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MANUAL NO:P30051

OWNER'S MANUAL

FOR

DIGITAL INVERTER

DP270C

INVERTER CONTROLLED WELDING POWER SOURCE

DO NOT DESTROY

IMPORTANT: Read and understand the entire contents of this
manual, with special emphasis on 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 operation of welding
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.

DAIHEN Corporation

WELDING PRODUCTS DIVISION

July 8, 2008

Upon contact, advise MODEL and MANUAL NO.

12-2-095-1

MODEL: DP-270C

P30051

MAG

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Содержание DP270C

Страница 1: ...nstalling 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 equipment Do not allow untrained...

Страница 2: ...TION AND ACCESSORIES 9 5 FUNCTION OF EQUIPMENT 11 6 NECESSARY POWER SOURCE EQUIPMENT 13 7 TRANSPORT AND INSTALLATION 14 8 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE 16 9 WELDING PREPARATION 19 10...

Страница 3: ...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 and understa...

Страница 4: ...Do not use worn damaged undersized or poorly spliced cables 8 Do not touch electrodes or any metal object if POWER switch is ON 9 Do not wrap cables around your body 10 Turn off POWER switch when not...

Страница 5: ...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 boots and a...

Страница 6: ...horized by the manufacturer WARNING Be sure to observe the followings for preventing physical injuries a fire and electric shock Handling of plastic parts Front panel and the likes on this power sourc...

Страница 7: ...d adjacent to the arc welding equipment 2 radio and television transmitters and receivers 3 computer and other control equipment 4 safety critical equipment for example guarding of industrial equipmen...

Страница 8: ...Society 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 Societ...

Страница 9: ...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 product damage The figure...

Страница 10: ...fer to the optional parts of Section 13 PART LIST for the part except these Description Part number Q ty Remarks Pressure roll K5439C00 2 for steel Gear U5185P00 2 for steel Feed roll 0 9 1 0 1 2 K543...

Страница 11: ...ble gas for welding method Carbon dioxide gas CO2 gas For welding purity 99 9 or more moisture content 0 002 or less MAG gas 80 argon Ar 20 carbon dioxide gas CO2 gas MIG gas for mild steel 90 argon A...

Страница 12: ...k side Carrying handle Grommet with film For pulling out external connecting cables Input cable Gas Inlet 9 16 18UNF Power switch Rubber feet Main power lamp Socket for analog remote control Output te...

Страница 13: ...No P30051 12 5 FUNCTION OF EQUIPMENT continued 5 2 Welding Power Source Left side Wire feeding unit Wire reel shaft...

Страница 14: ...duct damage Contact an engine welder manufacturer for improvement of voltage waveform To prevent the engine generator or auxiliary power from being damaged follow the instructions below Set the output...

Страница 15: ...ent dross coming into contact with combustible objects If that not possible cover them with noncombustible covers To avoid gas poisoning and danger of suffocation wear a gas mask or adequately ventila...

Страница 16: ...welding site as possible Add a noise filter to the input cables Mount an input cable in the grounded metallic conduit Shield the whole welding places from electromagnetic trouble If electromagnetic t...

Страница 17: ...itch inside the switch box all turned off ground and connect the welding machine Do not use a cable with lack of capacity or a seriously damaged cable Tighten and insulate the connections of cables Se...

Страница 18: ...to do so may result in physical injuries The gas flow regulator for high pressure gas must be used 1 Securely attach the gas hose to the gas inlet located on the rear side of the Welding power source...

Страница 19: ...use or a circuit breaker for motor to the input sides of each welding machine CAUTION Be sure to ground the case of the welding power source Use a grounding cable 4mm 2 or more in thickness If the wel...

Страница 20: ...g machine near the places where degreasing cleansing or spraying is performed Otherwise poisonous gas may be generated Be sure to wear a gas mask or adequately ventilate when welding a coating steel p...

Страница 21: ...lights up When the wire appears from the end of the torch release the INCHING key Cut the wire at about 10 mm from the end of the torch When adjusting wire feed rate use the parameter adjusting knob I...

Страница 22: ...Detach the cap knob from the wire reel shaft 4 Mount the wire reel on the wire reel shaft NOTE Check the positions of the wire reel stop pin and the wire reel stop hole to insert and fully seat the p...

