Dahen DA300P Owner's Manual

MANUAL NO:P30029



OWNER'S MANUAL

FOR

DIGITAL INVERTER
DA300P

MODEL: DA-300P P30029
P10535

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

Nobember 25, 2010

Upon contact, advise MODEL and MANUAL NO.

12-2-083-5

TABLE OF CONTENTS

1. SAFETY INFORMATION…………………………………………………………… 2

2. ARC WELDING SAFETY PRECAUTIONS……………………………………… 2

3. GENERAL NOTICE OF OPERATION…………………………………………….. 8

4. STANDARD COMPOSITION AND ACCESSORIES…………………………… 9

5. FUNCTION OF EQUIPMENT……………………………………………………… 10

6. NECESSARY POWER SOURCE EQUIPMENT………………………………… 12

7. TRANSPORT AND INSTALLATION……………………………………………… 13

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE………….. 15

9. WELDING PREPARATION………………………………………………………… 21

10. OPERATION…………………………………………………………………………. 27

11. APPLIED FUNCTION……………………………………………………………….. 58

12. MAINTENANCE AND TROUBLESHOOTING…………………………………… 67

13. PARTS LIST…………………………………………………………………………. 74

14. SPECIFICATIONS…………………………………………………………………... 77

15. SERVICE AND SUPPORT………………………………………………………… 82

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1. SAFETY INFORMATION

The following safety alert symbols and signal words are used throughout this manual to
identify various hazards and special instructions.

WARNING

CAUTION

WARNING gives information regarding possible personal injury
or loss of life.

CAUTION refers to minor personal injury or possible equipment
damage.

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 until consulting a doctor.

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

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

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

ARC WELDING is safe when precautions are taken.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work
circuits are electrically live whenever the output is on. The power line and internal circuits of
this equipment are also live when the line disconnect switch is on. When arc welding all metal
components in the torch and work circuits are electrically live.
Leaving piled-up dust in the welding machine may cause an insulation deterioration and
result 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 Owner’s 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 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 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 can
cause injury. NOISE can damage hearing.

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can
burn eyes and skin.
Noise from some arc welding can damage hearing.

1. Wear face shield with a proper shade of filter (See ANSI Z 49.1 listed in PRINCIPAL

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

2. Wear approved face shield 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 clothing 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 from the welding arc. The flying sparks,hot metal, spatter, hot base
metal and hot equipment can cause fire and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
Leaving piled-up dust in the welding machine may cause an insulation deterioration and result
in 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 possible to prevent the

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

9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

10. Do not use the welding power source for anything other than arc welding.

11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless 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 electrical 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 contacts
the frame or the work piece.

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

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2. ARC WELDING SAFETY PRECAUTIONS (continued)

FUMES AND GASES can be hazardous to your health.

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

your 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 manufacturer’s instructions 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 toxic 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 if damaged.

A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode.
Since gas cylinders are normally part of 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 publication P-1 listed in PRINCIPAL SAFETY STANDARDS.

7. Turn face away from valve outlet when opening cylinder valve.

8. Keep protective cap in place over valve except when 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.

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 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
sticking place with an organic solvent, chemicals, cutting oil and atmosphere such as
composition 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 operating
immediately and ask to repair and change.

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2. ARC WELDING SAFETY PRECAUTIONS (continued)

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

If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s 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, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.

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

ARC WELDING work areas are potentially hazardous.

FALLING or MOVING machine 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 instructed to do so.

2. Do not point the gun toward any part of the body, other people, or any metal when

threading welding wire.

This equipment uses high frequency for arc starting.

High-frequency may enter nearby units as shown below, causing electromagnetic trouble.
* Input cables, signal cables, telephone cables
* Radio sets, TV sets
* Computers and other control equipment
* Industrial detectors and safety units
* Pacemakers, hearing-aid sets
For preventing electromagnetic trouble,

1. Make the cable as shortest as possible.

2. Install cables along the floor or the ground as close as possible.

3. Put the power cable for base metal together with the torch side cable.

4. Do not use a common base metal ground with other machines.

5. Tightly close all of the doors and covers of this equipment, and secure them.

6. Do not press the torch switch other than when ready to start the arc.

7. When electromagnetic trouble occurs, take the measures shown in this instruction manual
until trouble is corrected.

Please contact OTC-DAIHEN , when necessary.

8. Pacemaker wearers must not come near this equipment during operation until consulting
your doctor.

Operation of the pacemakers will be affected badly by high frequency.

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2.ARC WELDING SAFETY PRECAUTIONS (continued)

To prevent electromagnetic troubles, read the following. Also, if electromagnetic

HF

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, control 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:
 Public supply system

Add a noise filter to the input cables.

 Maintenance of the arc welding equipment

Close and fix all doors and covers of the welding machine.

 Welding cables

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

 Equipotential bonding

Bonding of all metallic objects in the surrounding area should be considered.

 Earthing of the workpiece

The connection of the workpiece to earth should 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.

 Screening and shielding

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

troubles occur, check the following again.

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PRINCIPAL SAFETY STANDARDS

Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electro technical Commission

Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro
technical 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 American
Welding 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 Gas
Association.

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

T080904

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3. GENERAL NOTICE OF OPERATION

٨

٨

3.1 Rated Duty Cycle

CAUTION

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

duty cycle limitation may result in damage to the welding machine.

٨The rated duty cycle of the welding power source is the following:

- TIG WELDING: 40% (300 A)

- STICK WELDING: 40% (250 A)

NOTE:

When using a dust-proof fan filter as standard equipment, observe the duty cycle listed
above.
Use of any other filter may lead to an excess of the duty cycle limitations or damage to
the welding power source. Be sure to use the specified dust-proof fan filter. (Part
number: 4519-031)

٨The duty cycle of 40% means the machine must

be rested for 6 minutes after 4 minutes of
continuous welding at the rated current.

٨ Failure to observe duty cycle limitations may

cause the temperature inside the welding power
source to excess tolerance levels. This may
cause to premature welding power source failure
or product damage.

٨The figure shown right indicates the relation

between welding current and duty cycle. Use
the welding power source within its usable
range, based on the appropriate duty cycle for
the welding current.

٨The duty cycle of the welding power source is

also limited by the duty cycles of accessories
combined with it, such as welding torches. Use
the welding power source within the lowest
rated duty cycle of the accessories.

٨Choking the filter by dust may cause decrease

duty cycle. And also it may cause damage to
the welding power source. So check the filter
periodically.

ON

OFF

4 min.

6 min.

10 min.

Operation cycle of 40% duty cycle

100

50

Duty cycle (% )

0

100

50

Usable range
at STICK welding

Duty cycle (% )

0

Usable range
at TIG welding

100 200 300

Welding current (A)

100 200 250

W eld ing cu rr en t (A)

100(190A or less)

60(245A)

100%(160 A or less)

60% (204 A)

40% (250 A)

40(300A)

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4. STANDARD COMPOSITION AND ACCESSORIES

A

A

V

r

f

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4.1 Standard Composition

٨The part names indicated in the boxes are standard parts. They are not supplied with this

welding machine. Preparation of the standard parts except the welding power source is
required to use the welding power source.

٨Input cable and grounding cable

For a switch box, the 2m input and grounding cables are from the back panel of welding power
source.

Input cable
Grounding cable

AWG12 4mm
AWG12 4mm

Gas regulato

3Ǿ400

2

with 10mmǾ terminal x 3

2

with 10mmǾ terminal x 1

Inputcables (2m)

rgon

gas

Gashose

Water hose

Tap water or water cooler
(not needed for STICK welding
and for use of the air-cooled
torch)

Weldingpowersource

Connecttothewater wastetreatmentequipment
orthewatercooler(whenusingthewater-cooledtorch)

4.2 Accessory

Check the quantity of parts when opening the package.

Description Specification Q’ty Part No. Remarks

Power Cable connector DIX SK 50 1 4734-016

4.3 Other Equipment

(1) TIG Welding

٨Use argon gas for welding with 99.9 % or more purity.
٨Use the proper filler wire for material, plate thickness, etc.

(2) STICK Welding

٨Use the proper stick welding electrode for purpose of use, welding position, shape of joint,

etc.

٨Use the electrode holder electrically insulated.

Ground a work piece i
required by local law.

Digitalremotecontrol

㧔Optionallyavailable㧕

Weldingtorch

nalogremotecontrol㧔Optionallyavailable㧕



For base metal and holder
cable

Torchswitch

Basemetal

Basemetalcable

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㧰㧭 㧟㧜㧜 㧼

#

#

# #

㧙

5.1 Welding Power Source

㧕

5. FUNCTION OF EQUIPMENT

Input terminals

For pulling out external connection cables

Grommet with film

㧔

Input cable

Gas inlet

(9/16 - 1 8 U N F)

Rubber feet

Carrying handle

Parameter adjusting knob

Main power lamp

f

AC-DC

FREQ.

㧭㧯

FREQ.

ACBALANCE

JOBNO.

%

Sec

Hz

WATER

CURR.

CRATER-FILL.

SLOPE

DOWNSLOPE

㧕

LIFT

DC NO-LOAD VOLTAGE

A

WARNING

LOAD

MEMORY

JOB

START

PULSEFREQ.

BASECURR.

WELDINGCURR.

㧔

PULSECURR.

ON ON ON ON

UPSL OPE

CURR.

INITIAL

INITIALCURR.

T1 T2

㧲

SAVE

ENTER

DC-TIG

DC-STICK

DC-TIG

AC-DC TIG

TORCH

WELDING

METHOD

STANDARD

SOFT

HARD

PULSE

㧭㧯

WAVE

REPEAT

SPOT

OFF

ON

FILL.

CRATER

GAS

CHECK

t

SPOTTIME

Cap

Power switch

Negative (- ) output terminal

Gas connection(9/16 -18UN F)

Rubber feet

Cap

Socket for analog

Sock e t for to rch switc h

remote control

Positive (+) output termial

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5.2 Welding Torch

Torch body

5. FUNCTION OF EQUIPMENT (continued)

Torchswitch2P

Water i n hose
(5/8-18UNF)

Gas hose
(9/16-18UNF)

Water out hose
(5/8-18UNF)

Power cable connector

Cap

Nozzle

Tungsten electrode

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6. NECESSARY POWER SOURCE EQUIPMENT

6.1 Welding Power Source Equipment (for commercial use)

WARNING

٨When the welding machine is used in a humid environment such as a construction site, on a

steel plate, or on a steel structure, install a leakage breaker.

CAUTION

٨Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each

welding machine.

Capacity of Necessary Power Source Utility

AC-TIG DC-TIG STICK

Power supply voltage 400 V, three phase
Tolerance range of fluctuation of power

supply voltage
Installed capacity 12.5kVA or more 11.9kVA or more 13.2kVA or more
Capacity of switch/circuit breaker

6.2 Precautions for Use of the Engine Generator

CAUTION

Use the auxiliary power of engine welder with an improved voltage waveform. Some engine

٨

welders have poor electricity, which may cause product damage. Contact an engine welder
manufacturer for improvement of voltage waveform.

