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7. TRANSPORT AND INSTALLATION

7.1 Transport

WARNING

Follow the instructions below to avoid accident and product damage when carrying the
welding power source.



Do not touch the live electrical parts inside or outside the welding power
source.



Be sure to disconnect the line disconnect switch before carrying the
welding power source.



Use eye bolts when hanging the welding power source by a crane.

Sketch of hoisting



During hoisting of the welding power source,
hoisting rings at two points must be applied. Single
point hoisting is prohibited.

Wminfo

Содержание CPVE-400

Страница 1: ...afety 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 operatio...

Страница 2: ...nforced starting on January 1 1995 Please make sure that this product is not allowed to bring into the EU after January 1 1995 as it is The same restriction is also applied to any country which has si...

Страница 3: ...AND ACCESSORIES 9 5 NAME OF EACH PART 12 6 NECESSARY POWER SOURCE EQUIPMENT 13 7 TRANSPORT AND INSTALLATION 14 8 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE 17 9 WELDING PREPARATION 25 10 OPERATION...

Страница 4: ...S 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 an...

Страница 5: ...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 swi...

Страница 6: ...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 b...

Страница 7: ...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 or...

Страница 8: ...ice 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 Cont...

Страница 9: ...rated current Failure to observe duty cycle limitations may cause the temperature inside the welding machine to exceed tolerance levels This may contribute to premature welding machine failure or pro...

Страница 10: ...Different wire feeders will require relevant reset to internal function F14 Details of setting please see 10 2 1 setting of internal function 14 Switch of Wire feeding machine selection 3 4 Gas mixtu...

Страница 11: ...ifications 5m 10m 15m 20m as necessary Refer to Section 11 4 1 Extension Cables and Extended Gas Tubes For MAG MIG welding use Gas hose 3m Welding Power Source Gas regulator Wire feeder Welding Cable...

Страница 12: ...tput terminal screw Heat shrink tube 40mm 2 For terminals of output cables Glass fuse 10 A 250 V 1 For circuit board P30110Q Glass fuse 2 A 250 V 1 For circuit board P30110Q Ceramic fuse 4 A 500 V 1 F...

Страница 13: ...ed MAG Gas Argon Ar 80 carbon dioxide CO2 20 MIG Gas Argon Ar 98 Oxygen O2 2 2 Welding Wire Use a suitable wire for welding method 3 Input Cable and Grounding Cable Prepare input cables and grounding...

Страница 14: ...on Cable clamp 1 0 1 2 WIRE DIA CRATER FILLER WIRE TYPE GAS 0 9 0 8 INCHING GAS CHECK FLUX CORED SOLID ARC SPOT REPEAT ON OFF MAG CO 2 JOB No m min PUSH HOLD JOB MEMORY KEY LOCK SYNERG ENTER SAVE LOAD...

Страница 15: ...elding machine Some engine welders have poor electricity which may cause product damage Contact an engine welder manufacture for improvement of voltage waveform CAUTION To prevent the engine generator...

Страница 16: ...the live electrical parts inside or outside the welding power source Be sure to disconnect the line disconnect switch before carrying the welding power source Use eye bolts when hanging the welding p...

Страница 17: ...caused by fume wear a gas mask or weld at a partial exhaust facility approved by local regulations Adequately ventilate or wear a gas mask when using the welding machine in a tank boiler or the hold...

Страница 18: ...ace 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 shiel...

Страница 19: ...expose the conductor parts of the wiring terminals for welding cables Use the auxiliary heat shrinkable tubes or high temperature insulating tapes for good insulation 8 1 Input voltage selection The i...

Страница 20: ...e is indicated by a plate with two labels on both sides The plate is fixed on the rear panel of the welding power source Take down the plate and fix it again with the label of INPUT 380V outward 7 In...

Страница 21: ...the cable at the wire feeder side The grounding of the workpiece and welder shall not be shared by other Connection fault may damage the output connection terminals of the power source so please abide...

Страница 22: ...ten the nut to avoid contact of the welding cable with the bottom of the rack or the terminal block and ensure sufficient insulation for the terminal area by means of insulating tapes 5 Connect the co...

Страница 23: ...welding cable between the base metal and output terminal base metal of the power source 3 Connect the welding cable to the output terminal welding torch 4 Connect the welding cable to the welding ele...

Страница 24: ...esult 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 Connec...

Страница 25: ...in construction sites or other damp locations or on iron plates steel structures etc CAUTION Be sure to install a switch with fuse or a circuit breaker for motor o the input sides of each welding mac...

Страница 26: ...ed 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 So...

Страница 27: ...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 co...

Страница 28: ...CURRENT adjusting knob on the analog remote control However the adjusting knobs on the control panel will become invalid after a remote control box is connected 5 Turn the flow adjusting knob to OPEN...

