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Service Manual No.C0056-1

 

 

 

 

 

 

 

 

SERVICE MANUAL 

 
 
 

DAIHEN DC arc welding power source 

 

 

                             

                             

350/500

 

                     

 

   

CPXD- 350      C0056 
CPXD- 500      C0052 

 
 
 
 
 
 
 
 

 

 
 

DAIHEN Corporation

   

WELDING PRODUCTION DIVISION 

Aug.11.2006 

 

CO

2

/MAG

DYNA AUTO 

NOTE: Ther is a case that contents of thes service 
munual is different  from  the  latest  information  by 
revision  after  product  shipment.  Use  the  owner’s 
manual of this procuct together. 

Summary of Contents for C0052

Page 1: ...PXD 350 C0056 CPXD 500 C0052 DAIHEN Corporation WELDING PRODUCTION DIVISION Aug 11 2006 CO2 MAG DYNA AUTO NOTE Ther is a case that contents of thes service munual is different from the latest information by revision after product shipment Use the owner s manual of this procuct together ...

Page 2: ...asuring instrument be careful not to cause an electric shock accident 1 2 Handling of printed circuit board 1 Do not to touch the potentiometer which fixed by white pen on the printed circuit board It cause to trouble in welding machine 2 Insert all printed circuit board certainly to take a lock of circuit board support for attachment 3 Insert connector with matching connector number or wiring num...

Page 3: ... the case Then insulate this earth cable due to not touch the case 3 Short circuit the contact interval line No 1 4 of magnet switch 4 Turn on the control power source S1 Be sure to reconnect the cables after carrying out measurement of insulation resistance and withstand voltage test 1 5 Only to check operation of sequence When only to check operation of sequence follow the steps below 1 Turn off...

Page 4: ... Zero cross detective circuit Input voltage detective circuit Primary voltage detective circuit Emergency stop detective circuit Fan frame CPXD 350 Chassis CPXD 500 C0045Q Common in all models Power source circuit Governor circuit Thyristor drive circuit Short circuit detective circuit Relay circuit P10174X Common in all models Remote control one line circuit CM 2301 2302 reshuffling C0056P and C0...

Page 5: ...h as the figure below Same as CH6 CH8 SCR trigger 3 S CH1 CH8 Pulse waveform such as the figure below Same as CH6 CH9 Zero cross 1 S CH1 CH9 Pulse waveform such as the figure below CH10 Zero cross 2 S CH1 CH10 Pulse waveform such as the figure below Same as CH9 CH11 Zero cross 3 S CH1 CH11 Pulse waveform such as the figure below Same as CH9 CH12 Input voltage T CH1 CH12 When rated input voltage be...

Page 6: ...easing CH10 Short circuit detection T CH1 CH10 15V When short circuit 0V When outputting voltage 2 2 3 Check terminal on printed circuit board P10174X No Signal name Explanation CH1 0V Ground CH2 15V T CH1 CH2 15V CH3 15V T CH3 CH1 15V CH4 Missing number CH5 Exchanging signal S CH1 CH5 Pulse waveform such as the figure below CH6 TS WV S CH1 CH6 Pulse waveform such as the figure below CH7 Inching W...

Page 7: ...left R70 Slow down speed Adjust slow down speed Jumper switch of printed circuit board C0056P No Signal name Explanation S1 1 Simple substance inspection Use for simple substance inspection of printed circuit board Use it in regular OFF S1 2 Initial current Initial current function is possible to use with turning to ON when crater is ON or REPEAT S1 3 Wire feeder exchange function Set it suitable ...

Page 8: ...from welding voltage greatly Change J1 to ADJ when adjusting It becomes lower with turning to an anti clock and becomes highly with turning to a clock R39 Iref fine adjustment Use it to adjust when the current scale of remote control deviates from welding current greatly Change J2 to ADJ when adjusting It becomes lower with turning to an anti clock and becomes highly with turning to a clock Jumper...

Page 9: ...CPXD 350 500 SERVICE MANUAL 8 2 Function of each printed circuit board continued 2 4 Check point position of each printed circuit board 2 4 1 C0056P C0056P ...

