart shows the relationship between external current control voltage an...

Page 47: ...aration relay It operations when there is no abnormality such as lucking operation stop temperature error and when the power source switch is on Function No 12 is factory setting 2 Pulse synchronizing...

Page 48: ...self holding period in the Crater ON or Crater ON Repeat mode Function No 18 The current change amount is set up by single clicking Function No 19 The current change amount is set up by double clicki...

Page 49: ...s read but also the feeding condition number 2 is read from the feeding condition memory of the TIG filler controller When Function No 21 is turned ON the memory condition is synchronized The factory...

Page 50: ...initial current is OFF welding starts with main current When slope is OFF this function doesn t operate 10 1 18 Analog remote control K5416T optional accessory When the power switch was turned ON the...

Page 51: ...g current may be set with the parameter adjusting knob 4 in the range specified in the table shown below Current range is 10A 250A 10 2 3 Internal function setting The function listed below may be adj...

Page 52: ...ter selection key 3 will start blinking The average display of the output current is possible adjust offset in the range of r10A by Function No 10 Adjustment quantity is added subtracted at the all cu...

Page 53: ...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 an...

Page 54: ...analog remote control are valid 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 pressin...

Page 55: ...the welding conditions to any condition number then carry out readout Reading out the preset welding conditions 1 When pressing the LOAD key 17 the machine enters the readout mode LOAD lamp located a...

Page 56: ...g the parameter adjusting knob Press the parameter selector key to check the parameter value Press the ENTER key The memory mode quits The welding conditions are set to the number you selected Discont...

Page 57: ...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...

Page 58: ...ollowing these steps Turn on the power switch with only the F key 10 held down After powering the welding power source the version number appears in the display Example Right and left displays P10464...

Page 59: ...welding machine 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 foll...

Page 60: ...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...

Page 61: ...ng 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 710 Display If E...

Page 62: ...tc during welding operation Do not pull out the wiring on the printed circuit board to outside except the wiring to the external connection terminal block 11 2 External Connection of Inside Terminal B...

Page 63: ...nning 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 2 WCR OUTPUT Current Detecti...

Page 64: ...the figures shown below Do not confuse the water feeding hose with the condensate hose 2 Air Cooled Torch Model AW P 17 AW 18 AWD 18 AW 26 AWD 26 Rated Current DC 150 A 300 A 200 A AC 130 A 260 A 160...

Page 65: ...1 11m Control Cable for Torch Switch 2 conductors K527K00 1 11m Adapter and connecting cover is equivalent to BAWS 1504 BAWH 1516 Parts for extending AW P 17 cable length 4m to 20m Extension Torch Cab...

Page 66: ...ch 2 conductors K527K00 1 11m Connecting Cover H558M01 1 BAWS 3016 Parts for extending AW D 18 cable length 4m to 20m Extension Gas Hose K527C00 1 16m Extension Water Hose for feeding water K527E00 1...

Page 67: ...grey mark or thoriated tungsten electrode red mark Using DAIHEN cerium tungsten electrode that is hardwearing realizes good arc start and better work efficiency Cerium Tungsten Electrode Part No Elect...

Page 68: ...g 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 awa...

Page 69: ...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 The dust protective filter located on the inlet of...

Page 70: ...fire explosion and rupture Do not charge short circuit disassemble heat deform and or solder batteries Do not throw batteries into a fire Make sure the positive and negative polarity is correctly con...

Page 71: ...r to Section 11 1 How To Solve an Error 5 Shield gas is not generated when the torch switch is pressed Gas is not generated when the GAS CHECK key is pressed The discharge valve of the gas cylinder is...

Page 72: ...o low Set to the proper electrode and current When measuring output voltage in STICK mode no load voltage is generated Trouble with the main circuit of inverter After turning off the power switch cont...

Page 73: ...72 This page is intentionally left blank...

Page 74: ...73 12 MAINTENANCE AND TROUBLESHOOTING continued 12 6 Schematic Diagram P10346P...

Page 75: ...00 THP3 THP2 PCB5 P10535T00 PCB9 P10535R00 PCB3 P10532Q00 L8 PCB4 P10538V00 PCB13 P10541T00 FM2 L2 Bottom Chassis Middle Chassis Top Chassis Rear Panel Back Side of Front Panel Front Panel Behind of F...

Page 76: ...ite core E04RA310190100 1 L4 5 6 4739 497 Ferrite core E04RA400270150 3 L7 4739 497 Ferrite core E04RA400270150 1 L8 4739 497 Ferrite core E04RA400270150 2 L9 14 4739 543 Ferrite core E04RA310190100 6...

Page 77: ...QYX1H474JTP 1 50V 0 47 F CON1 100 0095 Metal consent socket DPC25 2BP Z 1 2P CON2 100 0094 Metal consent socket DPC25 4BP Z 1 4P CON3 P10464X02 Cable with 3P connector P10464X02 1 CON4 P10541X04 Cabl...

Page 78: ...anel sheet P10464W02 1 4739 476 Cap W W02814 2 P5801G03 Carrying handle P5801G03 2 P10263G12 Bush P10263G12 4 P10263J01 Front cover P10263J01 1 P10263J02 Control panel cover P10263J02 1 4734 007 Machi...

Page 79: ...me 0 1 10 sec Down slope time 0 1 10 sec Arc spot time 0 1 10 sec Crater fill operation ON OFF REPEAT Pulse frequency 0 1 500 Hz Pulse peak ratio 50 Changing with F function key from 5 to 95 AC freque...

Page 80: ...79 14 SPECIFICATIONS continued 14 2 External View 398...

Page 81: ...80 This page is intentionally left blank...

Page 82: ...ALID F9 Result display holding time 20 sec 0 60 sec F10 AC ratio 70 10 90 F11 Change of operation sound ON ON VALID OFF INVALID F12 Change of external output terminal 1 1 1 Power preparation 2 Pulse s...

Page 83: ...Conditions 1 Pressing the SAVE key enters the save 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 wel...

Page 84: ...on 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 n...

Page 85: ...Da Dao Shanghai The People s Republic of China Post Code 200120 Phone 86 21 5882 8633 Fax 86 21 5882 8846 OTC Taiwan Co Ltd 2F No 153 Huanbei Rd Chung Li City Taoyuan Hsien Taiwan R O C Phone 886 3 4...

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