Daihen OTC AC/MIG/201 CPDACA-200 Owner'S Manual Download Page 2

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No.P10224

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CONTENTS

1. SAFETY INFORMATION

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2. ARC WELDING SAFETY PRECAUTION

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3. GENERAL NOTICE OF OPERATION

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4. STANDARD ACCESSORIES

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5. LOCATION AND FUNCTION OF CONTROL

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6. NECESSARY POWER SOURCE EQUIPMENT

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7. TRANSPORT AND INSTALLATION

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8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

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9. WELDING PREPARATION

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10. WELDING OPERATION

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11. APPLIED FUNCTION

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12. MAINTENANCE AND TROUBLESHOOTING

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13. PARTS LIST

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14. SPECIFICATIONS

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15. SERVICE AND SUPPORT

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Summary of Contents for OTC AC/MIG/201 CPDACA-200

Page 1: ...al 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...

Page 2: ...9 5 LOCATION AND FUNCTION OF CONTROL 10 6 NECESSARY POWER SOURCE EQUIPMENT 13 7 TRANSPORT AND INSTALLATION 14 8 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE 16 9 WELDING PREPARATION 20 10 WELDING O...

Page 3: ...RNING ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH Be sure to Keep children away Keep pacemaker wearers away until consulting a doctor Read and unders...

Page 4: ...pliced cables 8 Do not touch electrode and 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 ARC RAYS can burn eyes and skin FLYING...

Page 5: ...nd 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 other than arc welding 11 Wear oil free protectiv...

Page 6: ...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 valve out...

Page 7: ...solidly on a flat surface Do not pull the welding power source across a floor laid with cables and hoses Do not put wire feeder on the welding power source Do not put the welding power source and wir...

Page 8: ...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 Co...

Page 9: ...sted for 2 minutes after 8 minutes of continuous welding at the rated current 10 min 100 50 0 100 100 Less than 178A Usable range Duty cycle Welding current A 200 80 200A 27V 40 When the welding power...

Page 10: ...power source is combined with other welding machines to use refer to the manual of the machine 4 STANDARD ACCESSORIES 4 1 Accessory kit Your package contains the accessory kit listed below Descriptio...

Page 11: ...pper cover Panel cover Right side panel ICN4 receptacle to manipulator Left side panel Negative output terminal to base metal Positive output terminal to torch side Terminal block with 12 pins Front c...

Page 12: ...n switching turn off the power switch PROGRAM switch To select a welding method and a wire size while pressing or Set the only wire sizes listed in WELDING MODE AND WIRE SIZE on the next page Fuses CU...

Page 13: ...035 63 0 040 64 AC PULSED MIG Stainless steel 0 045 71 0 030 72 0 035 73 0 040 74 DC 0 045 81 0 030 82 0 035 83 0 040 84 AC PULSED MIG Mild steel 0 045 Gas switch This welding power source automatica...

Page 14: ...tage range between 460 and 483V Setting to excessive high output voltage may result in product damage Use the engine generator with a damper winding of which capacity is more than twice as much as the...

Page 15: ...the welding machine follow the instructions below to avoid fire caused by welding and physical damages by fume gas Do not install the welding machine near combustible materials and inflammable gas Re...

Page 16: ...metallic conduit Provide electromagnetic shield to the whole welding places If electromagnetic troubles can not be solved after trying the above measures consult your nearest DAIHEN dealer CAUTION Us...

Page 17: ...voltage in capacitor Do not use a cable with lack of capacity or a seriously damaged cable Tighten and insulate the connection of cables Do not remove a case or a cover of the welding machine when us...

Page 18: ...e of charging voltage in capacitor Do not use a cable with lack of capacity or a seriously damaged cable Tighten firmly and insulate the connection of cables Follow the instructions below to connect t...

Page 19: ...cylinder Gas cylinder stand Outlet of gas regulator Gas hose Follow the instructions below to connect the gas hose 1 Attach the gas cylinder nut to the gas cylinder with a monkey wrench 2 Connect the...

Page 20: ...ay cause an electric shock Be sure to ground the case of the welding power source or jig 8 3 Grounding and connection of input side Be sure to properly ground welding power source to avoid electric sh...

Page 21: ...ly ventilate when welding a coating steel plate poisonous gas and fume may be generated Use a wind shield to protect arc from wind when using an electric fan for ventilation or welding outdoors Failur...

Page 22: ...Turn on POWER switch Set the gas check switch to CHECK Set the gas regulator to SHUT and turn on gas at the main Turn gas flow regulator to OPEN to adjust the amount of gas flow After adjusting the a...

Page 23: ...the control device If CURR VOLT CONTROL switch is set to PANEL pre flow period will be 0 08 sec and post flow time 0 35 sec Crater filler period When current stops during welding monitor period Anti s...

Page 24: ...t can be controlled while welding to match the ratio of EP current torch with positive polarity current and EN current torch with negative polarity current EP EN 10 3 Adjusting penetration The amount...