Page 10: ...CPXD 350 500 SERVICE MANUAL 9 2 Function of each printed circuit board continued 2 4 Check point position of each printed circuit board continued 2 4 2 C0045Q C0045Q ...

Page 11: ...CPXD 350 500 SERVICE MANUAL 10 2 Function of each printed circuit board continued 2 4 Check point position of each printed circuit board continued 2 4 3 P10174X ...

Page 12: ...and the welding power source stops automatically In this case wait until the fan stops with the CONTROL POWER switch turned on When starting the welding operation again use the welding machine lower the duty cycle or the welding current Input over voltage error When input voltage goes beyond 460V the WARNING lamp lights up and the welding power source stops automatically Disconnect the CONTORL POW...

Page 13: ...p flashes two times After the warning lamp flashes the welding machine automatically stops Trouble of output voltage When the TORCH switch is turned off and voltage on the output terminals presents the WARNING lamps flashes Flash 2 and the welding machine automatically stop welding In case of welding same work piece with several welding machines turn off the power switch and check whether wire or ...

Page 14: ...k and accident in particular And resistance value in the list is changed by internal resistance of tester digital tester in particular that is used So regard as it is standard 3 2 1 Thyristor module Tester red Tester black Measured value Ω K1 K2 G1 G2 A K1 K1 A A G1 G1 A G1 K1 20 K1 G1 20 A G2 A K2 A G3 A K3 are same as this list A is heat sink attachment side ...

Page 15: ...trol Check the connections of P10174X match wire feeder connected to this welding power source Settings of current and voltage Welding mode and wire diameter set Improper welding conditions Distance between torch and base metal No insulator on surface of base metal Complete connection of base metal and torch cable Bad arc start Incomplete power supply Tip worn out Complete connection of base metal...

Page 16: ...o pre heat function setting fan automatically stops when welding machine keeps to stop operation while CONTROL POWER switch turned on Main POWER lamp PL1 lights up Trouble of P C B control circuit After checking C0056P and C0045Q replace them if needed Trouble of P C B gas control circuit After checking C0056P and C0045Q replace them if needed 4 Shield gas does not stop Trouble of gas electromagne...

Page 17: ...hyristor SCR1 or 2 Replace the thyristor SCR1 or 2 if needed Trouble of hall element CT Replace the current detector CT Check wire number 1 3 8 13 17 21 26 Check the wiring 8 Being out of control welding machine causes large current flow Trouble of P C B control circuit and thyristor C0056P ignition circuit C0045Q After checking C0056P and C0045Q replace them if needed Breaking of remote control c...

Page 18: ...CPXD 350 500 SERVICE MANUAL 17 4 Block diagram ...

Page 19: ...on C0056P 5 4 Changing wire feeder Set C0056P and P10174X suitable for wire feeder like the list below CPXD 350 500 C0056P Wire feeder model S1 3 S1 5 P10174X CN1 3 Remarks CM 2302 OFF OFF A side Factory setting CM 2301 ON OFF B side CML 2302 OFF ON A side CML 2301 ON ON B side If making a mistake in setting Mistake in dip switch Scale of remote control and the fact current and voltage is not suit...

Page 20: ...ging crater repetition period Crater repetition period is 2 sec at the shipment but it becomes usable to adjust time by R18 on C0056P 5 8 Using AC100V heater receptacle Extra heating is necessary to use gas regulator with heater turn S1 No 4 to ON when use AC100V heater receptacle Turn S1 No 4 to OFF when not to use heater receptacle An energy saving function is operating Function of S1 No 4 ON MS...

Page 21: ...imer is located close to 4P terminal board on fan frame 2 Lead in cables connected with arc spot timer through grommet with film on the rear side of the welding machine to insert into the connectors 3 Close the upper cover of the welding machine 4 Bolt the arc spot timer together with the upper cover See the figure shown below When using arc spot timer initial current self hold and crater are not ...

Page 22: ...to house programs are incorporate to one chip so it is impossible to change only ROM Then if using special correspondence which includes changing software exchange includes printed circuit board These two terminals are used for external operation stop When opening these terminals it stops emergency and stop operation When close these terminals it cancels emergency stop and start operation These tw...

