Daihen OTC CPTX-I 400 2W Owner'S Manual Download Page 10

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4. STANDARD CONFIGURATION AND ACCESSORIES

4.1 Standard Configuration

⚫

The devices shown in the boxes

are standard composition. Other parts must be

prepared by the customers.

⚫

Standard cable length is 2/5/10m. You can select extension cable as optional accessary.

Please refer to section 11.4.1.

For MAG/MIG welding use

Welding Power Source

Wire feeder

Water-cooling

unit

Trolley

Summary of Contents for OTC CPTX-I 400 2W

Page 1: ...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 op...

Page 2: ...ION AND ACCESSORIES 9 5 NAME OF EACH PART 11 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 OPERA...

Page 3: ...incipal 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 ma...

Page 4: ...rely in place 7 Do not use worn damaged undersized or poorly spliced cables 8 Do not touch electrodes or any metal objects if POWER switch is ON 9 Do not wrap cables around your body 10 Turn off POWER...

Page 5: ...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 trouse...

Page 6: ...gas regulator except if you are authorized by the manufacturer Rotating parts may cause injuries Be sure to observe the following If hands fingers hair or clothes are put near the fan s rotating parts...

Page 7: ...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...

Page 8: ...nd then remove dust by blowing moisture free compressed air on each part The rated duty cycle of the welding power source is the following CPTX I 400 2W 100 at 400A CPTX I 500 2W 100 at 500A The duty...

Page 9: ...n the figure below 3 3 Gas mixture ratio and wire extension Gas mixture ratio has affections to welding may causing the difference between output and set value The change of wire extension will affect...

Page 10: ...n in the boxes are standard composition Other parts must be prepared by the customers Standard cable length is 2 5 10m You can select extension cable as optional accessary Please refer to section 11 4...

Page 11: ...a moisture content below 0 05 Use CO2 gas with a higher purity for higher welding quality as required MAG Gas Argon Ar 80 carbon dioxide CO2 20 MIG Gas Argon Ar 97 5 carbon dioxide CO2 2 5 2 Welding W...

Page 12: ...rt of CPTX I 400 500 2W Drainage water Input terminal Socket for wire feeder Socket for remote control box Output terminal Water feed Water condensate Operation panel Indicator for main power supply P...

Page 13: ...ent of voltage waveform CAUTION To prevent the engine generator or auxiliary power from being damaged follow the instructions below Set the output voltage of the engine generator to voltage range betw...

Page 14: ...id gas poisoning and risk of suffocation wear a gas mask or adequately ventilate when the welding machine is used in a place regulated by a local law To prevent injury or poisoning caused by fume wear...

Page 15: ...place where metal material such as spatter enters the welding power source Keep an installation distance of 30cm between the welding power source and the wall or other welding power Install a wind sh...

Page 16: ...ity or a seriously damaged cable Tighten and insulate the connections of cables Securely attach the cover of the welding machine after connection of the cables Do not expose the conductor parts of the...

Page 17: ...lding cable between the base metal and output terminal base metal of the power source 3 Connect control cable power cable gas hose and water feed condensate hoses to the wire feeder 4 Connect the othe...

Page 18: ...e metal If required by the local law or codes 2 Connect the welding cable between the base metal and output terminal base metal of the power source 3 Connect the welding cable to the output terminal w...

Page 19: ...y result from the gas cylinder toppling over Attach a proper gas regulator to a gas cylinder Failure to do so may result in physical injuries The gas regulator for high pressure gas must be used 1 Con...

Page 20: ...necting the cables cover the power source with the cover or the case Use a leakage protector when operating the welding power source in construction sites or other damp locations or on iron plates ste...

Page 21: ...exceed 6mm If ungrounded the inner circuit of the power source can form voltage with capacitance between the shell or with stray capacitance input side conductor and shell metal may form intermetallic...

Page 22: ...ate 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...

Page 23: ...be careful for overflowing of the coolant 2 After connecting torch to welding power supply when the quantity of the coolant decrease and become close to MIN level please add the coolant in tank 5 Tur...

Page 24: ...our face or eyes Keep your face eyes and body away from the welding torch which otherwise may cause injuries Keep your hands fingers hair clothes etc away from the rotating parts when inching because...

