DW-300(P10537-8)

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MANUAL NO:P10537-8

OWNER'S MANUAL

FORDIGITAL INVERTER

DW300

MODEL: DW-300 P10537

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 DIVISIONSeptember 26, 2008

Upon contact, advise MODEL and MANUAL NO.

MAG/MIG

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CONTENTS

1. SAFETY INFORMATION 2

2. ARC WELDING SAFETY PRECAUTIONS 2

3. GENERAL NOTICE OF OPERATION 7

4. STANDARD COMPOSITION AND ACCESSORIES 8

5. FUNCTION OF EQUIPMENT 10

6. NECESSARY POWER SOURCE EQUIPMENT 11

7. TRANSPORT AND INSTALLATION 12

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE 14

9. WELDING PREPARATION 17

10. OPERATION 25

11. APPLIED FUNCTION 70

12. MAINTENANCE AND TROUBLESHOOTING 76

13. PARTS LIST 89

14. SPECIFICATIONS 92

15. SERVICE AND SUPPORT 97

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1. SAFETY INFORMATION

The following safety alert symbols and signal words are used throughout this manual toidentify various hazards and special instruct ions.

WARNINGWARNING gives information regarding possible personal injury

or loss of life.

CAUTIONCAUTION refers to minor personal injury or possible equipmentdamage.

2. ARC WELDING SAFETY PRECAUTIONS

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 unt il consult ing a doctor.

2. Read and understand the summarized safety information given below and the orig inalprincipal information that will be found in the PRINCIPAL SAFETY STANDARDS.

3. Have only trained and experienced persons perform installation, operation, andmaintenance of this equipment.

4. Use only well-maintained equipment. Repair or replace damaged parts at once.

ARC WELDING is safe when precautions are taken.

ELECTRIC SHOCK can kill.

Touching li ve electrical parts can cause fatal shocks or severe burns. The electrode and workcircuit s are electrically li ve whenever the output i s on. The power line and internal circuits ofthis equipment are also l ive when the line disconnect sw itch is on. When arc welding all metalcomponents in the torch and work c ircuits are electrically live.Leaving accretive dust in the welding machine may cause an insulation deterioration andresult in electrical shock and fire.1. Do not touch live electrical parts.

2. Wear dry insulating gloves and other body protection that are free of holes.3. Insulate yourself from work and ground using dry insulating mats or covers.4. Be sure to disconnect the line disconnect switch before installing, changing torch parts

or maintaining this equipment.5. Properly install and ground this equipment according to its Owners Manual and national,

state, and local codes.6. Keep all panels and covers of this equipment securely in place.7. Do not use worn, damaged, undersized, or poor ly spl iced cables.8. Do not touch electrodes or any metal object if POWER swi tch is ON.9. Do not wrap cables around your body.10. Turn off POWER swi tch when not in use.11. Remove dust by blowing moisture-free compressed air on each part periodically.

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2. ARC WELDING SAFETY PRECAUTIONS (continued)

ARC RAYS can burn eyes and skin: FLYING SPARKS AND HOT METAL cancause in jury. NOISE can damage hearing.

Arc rays from the welding process produce intense heat and strong ul traviolet rays that canburn eyes and skin.Noise from some arc welding can damage hearing.1. Wear face shield with a proper shade of fi lter (See ANSI Z 49.1 lis ted in PRINCIPAL

SAFETY STANDARDS) to protect your face and eyes when welding or watching a welderwork.

2. Wear approved face shields or safety goggles. Side shields recommended.3. Use protective screens or barriers to protect others from flash and glare: warn others not

to look at the arc.4. Wear protective clo thing made from durable, flame-resistant material (wool and leather)

and foot protection.5. Use approved earplugs or earmuffs if noise level is high.

Chipping and grinding can cause flying metal. As welds cool , they can throw off slag.

6. Wear proper body protection to protect skin.

WELDING can cause fire and explosion.

Sparks and spatter fly off f rom the welding arc. The flying sparks, hot metal, spatter, hot basemetal and hot equipment can cause fire and explosion. Accidental contact of electrode orwelding wi re to metal object can cause sparks, overheating, or fire.Leaving accretive dust in the welding machine may cause an insulation deterioration and resultin electrical shock and fire.

1. Protect yourself and others from flying sparks and hot metals.2. Do not weld where flying sparks can strike flammable material.3. Remove all flammables within 10m (33ft) of the welding arc. If this is not possible, tightly,

cover them with approved covers.4. Be alert that welding sparks and hot metals from welding can easily pass through cracks

and openings into adjacent areas.5. Watch for fire, and keep a fire extinguisher nearby.6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.7. Do not weld on closed containers such as tanks or drums.8. Connect power cable for base metal as close to the welding area as poss ible to prevent the

welding current from traveling along unknown paths and causing electric shock and firehazards.

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 anything other than arc welding.11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuff less trousers,

boots, and a cap.12. A loose cable connection can cause sparks and excessive heating.13. Tighten all cable connections.14. When there is an electri cal connection between a work piece and the frame of wire feeder or

the wire reel stand, arc may be generated and cause damage by a fire if the wire contactsthe frame or the work piece.

15. Remove dust by blowing moisture-free compressed air on each part periodically.

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FUMES AND GASES can be hazardous to your health.

Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous toyour health.

1. Keep your head out of the fumes. Do not breathe the fumes.2. Ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.3. If ventilation is poor, use an approved air-supplied respirator.4. Read the Material Safety Data Sheets (MSDS) and the manufacturers inst ruct ions on

metals, consumables, coatings, and cleaners.5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations.

The heat and arc rays can react with vapors to form highly tox ic and irritating gases.6. Work in a confined space only if it is well ventilated, or while wearing an air-supplied

respirator. Shielding gases used for welding can displace air causing injury or death.Be sure the breathing air is safe.

CYLINDER can explode i f damaged.

A shielding gas cyl inder contains high-pressure gas. If damaged, a cylinder can exp lode.Since gas cyl inders are normally part o f the welding process, be sure to handle them carefully.1. Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the

specific application; maintain them in good condition.2. Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent

falling or tipping.

4. Keep cylinders away from any welding or other electrical circuit.5. Never touch cylinder with welding electrode.6. Read and follow instructions on compressed gas cylinders, associated equipment, and the

CGA publ ication P-1 listed in PRINCIPAL SAFETY STANDARDS.7. Turn face away from the valve outlet when opening cylinder valve.8. Keep protective cap in place over valve except when a gas cylinder is in use or connected

for use.9. Do not disassemble or repair the gas regulator except if you are authorized by the

manufacturer.

ARC WELDING work areas are potential ly hazardous.

FALLING or MOVING machines can cause serious injury.1. When hanging the welding power source by a crane, do not use the carrying handle.2. Put the welding power source and wire feeder solidly on a flat surface.3. Do not pull the welding power source across a floor laid with cables and hoses.4. Do not put wire feeder on the welding power source.5. Do not put the welding power source or wire feeder where they will pit or fall.

WELDING WIRE can cause puncture wounds.1. Do not press the gun trigger until instruc ted to do so.2. Do not point the gun toward any part of the body, other people, or any metal when threading

welding wire.

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WARNING

Be sure to observe the followings for preventing physical inju ries, a fire and electric shock.

Handling of plastic partsFront panel and the likes on this power source are made of polycarbonate.

Make sure to observe the following notice.1. Do not apply external force and a shock to front panel and the likes. Otherwise it maybe

broken and in trouble.2. Polycarbonate can endure wiping off with water and alcohol in general but using at a

stick ing place with an organic solvent, chemicals, cutting oi l and atmosphere such ascomposit ion oil, it gives bad influence to polycarbonate and it causes a crack(breaking) and a strength down.If abnormality was discovered such as crack on the front panel, stop operatingimmediately and ask to repair and change.

Rotating parts may cause injuries. Be sure to observe the following.

If hands, fingers, hair or clothes are put near the fans rotating parts or wire feeders feed roll,injuries may occur.1. Do not use this equipment if the case and the cover are removed.2. When the case is removed for maintenance/inspection and repair, certif ied or experienced

operators must perform the work. Erect a fence, etc. around th is equipment to keep othersaway from it .

3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.

To prevent electromagnetic troubles, read the fol lowing. Also, if electromagnetictroubles occur, check the following again.