Страница 29: ...ead 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 to...

Страница 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 thick...

Страница 31: ...ouble 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 6 1...

Страница 32: ...lding 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 20 2...

Страница 33: ...80 30 40 1 4 350 32 50 1 6 380 34 65 8 1 2 300 31 30 1 4 350 33 45 1 6 380 34 52 9 1 2 320 32 30 1 4 350 34 40 1 6 380 34 40 9 4 3 Example Welding Conditions of MAG Short Arc Material Soft steel Gas M...

Страница 34: ...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 CRA...

Страница 35: ...g 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 customer needs The optional modes are shown in the table below Supported Not su...

Страница 36: ...wire diameters of 0 9 and 1 4 are indicated by means of lighting two LED lamps 0 8 mode 0 9 mode 1 0 mode 1 2 mode 1 4 mode 1 6 mode 0 8 and 1 0 lamps lighting 1 2 and 1 6 lamps lighting When setting...

Страница 37: ...dition 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 If C...

Страница 38: ...N 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 CRATE...

Страница 39: ...l 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 burnback time Post flow time...

Страница 40: ...eatment 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 2...

Страница 41: ...When holding time of the torch switch is shorter than the ARC SPOT time welding will end at the same time the torch switch is OFF Note In the ARC SPOT mode the penetration control function F13 is una...

Страница 42: ...value of the arc characteristic is set in the negative direction down to 99 arc condition becomes harder As the setting value is set in the positive direction arc condition becomes softer up to 99 Whe...

Страница 43: ...ny operation is done nor DISPLAY CHANGE key 7 is pressed within 5 seconds the digital meters will automatically return to the average value display mode When pressing the welding torch switch the LEDs...

Страница 44: ...ing conditions from the 11th to the 30th one can not be read out by using the reading function of the analog remote control Remote Affects the settings through Remote Control Box knobs LOAD The stored...

Страница 45: ...nternal Function F1 Fine adjustment of anti stick burnback time F11 Fine adjustment of JOB MEMORY F2 Fine adjustment of anti stick burnback Voltage F12 Setting of soft arc mode F3 Fine Adjustment of S...

Страница 46: ...ease the standard anti stick burnback time by 0 1 sec 2 Fine adjustment of anti stick burnback Voltage F2 Anti stick burnback voltage means the voltage which is output when processing is carried out t...

Страница 47: ...e adjustment can only be performed through a remote control box or the control panel but not by means of external voltage signal In semi auto mode the setting values by the control panel will be appli...

Страница 48: ...ctory 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 d...

Страница 49: ...nction set F11 to on Setting both CURRENT and VOLTAGE knobs to the center of the scales allows the welding power source to work under the conditions already stored in the JOB MEMORY To increase weldin...

Страница 50: ...ng speed CM 8201 0 22m min CMXL 2301 1 18m min CM6201 2 22m min Power factory default settings for 0 the corresponding standard wire feeding machine CM 8201 15 Setting of INITIAL Condition F15 The fac...

Страница 51: ...ration is the same as the standard Key Lock If the password has been set the welding power source will ask the password to un lock Until you enter the correct password the welding power source never u...

Страница 52: ...y 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 will d...

Страница 53: ...eed 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 password...

Страница 54: ...tting 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 ENTER k...

Страница 55: ...re 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 not...

Страница 56: ...r 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 condit...

Страница 57: ...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 conditi...

Страница 58: ...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 adjusting...

Страница 59: ...l 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 press...

Страница 60: ...gain 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 software v...

Страница 61: ...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 out t...

Страница 62: ...ing of gas valve To use this terminal when gas valve open or close through external signal Open the gas valve when shortcircuit occurs between terminals 9 10 Ammeter Terminals for connecting an ammete...

Страница 63: ...n internal function F4 must be set to 1 to switch to Auto mode for setting current and voltage by external voltage signal Refer to 10 2 1 4 Switch of Auto Semi auto Mode for more details 2 Starting Si...

Страница 64: ...ccessories 11 4 1 Extension Cables and Extended Gas Tubes CAUTION Do not connect an unnecessarily long extension cable When using an extension cable roll it out Failure to observe the demand may resul...

Страница 65: ...BKCPP 0407 BKCPP 0412 BKCPP 0417 BKCPP 0422 CM 6201 4 Control Cable for Analog Remote Control 6 pin 5m 10m 15m 20m Model BKCPJ 0605 BKCPJ 0610 BKCPJ 0615 BKCPJ 0620 11 4 2 MAG Flow meter for MAG weld...

Страница 66: ...ire feeder please see wire feeder instruction book 11 4 5 Flow meter of argon gas for MAG MIG welding use Please use dedicated argon gas flow adjuster Flow meter of argon gas Ar is the professional fl...