To prevent the welding power source from being damaged because of engine generator, follow the
instructions below.

Set the output voltage of the engine generator to the voltage range between 400 and 420V at

٨

no-load welding operation. Setting to extremely high output voltage may result in product damage.
Use an engine generator with a damper winding that has a capacity of more than twice that of the

٨

rated input of the welding power source. Generally, the recovery time of the engine generator’s
voltage for load change is slower than that of the commercial input power source, and if the engine
generator does not have sufficient capacity, sudden current change such as arc start will occur.
This may cause abnormal decrease in output current or arc loss. Ask an engine generator
manufacturer for a damper winding.

Do not combine more than two welding machines with a single engine generator. The effect of

٨

each welding machine may cause easy loss of arc.

50 A 50 A 50 A

400V±15%

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7. TRANSPORT AND INSTALLATION

7.1 Transport

WARNING

To prevent accidents and damage of the welding machine during transportation, observe the
following.

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

machine.

٨When hanging the welding power source by a crane, cover the power

source with the cover or the case and tighten eye-bolts.

٨Lift one welding power source with two wires. Lifting the welding power

source and other equipment together may cause them to drop.

٨When carrying the welding machine with a fork lift, etc., securely make

scotch-block.

٨When hanging the welding power source by a crane, do not use the carrying

handle.

7.2 Installation

WARNING
When installing the welding machine, follow the instructions below to avoid a fire caused by
welding or physical injury from gas fumes.

٨Do not place the welding machine near combustible materials or flammable

gas.

٨Remove combustible materials to prevent dross coming into contact with

combustible objects. If that is not possible, cover them with
noncombustible covers.
To avoid gas poisoning and danger of suffocation, wear a gas mask or

٨

adequately ventilate when the welding machine is used in the place
regulated by local law.
To prevent injury or poisoning caused by fume, wear a gas mask or weld at

٨

a partial exhaust facility approved by the local regulation.
Adequately ventilate or wear a gas mask when using the welding machine

٨

in a tank, in a boiler or in a hold of a ship, because heavier gasses such as
carbon dioxide or argon gases are settle there.
When using the welding machine at a narrow space, comply with a trained

٨

supervisor’s directions. And be sure to wear a gas mask or adequately
ventilate.

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7. TRANSPORT AND INSTALLATION (continued)

7.2 Installation (continued)

CAUTION

To prevent electromagnetic troubles, read the following.

HF

Change the installation place of the welding machine.

٨

Mount an input cable in the grounded metallic conduit.

٨

Provide electromagnetic shield to the whole welding places.

٨

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

٨Do not put heavy things on the welding machine.
٨Do not cover the ventilation port of the welding machine.
٨Do not install the welding power source in the place subject to direct sunlight or rain.
٨Do not place the welding power source, wire feeder, torch, control unit, conduit and

control cable (including the extension cable) in an area where the equipment can become
wet. Place the welding machine on a strong and stable surface.

٨Install the welding machine in the place where the ambient temperature is between -10 ˚C

and +40 ˚C (+14 ˚F and +104 ˚F).

٨Do not install the welding machine in the place where metal material such as spatter

enters the welding power source.

٨Keep the install distance of 30 cm between the welding power source and the wall or other

welding power source.

٨Install a wind shield to protect arc from wind.

Fix the gas cylinder to the stand specifically made for gas cylinder.

٨

Also, if electromagnetic troubles occur, check the following again.

CAUTION

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8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

WARNING

Observe the following to prevent electric shock.

Do not touch the live electrical parts; otherwise, you might receive serious electric shock or
get burned.

Do not touch the live electrical parts.

٨

Have a qualified electric engineer ground the case of the welding power source. Have a

٨

qualified electric engineer ground the base metal or jig electrically connected, following a
local low.
Connect the welding machine with all the line disconnect switches inside the switch box

٨

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

٨

Tighten and insulate the connections of cables.

٨

Attach the case properly after connecting the cable.

٨

8.1 Connecting of the Welding Power Source

CAUTION

To prevent electromagnetic troubles, read the following.

HF

Also, if electromagnetic troubles occur, check the following again.

Do not use an unnecessarily long cable.

٨

The welding cable is placed as closely on the floor or ground as possible.

٨

Place a base metal cable and an electrode cable as closely as possible.

٨

Do not ground the welding power source commonly with other machines.

٨

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

8.1.1 TIG WELDING (water-cooled torch)

Torchswitchcable

㧙

٤

٤

+

Base metal cable

2

(38 mm or more)

Follow the steps below to attach the cables to the output connectors of the welding power source
referring to the illustrations of “Connection of the Welding Power Source“.

1. Ground the base metal (if required by local laws or codes).

2. Connect between the “base metal + ” terminal and the base metal with the base metal cable.

3. Attach the torch cable to the “torch Θ” output terminal.

4. Connect the water supply hose to the cooling water connection.

5. Connect the gas hose to the gas connection.

6. Connect the torch switch or foot switch to the socket for torch switch.

7. Make drainage treatment (when using tap water).

When using the circulation system, attach the water out hose to it.

* When using the air-cooled torch, the water hose is not necessary.

Firmly attach the torch switch to the torch with the supplied bands.

Torch swit ch

Torch power cable

Gas hose

Water supply hose*

Condensate hose*

Firmly attach the cable to the base metal .

Torch

Base met al

Pull the other ends

ԙ



through the loops, then

cut down the excessive

length of the bands.

Ԙ



With the rough sides of the bands

facing inside, put the bands around the

handle of the torch body.

- 16 -





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

8.1.2 STICK WELDING

The following figure shows the cable connections for stick welding with DC electrode positive
(welding stick positive, base metal negative). When using DC electrode negative, switch the
holder cable with the base metal cable.

Holder

Weldin g cable

Base metal

+

٤

㧙

٤

Base metal cable

38mm2or more)

㧔

Firmly at tach the base metal cable t o the base metal .

1. Ground the base metal (if required by local laws or codes).

2. Connect the base metal cable to the negative ٤- output terminal on the welding power
source.

3. Connect the holder to the positive ٤+ output terminal on the welding power source.

8.2 Connecting of the Base Metal Cable and Stick Holder Cable

When connecting the base metal cable and stick holder cable to the welding power source,
attach the cable plug DIX SK 50 (supplied).

Groove

Cable

Conductor

Biss

Gri p

Sleeve

Connector

- 17 -





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

r

r

r

8.3 Connecting of the Gas Hose

WARNING

٨There is a danger of suffocation caused by lack of oxygen when shield gas

keeps drifting in a closed place. Be sure to turn off the shield gas at the main
when the welding power source is not in use.

٨Be sure to connect the gas hose after fixing gas cylinder to the stand, as physical injuries

may result from falling down of it.

٨Attach a proper gas regulator to a gas cylinder. Failure to observe the demand may result in

physical injuries. The gas 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
with a monkey wrench, etc.

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

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

Nutforattachinggascylinde

CAUTION

Gas regulato

Pressure gauge

Gascylinde

ԙ

Ԛ



Gasoutlet

Ԙ

WeldingPowersource

8.4 Grounding and Connecting of Input Power Source

WARNING

Observe the following to prevent electric shock.

Do not touch the live electrical parts; otherwise, you might receive serious electric shock or get
burned.

Do not touch the live electrical parts.

٨

Have a qualified electric engineer ground the case of the welding power source. Have a

٨

qualified electric engineer ground the base metal or jig electrically connected, following a
local law.
Connect the welding machine with all the line disconnect switches inside the switch box

٨

turned off.
Attach the case properly after connecting the cable.

٨

When the welding machine is used in a humid environment such as a construction site, on a

٨

steel plate, or on a steel structure, install a leakage breaker.

- 18 -





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

CAUTION

To prevent electromagnetic troubles, read the following.

HF

Also, if electromagnetic troubles occur, check the following again.

Add a noise filter to the input cables.

٨

Do not ground the welding power source commonly with other machines.

٨

CAUTION

٨Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each

welding machine.

The following figure shows the cable connections. When using the air-cooled torch, the water supply
hose is not necessary. For STICK welding, the water/gas hoses are not necessary.

ԘGas regulator



Mountthelinedisconnectswitchwithfuse

oreachno-fusebreakeroneachweldingmachine.

ԛGREEN/YELLOWcablefor groundingcable

ԚWater-cooling hose

ԙGashose

ԜInputcables
andGroundingwire

CAUTION

Be sure to ground the case of the welding power source.
Use a grounding cable 4mm

2

or more in thickness.

٨If the welding power source which is not grounded is used, voltage will be generated in the

case through the capacitor between the welding power source input circuit and the case or
stray capacity (electrostatic capacity naturally generated between the input circuit and the
metal enclosure). 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 or jig.

Basemetalorjig

Ground a work piece if a
local law requires.

Surelyconnecttheinputandgrounding

Cables 4mm

2

tothecircuitbreaker.

- 19 -





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

b c

()

()

()

()

()

()

()

()

(a) Insert the hose to

faucet directly.

No. Description Parts No. Remarks

(1) 5-meter water supply hose P1042L00
(2) Hose connector P1042M02
(3) Rubber hose (for tap water) None
(4) Feed water port (for water supply hose)* P1042M01
(5) Nipple (1/2) None Not supplied

(b) Using a faucet that a 1/2

gas thread is cut.

(c) Employing a stop valve

Tap water kit
BBDW-3001

- 20 -





9. WELDING PREPARATION

r

9.1 Preparing the Protective Equipment

CAUTION

Check the followings before welding.

HF

The whole doors and covers of the welding machine are surely closed and fixed.

٨

The welding cable is placed as closely on the floor or ground as possible.

٨

Place a base metal cable and an electrode cable as closely as possible.

٨

Proper flow rate of shield gas is supplied. Improper flow rate may lead to bad arc start and

٨

unnecessary high frequency.

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

When performing or monitoring welding operation, wea

٨

blocking effect or face shield.
Wear protective glasses to protect your eyes from the spattering dross.

٨

Wear protective equipment such as protective gloves, long-sleeve clothes, leg covers, and

٨

leather apron.
Install protective screens or barriers to protect the eyes of others in the work area from arc

٨

ray.
Wear an ear protector when noise level is high.

٨

an eye protector with a good light

- 21 -





9. WELDING PREPARATION (continued)

r

9.2 Operating the Switches and Controlling the Gas Regulator

CAUTION

٨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.

ԚPress the GAS CHECK

key. (The GAS CHECK
lamp lights up.)

ԝPress the GAS CHECK

button again. (The GAS
CHECK lamp goes out.)

9.3 Selecting the cooling method

When using the wate

٨

water on the rear panel of the welding power source. And turn torch change-over key to the
"WATER COOLED" side.
If cooling water is supplied directly to the torch with the welding power source bypassed,

٨

and the water-cooled torch is used with the torch selector key set at air side, it cannot be
detected whether cooling water is flowing, and in case where no cooling water is flowing, the
torch may be burnt.

ԘTurn on the line disconnect

switch. (400V, 3Ǿ)

CAUTION

-cooled torch, supply water-cooled torch from the outlet for cooling

When using a water-cooled torch, select “WATER” by pressing the
TORCH key once.