Страница 23: ...older 8 After pulling out the wire thread it from the pilot to outlet guide through the center guide 9 Return the pressure reel holder first the pressure handle 9 5 Mounting of the Feed Roll Confirmin...

Страница 24: ...wire feeder facing out Adjusting of the wire pressure and straightener Set to the proper wire pressure for the wire type by turning the pressure handle The numeral on the pressure scale set with the r...

Страница 25: ...ake has been properly adjusted before shipment Therefore readjustment of the brake is not required for welding in standard welding conditions How to adjust the wire reel hub 1 Detach the cap knob from...

Страница 26: ...Wire extension is too short Easy generation of spatter Long arc length Wide bead width Welding voltage is too high Shallow penetration and flat bead Stick to base metal and easy generation of spatter...

Страница 27: ...0 50 60 15 20 2 3 3 0 3 5 0 9 1 2 120 140 19 21 50 60 15 20 3 2 3 0 4 0 0 9 1 2 130 170 19 21 45 55 15 20 4 5 4 0 4 5 1 2 190 230 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...

Страница 28: ...1 2 1 5 1 2 220 260 24 26 40 50 15 20 Back 1 2 4 Example Welding Conditions of Lap Fillet Plate thickness t mm Wire diameter mm Welding current A Welding voltage V Travel speed cm min Mark position C...

Страница 29: ...ple Welding Conditions of Horizontal Fillet Welding Plate thickness t mm Leg length l mm Aim angle and position Number of layers Welding current A Welding voltage V Travel speed cm min 3 2 3 2 1 150 2...

Страница 30: ...g current A Welding voltage V Remarks 12 100 110 20 21 Weaving Leg length 10 0mm 4 Both Side Welding Conditions Plate thickness t mm Groove shape Number of layers Welding current A Welding voltage V T...

Страница 31: ...6 27 3 280 26 27 4 280 26 27 5 280 26 27 6 280 26 27 7 280 26 27 Oscillation 1 100 20 21 2 130 21 22 3 130 21 22 4 130 21 22 5 130 21 22 6 120 19 20 Vertical position Oscillation 1 100 200 20 22 2 200...

Страница 32: ...Welding voltage V Travel speed cm min Wire extension mm Gas flow rate min 1 5 1 2 60 80 16 18 60 80 12 15 20 3 0 1 2 70 80 17 18 40 50 15 20 6 0 1 2 80 100 17 18 40 50 15 20 9 7 6 Example Short Weldi...

Страница 33: ...E N E TR A TIO N 100Ar BRAZING BRAZING 90Ar 10CO 2 80Ar 20CO 2 CO MI G 100Ar 97 5Ar 2 5C O 2 MI G MI G 98Ar 2O2 DC DC W AVE PULSE DC TIG DC STICK O PTIO N ON M ILDSTEEL M ILDSTEEL M ILDSTEEL S TAIN LE...

Страница 34: ...available wire diameters are automatically decided according to the welding method Then select wire gas using the WIRE GAS selector keys 2 Finally set the wire diameter with the WIRE DIA mm key 3 For...

Страница 35: ...ing DC TIG Welding DC Pulse 80 20 CO2 Mild Steel Solid O O O DC Pulse 80 20 CO2 Mild Steel Cored O DC Pulse 80 20 CO2 SUS Cored O DC Pulse 90 10 CO2 Mild Steel Solid O O O DC Pulse 97 5 2 5 CO2 SUS So...

Страница 36: ...values of voltage current and wire feed speed Use the values in the displays as approximates WARNING O O K P d 5GE 1 0Q H z d T1 T2 MAIN CONDITION INITIAL CONDITION CRATER FILL CONDITION A m m in V D...

Страница 37: ...e setting values of initial conditions are displayed in the displays 3 Setting of the Main Conditions Once the main conditions are chosen the setting values of the main conditions are displayed in the...

Страница 38: ...o ON When treating a crater set to ON or ON In the event that crater fill is carried out set the CRATER FILL key to ON or ON Depressing the CRATER FILL key 7 changes the crater fill mode in the follow...

Страница 39: ...RATER time When selecting ON no pulse welding is performed during the CRATER time regardless of the settings of the welding method Welding method at the INITIAL time is the same as that at the MAIN WE...