Page 23: ...CPXD 350 500 SERVICE MANUAL 22 6 Schematic diagram and parts layout 6 1 Schematic diagram for CPXD 350 ...

Page 24: ...CPXD 350 500 SERVICE MANUAL 23 6 Schmatic diagram and parts layout continued 6 2 Schematic diagram for CPXD 500 ...

Page 25: ...BLACK CN23 ＳＣＲ CONECTION ＳＣＲ TERMINAL WIRE NUMBER WIRE COLOR CONNECTOR PIN NUMBER Input terminal FRAME HEATSINK LOWER UPPER RED WHITE REAR PANEL RED WHITE WHITE BULE RED WHITE RED OUTPUT PANEL CASE GROUND CON3 2A ＦＭ for R2 Ｔ４ 0V 0V 19 5V 415V Ｔ３ 0V 0V 415V 19 5V R15 C13 80 173 Ｆ５ Ｆ４ 167 2 1 168 Ｌ４ S 5 S 3 0 V 2 0 0 V 1 8 5 V 0 V S 2 S 1 S4 1 8 5 V 1 8 5 V 0 V 0 V 0 V 8 V P 0 V 3 8 0 V Ｔ２ 0 1 A 0 2...

Page 26: ...K SIDE UPPER A V 116 115 61 60 for PCB1 CN9 for PCB1 CN1 for PCB1 CN10 CRATER FILLER VOLTAGE R3 R4 62 63 64 65 62 65 F1 CONTROL POWER MOTOR F2 AC100V F3 PL1 CONTROL POWER PL3 WARNING 127 128 126 125 72 70 29 27 168 167 for PCB1 CN4 for T2 T3 SHIELDING GAS VOLT CURR CONTROL CRATER FILLER S5 CHECK WELD ONE KNOB SEPARATE OFF ON 88 100 100 S6 C 81 82 83 84 85 AUTO PROGRAM S4 87 86 S3 S1 170 169 3 167 ...

Page 27: ...V 180 for CON4 FRONT REAR Fan belonging condenser 131 132 ARC SPOT TIMER S CONNECTOR ＣＮ L4 for MS for MS SCR2 Ｆ５ Ｆ４ 167 2 1 A V 116 115 61 60 C RA T ER F IL LE R VO LT AG E R 3 R 4 62 63 64 65 S19 62 65 C RE AT E R FI LL ER C UR RE NT S 6 C 81 82 83 84 85 S 1 F 1 C ON T RO L P O W ER MO T OR F 2 P L 1 C ON T RO L P O WE R P L 3 W AR N IN G O FF 127 128 72 70 170 171 169 3 167 29 27 167 SH I EL D I...

Page 28: ...18 CN19 CN20 CN21 CN22 CN23 CN24 CN25 CN26 CN5 CN6 CN1 CN2 CN3 CN4 CN7 CN8 CN9 CN10 CN11 G K CASE GROUND SCR3 A ＰＣＢ３ CN27 Ｒ２ 134 133 CHASSIS view from the back side 4P CONNECTOR 95 WELDING CURRENT CONTROL INCHING SPEED WELDING VOLTAGE CONTROL INCHING SWITCH Ｒ５ Ｒ６ ＰＢ R6 R5 PB DR1 DR2 DR3 DR4 95 98 99 150 95 95 147 148 149 147 148 98 99 150 REMOTE XD350 500 6 Schmatic diagram and parts layout contin...

Page 29: ...2 015 Rotary thumb switch A7BS 206 1 1 1 S6 4739 369 One touch fixture A7B M 1 1 1 S7 4254 118 Switch DS 850K F1 00 Black 1 1 PL1 4600 342 Neon lamp N46010A7KR 01 1 1 PL3 4600 345 Neon lamp N46010A7KR 01 1 1 V 4401 016 DC voltmeter 209390 HT Z DC75V 1 1 4403 049 209390 HT Z 600A 1MA 1 A 4403 127 DC ammeter 209390 HT Z 400A 1MA 1 4501 039 Variable resistor RV24YN20SB 5KΩ 2 2 R3 4 4735 008 Knob K219...