[WATER]: The TORCH lamp is on.
[AIR]: The TORCH lamp is off.

Gas flow rate adjusting knob

ԛ Set the gas regulator to “SHUT”, then

turn on gas at the main valve.

Ԝ Set the gas regulator adjusting knob

to “OPEN” to adjust the gas flow rate.

ԙPlace the power switch in the “I” (ON)

position.

- 22 -





9. WELDING PREPARATION (continued)

–

–

–

–

–

9.4 TIG Welding Condition㧔for reference㧕

(1) TIG Welding Condition㧔PULSE “OFF”㧕

Material

Stainless
Steel
(DC,
Electrode
Negative)

Deoxidized
Copper

(DC,
Electrode
Negative)

Aluminum

(AC)

Magnesium

(AC)

Plate

Thickness

(mm)

0.6 1, 1.6 0 - 1.6 20 - 40 4 1 (a), (b)

1.0 1, 1.6 0 - 1.6 30 - 60 4 1 (a), (b)

1.6 1.6, 2.4 0 - 1.6 60 - 90 4 1 (b)

2.4 1.6, 2.4 1.6 - 2.4 80 - 120 4 1 (b)

3.2 2.4, 3.2 2.4 - 3.2 110 - 150 5 1 (b)

4.0 2.4, 3.2 2.4 - 3.2 130 - 180 5 1 (d), (c)

4.8 2.4, 3.2, 4 2.4 - 4.0 150 - 220 5 1 (d), (c)

6.4 3.2, 4, 4.8 3.2 - 4.8 180 - 250 5 1 - 2 (a), (c)

0.6 1, 1.6 0 - 1.6 50 - 70 3 - 4 1 (a), (b)

1.0 1.6 0 - 1.6 60 - 90 3 - 4 1 (a), (b)

1.6 2.4 1.6 - 2.4 80 - 120 3 - 4 1 (b)

2.4 2.4, 3.2 2.4 - 3.2 110 - 150 4 1 (b)

3.2 3.2, 4 3.2 - 4.8 140 - 200 4 - 5 1 (c)

4.0 3.2, 4, 4.8 4.0 - 4.8 180 - 250 4 - 5 1 (d), (c)

4.8 4, 4.8 4.8 - 6.4 250 - 300 5 - 6 1 (d), (c)

6.4 4, 4.8, 6.4 4.8 - 6.4 300 - 400 5 - 6 1 - 2 (d), (c)

1.0 1.6 0 - 1.6 50 - 60 5

1.6 1.6, 2.4 0 - 1.6 60 - 90 5 – 6 1 (a), (b)

2.4 1.6, 2.4 1.6 - 2.4 80 - 110 6 - 7 1 (b)

3.2 2.4, 3.2 2.4

4.0 3.2, 4.0 3.2 - 4.8 140 - 180 7 - 8 1

4.8 3.2, 4.0, 4.8 4.0 - 6.4 170 - 220 7 - 8 1

6.4 4.0, 4.8 4.0 - 6.4 200 - 270 8 – 12 1 - 2 (d), (c)

1.0 1.6 0 - 1.6 30 - 40 3

1.6 1.6, 2.4 1.6 - 2.4 40 - 70 4 – 5 1 (b)

2.4 1.6, 2.4 1.6 - 2.4 60 - 90 4 – 5 1 (b)

3.2 1.6, 2.4 2.4

4.0 2.4, 3.2 3.2 - 4.0 90 - 120 5 – 6 1

4.8 3.2, 4.0 3.2 - 4.8 110 - 150 5 - 6 1

6.4 3.2, 4.0 4.0

Electrode Dia.

(mm)

Filler Wire Dia.

Current

(mm)

4.0 100 - 140 6 - 7 1

3.2 75 - 110 5 - 6 1

4.8 130 - 170 6 - 7 1 - 2 (d), (c)

(A)

t

Argon Gas

Flow Rate

(ℓ/min)

6 1 (a), (b)

4 1 (a)

No. of
Layer

90q

Bevel

Shape

(b)
(b)
(b)

(b)
(d), (c)
(d), (c)



(a) (b)

- 23 -



C ҇ t/3

(c)

(d)

9. WELDING PREPARATION (continued)

(2) Welding Condition of DC TIG Pulse

Flat position and butt joint welding

ٟ

Material Joint Geometry

Mild Steel

spcc

Stainless

Steel

SUS304

㧝㧚㧞

㪞

0

㧝㧚㧞

㪞

Copper

C1100P

㧝㧚㧠

㪞

Titanium

TP270

㧞㧚㧜

㪞

Shield gas : Argon (10 ℓ/min) Electrode : Thoriated Tungsten䋨3.2mm㱢䋩
Filler Wire : 1.2mm㱢 Arc Length : 2mm

Gap G

(mm)

0

1.2

1.6

1.2

1.6

2.0

0

1.2

1.6

0 200 100 1 30 25 0

Pulse

Current

(A)

200
150
130

150
150
130
130

280
280
280

Pulse Condition

Base

Current

Frequency

(A)

50
20
20

50
20
20
20

50
50
30

(Hz)

2.5

1.5
1

3.1
1

0.8

0.8

3.1
2

1.5

Pulse
Width

(%)

50
46
50

50
35
30
30

50
50
42

Travel
speed

(cm/min)

60
30
15

80
17
10
83

80
50
25

Wire

Feeding

Speed

(cm/min)

60
60
40

0
40
40
40

0
75
75

- 24 -





9. WELDING PREPARATION (continued)

Weld joints with different heat capacity

ٟ

Material Joint geometry

Copper

㧗

Mild Steel

Stainless

Steel

㧗

Mild Steel

Mild Steel

Stainless

Steel

52%%

52%%



1 120 50 2 50 20 30

52%%

575



.GPIVJOO
575





%2

575



%W

575



Pulse condition

No. of

Layer

Pulse

Current

(A)

1 250 50 0.8 20 10

1 170 60 2.5 50 50

4 160 50 1.5 46 8.5 60

Base

Current

(A)

Pulse

Freq.

(Hz)

Pulse
Width

(%)

Travel
speed

(cm/min)

Filler wire

Feeding

Speed

(cm/min.)

60

( Cu )

60

( SUS )

Shielding Gas : Argon (10ℓ/min.) Electrode : Thoriated Tungsten ( 2.4mmǾ)

Filler Wire : 1.2mmǾ Arc Length : 2 - 3mm

- 25 -





9. WELDING PREPARATION (continued)

Material Joint geometry

㪍㪇㫦

Aluminum

Filler wire

Feeding

Speed

(cm/min.)

75
95
75

95
290
170
250

No. of

Layer

1.0

1.5

1.5

1.5

3.2

3.0

6.0

Pulse

Current

(A)

70
80
90

85
170
170
220

Pulse condition

(A)

25
40
25
25
25
25
25

Pulse

Freq.

(Hz)

1
1
1
1
1
1
1

Base

Current

Pulse
Width

(%)

50
50
50
50
50
50
50

Travel
speed

(cm/min)

1.6

1.6

1.6

1.2

1.2

1.6

1.6

6.0 180 25 1 50 1.6 250

3.2

6.0

170
220

25
25

1
1

50
50

1.2

1.6

290
270

㪐㪇㫦

3.0 120 25 1 50 1.6 60

(4) Post-Flow Time

Adjust to the proper post-flow time for the electrode diameter.

Electrode diameter (mm) Post-Flow Time (s)

1.6 3 - 5

2.4 5 - 8

3.2 8 - 12

4.0 12 - 17

4.8 17 - 21

6.4 21 - 26

- 26 -





10. OPERATION

㧙

Front panel

[19][18] [17] [3] [11] [13]



[14]

[3] [4] [6] [7]



JOB

MEMORY

LOAD

SAVE

ENTER

GAS

CHECK

DC NO- L OAD VOLTAGEWAR NI N G

ASec

PULSE FREQ.

UP SL OPE

WELDING CURR.

BASE CURR.

T1 T2

I NI TI AL CURR. CRATER- FI L L.

ON ON ON ON W AT ER

㧔

PULSE CURR.

IN IT IAL

㧲

OFF

CURR.

PULSE

STANDARD

LIFT

START

DOWN SLOPE

㧕

CURR.

SLOPE

TORCH

Hz

%

JOB NO.

㧭㧯

FREQ.

AC BALANCE

f

AC- DC
FREQ .

AC- TIG

ON

REPEAT

t

SPOT TIME

[16] [9] [5] [10] [2] [12] [1] [15] [8]

[1] WELDING METHOD change-over key [9] ARC SPOT TIME setting key [17] LOAD key
[2] AC WAVE change-over key [10] Function selection key [18] SAVE key
[3] Parameter selection key [11] INITIAL CURR. selection key [19] ENTER key
[4] Parameter adjusting knob [12] PULSE selection key
[5] CRATER FILL. key [13] LIFT START key
[6] AC FREQ. key [14] SLOPE selection key
[7] AC BALANCE key [15] TORCH change-over key
[8] AC-DC change-over frequency set up key [16] GAS CHECK key

SPOT

CRATER

FILL.

㧭㧯

WAVE

SOFT

HARD

WEL D I NG
METHOD

AC- DC TI G

DC- TIG

DC- STICK



- 27 -

10. OPERATION (continued)

WARNING

Observe the following to prevent electric shock.

*Do not touch the live electrical parts; otherwise, you might receive serious

electric shock or get burned.

٨Do not touch the electrode while pressing the TORCH switch.
٨Disconnect the welding power source form input power supply before

replacing the electrode.

٨Wear dry clothes and gloves during welding.

CAUTION

This welding machine should be operated by persons only after reading and

٨

understanding contents of this owner’s manual and having knowledge and skills for
handling the welding machine safely.
Use this welding power source at or under the rated duty cycle. Exceeding the rated duty

٨

cycle limitation may result in damage to the welding machine.

CAUTION

Observe the followings to perform TIG welding safely.

㧴㧲

Adjust the amount of shield gas with the GAS CHECK key. Using the torch switch for

٨

adjustment of shield gas may result in generating unnecessary high frequency for a long
time period.
Using improper electrode may cause failure of arc start, and generate useless high

٨

frequency.
Improper shielding gas flow may cause failure of arc start, and generate useless high

٨

frequency.

When reading the operating instructions described below, unfold page (section 14) so that you can
read them confirming the location of the keys on the front panel.

10. 1

TIG Welding



10.1.1 DC TIG Welding
Set the welding process to DC TIG ( ), AC TIG ( ) or AC-DC TIG( )
with the WELDING METHOD key [1].

10.1.2 Parameter setting

Choose parameter by anti-clockwise direction Choose parameter by clockwise

direction

PULSE FREQ.

UP SLOPE

DOWN SLOPE



WELDI NG CURR.

BASE CURR.

T1 T2

IN IT IA L CU R R. C R A T ER-FIL L

㧔

PULSE CURR.

㧕

CURR.

Part of sequence parameter settingޤ

ޣ



- 28 -

10. OPERATION (continued)

The parameters listed below may be selected with the parameter selection key [3] and adjusted
with the parameter adjusting knob [4]. The set value of the parameter selected appears on the
digital display with the respective unit indicator LED turned ON.