Before installing arc welding equipment the user shall make an assessment of potential

electromagnetic problems in the surrounding area. The following shall be taken into account:

1. other supply cables, cont rol cables, signalling and telephone cables, above, below and

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 equipment;

5. the health of the people around, for example the use of pacemakers and hearing aids;

6. equipment used for calibration or measurement;

7. The user shall ensure that other equipment being used in the environment is compatible;

8. the time of day that welding or other activities are to be carried out;

Methods of reducing EMC:

z Public supply systemAdd a noise f il ter to the input cables.

z Maintenance of the arc welding equipmentClose and fix all doors and covers of the welding machine.

z Welding cablesDo not use an unnecessarily long cable.Place a base metal cable and a torch side cable as closely as possible.

z Equipotential bondingBonding of all metallic objects in the surrounding area should be considered.

z Earthing of the workpieceThe connection of the workpiece to earth shou ld be made by a direct connection to the

workpiece, but in some countries where direct connection is not permitted, the bonding

should be achieved by suitable capacitance, selected according to national regulations.z Screening and shielding

It is selective screening and shielding of other cables and equipment in the surrounding area.

HF

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PRINCIPAL SAFETY STANDARDS

Arc welding equipment Installation and use, Technical SpecificationIEC 62081, from International Electro technical Commission

Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electrotechnical Commission

Arc welding equipment Part 10: Electromagnetic compatibility (EMC) requirements IEC 60974-10,from International Electro technical Commission

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.Government Printing 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 Containers That Have

Held Hazardous Substances, American Welding Society Standard AWS F4.1, from AmericanWelding Society.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed GasAssociation.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian StandardsAssociation, Standards Sales.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,from American National Standards Institute.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.

NOTE: The codes listed above may be improved or eliminated. Always refer to the updated codes.

M080904

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3. GENERAL NOTICE OF OPERATION

3.1 Rated duty cycle

CAUTION

Use this welding power source at or under the rated duty cycle. Exceeding the rated duty

cycle limi tation may result in damage to the welding machine.The rated duty cycle of the welding power source is 80% at 300A 29V:

NOTE: When using the dust filter, perform 65% or less duty-cycle operation (withoutclogging). Otherwise, the welding machine may be damaged. Refer to Section 3.1, Rated Duty Cycle .

The rated duty cycle of 80% means the machine must be rested for 2 minutes after 8minutes of continuous welding at the rated current.

Operation cycle of 80% duty cycle

Failure to observe duty cycle limitations may cause the temperature inside the weldingmachine to exceed tolerance levels. This may cause to premature welding machinefailure or product damage.

The figure shown right indicates the relationbetween welding current and duty cycle. Usethe welding machine within its usable range,

based on the appropriate duty cycle for thewelding current.

The duty cycle of the welding power source isalso limited by the duty cycles of accessoriescombined with it, such as welding torches. Usethe welding machine within the lowest ratedduty cycle of the accessories.

For use of exceeds rated voltage, duty cycle is60% at 300A, 36V.

3.2 Applicable welding process and wire diameterRefer to Section 10.1.1, Setting of Welding Mode for details of applicable welding method andwire diameter.

8 min. 2 min.

10 min.

ON OFF

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Ground a work piece ifa local law requires.

Basemetal

Analogremote control with3mcontrol cableOptionallyavailable

Digital remotecontrolOptionallyavailable

2mInput cable

withgrounding

Gas regulator

Control cable forwirefeeder2m

Shieldgas

Gas hose3m

Powercableforwirefeeder2m

WirefeederWeldingtorch

Powercable forbasemetal2m

Weldingpowersource

3phase 400V

Basemetal

Analogremotecontrol with3mcontrol cableOptionallyavailable

Digital remotecontrolOptionallyavailable

Gas regulator

Control cable forwirefeeder2m

Shieldgas

Gas hose3m

Powercable forwirefeeder2m

WirefeederWeldingtorch

Powercable forbasemetal2m

Weldingpowersource

Water cooler3phase400V

2mInput cable

withgrounding

4. STANDARD COMPOSITION AND ACCESSORIES

4.1 Standard composition

The part names indicated in the boxes are standard parts. Preparation of the other parts isrequired to use the welding power source.

Input cable and grounding cableFor a switch box, the 2m input and grounding cables are from the back panel of welding powersource.

Input cable AWG10 5mmwith 10mm terminal x 3

Grounding cable AWG10 5mmwith 10mm terminal x 1

For air cooling torch

*Extension cables / hoses (5m, 10m, 15m and 20m) are available.

Ground a work piece ifa local law requires.

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4. STANDARD COMPOSITION AND ACCESSORIES (continued)

4.2 Accessory

Make sure you have the item below before you start using the welding power source.

NOTE:When using the dust filter, perform 65% or less duty-cycle operation (without clogging).Otherwise, the welding machine may be damaged. Refer to Section 3.1, Rated DutyCycle.

4.3 Accessory (not supplied)

(1) Shield GasUse a suitable 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 stainless steel, MIG gas for mild steel with AC pulse98% argon (Ar) +2% carbon dioxide gas (CO2 gas)

MIG gas for AluminumPure argon (Ar)

Description Specification Qty Part number Remarks

Dust filter 109-1000M13 2 4519-031 For the fan on the rear panel ofwelding power source

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5. FUNCTION OF EQUIPMENT

5.1 Welding power source

Mainpow

erlamp

Powersw

itch

Caster

Outputte

rminal

(connect

towirefeeder)

Socketforw

irefeeder

Outputterminal

(conne

cttothe

basemetal)

Socketforanalogremote

controller

Cap

Caster

Parameteradjustingknob

Inputcable

Coolingfan

Frontpanel

Carryinghandle

Grommetswithfilm

(forpullingoutexternal

connectioncables)

Cap

Eyebolt

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6. REQUIREMENT OF INPUT POWER

6.1 Welding power source equipment (for commercial use)

WARNING

When the welding machine is used in a humid environment such as a construction site, on asteel plate, or on a steel structure, install a leakage breaker.

CAUTION

Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of eachwelding machine.

Capacity of necessary power source utility

MODEL DW-300

Power supply voltage 400V, Three phase

Tolerance range of fluctuation of power supply voltage 400V15%

Installed capacity 18kVA or more

Capacity of switch/circuit breaker 30 A

6.2 Precautions for use of the engine generator

CAUTION

Use the auxiliary power of engine welder with an improved voltage waveform. Some enginewelders have poor electricity, which may cause product damage. Contact an engine weldermanufacturer for improvement of voltage waveform.

To prevent the engine generator or auxiliary power from being damaged, follow the instructionsbelow.

Set the output voltage of the engine generator to the voltage range between 400 and 410V atno-load welding operation. Setting to extremely high output voltage may result in product damage.

Use the engine generator with a damper winding that has a capacity of more than twice that of therated input of the welding machine. Generally, the recovery time of the engine generators voltagefor load change is slower than that of the commercial input power source, and if the enginegenerator does not have sufficient capacity, sudden current change such as arc start will occur.This may result in abnormal decrease in output current or arc loss. Ask an engine generatormanufacturer for a damper winding.

Do not combine more than two welding machines with an engine generator. The effect of eachwelding machine may cause easy loss of arc.

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7. TRANSPORTATION AND INSTALLATION

7.1 Transportation

WARNING

Follow the instruc tions below to avoid trouble and product damage when carrying the weldingmachine.

Do not touch the live electrical parts inside or outside the welding machine. Be sure to disconnect the line disconnect switch when carrying the welding

machine.

When carrying the welding power source by a crane, do not use the handle andhang the welding power source with the eyebolt surely.

Do not hang welding power source without eyebolt by a crane.

7.2 Installation

WARNING

When installing the welding machine, follow the instruct ions below to avoid a fire caused bywelding and physical injury from gas fumes.

Do not place the welding machine near combustible materials and flammablegas.

Remove combustible materials to prevent dross coming i nto contact withcombustible objects. If that not possible, cover them with noncombustiblecovers.

To avoid gas poisoning and risk of suffocation, wear a gas mask oradequately ventilate when the welding machine is used in the place regulatedby a local law.

To prevent injury or poisoning caused by fume, wear a gas mask or w eld at apartial exhaust facility approved by the local regulation.

Adequately ventilate or wear a gas mask when using the welding machine in atank, a boiler, a hold of a ship, because heavier gas such as carbon dioxide orargon gases are drifting there.

When using the welding machine at a narrow space, comply with a t rainedsupervisors directions. And be sure to wear a gas mask.

Do not operate the welding machine near the place where degreasing,cleansing, and spraying are performed. Otherwise, poisonous gas may begenerated.

Be sure to wear a gas mask or adequately ventilate when welding a coatingsteel plate. (Poisonous gas and fume may be generated.)

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7. TRANSPORTATION AND INSTALLATION (continued)

CAUTIONTo prevent electromagnetic troubles, read the fol lowing. Also, if electromagnetictroubles occur, check the following again.