Страница 67: ...he 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 m...

Страница 68: ...y 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 mois...

Страница 69: ...circuit TR1 3 1 1 2 TR2 3 1 1 2 one by one 5 Short circuit the positive and negative charges of diode DR2 DR4 6 Short circuit all input terminals and output terminals 7 Close NF ON Restore all wiring...

Страница 70: ...auto Mode for more details 2 E 010 blinking Torch switch off state waiting Typically after turning on the power switch the machine will switch to an operating state 1 second after the digital meters...

Страница 71: ...ill automatically stop operation Shut off the power switch verify the connector assembly CN3 CN5 of the circuit board P30110P P30066S and then turn on the power supply again to remove this abnormality...

Страница 72: ...lay 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 on th...

Страница 73: ...ntrol After inspecting the cable and plug for remote control or the remote control replace them if it necessary Error in voltage detection Check the connection for CN5 on circuit board P30110P 9 Wire...

Страница 74: ...1 2 CN5 6 5 4 3 2 7 1 8 CN8 2 3 1 4 CN6 1 3 2 CN1 55 56 57 58 59 60 61 62 63 64 65 FM FM 35 36 E6 E6 B A 38 37 1 2 CN1 3 1 CN5 AC 380V 3 2 1 4 5 6 7 CN7 T3 6 5V 18 5V 18 5V 18 5V S1 S2 S3 S4 S5 S6 6...

Страница 75: ...73 12 MAINTENANCE AND TROUBLE SHOOTING Continued 12 7 Parts Layout NF TM2 TM3 CON1 CON2 4 3 PL1 Front Panel TM1 Fan guard 2 Cable Clamp Back Panel PCB2 TM5 PCB5 T3 T2 1 L5 6 L4 Over chassis Wminfo...

Страница 76: ...74 12 MAINTENANCE AND TROUBLE SHOOTING Continued Around TR Right Side Left Side 5 R1 4 PCB3 T1 LF1 CT C5 L7 THP2 CT2 PCB4 SH FM L1 TR1 C1a DR1 THP1 14 R13 TR2 L8 R7 8 R5 6 Wminfo...

Страница 77: ...75 12 MAINTENANCE AND TROUBLE SHOOTING Continued C3 DR2 R9 R10 C4 DR3 Around DR CPVE 400 S 2 DR2 DR3 DR4 R10 C3 R9 C4 Around DR CPVE 500 S 2 Wminfo...

Страница 78: ...0850 FINGER GUARD QW W00049B 1 1 C1a b 100 1953 FILM CAPACIOTR MFD DA01 DC1200V 20 F 2 2 C2 100 1290 CAPACIOTR CBB80 2000V 473J 1 1 C3 4 100 1396 CAPACIOTR CBB81 2000V 223J 2 2 C5 100 1397 CAPACIOTR...

Страница 79: ...INAL EDZ95b B 1 100 1411 EDZ120b B 1 TM5 100 2057 TERMINAL BLOCK TB 1512 1 1 1 4735 038 KNOB K 100 22RSB RHOS 2 2 2 4735 039 CAP K 100 22CSBL RHOS 2 2 3 W W03637 GROMMET WITH FILM W W03637 5 5 4 100 0...

Страница 80: ...oad voltage 34V 39V Output current range 30 400A 30 500A Output voltage range 12 38V 12 45V Rated no load voltage 72V 78V 70V 76V Rated duty cycle 60 100 Storage memory number for welding conditions 3...

Страница 81: ...79 14 SPECIFICATIONS Continued 14 2 External View 1 6 mm 1 2 mm 1 0 mm 0 8 mm OFF ON REPEAT ARC SPOT INITIAL MAIN DIGITAL INVERTER GAS sec INCHING 0 1 CO 2 MIG MAG A V A V 266 Wminfo...

Страница 82: ...nal Function for more details F Function Initial value Setting range F1 Fine adjustment of anti stick burnback time 0 50 0 50 sec decrement 50 0 50 sec incremental F2 Fine adjustment of anti stick bur...

Страница 83: ...select key 3 WIRE DIAMETER select key 4 CURRENT adjusting 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 1...

Страница 84: ...ase value In 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...

Страница 85: ...nction mode Then the left display 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 CUR...

Страница 86: ...UBLE 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 Manu...

Страница 87: ...ty Taoyuan Hsien Taiwan Phone 886 3 461 3962 Fax 886 3 434 2394 OTC DAIHEN Asia Co Ltd 23 43 16th F1 Sorachai Building 23 Soi 63 Sukhumvit Road Klongtonnua Wattana Bangkok 10110 Thailand Phone 66 2 71...

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