Page 25: ...e bead width Shallow penetration and flat bead Welding voltage is too low Stick to base metal and easy generation of spatter Narrow bead width Deep penetration and high excess metal Welding current is...

Page 26: ...30 22 24 45 55 15 20 6 0 5 0 6 0 1 2 250 280 26 29 40 50 15 20 9 0 6 0 7 0 1 2 280 300 29 32 35 40 15 20 12 0 7 0 8 0 1 2 300 340 32 34 30 35 20 25 2 Example Welding Conditions of Down Fillet Plate th...

Page 27: ...nd Double Grooves Bevel shape Plate thickness t mm Root gap g mm Root face h mm Wire dia mm Number of layers Welding current A Welding voltage V Travel speed cm min CO2 gas flow rate L min 12 0 0 5 4...

Page 28: ...A Welding voltage V Travel speed cm min Mark position CO2 gas flow rate L min 1 2 0 8 1 0 80 100 18 19 45 55 A 10 15 1 6 0 8 1 2 100 120 18 20 45 55 A 10 15 2 0 1 0 1 2 100 130 18 20 45 55 A or B 15 2...

Page 29: ...2 280 30 40 1 6 380 34 65 8 1 2 300 31 30 1 6 380 34 52 9 1 2 320 32 30 1 6 380 34 40 9 4 3 Example Welding Conditions of MAG Short Arc Material Soft steel Gas Mixture gas 80 Ar 20 CO2 10 15 L min Joi...

Page 30: ...y 8 ARC CONTROL key 2 WIRE TYPE select key 9 SYNERG INDIV key 3 WIRE DIAMETER select key 10 GAS CHECK key 4 WELDING CURRENT adjusting knob 11 INCHING key 5 WELDING VOLTAGE adjusting knob 12 LOAD key 6...

Page 31: ...n of the key on the digital panel 10 1 Basic setting 10 1 1 Setting of Welding Condition Set a welding mode by using GAS select key 1 WIRE TYPE select key 2 and WIRE DIA select key 3 in accord with cu...

Page 32: ...a shielding gas by GAS select key NOTE 3 1 Push and hold down GAS key 1 for a few seconds to switch to the DC STICK mode Output current range is shown in below CPTX I 400 2W 30 to 300A CPTX I 500 2W...

Page 33: ...condition is selected the digital meter will display the setting value of MAIN condition 3 Setting of CRATER condition CRATER condition can be selected only when CRATER FILLER is set to ON or REPEAT I...

Page 34: ...to ON or REPEAT The crater fill mode is switched in the following order each time the key is pressed OFF ON REPEAT ARC SPOT The schematic diagrams for different CRATER FILLER settings are as follows C...

Page 35: ...will not be carried out during the CRATER period ON OFF ON OFF Torch switch Gas flow Voltage between output terminal Wire feed speed Welding current Pre flow time Anti stick burn back time Post flow t...

Page 36: ...treatment as many times as you need Even if welding PENETRATION CONTROL function F13 is set to ON the function will not be carried out during the CRATER period MAIN WELDING CRATER CRATER CRATER Within...

Page 37: ...E key 7 again Torch switch Output current Keep the torch switch pressed and held during the Arc Spot time Torch switch Output current When holding time of the torch switch is shorter than the ARC SPOT...

Page 38: ...setting NOTE The welding voltage at SYNERGIC control etc may not be adjusted properly with use of mixture gas other than the mixture ratio of the following gas MAG gas 80 Argon Ar 20 carbon dioxide C...

Page 39: ...tions and the CRATER conditions can be changed during the INITIAL welding MAIN welding and CRATER welding respectively Pressing the ARC CONTROL key 8 after changing to the parameter setting value disp...

Page 40: ...s are for reference only and it is not guaranteed that they can be used as metering management data 10 1 12 Using the Analog Remote Control When the switch on the analog remote control box is set to O...

Page 41: ...as shown in the following table This welding power source has all kinds of special internal functions which can be set through DISPLAY CHANGE key 7 No Internal Function No Internal Function F1 Fine a...

Page 42: ...ion continued The following functions can be set or adjusted 1 Fine adjustment of Anti stick burn back time F1 Anti stick burn back time means the processing time to prevent electrode wire from fusing...