Change the installation place of the welding machine.

Mount an input cable in the grounded metallic condui t.

Shield the whole welding places from electromagnetic trouble.

CAUTION

Follow the instruc tions below when selecting an installation place of the welding power source.

Do not put heavy things on the welding power source.

Do not cover the ventilation port of the welding machine.

Do not install the welding power source in the place subject to d irect sunlight and rain.

Place the welding machine on a strong and stable surface. Install the welding machine in the place where the ambient temperature is between -10 C and

+40 C (+14 F and +104 F).

Do not install the welding machine in the place where metal material such as spatter enters thewelding power source.

Keep the install distance of 30 cm between the welding power source and the wall or otherwelding power.

Install a wind shield to protect arc from wind.

Fix the gas cylinder to the stand only for gas cylinder.

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8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

WARNING

Follow the instructions below to avoid electric shock.

Do not touch the live electrical parts, as this will result in fatal shock and severe burn. Do not touch the live electrical parts of the welding machine.

Have a qualified electric engineer ground the case of the welding power source and the basemetal or jig electrically connected, following a local low.

With the line disconnect switch i nside the switch box all turned off, ground and connect thewelding machine.

Do not use a cable with lack of capacity or a damaged cable.

Tighten and insulate the connections of cables.

Surely attach the cover of the welding machine after connection of the cables.

8.1 Connecting of the Welding Power Source

When using the air-cooled torch

When using the water-cooled torch

NOTE: In case of putting the Abnormal water pressure signal into the welding powersource, see 11.2.

Base metal

Analogremotecontrol

Optionallyavailable

Weldingpowersource

Weldingtorch

Powercableforbasemetal

Wire

feeder

Gas regulator

Control cable forwirefeeder

Shieldgas Gas hose

Powercable forwirefeeder

ControlcableforremotecontrolM10terminal

Surely insert the connector plugsinto the sockets for wire feederand for analog remote control upto the stop by turning themclockwise.

Basemetal

Analog remote control

Optionallyavailable)

Weldingpowersource

Weldingtorch

Powercableforbasemetal

Control cable forwirefeeder

Shieldgas

Powercable forwirefeeder

Controlcable forremotecontrol

Wire feeder

Gas hose

Water cooler

Waterhose

M10terminal

For feedingwater

Gas regulator

Ground a work pieceif a local law requires.

Ground a work pieceif a local law requires.

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Gas cylinder

Gas outlet

Nut for attachinggas cylinderGas regulator

Wire feeder

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Follow the steps below to attach the cables to the output connectors of the welding power sourcereferring to the illustrations of Connection of the Welding Power Sourceon the previous page.

1. Connect between the base metal - terminal and the base metal using the power cable forbase metal.

2. Attach the power cable for wire feeder to the torch + output terminal.3. Remove the right-side plate of the wire feeder, and then attach the power cable for wire feeder tothe M10 terminal. Surely fix the power cable in position not to contact with the bottom of theframe and the terminal board. Put around the terminals with insulating tape.

4. Insert the control cable for wire feeder into the socket for wire feeder.5. Attach the gas hose to the gas inlet on the wire feeder.6. Connect the welding torch to the wire feeder.7. Connect the hoses for water-out and for water-in to the water cooler. (When using a

water-cooled torch.)

8.2 Connecting of the Gas Hose

WARNING

There is a danger of suffocation caused by lack of oxygen when shield gaskeeps drif ting in a closed place. Be sure to turn off the shield gas at the mainwhen the welding power source is not in use.

CAUTION

Be sure to connect the gas hose after fixing to the stand, as physical injuries may resultfrom falling down of gas cylinder.

At tach a proper gas flow regulator to a gas cylinder. Failure to observe the demand mayresult in phys ical injuries. The gas flow regulator for high pressure gas must be used.

Securely attach the gas hose to the gas inlet located on the rear side of the wire feeder with amonkey wrench, etc.

Fix the nut for attaching the gas cylinder to the gas cylinder with a monkey wrench, etc.

Securely attach the gas hose to the gas outlet with a monkey wrench, etc.

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Mounta switchwith fuseora circuitbreakeroneachweldingmachine.

GREENcablefor Groudingcable

Base metal/J IG

Input cable

Surelyconnect the inputandgroundingcablesAWG10 (5mm2) to the circuitbreaker .

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

8.3 Grounding and connection of input power

WARNING

Follow the instructions below to avoid electric shock.

Touching the live electrical parts may result in fatal electric shock and severe burn. Do not touch the live electrical parts of the welding machine.

Have a qualified electric engineer ground the case of the welding power source and the basemetal or jig electrically connected in accordance with a local low.

With the line disconnect switch i n the switch box all touched off, ground and connect thewelding machine.

At tach the case properly after connecting the cable.

When the welding machine is used in a humid environment such as a construction s ite, on asteel plate, or on a steel structure, install a leakage breaker.

CAUTION Be sure to install a switch w ith fuse 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 14mm

2or more in thickness.

If the welding power source which is not grounded is used, voltage will be generated in thecase through the capacitor between the welding power source input circuit and the case orfloating capacity (electrostatic capacity naturally generated between the input conductor andthe case metal). If you touch the case or the base metal, you may suffer from electric shock.Be sure to ground the case of the welding power source.

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9. WELDING PREPERATION

9.1 Preparing the protective equipment

To protect you from gas generated from welding, fume, and lack of oxygen,wear protective equipment.

To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately ventilatewhen the welding machine is used in the place regulated by a local law.

To prevent disorder or poisoning caused by fume, wear a gas mask o r weld at a partialexhaust facility approved by the local regulation.

Adequately venti late or wear a gas mask when using the weld ing machine in a tank, a boi ler,a hold of a ship, because heavier gas such as carbon dioxide or argon gases are drifting.

When using the welding machine at a narrow space, comply with a trained supervisorsdirections. And be sure to wear a gas mask.

Do not operate the welding machine near the places where degreasing, cleansing, andspraying are performed. Otherwise, poisonous gas may be generated.

Be sure to wear a gas mask or adequately ventilate when welding a coating steel plate.

(Poisonous gas and fume may be generated.)

NOTE: Install a windshield to protect arc from wind when using an electric fan forventilation or when welding outdoors. Failure to observe the demand may result in poorwelding.

CAUTION

Use the protective equipment to p rotect you and other workers from arc rays,spattering dross, and noise from welding operation.

When performing or monitoring welding operation, wear an eye protector with a good lightblocking effect or face shield.

Wear protective glasses to protect your eyes from the spattering dross.

Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, andleather apron.

Install protective screens or barriers to pro tect the eyes of others in the work area from arcray.

Wear an ear protector when noise level is high.

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0.8

mm

0.9

1.0

1.2

1.4

1.6

WARNING

LOAD

SAVE

ENTER

JOB

MEMORY

Sec

JOBNO.

V

A

m/min

A

m/min

V

T1 T2

MAINCONDITION

INITIALCONDITION

DISPLAY

CHANGE

VOLT. CONTROL

ON

INITIAL

COND.

SYNERG.

SYNERG.

INDIV.

SPOTTIME

GASCHECK

INCHING

WELDING

METHOD

WIREDIA.

MILDSTEEL

STAINLESSSTEEL

AL/PURE

AL/MG

MIG

MAG

MIG

WATER

TORCH

%

Hz

f

ACPULSE

DCWAVEPULSE

WAVEFREQ.

CRATER-FILL.CONDITION

CRATER

FILL.

ARC

CONTROL

OP1

OP2

ACWAVEPULSE

DCPULSE

MILDSTEEL

CuSi

CuAl

DCNO-LOADVOLTAGE

ENRATIO

MONITOR

OFF

ON

REPEAT

SPOT

WELD

( OPTION)

Refertomanualf orrecommendedshielding gases

0.8

mm

0.9

1.0

1.2

1.4

1.6

WARNING

LOAD

SAVE

ENTER

JOB

MEMORY

Sec

JOBNO.

V

A

m/min

A

m/min

V

T1 T2

MAINCONDITION

INITIALCONDITION

DISPLAY

CHANGE

VOLT.CONTROL

ON

INITIAL

COND.

SYNERG.

SYNERG.

INDIV.

SPOTTIME

GASCHECK

INCHING

WELDING

METHOD

WIREDIA.

MILDSTEEL

STAINLESSSTEEL

AL/PURE

AL/MG

MIG

MAG

MIG

WATER

TORCH

%

Hz

f

ACPULSE

DCWAVEPULSE

WAVEFREQ.


CRATER

FILL.