Unit LED

WARNING



Digital meter

Pre flow time

㧔1㧕

When the parameter “pre flow time” is selected, the set value appears on the right digital
display with the unit indicator LED for “sec. (sec)” turned ON. In this state, the pre flow time
may be adjusted in the range between 0 and 20 sec. by the use of the parameter adjusting
knob [4].

For lift start mode, however, the parameter “pre flow time” may not be selected.

Initial current

㧔2㧕

This parameter may be selected only if the initial current setting is “ON”. When this

parameter is selected, the set value appears on the left digital display with the unit indicator
LED for “ampere (A) ” turned ON. In this state, the initial current may be adjusted in the
range as specified in the table shown on the following page by the use of the parameter
adjusting knob [4].

Upslope time

㧔3㧕

This parameter may be selected only if both initial current and slope settings are “ON”.
When this parameter is selected, the set value appears on the right digital display with the
unit indicator LED for “sec. (sec) ” turned ON. In this state, the upslope time may be
adjusted in the range between 0 and 10 sec. by the use of the parameter adjusting knob [4].

Pulse current

㧔4㧕

This parameter may be selected only if the pulse setting is “ON”. When this parameter is
selected, the set value appears on the left digital display with the unit indicator LED for
“ampere (A) ” turned ON. In this state, the pulse current may be adjusted in the range as
specified in the table shown on the following page by the use of the parameter adjusting
knob [4].

Welding current (or Base current)

㧔5㧕

When this parameter is selected, the set value appears on the left digital display with the
unit indicator LED for “ampere (A) ” turned ON. In this state, the welding current may be
adjusted in the range as specified in the table shown on the following page by the use of the
parameter adjusting knob [4].

If the pulse setting is “ON”, the base current may be set and adjusted in the range same as

that for the welding current.

ASec

Hz
%

JOB

Part of Indicationޤ

ޣ



- 29 -

㧔6㧕

㧔7㧕

㧔8㧕

㧔9㧕

٨

10. OPERATION (continued)

Pulse frequency

This parameter may be selected only if the pulse setting is “ON”. When this parameter is
selected, the set value appears on the right digital display with the unit indicator LED for
“hertz (Hz) ” turned ON. In this state, the pulse frequency may be adjusted in the range
between 0.1 and 500 Hz by the use of the parameter adjusting knob [4].

Down slope time

This parameter may be selected only if the crater setting is “ON”, “REPEAT” or “ARC
SPOT” and the slope setting is “ON”. When this parameter is selected, the set value
appears on the right digital display with the unit indicator LED for “sec. (sec) ” turned ON. In
this state, the down slope time may be adjusted in the range between 0 and 10 sec. by the
use of the parameter adjusting knob [4].

Crater current

This parameter may be selected only if the crater setting is “ON”, “ON (REPEAT)” or “ARC
SPOT”. When this parameter is selected, the set value appears on the left digital display
with the unit indicator LED for “ampere (A) ” turned ON. In this state, the crater current may
be adjusted in the range as specified in the table below by the use of the parameter
adjusting knob [4].

Post flow time

When the parameter “post flow time” is selected, the set value appears on the right digital
display with the unit indicator LED for “sec. (sec)” turned ON. In this state, the post flow
time may be adjusted in the range between 0 and 30 sec. by the use of the parameter
adjusting knob [4].

For suitable electrode diameter and post-flow time, see Section 9.4, “TIG Welding

Condition”.

Setting Current range

Welding

method

AC wave form DA-300P

DC TIG 4A - 300A

Output Current Setting Range

AC TIG

AC-DC TIG



- 30 -

STANDARD

HARD

SOFT 10A - 200A

10A - 300A

10. OPERATION (continued)

10.1.3 AC TIG Welding
The AC TIG welding process is such that the polarity of electrode plus (+) from which cleaning
action is obtained and that of electrode minus (-) in which electrode consumption is small are
inverted alternately to take advantage of the feature of both polarities. This type of welding is
suitable mainly for aluminium welding.

10.1.4 AC-DC TIG Welding
The AC-DC TIG welding process is such that the alternating current period during which
cleaning action is obtained and the direct current period during which deep penetration is
obtained are outputted alternately in a cyclical manner. This type of welding is suitable mainly
for automatic welding of aluminium.

10.1.5 Notice of using AC TIG mode

When using AC TIG 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 above
cannot be performed by all means,
lay the torch cable on the base
metal.



- 31 -

10. OPERATION (continued)

3. If an overlong torch side 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.

Winding method of excess cable

1 2 3

Refer to the figure below “winding method of

࡮

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

Top view

Side view

Explanation

Separate the excess cable
into A and B.
Wind it respectively as
followings.

Same winding direction.

࡮

Same turns of winding.

࡮

Same diameter of

࡮

Windings.

Place B over A in the
opposite direction.

After placing B over A, bind
the winding cable not to be
loose.



- 32 -

10. OPERATION (continued)

10.1.6 AC Waveform

In the case of AC TIG and AC-DC TIG welding, the following three output current waveforms
can be selected with the AC waveform selection key (ԙ). Use these current waveforms while
taking advantage of the respective features.
Also, the AC frequency and AC balance are stored in memory for each AC waveform.

Mode Output current wave-form Characteristic

STANDARD

HARD

SOFT

Sine wave-form which peak

Rectangular pulse wave­form which peak value of
straight and reverse polarity
current are equal.

Rectangular pulse wave­form which peak value of
straight polarity current is
different from reverse
polarity current.

values of straight and
reverse polarity current are
equal.

*CAUTION:
If the welding current exceeds 200A in the hard mode, the bead width is larger than the AC
balance, thus ceasing to place a favorable bead. Accordingly, the hard mode is suitable for the
case when the welding current is smaller than 200A.

Welding operation can be carried out in
a wide range from thin to thick plates.
Also, since stable welding operation
can be performed in the whole current
area, this waveform can be utilized
most generally.
Such centralized arc as in DC TIG
welding is obtained. This waveform is
effective for fillet welding of a thin plate
and for the 1

st

layer of bevel or the like.
Among these three modes, electrode
consumption is the smallest in this
mode, but an arc sound becomes
larger.

Soft arc is obtained. This mode is
effective for thin plate butt welding, etc.
Also, the arc sound level is low.
Maximum welding current is 200A.

10.1.7 AC Frequency
When the initial conditions, main conditions or crater filler conditions are being selected, press
the AC frequency setup key (ԝ), and the LED in the left upper part lights up, the set point is
displayed on the right-side digital meter, then the “Hz” LED lights up. On the left-side digital
meter, the standard value is flashing on the display. In this condition, it is possible to set up the
AC frequency in AC TIG and AC-DC TIG welding, using the parameter adjusting knob (ԛ). The
setup range is 50Hz to 200Hz.
By pressing the AC frequency setup key again or the parameter selection key (Ԛ), the system
display screen returns to the parameter item in which the parameter was adjusted to the value
of one step ago.
If the AC frequency is made high, the arc concentration will increase and if it is lowered, the arc
spread is on the increase. Also, even when AC frequency is changed, the depth of penetration
remains unchanged – constant.
In the condition that the AC waveform is “Standard” and “Soft”, the standard value for AC
frequency is 70Hz, while the standard value becomes 100Hz in “Hard”.



- 33 -

10. OPERATION (continued)

(-)

)

10.1.8 AC balance Setup ( )

By pressing the AC BALANCE key (Ԟ) when the initial conditions, main conditions or crater
filler conditions are being selected, the left-upper LED lights up and the set point is displayed
on the right-side digital meter. (At this time, all unit LEDs are going out.) In this condition, it is
possible to set up the intensity of arc cleaning action indispensable to AC TIG welding of
aluminum or the like with the parameter adjusting knob (ԛ). The setup range is 0 to r20.
By pressing the AC BALANCE key again or parameter selection key (Ԛ), the parameter item
in which the parameter was adjusted to the value of one step ago is selected.

For the AC balance set point, with “0” as standard, the AC balance becomes small in the
minus direction, whose set point is “-20” max., and in the plus direction, the AC balance
becomes large, whose set point is “20” max.

The relationship between the AC balance setup and welded results & electrode consumption
extent or degree is as shown in the table below.

Minus Direction
Small
Deep
Less

Low

“EN” refers to the period in which the base metal is positive in polarity (+) and the torch is
negative in polarity (-), and “EP” refers to the period in which the base metal is negative in
polarity (-) and the torch is positive in polarity (+).

EN

㧜

EP( +

By adjusting this AC balance, the EP ratio changes by 1% in relation to the manipulated
variable “1”. The EP ratio standard value (when the center position is “0”) differs among AC
waveforms, and the maximum and minimum values that can be set up as EP ratio also differ.
The value indicated on the digital meter can also be used as EP ratio in AC balance setup. For
details, see “10.1.17 – Internal Function”.

The AC waveform, standard EP ratio and settable maximum and minimum values are as
shown in the table below.

AC Wave form Standard Value

STANDARD 30%

SOFT 30%
HARD 20%

㪚㫃㪼㪸㫅㫀㫅㪾㩷㪮㫀㪻㫋㪿㩷㪪㪼㫋㫌㫇 㪧㫃㫌㫊㩷㪛㫀㫉㪼㪺㫋㫀㫆㫅
㪚㫃㪼㪸㫅㫀㫅㪾㩷㫎㫀㪻㫋㪿 㪣㪸㫉㪾㪼
㪧㪼㫅㪼㫋㫉㪸㫋㫀㫆㫅 㪪㪿㪸㫃㫃㫆㫎
㪜㫃㪼㪺㫋㫉㫆㪻㪼㩷㪺㫆㫅㫊㫌㫄㫇㫋㫀㫆㫅 㪤㫌㪺㪿
㪜㪧㩷㫉㪸㫋㫀㫆 㪟㫀㪾㪿

Ien

The EP ratio is such that the current
ratio of EP polarity at one cycle of
alternating current is expressed in
“percent”, which is defined by the
following equation:

 Iep

Iep

EP ratio=

 Ien + Iep

  100%

㪤㪸㫏㫀㫄㫌㫄㩷㪭㪸㫃㫌㪼 㪤㫀㫅㫀㫄㫌㫄㩷㪭㪸㫃㫌㪼

㪌㪇㩼 㪈㪇㩼
㪌㪇㩼 㪈㪇㩼
㪊㪇㩼 㪌㩼



- 34 -

10. OPERATION (continued)

g

10.1.9 AC-DC Change-over Frequency Setup ( )

When the initial conditions, main conditions or crater filler conditions are being selected, press
the AC-DC change-over frequency setup key (ԟ), and the LED in the left upper part lights up,
the set point is displayed on the right-side digital meter, then the “Hz” LED lights up. In this
condition, it is possible to set up the AC-DC change-over frequency in AC-DC TIG welding,
using the parameter adjusting knob (ԛ). The setup range is 0.1Hz to 50Hz.
By pressing the AC-DC change-over frequency setup key again or the parameter selection
key (Ԛ), the system display screen returns to the parameter item in which the parameter was
adjusted to the value of one step ago.