Page 43: ...in the positive direction it increase The fine adjustment range is 0 m min 1 0 m min When poor arc start occurred lower the slow down speed Even when arc start is good the slow down speed can be incre...

Page 44: ...d to E1 and E2 must be within 0 15V Exceeding 15 V will damage to the control circuit of the welding power source E1 and E2 signals shall be inputted 100 ms before the input of starting signal otherwi...

Page 45: ...setting for upslope time is 0 second and it can be adjusted by F6 with a setting range 0 10 seconds This function is used when wire burns up while conditions are switched over due to the large differe...

Page 46: ...ob and the WELDING VOLTAGE knob located on the analog remote control The initial setting of F11 is OFF When activating the function set F11 to on Setting both CURRENT and VOLTAGE knobs to the center o...

Page 47: ...ndition is existing When INITIAL Condition is ON initial current and voltage can be adjusted after switching to INITIAL status through DISPLAY CHANGE key 7 NOTE Only when INITIAL Condition is set to O...

Page 48: ...ing 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 you ca...

Page 49: ...k it If you want to change the password you have to enter the current password first Therefore please manage the password well and never forget it In the password setting or entering mode the welding...

Page 50: ...E key again digit blinking will return to the hundreds digit 5 After completion of all digits press the ENTER key 14 for confirmation The left display meter will display Loc the right digital meter wi...

Page 51: ...ou need to input the current password correctly before setting new password 3 After completion of password input press ENTER key 14 If the password input is correct good will be displayed and the pass...

Page 52: ...r setting knobs Set the tens digit of password by the parameter setting knobs Set the units digit of password by the parameter setting knobs Press DISPLAY CHANGE key Press DISPLAY CHANGE key Press ENT...

Page 53: ...n 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 We shall n...

Page 54: ...mber S 1 flickeringly and the left display meter will flickeringly display as shown in the figure below 2 Press ENTER key 14 to confirm memory data After pressing the ENTER key 14 if the specified con...

Page 55: ...r 1 In this status you can change JOB number by VOLTAGE adjusting knob 5 If the set condition number has no memory data for example the right display meter will blink display a read mode code and cond...

Page 56: ...de Press LOAD key To memorize data by the JOB No selected To cancel Reset a condition number Confirm parameter value by DISPLAY CHANGE key To cancel Press LOAD key Set a condition number by the adjust...

Page 57: ...all memory data Note If using the ALL setting to delete all memory data the welding condition being used will also be deleted Therefore all parameters will restore to their initial setting 3 After pr...

Page 58: ...on again The status after initialization See section 14 3 initial value and setting range about initial values for all parameters and functions 10 2 6 Confirming Software Version To confirm the softwa...

Page 59: ...nal on the chassis further away from the welding power cable or the torch cable when making an external connection Otherwise equipment may be caused by noise etc during welding operation Do not pull o...

Page 60: ...g of gas valve To use this terminal when gas valve open or close through external signal Open the gas valve when short circuit occurs between terminals 9 10 Ammeter Terminals for connecting an ammeter...

Page 61: ...lf made remote control box use a potentiometer R12 made for setting current a potentiometer R13 made for setting voltage and the wire feeding switch PB that are specified in 13 1 PARTS LIST Refer to t...

Page 62: ...function please see 10 2 1 10 F10 Disabling Power Saving Function 11 4 Optional Accessories 11 4 1 Extension Cables and Extended Gas Tubes CAUTION Do not connect an unnecessarily long extension cable...

Page 63: ...model Maximum wire feeing speed F14 Number Remark WF 04 22m min 0 Two round continuous integrated wire feeder 11 4 4 Wire feeding rolls To ensure welding performance please abide by the following Wir...

Page 64: ...r 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 part...

Page 65: ...ouble 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...

Page 66: ...out by personnel who have knowledge and skills for the safety operation and barriers etc shall be set up around the welding power source to forbid the access of unnecessary people Confirm that the ca...

Page 67: ...e 6 E 200 Primary or secondary current detection error 7 E 210 Error in the output voltage detection 8 E 220 Error in the inverter feedback 9 E 300 Thermal overload 10 E 700 Output over current error...

Page 68: ...p operation Shut off the power switch verify good connection of the connector assembly CN2 and CN4 of circuit board P30110P and then turn on the power supply again to remove this abnormality 7 E 210 b...