ARCCONTROL

OP1

OP2

ACWAVEPULSE

DCPULSE

MILDSTEEL

CuSi

CuAl

DCNO-LOADVOLTAGE

ENRATIO

MONITOR

OFF

ON

REPEAT

SPOT

WELD

( OPTION)

Referto manualforrecommendedshiel dinggases

9. WELDING PREPARATION (continued)

9.2 Operating the switches and controlling the gas regulators for gas cylinders

CAUTION

Do not put your hands, fingers, hair, clothes and metal near the fan rotating.

Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as

burst of high-pressure gas may result in physical injuries.

NOTE: Gas checking automatically stops in two minutes.

9.3 Inching Operation

WARNING

Do not look into the tip hole to check for the rate of wire feeding whi le inching.The wire might fly out and hit the face or eyes, and you may get injured.

Do not bring the tip of the welding torch close to the face, eyes, or bodies. Youmay get injured.

CAUTION

Keep away your hands, fingers, hair or clothes from the rotating parts of the feedroll, etc. to prevent you from being caught into the rotating parts while inching.

After straightening the welding torch, feed the wire whilepressing the inching button. (INCHING lamp lights up).When the wire appears from the end of the torch, releasethe INCHING key. Cut the wire at about 10 mm from theend of the torch. When adjusting wire feed rate, use theparameter adjusting knob. Inching operation can becontrolled by using the INCHING button on the analogremote control (optional accessory). When controllinginching operation with the remote control, the INCHINGkey on the front panel does not function.

INCHING key

Parameter adjusting knob

Turn on the line disconnectswitch.

Set the gas regulators for gascylinders to SHUT , then turn on gas atthe main. Set the gas flow rate adjusting knobto OPEN to adjust the gas flow rate. Place the power switch inthe I (ON) position.

Press the GAS CHECK

key again. (The GASCHECK lamp goes out.)

Press the GAS CHECKkey. (The GAS CHECKlamp lights up.)

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9.4 Welding Conditions

When setting to the improper welding conditions, the following troubles will occur.

Cause Trouble

Wire extension is too long. Long Arc lengthWide bead width

Poor shield

Short arc lengthWire 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

Narrow bead width

Welding voltage is too low.

Deep penetration and low excess metal

Wide bead widthWelding current is too high.Deep penetration and high excess metal

Narrow bead widthTravel speed is too fast.

Shallow penetration and low excess metal

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The data in the tables below is only for reference. Please find the optimum welding conditions forweldment shape and welding position.

9.4.1 Example Aluminum AC pulsed MIG Welding Conditions (reference)Wire: A5183 Wire diameter:1.2mm Base metal: A5052Gas: Ar gas (20 liter/min)

(1) Lap fillet welding condition example

Platethickness

(mm)

Gap(mm)

Weldingcurrent *1

(A)

Weldingvoltage *1

(V)

Travelspeed

(cm/min)

Aimposition *2

Wire feedingspeed

(cm/min)

EN ratioadjustment

0 33 14.2 60 A 275 50.8

1.0 31 14.7 60 A 275 10

0 45 13.8 50 A 330 0

1.0 46 14.0 50 A 330 0

1.5 40 15.4 60 A 363 51.0

2.0 39 16.8 60 A 363 10

0 46 13.4 50 B 330 0

1.0 45 13.6 50 A 330 0

1.5 48 14.0 50 A 385 01.2

2.0 45 14.1 50 A 385 5

0 53 14.0 50 B 385 0

1.0 53 14.0 50 A 385 0

1.5 56 14.5 50 A 407 01.5

2.0 55 14.6 50 A 407 5*1 Welding current and Welding voltage are measured value.*2 Aim position A: Upper plate angle aim B: Lower plate aim

(2) Butt Lap fillet welding condition example

Plate

thickness(mm)

Welding

current *1(A)

Welding

voltage *1(V)

Travel

speed(cm/min)

Wire feeding

speed(cm/min)

EN ratioadjustment

0.8 39 15.2 150 330 5

1.0 39 14.0 70 275 0

1.2 40 13.8 70 300 0

1.5 40 13.9 70 300 0*1 Welding current and Welding voltage are measured value.

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9.4.2 Example aluminum pulsed MIG welding conditions

(1) I shape butt joint welding condition example (reference)

Platethickness

(mm)

Wirediameter

(mm)

Weldingcurrent

(A)

Weldingvoltage

(V)

Travelspeed

(cm/min)

Wireextension

Gas flow rate(liter/min)

1.5 1.2 60-80 16-18 60-80 12-15 20

2.0 1.2 70-80 17-18 40-50 15 20

3.0 1.2 80-100 17-20 40-50 15 20

4.0 1.2 90-120 18-21 40-50 15 20

6.0 1.21.6 150-180 20-23 40-50 15-18 20

(2) Flat fillet welding condition example (reference)

Platethickness

(mm)

Wirediameter

(mm)

Weldingcurrent

(A)

Weldingvoltage

(V)

Travelspeed

(cm/min)

Wireextension

Gas flow rate(liter/min)

1.5 1.2 60-80 16-18 60 15 15-20

3.0 1.2 100-120 19-21 60 15 15-20

6.0 1.21.6 150-180 20-23 50-60 15 20

9.4.3 Example pulsed MAG welding conditions(1) Example Welding Conditions of Horizontal Fillet Welding

Platethickness

(mm)

Leglength(mm)

Aim angleand

position

Numberof

layers

Weldingcurrent

(A)

Weldingvoltage

(V)

Travelspeed

(cm/min)

3.2 3 4 1 150 26-27 60

4.5 5.0 1 170 26-27 40

6.0 6.0 1 200 27-28 40

8.0 8.0 1 250 29-30 35

12.0 10.0123

180-200180-200180-200

25-2725-2825-28

454545

16.0 12.0

1

23

220-230

220-230210-230

25-28

25-2825-28

45

4545

(2) Example welding conditions of downward weldingPlate

thickness(mm)

Shape ofjoint weld

Weldingcurrent

(A)

Weldingvoltage

(V)

Travelspeed

(cm/min)Remarks

2.3 butt 100 22-23 70 Back bead appearance is good.

3.2 fillet 100 21-22 70Leg length: 4 - 5mm,Throat depth: 2.5mm

30-40

Focus here.

Angle of advance: 10

1 mm2 - 3 mm

1 2

3

30-40

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(3) Example welding conditions of upward weldingPlate

thickness(mm)

Shape of joint weldWeldingcurrent

(A)

Weldingvoltage

(V)Remarks

12100-110 20-21 WeavingLeg length: 10.0mm

(4) Both side welding conditions of (Semi-automatic)

Platethickness

(mm)Groove shape

Number oflayers

Weldingcurrent

(A)

Weldingvoltage

(V)

Travelspeed

(mm/min)

6.01

2

170

180

25-26

26-27

30

30

9.01

2

270

290

29-30

30-31

30

30

12.01

2

280

330

30-31

33-34

40

40

19.0

Front 1Front 2Rear 1Rear 2

300300340280

31-3231-3232-3330-31

45454545

25.0

Front 1Front 2Front 3Rear 1Rear 2Rear 3

300320320340320320

31-3232-3332-3332-3332-3332-33

454545454545

Stop at both ends

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(5) Example welding conditions of single side welding conditions (Automatic)

Platethickness

(mm)Groove shape

Number oflayers

Weldingcurrent

(A)

Weldingvoltage

(V)

Travelspeed

(cm/min)

3.2 1 140 24-25 50

6.01

2

130

150

23-24

25-26

25

25

12.01

2

180

290

24-25

30-32

25

25

12.0123

180-190200200

24-2525-2626-27

252525

19.0123

180300300

24-2529-3029-30

252525

Oscillation width: 2 mmOscillation times: 120 times/min.

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(6) Single bevel groove penetration welding conditions (Semi-automatic)

Groove shapeNumber of

layers

Weldingcurrent

(A)

Weldingvoltage

(V)Remark

Flat position 1 100 20-21

2 280 26-273 280 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 24-25

3 200 24-25

4 200 24-25

5 200 24-25

6 200 24-25

7 200 24-25

8 200 24-25

9 180 24-25

10 180 24-2511 180 24-25

12 180 24-25

Nooscillation

Wire diameter: 1.2 mmGas: 20% CO2 + Ar

3.2

32

45

32

3.2

45

32

3.2

45

Unit: mm

Unit: mm

Unit: mm

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[8]

[16] [1][2][15][14][3][12][7][11][18][17] [22]

[5][13][4][19][20][21] [9] [10][6]

0.8

mm

0.9

1. 0

1. 2

1. 4

1. 6

WARNING

LOAD

SAVE

ENTER

JOB

MEMORY

Sec

JOBNO.