Page 30: ...erminal K3927B00 2 K2851B00 Secondary terminal K2851B00 2 On output terminal board CON5 4732 017 AC plug AC T04FB04 1 1 K3904B00 Input terminal board K3904B00 1 1 K3904C00 Input terminal cover K3904C00 1 1 On rear panel SCR3 4530 412 Thyristor SG25AA20 1 1 K5374P00 P C B K5374P00 1 1 On Chassis C0052X00 C0052X00 1 P C B 1 C0056X00 Micro controller On P C B K5374P00 C0056X00 1 On P C B K5374P00 C00...

Page 31: ...0 99 119 170 CO2 0 8mm Welding voltage V 17 0 18 5 19 0 20 0 22 0 24 0 27 0 Speed rpm 21 35 49 69 91 106 145 MAG 0 8mm Welding voltage V 15 0 17 0 18 0 19 0 20 0 21 0 23 0 Speed rpm 17 21 28 39 54 80 93 124 148 CO2 0 9mm Welding voltage V 17 0 18 0 18 5 19 0 19 5 21 0 23 5 25 0 26 5 Speed rpm 16 20 30 41 61 73 93 112 137 MAG 0 9mm Welding voltage V 15 0 15 5 17 0 18 0 19 0 20 0 21 0 22 0 24 0 Spee...

Page 32: ...tage V 16 18 19 24 28 31 35 38 Speed rpm 13 19 33 46 69 97 119 148 179 212 MCW 1 4mm Welding voltage V 16 18 20 24 28 31 35 38 41 45 Speed rpm 12 15 19 32 44 58 72 87 107 135 161 185 CO2 1 6mm Welding voltage V 16 18 19 22 25 30 33 36 40 43 45 50 Speed rpm 12 13 17 30 42 56 70 83 103 130 150 175 MAG 1 6mm Welding voltage V 13 15 17 19 23 28 32 34 36 38 40 45 Speed rpm 12 16 24 35 50 69 97 125 160 ...

Page 33: ...l scale Output current A Order voltage V Output current A Order voltage V Output current A Order voltage V 100 4 0 100 3 0 15 1 0 150 6 5 150 5 0 18 3 0 200 9 5 200 7 0 21 4 5 250 12 0 250 9 0 24 6 0 300 15 0 300 11 0 27 8 0 350 13 0 30 9 5 33 11 0 36 13 0 CPXD 500 Current setting Current setting Voltage setting Use inside scale Use outside scale Use individual scale Output current A Order voltage...

Page 34: ...e V Current A Voltage V Current A Voltage V 0 55 6 0 55 5 0 55 5 0 55 6 0 55 6 10 29 3 10 35 5 10 40 3 10 46 2 10 47 5 20 28 20 34 1 20 39 7 20 46 1 20 47 8 40 25 2 40 32 7 40 39 1 40 45 1 40 47 3 60 24 1 60 32 2 60 38 6 60 45 60 46 9 80 23 6 80 31 8 80 38 1 80 44 6 80 46 3 100 23 100 31 1 100 37 7 100 44 1 100 45 9 150 21 9 150 30 150 36 5 150 43 150 44 8 200 20 5 200 29 200 35 2 200 42 200 43 3 ...

Page 35: ... 43 20 27 2 20 36 20 43 8 20 51 20 56 8 40 24 5 40 35 40 43 2 40 50 5 40 56 5 60 24 60 34 5 60 43 60 50 2 60 56 80 23 5 80 34 80 42 5 80 49 7 80 55 8 100 23 100 33 8 100 42 2 100 49 2 100 55 2 150 22 5 150 33 2 150 41 2 150 48 2 150 54 2 200 21 5 200 32 5 200 40 5 200 47 2 200 53 2 250 20 8 250 31 8 250 39 5 250 46 2 250 52 2 300 20 300 30 8 300 38 5 300 45 2 300 51 2 350 19 350 30 350 37 5 350 44...

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