Page 69: ...short circuit after eliminating the faults shut off the power switch and then start up again 11 E 710 blinking Input Open phase When primary input open phase is detected E 710 will be displayed flicke...

Page 70: ...display Indicator for main power supply PL1 not lighting up Refer to No 2 in this list PL1 lights Trouble with the power circuit After Inspecting PCB P30110Q replace them if necessary 4 When turning o...

Page 71: ...ard P30256P 9 Wire is not fed Incomplete insertion or breaking of the control cable for wire feeder After inspecting the contacts of the plug and cable replace them if necessary Trouble with the motor...

Page 72: ...71 12 MAINTENANCE AND FAULT REPAIR Continued 12 6 Schematic diagram Input 3 phases 400V AC Note In the case of CPTX I 500 2W replace the circuit enclosed by dash line with right circuit...

Page 73: ...72 12 MAINTENANCE AND TROUBLE SHOOTING Continued 12 7 Parts Layout Front Panel Back Panel Over chassis R1 4 PCB2 TM4 PCB5 T3 T2 2 L3 LF PCB6 CR PCB1 PCB3 C5 8...

Page 74: ...73 12 MAINTENANCE AND TROUBLE SHOOTING Continued Inverter Primary Circuit Right Side Left Side TR1 C1a DR1 THP1 Below C1b TR2 R7 8 R5 6 5 CT2 PCB4 SH FM1 L1 FM3 L6 T1 P FM2...

Page 75: ...74 12 MAINTENANCE AND TROUBLE SHOOTING Continued C3 DR2 R9 R10 C4 DR3 Inverter Secondary Circuit CPTX I 400 2W R9 DR2 DR3 C3 R10 DR4 C4 Inverter Secondary Circuit CPTX I 400 2W...

Page 76: ...06896 300 0406 FAN 200FZY8 S AC400V 1 1 606897 100 0850 FINGER GUARD QW W00049B 1 1 FM2 3 689241 300 0395 FAN TP2123HST 120X120X38 230VAC 2 2 F1 681431 4610 008 FUSE 250V 1A 1 1 678481 300 0444 FUSE H...

Page 77: ...W02 OPERATION PANEL SHEET C1032W02 1 606918 C1033W02 C1033W02 1 4 604023 300 0398 TANK TANK FOR WELLBEE 1 1 5 604664 300 0399 RADIATOR ART 258864 1 1 H 1 603279 Front panel cover upper 400 1 1 1 H 2 6...

Page 78: ...V Output current range 30 400A 30 500A Output voltage range 12 38V 12 45V Rated no load voltage 80V 80V Rated duty cycle 100 100 Storage memory number for welding conditions 30 30 Insulation level Cla...

Page 79: ...78 14 SPECIFICATIONS Continued 14 2 External View 720 1520 1120 740...

Page 80: ...10 2 1 Setting of Internal Function for more details F Function Initial value Setting range F1 Fine adjustment of anti stick burn back time 0 50 0 50 sec decrement 50 0 50 sec incremental F2 Fine adj...

Page 81: ...ng knob 5 VOLTAGE adjusting knob 6 CRATER FILLER key 7 DISPLAY CHANGE key 8 ARC CONTROL key 9 SYNERG INDIV key 10 GAS CHECK key 11 INCHING key 12 LOAD key 13 SAVE key 14 ENTER key F18 The operation ti...

Page 82: ...n addition faster rotational speed will make the increment or decrement each span larger After setting 2 3 some functions may not be selected Refer to Chapter 10 Operation for more details To adjust t...

Page 83: ...meter will display a function number and the right display meter will display the function status of the function number 2 Select a function number by turning the CURRENT adjusting knob to set a func...

Page 84: ...E SHOOTING before contacting your dealer for service 2 When contacting your dealer for service you are required to provide the following information Name Address Telephone number Product model Manufac...

Page 85: ...86 21 5882 8633 Fax 86 21 5882 8846 OTC Taiwan Co Ltd 2F No 153 Huanbei Rd Chung Li City Taoyuan Hsien Taiwan Phone 886 3 461 3962 Fax 886 3 434 2394 OTC DAIHEN Asia Co Ltd 23 43 16th F1 Sorachai Buil...

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