Page 25: ...dusts 10 5 Wave pulse welding When the PROGRAM switch is set to 11 13 DC or 21 23 AC wave pulse welding can be performed During wave pulse welding bead appearance with beautiful scale patterns can be...

Page 26: ...Narrow bead width Shallow penetration Low excess metal Easy undercut Easy occurrence of poor gas shield Wire extension too long Long arc length Large potential drop and output voltage decrease caused...

Page 27: ...e line disconnect switches and that more than 3 min has passed after the disconnection of the input power switch when switching the short socket or the dip switch Never touch the resistor painted whit...

Page 28: ...however can be exactly adjusted from the robot control device Refer to the manual of the robot control device for details 4 Adjusting anti stick voltage Anti stick is a voltage or welding cancellation...

Page 29: ...ic correction is used for the automatic detection of the errors in the welding voltage detecting circuit It is not for correction of the voltage fluctuation caused by the external factors such as the...

Page 30: ...e welding power source The functions of the terminal block are as illustrated below Connection with terminal block for external connection 12P terminal block starting 4 3 2 1 Arc voltage detection pos...

Page 31: ...C 2 4 V A V MEANING OPENING CLOSING GAS SOLENOID VALVE Gas purges when set to CLOSE WELD CURR RELAY WCR CONTACT OPERATION STOP Stop when set to OPEN POWER FOR PREP RELAY 24V DC AMMETER VOLTMETER FUNCT...

Page 32: ...and maintain the welding machine If errors occurred warning lamps on the front panel and red LED on P C B P6906P light and the welding power source automatically stops In this case check the errors in...

Page 33: ...easure the input voltage with a tester etc to make sure excessively high voltage is not output To cancel the error connect the POWER switch again after solving the error Output overcurrent error When...

Page 34: ...omputer error is detected the WARNING lamp lights and the welding machine stops automatically Communication error with robot When communication between the welding machine and the robot control device...

Page 35: ...le as straight as possible If it is impossible to do so layout the cable on the base metal 3 In case where the torch cable is coiled follow the instructions below CORRECT WRONG Cable coiled in two dir...

Page 36: ...voltage And install a protective wall around the welding machine to keep away others from the welding machine CAUTION Follow the instructions below as rotating parts may be the cause of injury Have a...

Page 37: ...switch Connection of input cables No WARNING lamp lights No difference in voltage between torch and base metal Control cable and socket Fuse of input power disconnect switch Connection of input cable...

Page 38: ...PL2 lights when main power switch is turned on Wiring of external connection terminal board on P C B P10153Q Wire to OPERATION STOP Outlet valve of gas cylinder closed Open valve Lack of gas pressure...

Page 39: ...s generated when pulling torch switch pulled but no no load voltage Operation stop of external connection terminal board on P C B P10153Q not short circuit Short circuit operation stop Trouble of cont...

Page 40: ...y result in damage of P C B and the machine P C B P6906P does not include EPROM When replacing P C B install the EPROM on the original P C B NOTE match the connector numbers when connecting 12 5 Insul...

Page 41: ...No P10224 P 40 47 12 6 Schematic diagram of CPDACR 200...

Page 42: ...No P10224 P 41 47 12 7 Parts layout of CPDACR 200...

Page 43: ...HA400S3EH 1 PL1 4600 341 Neon lamp N46010A7KW 01 1 PL2 4600 357 Neon lamp DB 41BR 1 PL3 4600 358 Neon lamp DB 41BG 1 PL4 4600 359 Neon lamp DB 41BY 1 F1 4610 003 Glass enclosed fuse 250V 2A 1 For cont...

Page 44: ...Resistor RD1S 200k J 1 R40 4504 944 Resistor KNP1W 10 1 R41a b 4509 818 Resistor 40SH 200 JA 2 R42 4509 707 Resistor RD1 4W 10k J 1 R43 4509 302 Resistor RS3B 100 k J 1 R44 45 4509 905 Resistor MHR20A...

Page 45: ...1 I F PCB6 P6848S00 Printed circuit board P6848S00 1 Secondary driver PCB7 P10153Z00 Printed circuit board P10153Z00 1 Restrike PCB8 P10153Y00 Printed circuit board P10153Y00 1 PCB9 P9943T00 Printed...

Page 46: ...d voltage 27V Output current range 40A 200A Output voltage range 13V 36V Max no load voltage 86V Rated duty cycle 80 Temperature rise 320F 160 Temperature range 32 104 0 40 F F C C Moisture range 20 8...

Page 47: ...14 4 365 Bush for external connection wire Output terminal Output terminal ICN4 receptacle to manipulator 0 6 15 Arc voltage direct detection terminal Base metal External connection terminal block IC...

Page 48: ...check section 12 MAINTENANCE AND TROUBLESHOOTING before requesting a repair 2 When requesting a repair you will need such information as your address name telephone number product model manufacture d...

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