V

A

m/min

A

m/min

V

T1 T2

MAINCONDITION

INITIALCONDITION

DISPLAY

CHANGE

VOLT. CONTROL

ON

INITIAL

COND.

SYNERG.

SYNERG.

INDIV.

SPOTTIME

GASCHECK

INCHING

WELDING

METHOD

WIREDIA.

MILDSTEEL

STAINLESSSTEEL

AL/PURE

AL/MG

MIG

MAG

MIG

WATER

TORCH

%

Hz

f

ACPULSE

DCWAVEPULSE

WAVEFREQ.


CRATER

FILL.

ARC

CONTROL

OP1

OP2

ACWAVEPULSE

DCPULSE

MILDSTEEL

CuSi

CuAl

DCNO-LOADVOLTAGE

ENRATIO

MONITOR

OFF

ON

REPEAT

SPOT

WELD

( OPTION)

Refertomanual forrecommendedshieldinggases

10. WELDING OPERATION10. Front Panel

[1] WELDING METHOD selector key [9] Arc characteristic setting key [17] GAS CHECK key

[2] Wire material/gas selector keys [10] WAVE FREQ. setting key [18] INCHING key

[3] WIRE DIA (mm) selector key [11] Arc spot time setting key [19] LOAD key

[4] Current setting display selector key [12] F (FUNCTION) selector key [20] SAVE key

[5] Voltage setting display selector key [13] Initial condition selection key [21] ENTER key

[6] Parameter adjusting knob [14] Synergic/Individual selector key [22] EN ratio setting key

[7] Crater selector key [15] Torch selector key

[8] DISPLAY CHANGE key [16] Weld monitor key (Option)

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10. WELDING OPERATION (continued)

CAUTION

This welding machine should be operated by persons only after reading and understandingcontents of this owners manual and having knowledge and skills for handling the weldingmachine safely.

Use this welding power source at or under the rated duty cyc le. Exceeding the rated duty cyclelimitation may result in damage to the welding machine.

When reading the operating instructions described below, unfold Page 91so that you can read them confirmingthe location of the keys on the front panel.

10.1 Basic Settings

10.1.1 Setting of Welding Mode

Choose the welding mode using WELDING METHOD selector key [1], the wire material/gas selector

keys [2] and the WIRE DIA (mm) selector key [3] in accord with the welding method, material, gas and

wire diameter used. The selectable welding modes are shown on the next page.

When setting the welding mode, select the welding method using the WELDING METHOD selector key[1] first. Once the welding method is set, the available material and gas are automatically decided

according to the welding method. Then, select wire/gas using the wire material/gas selector keys [2].

Finally, set the wire diameter with the WIRE DIA (mm) selector key [3].

Combination which is not in the tables below will cause abnormal indicator blink as welding method

setting error, ---and --- in the displays to blink, and the welding power source to stop.

Moreover, wire material/gas LED, and wire diameter LED which is the cause of abnormality, blink.

For example, when selecting MILD STEEL MIG while setting "AC PULSE AL/MIG MIG 1.6" with the

WELDING METHOD selector key [1], the "1.6" lamp blinks, which means the preset combination is

incorrect. In that case, select material and gas again using the wire material/gas selector keys [2] or

reset the welding method using the WELDING METHOD selector key [1]. Selecting the proper

combination of material and gas can cancel the error and activate the welding power source.Wrong combination of welding mode and wire diameter will cause ---and --- in the displays to blink,

the LED lamps to light, and the welding power source to stop.

Table of the welding

Welding method Type of wire Gas Wire diameter (mm)

AL/MG (Hard Aluminum) 1.0, 1.2, 1.6AC

AL/PURE (Soft Aluminum) 1.2, 1.6AL/MG (Hard Aluminum) 1.0, 1.2, 1.6

DC

WAVE PULSE

AL/PURE (Soft Aluminum) 1.2, 1.6AL/MG (Hard Aluminum) 1.0, 1.2, 1.6

AL/PURE (Soft Aluminum) 1.2, 1.6

BrazingCuSi 0.8, 0.9, 1.0, 1.2

AC

BrazingCuAl 0.8, 0.9, 1.0, 1.2AL/MG (Hard Aluminum) 1.0, 1.2, 1.6

AL/PURE (Soft Aluminum) 1.2, 1.6BrazingCuSi 0.8, 0.9, 1.0, 1.2

DC

PULSE

BrazingCuAl

MIG

(Ar)

0.8, 0.9, 1.0, 1.2Stainless 0.8, 0.9, 1.0, 1.2

ACMild Steel Solid 0.8, 0.9, 1.0, 1.2

Stainless

MIG(97.5%Ar+2.5%CO2

) 0.8, 0.9, 1.0, 1.2DC

PULSE

Mild Steel Solid MAG 0.8, 0.9, 1.0, 1.2

MAG gas

Argon (Ar) 80% / Carbon dioxide (CO2) 20%

MIG gas (Stainless / Mild steel solid)Argon (Ar) 97.5% / Oxygen (O2) 2.5%

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10.1.2 Setting the Parameter

Select a parameter using this key.

[Parameter selector]

Choose a desired parameter using the DISPLAY CHANGE key [8]. Display in the displays are

changed according to the parameters you select and the UNIT lamp of the parameter lights up.

[Parameter displays]

z When the wire feed speed is displayed, you can not set to the maximum feed speed using theparameter adjusting knob [6] depending on the welding mode settings (especially for large

diameter). You are only allowed to set the wire feed rate to the value that can achieve the

current setting determined by the rated output current.

z The values shown in the displays are not the actual data but the setting values of voltage,

current, and wire feed speed. Use the values in the displays as approximates.

WARNING

m/ mi n

Sec

J OB No.

%

Hz

T1 T2

MAINCONDITION

INITIALCONDITION

CRATER-FILLCONDITION

A

m/min

V

DISPLAY

CHANGE

Pressing the key while the A/m/min lamp (locatedat the upper left of the A/m/min selector key) is litchanges over displays of current setting and wirefeed rate. Pressing the A/m/min selector key

while the A/m/min lamp is not lit causes theA/m/min lamp to light. While the A/m/min lamp islit, current can be adjusted using the parameteradjusting knob [6].

Pressing the key while the V/ lamp (located at the

upper left of the V/ selector key) is lit changes voltagesetting and fine adjustment from the center of the oneknob adjustment. (Only for one knob adjustment)

Pressing the V/ selector key while the V/ lamp is notlit causes the V/ lamp to light. While the V/ lamp is lit,current can be adjusted using the parameter adjustingknob [6].

UNIT lamps

Digital Meter

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10.1.2 Setting the parameter (continued)

(1) Pre-flow time setting

Once the pre-flow time is chosen, the setting value is displayed in the left display and the "sec." lamp

lights. At this condition, you can set pre-flow time while turning the parameter adjusting knob [6].

The setting range of pre-flow time covers 0 second to 10 seconds.

(2) Setting of the initial conditions

The initial conditions can be chosen only when initial current is set to ON. Once the initial conditions

are chosen, the 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

displays.

(4) Setting of the crater conditions

Only for ON or REPEAT, the crater conditions can be selected. Once crater conditions are chosen,

the setting values of the crater conditions are displayed in the display.

(5) Setting of the post-flow time

Once the post-flow time is selected, the setting value is displayed in the left display and the "sec."

lamp lights up. At this conditions, the post-flow time can be set while turning the parameter adjusting

knob [6]. The setting range of post-flow time covers 0 second to 10 seconds.

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10.1.3 Setting of the CRATER-FILL functions

Crater is a depression left at the termination of the

weld. As it may cause cracks and poor welding, a

crater treatment called crater-filler is used to fill in thedepression.

When giving a crater treatment, set the crater selector key [7] to "ON" or "REPEAT".

Each press of the crater selector key [7] changes the crater-fill mode in order.

"OFF" "ON" "REPEAT" "SPOT"

CraterInitial

CurrentTiming Chart

OFF

Keep the torch switch pressed and held during welding.

Slow-down speed

Anti-stick (Burnback) time

Crater

Bead

Pool

Torch Switch

Gas Flow

Welding Voltage

Wire Feed Speed

Welding Current

Pre-flow time

No-load voltage

Post-flow time

MAIN WELDING

ON

OFF

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Welding Current


CraterInitial

CurrentTiming Chart

OFF

ON

ON

Even if the torch switch is switched off during welding, start signal will be self-hold. The

torch switch should be kept pressed and held during the INITIAL and CRATER period.