Страница 40: ...OT TIME key again or press the DISPLAY CHANGE key 8 to return to the last parameter item It is also possible to change the display to a current related parameter using the A m min selector key 4 and t...

Страница 41: ...ttings are the INDIVIDUAL mode V and the SYNERGIC mode adjustment In the SYNERGIC display mode the standard value is 0 The setting range of welding voltage is 0 to 30 10 1 6 CONSTANT PENETRATION Funct...

Страница 42: ...arc characteristic in the negative direction 10 1 8 WAVE PULSE Function optional In wave pulse welding the ripple bead appearance is changed by applying two separate pulses cyclically at low frequency...

Страница 43: ...18 the INCHING lamp located at the upper left of the INCHING key lights up and begins feeding wire Releasing the key stops wire feeding and causes the INCHING lamp to go out When changing the wire fee...

Страница 44: ...nd blink for about 20 seconds however the output conditions of crater fill are ignored Therefore the operators can verify the welding conditions right after the completion of welding and can use them...

Страница 45: ...disconnect the analog remote control When making the INDIVIDUAL adjustment Selecting the INDIVIDUAL adjustment allows you to set welding current and welding voltage individually NOTE INDIVIDUAL adjus...

Страница 46: ...to DC TIG or turning on the welding power source as TIG welding setting the touch sensing voltage is not outputted for 5 seconds After 5 seconds have passed the touch sensing voltage is outputted aut...

Страница 47: ...DC STICK welding or when turn on the switch with DC STICK welding is selected no load voltage is not provided for approx 5 seconds for safety 5 seconds later the voltage is automatically provided 10 3...

Страница 48: ...number lights and the function conditions blinks Under this condition functions can be preset by using the parameter adjusting knob 6 The number of function lights The condition of function blinks Con...

Страница 49: ...tick Burnback voltage means the voltage which is output when processing is carried out to prevent electrode wire from fusing to base metal at the end of welding Anti stick Burnback voltage is preset t...

Страница 50: ...ut current and output voltage for last one second blinks for about 20 seconds but the result display holding time can be set by F8 using F key 12 The setting range of result display holding time is 5...

Страница 51: ...o the center of the scales allows the machine to work under the conditions already stored in the welding conditions memories To increase welding current slightly turn the knob clockwise and to decreas...

Страница 52: ...us the value which is subtracted or added the fine adjustment value from the standard value When pressing the DISPLAY CHANGE key you can return to the fine adjustment value display mode Example of Fin...

Страница 53: ...condition L pulse peak current at wave pulse welding can be achieved by activating F16 using the F key 8 The value which is subtracted or added the fine adjusting value from the standard value of the...

Страница 54: ...osed ON Closed 5 ON Closed OFF Open OFF Open 6 ON Closed OFF Open ON Closed 7 ON Closed ON Closed OFF Open 8 ON Closed ON Closed ON Closed When the three signals described above are changed during wel...

Страница 55: ...The JOB MEMORY function enables welding conditions to be retrieved by storing the welding conditions in memory inside power source and by reading out the stored data at any time The number of welding...

Страница 56: ...selected the CRATER lamp the WELDING METHOD lamp etc also light up If no memory data is preset to the condition number you selected blinks in the left side display In this case the system skips the p...

Страница 57: ...er can be set while turning the parameter adjusting knob 6 Welding Current stored in memory Condition blinks In the event that any memory data is preset to the condition number you selected the CRATER...

Страница 58: ...e number you selected Discontinue Reset the welding condition number Press the ENTER key Press the SAVE key Press the LOAD key Discontinue Press the MEMORY key Set the welding condition number while t...

Страница 59: ...L is displayed 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 setti...

Страница 60: ...er source the version number appears in the display Example Right and left displays P30051 Software number P30051 is displayed Press the F key 12 Left display 001 Main software version Ver 001 is disp...

Страница 61: ...panel blinks then the welding power source stops automatically In this case check the errors in the following table When using this product with a robot of our company refer to Application arc weldin...

Страница 62: ...ncel 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 in the current detecting...

Страница 63: ...current If an overcurrent or short circuit on the secondary output continues for more than one second during welding the WARNING lamp lights up E and 700 in the display blinks then the welding power s...