㧱㧺㧔㧙㧕

㧱㧼㧔㧗㧕

The relationship between AC-DC change-over frequency setup and filler wire insertion interval is as
shown in the table below.

When frequency is low

The insertion interval is long.
The ripple spacing becomes
wide.
For low-speed weldin

(1) Manual insertion

In case where the AC-DC change-over frequency is 0.5Hz to 2Hz, insert a filler wire in
synchronism with AC period. Since the arc sound becomes large during AC period and it becomes
small during DC period, insert this filler wire with changes in arc sound as a guide.

(2) Automatic insertion

In case where a filler wire is inserted automatically, set it so that it is fed intermittently in
synchronism with the AC period.
The standard AC ratio is 70%. The AC ratio is such that the rate of AC period to one cycle of AC­DC is represented in “%”, which is defined by:
AC ratio (%) = a/b × 100
Also, this AC ratio can be changed by using the internal function. For details, refer to “10.1.17:
Internal Function”.

㧰㧯ᦼ㑆 㧰㧯ᦼ㑆 㧭㧯ᦼ㑆

DC period AC period

㧭㧯ᦼ㑆

㨍

㨎

㪘㪚㪄㪛㪚㩷㪚㪿㪸㫅㪾㪼㪄㫆㫍㪼㫉
㪝㫉㪼㫈㫌㪼㫅㪺㫐㩷㪪㪼㫋㫌㫇
㪝㫀㫃㫃㪼㫉㩷㫎㫀㫉㪼㩷㫀㫅㫊㪼㫉㫋㫀㫆㫅㩷㫀㫅㫋㪼㫉㫍㪸㫃 㪫㪿㪼㩷㫀㫅㫊㪼㫉㫋㫀㫆㫅㩷㫀㫅㫋㪼㫉㫍㪸㫃㩷㫀㫊㩷㫊㪿㫆㫉㫋㪅

㪙㪼㪸㪻㩷㫉㫀㫇㫇㫃㪼

㪮㪼㫃㪻㫀㫅㪾㩷㫊㫇㪼㪼㪻 㪝㫆㫉㩷㪿㫀㪾㪿㪄㫊㫇㪼㪼㪻㩷㫎㪼㫃㪻㫀㫅㪾

f

DC period AC period

AC-DC change-over frequency (Hz)

1



=

b (sec)

㪮㪿㪼㫅㩷㫋㪿㫀㫊㩷㪽㫉㪼㫈㫌㪼㫅㪺㫐㩷㫀㫊㩷㪿㫀㪾㪿

㪫㪿㪼㩷㫉㫀㫇㫇㫃㪼㩷㫊㫇㪸㪺㫀㫅㪾㩷㪹㪼㪺㫆㫄㪼㫊
㫅㪸㫉㫉㫆㫎㪅



- 35 -

10.1.10 Pulse setting ( )

Pulsing is a technique to cyclically vary the welding current for stabilized arcing, controlled
penetration geometry and/or controlled heat input, where arcing may be rigidified during high
current period for improved stability, and penetration geometry and heat input may be
controlled with the high/low current period ratio varied.

Pulse setting “ON” and “OFF” may be selected with the PULSE selection key [12]. The LED
located on the upper left corner of the selection key indicates the status of pulse setting “ON”
and “OFF” when it is turned ON and OFF respectively. If the pulse setting is “ON, the
parameters “pulse current” and “pulse frequency” may be selected with the parameter
selection key [3]. And the welding current becomes the base current.
Further, in case where the welding process used is “AC-DC TIG”, no pulse selection key can
be selected.

Subject Timinng Chart

10. OPERATION (continued)

Pulse

OFF

Pulse

ON

Low Pulse

frequency

(0.1Hz -15Hz)

Pulse

ON

High Pulse

frequency

(15Hz - 500Hz)

Tack welding

࡮

Repeat of short welding

࡮

Thin plate welding

࡮

Preventing bead hanging

down in URANAMI
welding or in fillet
welding in vertical
position.

Thin plate welding



Torch Switch

Welding Current



Torch Switch

Welding Current



Pulse Current Base Current



Torch Switch

Welding Current



Pulse Current Base Current

ON

ON

ON

The standard pulse peak ratio is 50%, which may be adjusted with the internal function.
Furthermore, in the case of DC TIG welding, the internal function also makes changing to a
soft pulse possible.
See Section 10.1.17, “Internal Functions” for further details.



- 36 -

10. OPERATION (continued)

10.1.11 Slope setting

Slope setting “ON” and “OFF” may be selected with the SLOPE selection key [14] if the

crater setting is “ON”, “REPEAT” or “arc spot”. The LED located on the upper left corner of
the selection key indicates the status of slope setting “ON” and “OFF” when it is turned ON
and OFF respectively. If the slope setting is “ON, the parameters “upslope time (only if the
initial current setting is ON) ” and “down slope time” may be selected with the parameter
selection key [3]. But if the crater setting is “OFF”, no selection may be made with the
SLOPE selection key.

10.1.12 Crater setting

Crater

Bead

Pool

Depressing the CRATER FILL. key [5], the crater setting is selected in the sequence
as shown below:

Crater OFF → Crater ON → Crater ON (REPEAT) → ARC SPOT

For crater-fill operation, select the setting “Crater ON” or “Crater on (REPEAT)”.

Crater Initial current Timinnig Chart

OFF

The torch switch hold turned ON during weld.

٨

At the end of welding, there remains a dent called
“crater”. This dent that might cause cracking or other
welding defects must be minimized in size; this
operation is called as “crater filler”.

ON

 

OFF

ON

When the torch switch is turned OFF during welding, the welding current is

٨

designed to be self-held. The torch switch must be held turned ON during initial
current and crater-fill operation.



- 37 -

㧔

Crater

ON

REPEAT㧕

Initial

current

OFF

ON

10. OPERATION (continued)

Timinnig Chart



Torch Switch
Welding Current

Welding Current



ON ON ON

Torch Switch

Welding Current



ON ON ON

Crater Current

Welding Current



Initial Current Crater Current

Even if the torch switch is turned OFF during welding, the welding current will

٨

be self-held. When the torch switch is turned ON again, it is switched to crater­fill current. During crater-fill operation, the torch switch must be held turned
ON. If the torch switch is turned OFF during crater-fill operation, it is switched
back to welding current again. Those switching operation will be repeated
cyclically. It is therefore needed to perform it with the torch lifted up to turn
OFF arcing.
In addition to turning OFF arcing with the torch lifted, it is also possible to turn

٨

OFF arcing with the torch switch held depressed for a longer time during
repetition. See Section 10.1.17, “Internal functions” for further details.

Welding with various functions combined

٨

With crater-fill, pulsing, and slope functions combined, it is possible to perform welding as shown
below:



- 38 -

10.1.13 ARC SPOT setting ( )

For arc spot processing, set the CRATER FILL. key [5] to ARC SPOT. Then, upon depression
of the Arc SPOT TIME key [5], the indicator LED located on the upper left corner of the setting
key turns ON and the set value appears on the right digital display with the unit indicator LED
for “sec. (sec)” turned ON. In this state, the arc spot time may be adjusted in the range
between 0.1 and 10 sec. by the use of the parameter adjusting knob [4].
Depression of the arc spot time setter key or the parameter selection key [3] will bring you
back to the previous parameter setting stage last adjusted.
In the modes other than arc spot, the arc spot time key may not be selected.



Torch Switch



Output Current

(Slope ON)

Possible adjustable parameters;
Arc spot time, Down slope time, Welding current, Crater current

10. OPERATION (continued)

ON (ON)

OFF

Arc Spot Period

Welding
Current

Down slope
Period

Controlled by
Torch Switch

Crater Current
Setting



Arc Spot Period



Possible adjustable
parameters;
Arc spot time, Welding current

Output Current

(Slope OFF)

Welding
Current

The current once provided with the torch switch turned ON will be held supplied during arc

٨

spot period (including down slope period if the slope setting is ON) even if the torch switch is
turned OFF.

For arc spot process, it is possible to turn OFF arcing even during arc spot period if the torch

٨

switch is turned OFF.

See Section 10.1.17, “Internal functions” for further details.





- 39 -

10. OPERATION (continued)

㧕

㧕

㧕

10.1.14START setting (Lift start or High frequency start)

Start mode may be selected with LIFT START key [13]. Start mode may be indicated with



the indicator LED on the upper left of the mode selection key that turns ON or OFF for “Lift
start” or “High frequency start” respectively.

High frequency start

㧔1㧕

Ԙ Depress torch switch with electrode separated from base

metal.
Arc is generated between electrode and base metal by

ԙ

means of a high frequency spark.

In the event that arcing does not start within approx. 5 sec. after high frequency is
generated, the high frequency and output voltage generation automatically stops. If
high frequency generation stops in such way, the torch switch must be turned OFF and
then it should be depressed again.
If such problem remains unsolved,

࡮check if the cable and the torch are properly connected, and/or

if the electrode tip has any irregularities.

࡮

Lift start

㧔2㧕

This is a method to start an arc generation by supplying current to a circuit formed
with an electrode and a base metal contacted and separating the electrode from
the base metal. Neither high frequency nor high voltage is generated at the start,
and no electromagnetic interference is caused.

ԘԙԚ

Ԙ Depress torch switch with electrode not contacted with base metal.
ԙ Bring electrode in touch with base metal.

It is also possible to depress torch switch with electrode touched with base metal.

Draw the electrode apart from the base metal to generate arc.

Ԛ

Notes:

1

Even if torch switch is depressed with electrode not contacted with base

metal, no-load voltage is not applied (though gas is released).

2

Frequent arc starts may cause electrode surface to be stained (whitened),

due to which smooth arc start may be prevented. In such events, regrind
the electrode.

3

Nonexistence of pre flow period allows immediate arc start when electrode is

drawn apart from base metal. But if any defects were caused to an area to
start welding, adjust the time between touching and separation of electrode
and base metal as needed to provide suitable pre flow period so that the
electrode and the parts to be welded may be isolated from ambient air with
argon.





- 40 -

10. OPERATION (continued)

10.1.15 Gas check ( ) with gas-saving function.

Used to adjust gas flow rate when the gas cylinder discharge valve is opened.
When the GAS CHECK key [16] is depressed once, the gas is discharged with the
indicator LED on the upper left corner of the key turned ON. When this key is
depressed once again, the gas discharge will discontinue with the indicator LED
turned OFF.
And this is also designed to automatically stop gas discharge in two minutes after
the GAS CHECK key is depressed. If the welding started during gas check period,
the gas flow is to be automatically prevented when the welding is finished (after the
end of post-flow period), and it is unlikely to occur that the gas continues to flow out
during down period.

10.1.16 Cooling torch selection ( )
With TORCH change-over key [15], set the cooling mode for the torch to be used.
The LED on the upper left of the key indicates the status of cooling mode selected,
[water-cooled] or [air-cooled] when it is turned ON or OFF respectively.
If cooling water is not supplied or the water pressure is lower than specified, an
error will be issued.