Slow-down speed

Anti-stick (Burnback) timeTorch Switch

Gas Flow

Welding voltage

Wire Feed Speed

Pre-flow time

No-load voltage

Post-flow time

MAIN WELDING

OFF

ON ON

OFF

CRATER

Welding current

Crater current

Slow-down speed

Anti-stick (Burnback) time

Gas Flow

Welding Voltage

Wire Feed S eed

Welding Current

Pre-flow time

No-load voltage

Post-flow time

MAIN WELDING

OFF

ON ON

OFF

CRATER

Welding current

Crater currentInitial current

INITIAL

Torch Switch

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CraterInitial

CurrentTiming Chart

OFF

ON

ON

(REPEAT)

Even if the torch switch is switched off during welding, start signal will be self-hold. The

torch switch should be kept pressed during the INITIAL and CRATER period.

When turning on the torch switch again within about 2 seconds after arc disappears,

welding condition starts with CRATER condition. The condition will continue until the

torch switch is turned off. Repetition of the same operation enables you to have crater

treatment as many times as you need.

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10.1.4 Setting of Arc Spot Time

When performing arc spot treatment, set to "SPOT" using the crater selector key [7]. Then, when

pressing the arc spot time setting key [11], the SPOT TIME lamp (located at the upper left of the

CRATER-FILL key) lights up, the setting value is displayed in the leftt display, then the "sec." lamp lights

up. At that condition, the ARC SPOT time can be set while turning the Parameter adjusting knob. TheARC SPOT time between 0.1 second and 10 seconds can be set. Press the arc spot time setting key

[11] 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 current setting display selector key [4]

and to a voltage-related parameter using the voltage setting display selector key [5].

The SPOT TIME key functions only during Arc Spot time.

Torch

Switch

ON

OFF

Output

Current

Keep the torch switch pressed and held during the Arc Spot time.

(When the torch switch is turned off during arc spot, the output is stopped.)

ARC SPOT time

Welding Current

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10.1.5 Adjusting welding voltage

Using the synergic/individual selector key [14] allows you to select one of the following voltage

adjustment methods.

(1) Making the INDIVIDUAL adjustment

The INDIVIDUAL adjustment can be achieved when the VOLT.CONTROL lamp (located at the upperleft of the synergic/individual selector key [14]) is off. In the case of the INDIVIDUAL adjustment, welding

current and welding voltage must be adjusted individually. When you want to set welding voltage, make

sure that the VOLT. CONTROL lamp is lit, then adjust the welding voltage while turning the Parameter

adjusting knob. When you want to set welding voltage, make sure that the VOLT. CONTROL lamp is lit,

then set welding voltage while turning the Parameter adjusting knob.

NOTE: When selecting only DC PULSE MILD STEEL sol id or STAINLESS STEEL solid, the

INDIVIDUAL adjustment can be achieved. For other welding method the SYNERGIG adjustment

function is automatically activated.

(2) Making the SYNERGIC adjustment

The SYNERGIC adjustment can be achieved when the VOLT. CONTROL lamp (located at the upper leftof synergic/individual selector key [14]) is on. For the SYNERGIC adjustment, the proper welding

voltage for the current setting is automatically set. When the VOLT. CONTROL lamp is lit, welding

voltage can be finely adjusted using the Parameter adjusting knob. In addition, it is also possible to

change over the display setting in the right display using the voltage setting display selector key [5]. The

selectable display settings 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 .

NOTE: Use of mix ture gas other than the mixtu re ratio of the fol lowing gas may not properly

adjust welding voltage at Synergic control , etc.

MAG gas

80% argon (Ar) +20% carbon dioxide gas (CO2 gas)MIG gas for stainless steel and mild steel solid

98% argon (Ar) +2% carbon dioxide gas (CO2 gas)

10.1.6 Arc characteristics function

When pressing the arc characteristic setting key [9] while the INITIAL CONDITION, MAIN CONDITION,

or CRATER-FILL CONDITION is selected the ARC CONTROL lamp (located at the upper left of the arc

characteristic setting key [9]) lights up, the setting value is displayed in the right display, and the V/

lamp lights up. At that condition, it is possible to set arc characteristics by using the Parameter

adjusting knob. The setting range is 0 to 10. Pressing the arc characteristic setting key [9] again or

pressing the DISPLAY CHANGE key [8] returns to the previous parameter setting. In addition, it is also

possible to change over the display to a current-related parameter by using the current setting displayselector key [4] and to a voltage-related parameter by using the voltage setting display selector key [5].

The standard setting value of arc characteristic is 0. As the setting value of the arc characteristic is set

in the negative direction (up to -10), arc condition becomes harder. As the setting value of the arc

characteristic is set in the positive direction, arc condition becomes softer (up to 10). When you use the

welding power source in the low current range, set the setting value of the arc characteristic in the

negative direction to obtain good welding results. When you use the welding machine in the high

current range, set the setting value of the arc characteristic in the positive direction to obtain good

welding results. If you can not obtain optimum arc condition due to use of the extension cables, set the

setting value of the arc characteristic in the negative direction.

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10.1.7 WAVE PULSE functionIn wave pulse welding, the ripple bead appearance can be obtained by applying two separate pulsescyclically at low frequency. This feature will also assist for aluminum welding or in welding joints thathave some poor fit up or gaps. Although, the wave mode is usually most applicable for fully automatic

welding, benefits are also achieved even in semi-automatic applications. Good bead appearances areobtained by setting the wave frequency to 5Hz or more even for semi-automatic.

When setting wave pulse frequency, select DC WAVE PULSE or AC WAVE PULSE with the

WELDING METHOD selector key [1]. When DC pulse or AC pulse is selected, wave pulse

frequency setting is invalid. When the WAVE PULSE key is pressed while INITIAL CONDITION/

MAIN CONDITION/ CRATER-FILL. CONDITION is selected, the WAVE PULSE lamp (located at

the upper left of the WAVE PULSE key) lights up, the setting value appears in the left display, the Hz

LED lamp lights up. Under these conditions, wave pulse frequency can be adjusted while turning the

Parameter adjusting knob. The setting range of wave pulse frequency is 0.5 Hz to 32 Hz. Adjust wave

pulse frequency until you can obtain the desired bead appearance.

When pressing the WAVE FREQ. key or DISPLAY CHANGE key again, return to the last parameterthat you have set. When changing the display to a current-related parameter, press the current setting

display selector key [4]. When changing the display to a volt-related parameter, press the voltage

setting display selector key [5].

high frequency

low frequency

NOTE:- Wave pattern of the welding bead may not appear clearly depending on the heat input during

welding.- When using sof t aluminum, bead surface may blacken somewhat if shorting occurs frequentlyduring the welding operation.

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10.1.8 EN ratio ( )

In the AC pulse welding, the EP current (the torch is +polarity) and the EN current (the torch is - polarity)output alternately, and the heat input to the base metal (penetration) can be controlled according to the EP andEN ratio. As a result, a high-quality welding can be obtained for very thin plate or the work which has gap.

For EN ratio setting, select AC PULSE or AC WAVE PULSE by WELDING METHOD selector key [1]. WhenDC pulse is selected, EN ratio setting is invalid.When pressing the EN ratio setting key [22] while the INITIAL CONDITION, MAIN CONDITION, or CRATER-

FILL CONDITION is selected the EN RATIO lamp (located at the upper left of the EN ratio setting key [22])

lights up, the setting value is displayed in the right display, and the LED lamp lights up. At that condition, it is

possible to set EN ratio by using the parameter adjusting knob [6]. The setting range is 0 to 30.

Pressing the EN ratio setting key [22] again or pressing the DISPLAY CHANGE key [8] returns to the previous

parameter setting. In addition, it is also possible to change over the display to a current-related parameter by

using the current setting display selector key [4] and to a voltage-related parameter by using the voltage setting

display selector key [5].

The average EN ratio (%) during welding is displayed in the left display.

The standard setting value of EN ratio is 0. As the setting value of the EN ratio is set in the negative direction,

EN ratio becomes smaller (down to -30). As the setting value of the EN ratio is set in the positive direction, EN

ratio becomes larger (up to +30)

The relation between EN ratio setting and welding result are shown in the table below.

Negative direction EN ratio setting Positive direction

Decreasing EN ratio Increasing

Slow Wire melting speed Quick

Small Gap tolerance Large

*It is substantially constant penetration.

EN means the period which the base metal is positive (+) and the torch is negative (-), and EP means the

period which the base metal is negative (-) and the torch is positive (+).

The EN ratio changes about 1% by adjustment amount 1 of the operation.