Страница 64: ...and an error in the torch or the wire feeder Refer to Section 10 3 1 7 Setting of Feed Motor Load Current Error Detection Level 14 E 830 Display If E and 830 in the displays blink it indicates the Mo...

Страница 65: ...tion Otherwise equipment failure may be caused by noise etc during welding operation Pull out only the wiring on the printed circuit board to outside 11 2 External Connection of Inside Terminal Block...

Страница 66: ...ding machine is stopped by running 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...

Страница 67: ...K5416L00 DP 270C Type 11 3 2 Cable Hose Extension of Work Space CAUTION Do not connect an overlong extension cable When using an extension cable roll it out Failure to do so may result in unstable ar...

Страница 68: ...rators or 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 Rotat...

Страница 69: ...ectifier may affect 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 loca...

Страница 70: ...wings for preventing a fire and the explosion Do not connect of the batteries with wire Do not disassemble heat and deform the batteries Do not solder anything directly to the batteries Do not throw b...

Страница 71: ...guide from the direction of the torch socket and then place the snap ring under the new outlet guide 5 Return the pressure roll holder first the pressure handle CAUTION Do not attempt to disassemble...

Страница 72: ...them if necessary 4 When turning on the power switch the WARNING and TEMPERATURE lamps light up and an error code appears in the display Refer to Section 11 1 How To Solve an Error The discharge valv...

Страница 73: ...cessary Trouble with the filter circuit After inspecting PCB P30051Z replace it if necessary Poor contact or breakdown in the encoder cable Check the socket Check the cables and replace them if necess...

Страница 74: ...No P30051 73 12 MAINTENANCE AND TROUBLESHOOTING continued 12 7 Schematic Diagram...

Страница 75: ...No P30051 74 12 MAINTENANCE AND TROUBLESHOOTING continued 12 8 Parts layout electric parts...

Страница 76: ...No P30051 75 12 MAINTENANCE AND TROUBLESHOOTING continued 12 9 Parts layout wire feeding unit parts 13 PARTS LIST...

Страница 77: ...L1 P30051L00 OUTPUT REACTOR P30051L00 1 L2 P30051C00 INPUT REACTOR P30051C00 1 L3 4739 497 CORE E04RA400270150 2 L4 4739 538 CORE RI 17 5 28 5 10 7 1 L5 4739 497 CORE E04RA400270150 1 L6 4739 538 CORE...

Страница 78: ...532Q00 PRINTED CIRCUIT BOARD P10532Q00 1 PCB4 P10538V00 PRINTED CIRCUIT BOARD P10538V00 1 PCB5 P30051Z00 PRINTED CIRCUIT BOARD P30051Z00 1 PCB6 P30051M00 PRINTED CIRCUIT BOARD P30051M00 1 PCB7 P10533Q...

Страница 79: ...uide block 1 11 U5185B05 Center guide 1 12 4802 206 Feed motor 1 13 U5185B06 Insulation board 1 14 U3971B04 Insulation bush 3 14 1 3361 895 Flat head screw 3 M6 x 20 15 U5185Q00 Drive gear 1 16 U5185B...

Страница 80: ...K5439B11 K5463R03 Feed roll 1 2 1 6 2 K5439B12 Feed roll 0 9 1 0 1 2 2 K5439B13 Feed roll 0 8 0 9 1 0 2 K5463R02 Feed roll 1 0 1 2 2 9 1 3361 880 Cap screw 4 M4 x 16 3361 880 Cap screw 8 M4 x 16 11 U...

Страница 81: ...voltage 27 5 V Rated output current range 30 300 A Rated output voltage range 12 30 V Maximum no load voltage 81 V Rated duty cycle 40 Number of welding condition 100 Temperature rise 160 C 320 F Usa...

Страница 82: ...No P30051 81 14 SPECIFICATIONS continued 14 2 External View...

Страница 83: ...tment of welding voltage SYNERGIC SYNERGIC INDIVIDUAL Penetration control OFF ON OFF Internal Functions Function Refer to Section 10 4 1 Using of internal functions Initial value Setting range F1 Fine...

Страница 84: ...ess the torch switch to start welding Protecting the Keys and Releasing the Key Protection Protecting of the keys Hold down the ENTER key the F key at a time for a few seconds The F lamp starts blinki...

Страница 85: ...Section 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 Teleph...

Страница 86: ...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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