- 41 -

10.1.17Internal Functions

This welding machine has various special functions that may be used by setting
with F-key (Function selection key) [10].

How to use internal functions

٨

When Function selection key [10] is depressed, the function No. starts blinking on

Ԙ

the left display described below and the status assigned to that function No.
appears on the right display. In this state, the function No. desired may be set
with the parameter adjusting knob [4].

It is possible function No. is changed by parameter adjusting knob [4].

The example given above shows that the function [F1] is set to [ON].



When Function selection key [10] is depressed while the desired function No.

ԙ

appears on the display, the function No. will light up while its status indication will
start blinking. In this state, the desired status can be selected with the parameter
adjusting knob [4].

 

It is possible function No. is changed by parameter adjusting knob [4].

The example given above shows that the function [F4] is set to [OFF].

When Function selection key [10] is depressed again, the displays will go back to

Ԛ

the state as shown above in Ԙ while the function No. will stop blinking. To exit
this function setting mode, hold Function selection key [10] depressed for a
longer time.

Note:
When the function settings are changed in this mode by selecting with the
parameter adjusting knob [4], they become effective immediately at once (without
asking you to confirm). Therefore it is needed to carefully check, before exiting
this mode, if the status is properly assigned to those functions as desired.

10. OPERATION (continued)

WARNING

Function No. blinks Status of function appears



↓

ASe

WARNING

ASe

Function No. appears Status of function blinks

↓

Hz
%

JOBNO.

Se
Hz

Hz
%

%

JOBNO.



- 42 -

10. OPERATION (continued)

The following functions can be adjusted by F selection key [10].
*Some parameters of F (function) can be memorized for each condition No. of the feeding condition
memory function, and others apply to all feeding conditions (The parameter cannot be memorized for
each condition No.). O or X is described to the right end of each parameter item of F function to show
which is applicable to the parameter.

O: The parameter can be set for each feeding condition.
X: The parameter is common to all feeding conditions.

Selecting start current level: Function No. 1 ---- X

㧔1㧕

The factory setting of this function is [ON] that means [high] start current. If any holes are
caused at the start of welding, the [low] start current should be selected by setting the status of
Function No. 1 to [OFF].

Changing sequence in arc spot mode: Function No. 2 ---- X

㧔2㧕

It is possible to change the operation sequence so that arcing may discontinue even during arc
spot process if the torch switch is turned OFF in “ARC SPOT” mode. To change the sequence
in such way, the status of Function No. 2 should be set to [ON].
If this function status is set to [ON], the torch switch must be kept turned ON during arc spot
process.

Changing sequence in crater ON (REPEAT) mode: Function No. 3 ---- X

㧔3㧕

It is possible to change the operation sequence so that the following welding operation may be
performed by momentarily (within 0.3 sec) depressing torch switch in “crater ON (REPEAT)”
mode. With torch switch unrepressed, the level is self-held during initial current and crater
current periods as well as welding current period. To terminate the welding, depress torch
switch for longer time (not shorter than 0.3 sec). To change the sequence in such way, the
status of Function No. 3 should be set to [ON].

Pre flow

Welding
Current

ON

Torch
Switch

OFF

Up slopeDownslope

Initial

Within 0.3sec

Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec 0.3sec

CraterMain

Post flow

End of Weld



- 43 -

٨

٨

٨

㧔4㧕

10. OPERATION (continued)

Selecting AUTO or MANUAL mode: Function No. 4 ---- X
Selecting AUTO mode allows operation stop to be cancelled with operation stop terminal
short-circuited. In addition, select AUTO mode to utilize external voltage supply to feed
welding current (base current) or pulse current for the operation combined with robot etc..
The factory setting of this function is “MANUAL” and the operation stop is only cancelled by
turning power supply switch to OFF and then to ON.
To select [AUTO] mode, the status of Function No. 4 should be set to “ON”.

Note:

The set values on the front panel are effective even though external voltage supply
is connected to the remote control receptacle with [MANUAL] mode selected.
When the analog remote control is connected, the set values on the remote control
have the highest priority regardless of AUTO or MANUAL mode.
To use Function No. 5 or No.6, [AUTO] mode must be selected.

To set the current and the voltage by the use of external power supplies, they must be

٨

connected as shown below. If the pulse setting is “OFF”, only the power supply E2 should
be used.

Available Plug;

Remote control receptacle

/#:O#

㧞

/#:O#

㧠

8㨪8

㧟

㧱㧝

%10

Spec DPC25-4A
P a r t N o . 4730-005



(Pulse Current)

PROHIBITION

㧱㧞

(Welding Current)

(Base Current)

٨Supply 0V to 15V to E1 and E2. Exceeding 15V may result in damage to the control circuit of

the welding power source.



CAUTION

٨Be sure to finish setting and inputting before 100 milliseconds when starting signal is input.

Inputting after starting signal is input or at starting signal may result in unstable start.



- 44 -

10. OPERATION (continued)







㪭

b

(5) External voltage (0-12V) control: Function No. 5 ---- X

When used in AUTO mode combined with INVERTER ARGO, selecting [ON] status for this
function allows to use the machine with almost same conditions by slightly adjusting external
control voltage (pulse current and welding current or base current).
As the factory setting of this function is [OFF], select the status [ON] for Function No. 5 to activate
this function.

(6) External voltage (0-10V) control: Function No. 6 ---- X

When used in combination with robot whose maximum control voltage is 10 volts or less, this
function should be utilized.
As the factory setting of this function is [OFF], select the status [ON] for Function No. 6 to activate
this function.
If the status of Function No. 6 is set to [ON], the status of Function No. 5 will be automatically set
to [OFF].

The following chart shows the relationship between external current control voltage and output

٨

current.

㪊㪌㪇

㪮㪼㫃㪻㫀㫅 㪾㩷㪚㫌 㫉㫉㪼 㫅㫋㩷㩿㪘㪀

㪊㪇㪇

㪉㪌㪇

㪉㪇㪇

㪈㪌㪇

㪈㪇㪇

㪌㪇

㪇

㪜㫏㫋㪅㩷㪺㫆㫅㫋㫉㫆㫃㩷㫍 㫆㫃㫋㪸㪾㪼㩷㪈

㪜㫏㫋㪅㩷㪺㫆㫅㫋㫉㫆㫃㩷㫍 㫆㫃㫋㪸㪾㪼㩷㪉

㪜㫏㫋㪅㩷㪺㫆㫅㫋㫉㫆㫃㩷㫍 㫆㫃㫋㪸㪾㪼㩷㪊

㪇 㪌 㪈㪇 㪈㪌

㪜㫏㫋㪼㫉㫅㪸㫃㩷㪺㫌㫉㫉㪼㫅㫋㩷㪺㫆㫅㫋㫉㫆 㫃㩷㫍㫆㫃㫋㪸㪾㪼㩷㩿㪭㪀

㪐㪅㪊㪭

㪈㪈㪅㪈㪭

㪈㪊㪅㪐

< Ext. control voltage 1 (factory setting) >

External control range is 0V(min.)-15V(max.).

< Ext. control voltage 2 (function No.5 is ON) >

External control range is 0V(min.)-12V(max.).

< Ext. control voltage 3 (function No.6 is ON) >

External control range is 0V(min.)-10V(max.).

(7) Pulse peak ratio adjustment: Function No. 7 ---- O

The factory setting is 50%, which may be adjusted by selecting Function No. 7. When selected,
the set value appears on the left digital display with the unit indicator LED for “%” turned ON.
Pulse peak ratio can be adjusted in the range between 5% and 95%.

Pulse Current Base Current

b

a

Pulse peak ratio is defined as
the percentage of pulse current
period in a cycle as follows.



Pulse peak ratio = ×100%

a



- 45 -

10. OPERATION (continued)

(8) Result display holding time setup: Function No. “9” ---- X

After completion of welding, the mean value of output current during last 1-sec. period is displayed
by flashing for approx. 20 sec., but this time can be set up with Function No. “9”. The setup range
is 0 to 60 sec.

(9) AC Ratio Adjustment: Function No. “10” ---- O

The AC ratio is factory preset to 70% before shipment. The adjustment of AC ratio can be set up
with Function No. “10”. At this time, the set point is indicated on the left-side digital meter, and the
“%” LED lights up.
The AC ratio is set up in the range from 10% to 90%.

(10) Operating sound switching: Function No. “11”  ---- X

By turning Function No. “11” OFF, the operating sound or noise arising when the panel key is
manipulated can be arrested. However, no operating sound volume can be controlled.

(11) External output terminal 1 switching: Function No. “12”  ---- X

External output terminal 2 switching: Function No. “13”  ---- X

The assignment of external output terminal 1 and that of external output terminal 2 can be
changed with Function No. “12” and Function No. “13” respectively.

The relationship between the function to be assigned and the number to be set up is as described
in the table below:

Setting No. Description Function

It works as for power source preparation relay.
It operations when there is no abnormality, such

1 Power source preparations

2 Pulse synchronizing output

3 EN synchronizing output

4 AC synchronizing output

(12) Pulse synchronizing input signal switching: Function No. “14” ---- x

By turning Function No. 14 “ON”, the pulse current and base current can be changed over by
inputting external signals into the pulse synchronizing input terminal. At this time, the panel pulse
must be set to “ON”. Also, the panel pulse frequency setting becomes impossible.
Closed circuiting across terminals produces pulse current and open circuit produces base current.

CAUTION:
Even when the pulse synchronizing input terminal is closed during initial current and
crater current period, no pulse output is produced.
Only when the input signal level was held at least 2 ms, the status can be switched.

as lucking, operation stop, temperature error
and when the power source switch is on.
Function No.12 is factory setting.
When the pulse is “ON”, the section across
terminals is closed.
Function No.13 is factory setting.
In AC TIG welding, the circuit is closed between
terminals during EN period (the electrode is
minus.)
In AD-DC TIG welding, the circuit is closed
between terminals during AC period.

(13) AC balance display change-over: Function No. “15” ---- x

By turning Function No. 15 “ON”, the value indicated on the digital meter can be used as EP ratio
in AC balance setup, and the “%” LED is also lit on the unit LED. Further, on the left-side digital
meter, the standard value is displayed by flashing.



- 46 -

10. OPERATION (continued)

(14) Soft pulse: Function No. “16” ---- x

By turning Function No. 16 “ON”, it is possible to change pulse welding to “soft pulse” in case
where the pulse is “ON” in DC TIG welding. In soft pulse, current is changed smoothly, and soft
arc is produced, compared with “standard” pulse, thereby reducing a welding sound. This soft
pulse is suitable for thin plate welding since it is hard to burn through or melt down, compared
with “standard” pulse at the same average current.
In case where a soft pulse is used, it is recommended that the pulse frequency should be set at
10Hz or more and the pulse width should be set at 40% to 60%.