A standard value of the EN ratio (value at center position '0') and the maximum value of the EN ratio are

different at the welding process and each current setting. Minimum value of the EN ratio is 0%. Lost of the EN

period and becomes direct current.

Note:

The EN ratio is as a guide, and it may become different result according to an actual welding condi tion

and the working environment.

Iep

Ien

EP

EN

EN ratio means the current ratio of the ENpolarities (ratio of the areas) at one ACcycle, and it was shown by percent.It is defined by the next expression.

IenEN ratio = 100%

Iep + Ien

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10.1.9 Notice of using AC pulse mode

When using AC pulse mode, observe the followings not to damage the welding power

source

1. Use proper extension cable and use as short cable as possible.

2. When using the extension cable, refer to following figure.

Bind the torch cable and base metal

cable each other with tape.

Straighten the cables as much as

possible.

If cable setting mentioned abovecannot be performed by all means,lay the torch cable on the base

metal.

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3. If overlong power cable is used reluctantly, wind it according to following figure of

Good example.

Bad example Good example

Do not wind the excess part of cable in the

same direction.

Refer to the figure below winding method of

excess cable, and make two windings in oppositedirection each other and pile up one on another.

Winding method of excess cable

1 2 3

Top view

Side view

Explanation Separate the excess cableinto A and B.

Wind it respectively as

followings.

Same winding direction.

Same turns of winding.

Same diameter of

Windings.

Place B over A in theopposite direction.

After placing B over A, bindthe winding cable not to be

loose.

Explanation

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10.1.10 GAS CHECK function (with gas save function)

This function is used when opening the discharge valve of the shield gas and when adjusting the gas

flow rate. When pressing the GAS CHECK key [17] once, the GAS CHECK lamp (located at the upper

left of the GAS CHECK key) lights up and allows gas to flow. Pressing the GAS CHECK key again

turns off the GAS CHECK lamp and stops discharging gas. In more than two minutes after the GAS

CHECK key is pressed, gas discharge automatically stops and the GAS CHECK lamp goes out. In theevent that the machine is started while gas is being checked, gas stops flowing after welding is

completed (upon completion of post-flow) and gas does not continue to flow during down period.

10.1.11 INCHING function

When pressing the INCHING key [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 feed rate by turning the parameter adjusting knob [6], make

sure that the A/m/min selector lamp lights up. When connecting to the analog remote control (optionally

available), the INCHING key on the front panel can not be used for inching operation. When connecting

to the analog remote control, use the inching switch on the remote control to activate the INCHING

function.

10.1.12 TORCH WATER/AIR selection

When an abnormal signal of water cooling unit is connected with connector CON4, select WATER/AIR

according to your torch by using the torch selector key [15]. When using a water-cooled torch, select

WATER by pressing the TORCH key once. When WATER is selected, the TORCH lamp (located

at the upper left of the TORCH key) lights up. When using an air-cooling torch, make sure that the

TORCH lamp goes out. When water cooling unit abnormal occurs while WATER is selected,

abnormal code E-510 blinks on the front panel digital meter

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10.1.13 Verifying the parameters in the displays

The displays on the front panel provides the following functions:

1. Display of parameter setting value

When setting to parameter setting values display mode during down period (excluding the result

display period right after the completion of welding) and during welding, values of parameters under

adjustment are displayed.

2. Display of output current during welding

The parameters shown in the displays automatically change to average values of output current

and output voltage according to the output conditions every about 0.5 second. When you want to

change the parameters during welding, switch to the parameter setting values display mode by

using the DISPLAY CHANGE key [8]. When no welding operation is carried out for about 5

seconds or the DISPLAY CHANGE key [8] is held down, the display mode automatically returns to

the average values display mode. When the TORCH key is pressed, the LED lamps of the

sequence parameters go on sequentially according to the welding operations. When the display

setting is switched to the "parameter setting values display" mode, each LED lamps (located at the

sequence parameter setting section) of the sequence that is currently outputting begin blinking.

Refer to Section 10.1.14, Using the Parameter Adjusting Knob for the parameters that can beadjusted using the parameter adjusting knob [6] during welding.

3. Display of welding results after completion of welding

Upon completion of welding, the average output current and voltage for last one second 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

as approximates when adjusting the welding conditions. This display is cancelled by starting the

next welding or by pressing any key on the front panel without waiting 20 seconds after the

completion of welding. The result display time can be preset to F8 by using the F (FUNCTION)

selector key [12]. The setting value is displayed in the left digital and the "sec" lamp lights up. The

setting range of the result display time is 5 seconds to 60 seconds.

NOTE: In the case where the less than one-second w elding such as tack welding, etc. is

performed, the correct results of the welding are not displayed.

4. Display of error message

If an error is detected in the welding power source, an error number indicating error messages

blinks. See Section 12.5, "Troubleshooting".

NOTE: The average output values shown in the displays are processed by software and are

not guaranteed as control data of measuring instruments. Display accuracy: Class

2.5 or equivalent).

10.1.14 Using the Parameter adjusting knobWhen adjusting parameters using the parameter adjusting knob [6] during welding, change over the

display mode to the parameter setting value display mode by pressing the DISPLAY CHANGE key

[8]. The initial conditions, the main conditions, and the fill crater conditions can be changed during

the INITIAL welding, MAIN welding, and CRATER welding respectively. After changing to the

parameter setting value display mode, pressing the arc characteristic setting key [9] adjusts the arc

characteristics. Pressing the WAVE PULSE key adjusts the wave frequency. Pressing the EN RATIO

key adjusts the EN ratio. In the average parameter value display mode, you can not adjust the

parameter.

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10.1.15 Using the analog remote control K5416U (optional accessory)

The welding machine automatically recognizes the analog remote control when the power switch is

turned on. When the analog remote control is connected to the welding power source, the analog

remote control is recognized first. Therefore, even when selecting welding current/voltage, the

welding current/voltage can not be adjusted by using the parameter adjusting knob [6] on the front

panel. When the analog remote control is connected, adjust the parameter while turning theWELDING CURRENT/VOLTAGE knobs on the analog remote control. It is possible to verify the

parameter setting values which are preset with the analog remote control, in the displays of the front

panel. Once the analog remote control is disconnected, the setting values preset with the remote

control are erased.

NOTE: With the power switch turned off, connect or disconnect the analog remote control.

Scale of the analog remote control i s up to 350A, but maximum output of this w elding

power source is 300A.

When making the INDIVIDUAL adjustment:

Selecting the "INDIVIDUAL" adjustment allows you to set welding current and welding voltageindividually.

When making the SYNERGIC adjustment:When selecting the "SYNERGIC" adjustment, welding voltage is automatically adjusted only byturning the WELDING CURRENT knob. To finely adjust welding voltage, use the VOLTAGE. knob.

NOTE: It is possible to adjust low-current region, where a small-diameter wire is used forweld, and to finely adjust w elding current by replacing w ith the full-scale 200A plate(suppl ied). To replace the scale plate, press the F (FUNCTION) selector key [12] andchange the in itial value of F9 to 200. Refer to Section 10.2.1(9), Selection of scaleplate of analog remote control .

WELDING CURRENT knob

INCHING button

To set welding current.

Pressing this switch feeds wire only. Thewire feed rate changes by turning the

WELDING CURRENT knob on the left.

Set welding voltage.Aligning to mark achieves the standardsetting. Turn the knob in the "HIGH" direction toincrease voltage and in the "LOW" direction todecrease voltage.

VOLTAGE knob / SYNERG.ADJ . knob

350

100

150

200

250

300

3505014

16

2022

24

30

32

34

36

2826

18

O2/ MAG/ MI G

LOOS

E

VA

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10.2 Applied settings

10.2.1 Using internal function

How to use internal functions When holding down the F (FUNCTION) selector key [12] for a few seconds, the function number

in the left-side display blinks, and the status of function assigned to the function number lights up

and is displayed in the right-side display. Under this condition, a function number can be preset by

using the parameter adjusting knob [6].

The number of function blinks. The conditions of function lights.

A function number can be preset with the parameter adjusting knob [6]

The above example indicates that F19 is set to on.

When pressing the F (FUNCTION) selector key [12] again after presetting the desired function

number, the function 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.

Conditions can be set while turning the parameter adjusting knob.

The above example indicates that F4 is set to off.

Pressing the F (FUNCTION) selector key [12] again causes the function number to light up and

returns to the step. To cancel the function mode, hold down the F (FUNCTION) selector key

[12] for a few seconds.

NOTE: In the function mode, no confirmation of the function is carried out when it is changed.