(15) Current adjustment by torch switch: Function No. “17” ---- x

By turning Function No. 17 “ON”, the output current can be changed by the current change
amount set up in advance by torch switch clicking operation only during the self-holding period in
the “Crater-ON” or “Crater-ON (Repeat)” mode.
Function No. “18”: The current change amount is set up by single clicking.
Function No. “19”: The current change amount is set up by double clicking.
The current change amount setup range is –50A to +50A.
(Example)
Crater-ON, no initial current, welding current 60A and crater current 20A
F18: -10A
F19: 20A

Welding
Current

60A

50A

40A

single
clicking

60A

50A

double
clicking

Torch
Switch

ON

OFF

Within 0.3sec

Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec Within 0.3sec 0.3sec

<Precautions>

1) If this function is set to “Effective” (ON), the function of F3 becomes invalid (OFF) automatically,
while this function becomes invalid (OFF) automatically by validating “F3” (ON).

2) It is necessary to press the switch for as long as 0.3 sec. or more during transfer to crater at
startup.

3) In case where the operation is transferred from crater to the main welding in the “Crater-ON”
(Repeat) mode, the operation starts with the welding current outputted before transferring to the
crater.

70A

60A

Crater
Current

20A



- 47 -

10. OPERATION (continued)



(16) Current offset adjustment: Function No. “20” ---- x

If a welding cable is made long in case for AC TIG welding in point of welding current
characteristics, the actual average welding current (value indicated on the ammeter) becomes
smaller than the set current, and as the welding current is larger, its difference becomes larger.
In such a case, the difference between the set current and actual average welding current can be
made smaller by regulating welding current with Function No. “20”. This function is effective if
used when no actual current reaches 300A, for example in case where the welding cable was
extended. This function also works in the case of DC TIG or DC manual welding.
The setup range is 0 to 30. If the set point is incremented by 1, as a standard, the average
welding current increases by approx. 1A. Also, the set adjustment amount is constantly added in
all current ranges.

(17) Memory condition interlocking function (At the time to connect TIG filler):Function No. “21”

When the welding power source is connecting with TIG filler controller HC-71D, the JOB memory
function of the welding power source and the feeding condition memory function of the TIG filler
controller can be synchronized; and the memory condition number can be shared. For example,
when condition number 2 is read, not only the welding condition number 2 is read but also the
feeding condition number 2 is read from the feeding condition memory of the TIG filler controller.
When Function No.21 is turned “ON”, the memory condition is synchronized. The factory setting
of this function is “OFF” and invalid.

(18) Current adjustment function with torch switch at pulse function: Function No. “22”

When the pulse is "on", and function number "17" is "on", and the function of the current fine­adjustment with the torch switch is effective, operation can be changed as follows by the function
number "22".
The factory setting of this product is "1".

“1”: Only the pulse current changes by the click operation. The base current doesn't

change.

“2”: Both pulse current and base current change with the click operation by the same

current amount (value is set with F18 and F19).

(19) Indication of welding voltage: Function No. “23”

Output voltage during welding is indicated on the right digital display by turning Function No.23
“ON”. This indication changes every 0.5 seconds by output condition. The representational
accuracy at this time is equal to 2.5 grades and it is the same class as general analog meter.
After weld is end, the last second average value of output current is blinked on and off and
displayed as the result indication time.
(However the output condition of crater filler should be ignored.)
The factory setting of this function is “OFF” and invalid.

NOTE
Average value of output on the digital meter is treated by software, which means it can
not guarantee as control date of measurement apparatus. (The representational is equal
to 2.5 grades.)



- 48 -

10. OPERATION (continued)

(20) 2 stroke slope function: Function No. “24”

When turning on the torch switch, welding current increase from initial current setting. Then after
up-slope time, current becomes main current. When turning off the torch switch, welding current
decrease to crater current setting. After down slope time, the weld is ended.
When turning the function No.24 ON, this function can be used. Then settings are changed
automatically such as crater: ON, initial current: ON, slope: ON. When turning function
No.24 OFF, ordinary sequence can be used. However crater, initial current and slope
condition do not change.
When initial current is OFF, welding starts with main current.
When slope is OFF, this function doesn’t operate.

10.1. 18Analog remote control (K5416T) (optional accessory)
When the power switch was turned ON, the analog remote control is automatically recognized.
When the analog remote control is connected to the machine, the only remote control is
effective and the parameters “welding current (base current)” and/or “pulse current” selected
on the front panel may not be adjusted by the parameter adjusting knob [4] on the front panel.
They must be adjusted on the analog remote control that is connected to the machine. Those
set values may be monitored on the digital display on the front panel.
When take off the remote control, setting figure disappear.

* Insert and withdraw the remote control always after turning the power switch “OFF”.



- 49 -

10. OPERATION (continued)

CAUTION

For electrode stick, follow the instruction below.

Keep the electrode stick in a place with low humidity.

٨

Dry the electrode stick sufficiently before using.

٨

When the gas burner is used for pre-heating or removing moisture of the base metal, be

٨

sure to heat to 100˚C or above.
Slag and fume generated when tack welding will cause wetting the part of base metal to

٨

be welded. Remove slag and fume immediately after tack welding.
When welding is performed outdoors and wind velocity exceeds 10ft/sec, use a wind

٨

shield.

10.2 DC STICK welding

10.2.1DC STICK welding

Set the welding process to DC STICK welding ( )
with the WELDING METHOD key [1].

The welding current setting mode is automatically selected and setting value is indicated on
the left digital display with the unit indicator LED for amperage “A” turned ON.
When switched to DC STICK welding, or when turn on the switch with DC STICK welding is
selected, no-load voltage is not provided for approx. 5 sec. for safety. 5 sec. later, the voltage
is automatically provided.

10.2.2Welding current setting

The welding current may be set with the parameter adjusting knob [4] in the range specified
in the table shown below:
Current range is 10A-250A.

10.2.3 Internal function setting

The function listed below may be adjusted with Function selection key [10]. See Subsection

10.1.17 for internal function setting.

(1) Hazard reducing function: Function No. 8

This is a safety function that reduces risks of an electric shock by limiting no-load voltage
of welder to lower level at any time except welding period.
It is therefore recommended to utilize this function when the machine is used at high site or
in confined environment.
The factory setting of this function is [OFF]. To activate this function, set Function No. 8 to
[ON].

10.2.4Analog remote control (K5416T)

This machine automatically recognizes the analog remote control. When the analog remote
control is connected to the machine, the only remote control is effective and the parameters
“welding current (base current)” and/or “pulse current” selected on the front panel may not be
adjusted by the parameter adjusting knob [4] on the front panel. They must be adjusted on
the analog remote control that is connected to the machine. Those set values may be
monitored on the digital display on the front panel.
When take off the remote control, setting figure disappear.



- 50 -

10. OPERATION (continued)

10.3 Information common to all models

10.3.1 Indication on digital display
Digital displays are designed to indicate the items listed below:
(1) Parameter set values

In the Set Value Indication mode during down period (except result indication period
immediately after welding process) and during welding period, the parameter set value
under adjustment is indicated.

(2) Output current at welding

During welding period, the indication of parameter set value on the digital display is
automatically switched to the indication of average output current which is updated every

0.5 sec. to reflect the latest output condition.
If it is required to change each parameter setting with its set value monitored during
welding, depress the parameter selection key [3] to change the indication mode into the
“Set Value Indication” mode where the parameter indicator LED starts blinking. If no action
is applied for 5 sec. more or less, or when a selectable parameter is back where it started,
the indication mode automatically returns to the “Average Indication” mode.
When the torch switch is depressed, the sequence parameter indicator LEDs will turn ON
sequentially in response to the welding process in operation. When switched to the “Set
Value Indication” mode, the indicator LED of sequence parameter selected with the
parameter selection key [3] will start blinking.
The average display of the output current is possible adjust offset in the range of r10A by
Function No.10. Adjustment quantity is added(subtracted) at the all current range. For this
adjustment, gain adjustment which is change adjust amount is not possible.

See Section 10.3.2, “Adjustor Knob” for the parameters that may be adjusted during
welding with the parameter adjusting knob [4].

(3) Result after the end of welding

When the welding is finished, the average output current for the last 1 sec. is indicated for
approx. 20 sec. by blinking (with no consideration given to the output conditions for crater
filler process). This indication may be used for a welding personnel to check the conditions
on which the welding has been completed and to adjust the conditions for better result.
This indication will disappear in 20 sec. or when the next welding starts or any key on the
front panel is depressed.
The indication period may be adjusted in the range between 0 and 60 sec. by selecting
Function No. 9 with Function selection key [10] where the set value will be indicated on the
left digital display with the unit indicator LED for “sec. (sec)” turned ON.

(4) Errors

Any error caused to the machine will be indicated with blinking numeral assigned to each
error type. See Section 11.1, “How to Solve an Error” for further details including error
numbers.



Note:

The mean value of output displayed on the digital meter is processed with
software, which cannot be guaranteed as measuring instrument management
data.



- 51 -

10. OPERATION (continued)

10.3.2 Adjustor knob
To adjust parameters with adjustor knob [4] during welding, depress the parameter selection
key [3] to change the mode into the Set Value Indication mode. The initial conditions, main
conditions and crater filler conditions become changeable during initial current, main welding
and crater, respectively.
During welding period, the welding current (base current) may be adjusted immediately after it
is switched to the Set Value Indication mode. In addition to welding current (base current), two
other parameters (pulse current and pulse frequency) may be also adjusted during welding
period with the parameter selection key [3] depressed. Also, even by pressing the AC FREQ.
key [6], AC BALANCE key [7] and AC-DC change-over frequency setup key [8], the set point
mode is selected, and the adjustment becomes possible during any period.
During welding period, the parameters may not be adjusted in the Average Indication mode.

10.3.3Key Lock (available only at TIG welding)

Key lock is a function to prevent the welding conditions from being changed by accidentally
operating keys and knobs on the front panel. Only the keys and parameter adjusting knob
which are used for changing each parameters and modes can be protected. However, the
settings can be checked and confirmed by using the Parameter selection key [3] and the Arc
SPOT TIME setting key [9].

10.3.4JOB MEMORY Function (available only at TIG welding)

The JOB MEMORY function enables welding conditions to be reproducible by storing the
welding conditions in memory inside power source and by reading out the stored data at any
time. The number of welding conditions that can be held in memory is up to 100.

Holding down both the F [10] key and ENTER key [19]

ENTER

T1

㧲

GAS

While keys are locked, the F lamp blinks

Even when the keys are locked, GAS CHECK, INCHING, and JOB MEMORY function
can be activated.

simultaneously

Holding down both the F key [10] and ENTER key [19]
simultaneously for a while brings the key-lock condition.
While keys are locked, the F lamp (located at the upper
left of the F key) blinks. Key lock can be cancelled by
holding both the F key and ENTER key simultaneously
for a while again. Key lock cannot be cancelled by
starting the machine up again.



- 52 -



10. OPERATION (continued)

CAUTION

٨The welding conditions (electronic data) stored by this function are susceptible to

occurrence of static electricity, impact, repair, etc., and there is a possibility that the
storage contents may be changed or lost. BE SURE TO MAKE A COPY FOR
IMPORTANT DATA.

٨Please note that we shall not assume any responsibility for any change or loss of

electronic data resulting from repair.