Upon change of the setting by using the parameter adjusting knob [6], the change

becomes valid. Therefore, before changing a function setting, carefully check to make

sure that the correct funct ion number is selected and that the proper setting value for

the function number is set.

sec

J OB No.

WARNNING

/min

Hz

%

J OB No.

WARNNING

/min

sec

Hz

%

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The following welding conditions can be adjusted by using the F (FUNCTION) selector key [12] and the

parameter adjusting knob [6], but only the welding conditions with* next to the function numbers can be preset

to the welding condition numbers.

(1) Fine adjustment of anti-stick (burnback) time: F1*

Anti-stick (burnback) time means the processing time to prevent electrode wire from fusing to base metalwhen welding is completed. Anti-stick (burnback) time is preset to proper conditions according to welding

methods and wire diameters at shipment, but it can be finely adjusted by activating F1. The standard anti-

stick (burnback) time is preset to "0", time decreases in the negative direction and increases in the positive

direction. The fine adjustment range is 0 to 50 and the unit is 0.01 seconds.

Ex. 1) When the setting value of anti-stick (burnback) time is 25, add 0.25 second to the standard anti-stick (burnback) time.

Ex. 2) When the setting value of anti-stick (burnback) time is -10, subtract 0.1 second from the

standard anti-stick (burnback) time.

(2) Fine adjustment of anti-stick (burnback) voltage: F2*

Anti-stick (Burnback) voltage means the voltage which is output when processing is carried out to preventelectrode wire from fusing to base metal at the end of welding. Anti-stick (Burnback) voltage is preset to

proper conditions according to welding methods and wire diameters at shipment, but it can be finely

adjusted by activating F2. The standard anti-stick (burnback) voltage is preset to 0. When the voltage is

set in the negative direction, it decreases. When the voltage is set in the positive direction, it increases.

The fine adjustment range is 0 V to 9.9V.

(3) Fine adjustment of slow-down speed: F3*

Slowdown speed means the speed to feed wire that is slower than the feed rate at normal welding during

the period from startup to arc start. The slowdown speed is preset to proper conditions according to

welding methods and wire diameters at shipment, but it can be finely adjusted by activating F3. 0 is

standard. When the slowdown speed is set in the negative direction, it decreases. When the slowdown

speed is set in the positive direction, it increases. The fine adjustment range is 0 m/min to 1.0 m/min.When poor arc start occurred, lower the slowdown speed. Even when arc start is good, the slow-down

speed can be increased to shorten tact time.

NOTE: The minimum slow -down speed is 0.4 m/min.

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(4) Selection of auto/semi-automatic:F4

"Automatic machine mode" and "Semiautomatic mode" can be switched by function number '4'. And there

are two kinds for automatic machine mode. The relation between the setting method and the function of

each mode is tables below.

Function No. 4 0 (factory setting) 1 2

Mode Semi-automatic Automatic 1 Automatic 2

Return from operation stopBy power source

returning on againBy short-circuit of the operation stop terminal

Stuck wire removal voltage Do not impressAfter the anti-stick completion, it impresses about

0.2 seconds.

Welding current and

voltage setting

By panel or analog

remote controlBy external voltage (*1)

By panel or analog

remote control

Retract function (*2) Out of use Possible to use

Inching from interface (*3) Out of use Possible to use

*1: The current and the voltage of main condition cannot be set with the parameter adjusting knob [6] of the

front panel.*2: Wire feed direction will be reversed by short-circuit between 4 and 6 of the 12 P terminal block (TM2) in the

welding power source; and turning on the inching signal (retract function).]

Refer to "11.2 External connection with an automatic machine by power source internal terminal" for details.

*3: This is a case for short-circuited between 5 and 6 of CON2 without using analog remote control.

About automatic machine 1 mode

For combination with the robot etc., this is used when the current and the voltage setting are input by using

an external voltage. And connection is shown in the figure below. For connection, current capacity of an

external power source must be 0.5mA or more.

PROHIBITION

Supply 0 - +15 voltage to E1 and E2. Exceeding +15V may result in damage to the controlcircuit of the welding power source.

CAUTION

Be sure to finish setting of and inputting to E1 and E2 within 100 milliseconds beforestarting signals are input. Inputting after 100 milliseconds or at start s ignals may result inaffecting start.

MAX0.5mA

MAX0.5mA

WeldingVoltage

WeldingCurrentCON2

0V 15V

Remotecontrolrece

tacle

Acceptable plug

Spec. DPC25-6A

Part No. 4730-009

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NOTE: - At the "Semiautomatic" mode, even if an external voltage is suppli ed to the remote control

outlet, a set value of the front panel becomes effective.

- Regardless of automatic or semi-automatic, when analog remote cont rol i s connected, a set

value of remote control is prio ritized.

Please combine with the welding condition memory fine adjustment function when the welding condition

memory function is used. P lease refer to "Setting of fine-tuning 10.2.1(11) welding condition memory" for

details.

About automatic machine 2 mode

Use this mode though this welding power source is used with automatic machine, you want to set all

setting by front panel or welding condition memory function.

Moreover, use this when you combine digital remote control with an automatic machine.

(5) For external setting voltage ranges between 0 and 10V: F5

When the welding machine is used by combining with a robot or an automatic machine and when themaximum command voltage from the robot or an automatic machine is output up to 10V, set F5 using the F(FUNCTION) selector key [12]. This function is preset to OFF for factory setting. Set F5 to "on" toactivate the function using the F (FUNCTION) selector key [12].

NOTE: It is necessary to set '4' of the function to "Automatic machine 1" mode '1' to make thisfunction effective.

The relationship between current/voltage command voltage from outside and welding current and welding

voltage is shown as follows. The welding current and welding voltage corresponding to welding conditions

setting voltage may differ from the indications in the graphs due to wire extension length and dragging of

output cable. These graphs are only for reference.

External Voltage 1: When command voltage is externally supplied in the range from 0V to 15V under thestandard settings.

External Voltage 2: When command voltage is externally supplied in the range from 0V to 10V with F 5 setto "on"

NOTE: The current and voltage indicated in the graphs above are not measured after fine

adjustment of unit pulse conditions. You may not obtain such the results as the graphs

show depending on finely adjustable range of pulse unit conditions.

0

50

100

150

200

250

300

350

0 5 10 15

Com m and voltage (V)

W

elding

current(V

External voltage 1

External voltage 2

0

5

10

15

20

25

30

35

40

0 5 10 15

Com m and voltade (V)

W

elding

voltage

(V

)

External voltage 1

External voltage 2

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(6) Setting of upslope time: F6*

Upslope time means the time for increasing welding conditions stepwise when initial current is changedto final current. The upslope time at shipment is set to 0 second, but can be adjusted by using F6. Thesetting range is 0 second to 10 second. This function is used when wire burns up while conditions arechanged over due to the great difference of setting between initial current and main current.

(7) Setting of down-slope time: F7*Down-slope time means the time for decreasing welding conditions stepwise when main current ischanged to crater current. The down-slope time at the time of product shipment is set to 0 second, butcan be adjusted by using F7. The setting range covers 0 second to 10 second. This function is usedwhen wire crashes into the base metal while the conditions are changed over due to the great differenceof setting between main current and crater current.

(8) Setting of result display holding time: F8

After completion of welding, the average value of output 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 (FUNCTION)

selector key [12]. The setting range of result display holding time is 0 seconds to 60 seconds.

(9) Selection of scale plate of analog remote control: F9

When the analog remote control (optional accessory) is used, it is possible to finely adjust a low-current

region where a small-diameter wire is used for weld by replacing the full-scale 350A scale plate with the

full-scale 200A scale plate (supplied). The analog remote control scale is changed over by using the F

(FUNCTION) selector key [12]. Set to "200" by using F9.

(10) Setting of feed motor load current error detection level: F10

In the event that contact resistance is applied to the wire feed line section due to worn liners, defectivetips, etc., the current supplied to the motor increases (when feed roll lacks smooth movement).Monitoring current of this motor can detect defective feed. The motor load current detection level atshipment is 70% (2.0A) of the rated motor current 2.8A (continuous), and if the current exceeds thesetting value, "E-" and "820" in the displays are displayed after welding operation is stopped. But, in thiscase, the welding machine stops operation automatically, then it self-restores by re-welding.

(Welding can be stopped by abnormal signal, refer to 10.2.1(16) setting switch of warning for detail.)This detection level can be changed by changing the setting of F10 using F (FUNCTION) selector key[12]. The setting range of motor load current trouble detection level is 20% to 150%.

NOTE: Adjust the detection level optionally and use it in the best detection level, because the

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