While the machine enters the memory and read-out modes, only the SAVE key, LOAD key,
and ENTER key can be operated. To exit the mode, press the LOAD key [17] if it is in the
memory mode and the SAVE key [18] if in the read-out mode. Memory can be copied to a
different condition number after reading the welding conditions you want to copy.

Note:
Even when welding conditions are read out while the analog remote control is

connected to the welding power source, the setting values preset at the analog remote
control are valid.

SAVE Function

Ԙ

Welding conditions being currently in use are stored in the memory inside the welding
power source.

Holding the welding conditions in memory

٨

(1) When pressing the SAVE key [18], the machine enters memory mode, the SAVE

lamp (located at the upper left of the SAVE key) lights up. See the following picture.
In the right display, condition number “1” blinks and the LED lamp of the welding
condition number lights up. In the left display, the setting value of welding current
preset to the condition number "1" is displayed. Under this condition, a condition
number can be set while turning the parameter adjusting knob [4].

In the event that any memory data is already preset to the condition number you
selected, the CRATER lamp, the WELDING METHOD lamp, etc. also light up. If no
memory data is preset to the condition number you selected, “- - -” in the left
display blinks. In this case, the system skips the parameter check condition of Step
(2) and jumps to Step (3).

WARNING

A

Welding Current setting value Condition number blinks
held in memory

WARNING

A

Se
Hz
%

JOBNO.

Se
Hz
%

JOBNO.



- 53 -

10. OPERATION (continued)

(2) When pressing the ENTER key [19] after setting the condition number, the ENTER lamp

blinks (located at the upper left of the key). Under this condition, you are allowed to confirm
the setting value of the parameter preset to the condition number by using the Parameter
selection key [3]. The setting value of the parameter you selected blinks.

Note:
In the save mode, you can not change the welding condition number or select any
memory/readout mode. To reset the condition number, press the SAVE key [18], then
return to the step (1).
To quit the setting and exit from the memory mode, press the LOAD key [17].

(3) Pressing the ENTER key [19] again holds the data in memory and allow you to exit from

the memory mode.

LOAD Function

ԙ

The welding conditions stored in memory are read out from the memory inside welding power
source.

Note:
The welding conditions currently used are overwritten with the welding conditions
that are read out. When you wan to save the welding conditions that have been used
until now, set the welding conditions to any condition number, then carry out readout.

Reading out the preset welding conditions

٨

(1) When pressing the LOAD key [17], the machine enters the readout mode, LOAD lamp

(located at the upper left of the LOAD key) lights up. See the figure below. The condition

number "1" in the right-side display blinks and the JOB No. LED lamp lights up. In the left-

side display, the setting of welding current preset to condition number "1" lights up. Under

this condition, a condition number can be set while turning the parameter adjusting knob [4].

In the event that any memory data is preset to the condition number you selected, the

CRATER lamp, the WELDING METHOD lamp, etc. also lights up. When no memory data

is preset to the condition number, "- - -" in the left-side display appears and blinks. See the

figure below.

(2) When pressing the ENTER key [19] after setting the condition number, the ENTER lamp

(located at the upper left of the key) blinks. Under this condition, you are allowed to confirm

the setting of each parameter you want to read out by using the Parameter selection key

[3]. The setting of the parameter you selected blinks.

WARNING

A

Welding Current held in memory

WARNING

A

Condition blinks



Se
Hz
%

JOBNO.

Se
Hz
%

JOBNO.



- 54 -

10. OPERATION (continued)

Note:
You are not able to change condition number or select a welding method, etc. To
reset the condition number, press the LOAD key [17], then return to the step (1). To
quit the setting and exit from the readout mode, press the SAVE key [18].

(3) When pressing the ENTER key [19] again, you can read out the preset welding conditions and

exit from the readout mode.

Memory mode operation

٨

Readout mode operation

٨

Discontinue

Discontinue

Press the LOAD key.

Discontinue

Discontinue

Press the SAVE key.

Press the MEMORY key.

Set the weld ing co ndition nu mber while
turning the parameter adjusting knob.

Press the ENTER key.

Press the MEMOR Y key.

Press the parameter selector key
to check the parameter value.

The welding conditions are set to the number you selected.

Reset the welding condition number.

Press the ENTER key.

The memory mode quits

.

Press the LOAD key.

Set the welding condition number while
turning the parameter adjusting knob.

Press the ENTER key.

Press the LOAD key.

Press the parameter selector key
to check the parameter value.

The welding conditions are set to the number you selected.

Reset the welding condition number.

Press the ENTER key.

The readout mode quits

.



- 55 -

Erasing the Welding Conditions

Ԛ

When you erase the welding conditions stored in memory, you can select either erasing all or
erasing one.

Erasing the welding conditions

٨

(1) Turn off the power switch and turn on the power switch with both the LOAD key [17] and

SAVE key [18] pressed. Release the keys after turning on the power switch, and then
"dEL" appear in the left-side display. See the picture below.



”dEL" display means the machine Condition number to be deleted blinks.
in the delete mode.

(2) Set the condition number to be deleted while turning the parameter adjusting knob [4].

When turning the knob counterclockwise, "ALL" appears in the right-side display as
illustrated below and you can erase all the welding conditions.

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 settings.

(3) Pressing the ENTER key [19] blinks "dEL." Confirm the condition number again and if

you want to cancel erasing of the condition number, press any key other than the ENTER
key [19] to return to step (2). To quit the delete mode, turn off the welding power source.

(4) Pressing the ENTER key [19] again deletes the welding condition that is preset to the

condition number. When "End" is displayed after end of data deletion, turn off the power
switch, then start up the welding machine.

Note:
When pressing the ENTER key [19] twice in the deletion mode, you can not
recover the erased welding conditions. When you attempt to delete a welding
condition that is held in memory, make sure that the condition number you
want to erase is surely selected.

10. OPERATION (continued)

WARNING

WARNING

"dEL" is displayed

ASe

ASe



Hz
%

JOB

Hz
%

JOB

"ALL" blinks



- 56 -

10. OPERATION (continued)

10.3.5Resetting to Initial Values
When resetting to the welding conditions to initial values, the welding conditions that are
currently used (including the welding condition currently used) are all reset to initial values.
But, even when resetting to initial values, the welding conditions held in memory are not
changed. To reset to initial values, turn off the power switch, and then turn on the power
switch with both the F key [10] and GAS CHECK key [16] held down. When "End"s appear in
the displays after turning on the power switch, release the keys, turn off the power switch,
then turn it on again. See the picture below.

WARNING

See “SPECIFICATIONS” for initial values of each parameter and function.

10.3.6Confirming software version
The version of software incorporated in the welding power source can be verified following
these steps. Turn on the power switch with only the F key [10] held down. After powering the
welding power source, the version number appears in the display.

(Example)
Right and left displays : "P10464"← Software number (P10464) is displayed.

↓ Press the F key [10].
Left display : "001" ← Main software version (Ver. 001) is displayed.
Right display : "000" ← Sub software version is displayed.

↓ Press the F key [10].
Left display : "- - -"
Right display : "000" ← Combination is displayed.

↓ Press the F key [10].
The welding power source starts up as usual and gets ready to perform welding.

10.3.7 Automatic Stop of Fan
The cooling fan automatically stops in 10 minutes after welding is finished and automatically
starts turning when welding is started. When turning on the welding power source, the cooling
fan is also turning but automatically stops in 10 minutes when no operation is carried out.

10.3.8 Fan noise reducing function
To reduce the fan noise level during welding suspension, the fan rotation is decelerated.
However, this function is effective only when used at the output current 250A max.

A

Se
Hz
%

JOBNO.



- 57 -

11. APPLIED FUNCTION

11.1 How to Solve an Error

WARNING

٨Do not touch the live electrical parts inside or outside the welding power source.
٨Only the certified operators or the person who understand the welding machine well can

change wiring or switch setting in the welding machine.

٨Turn OFF all power switches in the switch box and wait for 3 minutes or more before

touching the inside parts of the welding machine.

If an error occurs during use, an error code shown in the displays on the front panel blinks, then the
welding power source stops automatically. In this case, check the errors in the following table.

Displays

No.

on the front panel

Observe the following to prevent electrical shock.

Left Right

Classification of errors

1 d A I H E n Torch switch off state waiting

2 E - 0 0 0 Operation Stop

3 E - 1 0 0 Control power supply error

4 E - 2 0 0 Primary / secondary current detection error

5 E - 3 0 0 Thermal overload

6 E - 5 0 0 Lack of water pressure

7 E - 5 1 0 Pump error

8 E - 6 0 0 Battery low (warning)

9 E - 7 1 0 Lack of phase

10 E - 7 5 1 Secondary side over voltage error

11 E - 9 X X Microcomputer error



- 58 -

11. APPLIED FUNCTION (continued)

1) dAIHEn Display

If “dAI” and “HEn” in the displays blink, it indicates the “Torch switch off state waiting“.
When turning on the power switch, the displays on the front panel shows “dAI” and “HEn” for one
sec., then the welding power source becomes operable. But, if the torch switch remains on, the
safety circuit will function, the welding power source will hold a halt condition, then the WARNING
lamp and "dAI” and “HEn" shown in the displays will blink. In this case, turn off the torch switch to
reset the safety circuit and make the welding power source operable.

2) E-000 Display

If “ E-“ and “000” in the displays blink, it indicates the “Operation Stop “.

When disconnecting the wiring of the STOP terminals (Operation Stop terminals: wiring number

213) on the 12P external connection terminal block (TM1), “E-“ and “000” in the displays blink and
the welding power source stops. In this case, after turning off the power switch and eliminating the
possible causes of the stoppage of the welding power source, short-circuit the STOP terminals and
turn on the power switch to cancel the error.

Note:
When canceling the operation stop, it is also possible to solve the error only by short­circuiting the Operation Stop terminals again without starting the welding power source up
again. Refer to Section 10.1.17, “Internal Functions”.

3) E-100 Display

If “E-“ and “ 100” in the displays blink, it indicates the " Control power supply error ".
If there is an error in the control power source, the warning lamp will light up and “E-“ and “100” in
the displays will blink, then the welding power source will automatically stop. To cancel 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 area, “E-“ and “200” in the displays will blink and the
welding power source will stop automatically. In this case, turn off the power switch, then turn it on
again after making sure that CN8 and CN9 on the printed circuit board P10535U are surely
connected.

5) E-300 Display

If “E-“ and “300” in the displays blink, it indicates the "Thermal overload"
If the actual duty cycle exceeds the rated duty cycle of or temperature inside the welding power
source increases, "E-“ and “300" will blink and the welding power source will stop automatically. At
this time, the temperature lamp ( ) also will be lit. In this case, wait more than 10 minutes with the
power switch pressed and the fan turned. When restart welding, turn off the power switch and
restore the system after lowering the duty cycle and the welding current. Such action will cancel the
error. Repetitious welding without more than ten-minute rest may lead to damage to the welding
machine. Refer to Section 3.1, “Rated Duty Cycle” for the rated duty cycle of the welding power
source.

6)  E-500 Display

If “E-“ and “500” in the displays blink, it indicates the “Lack of water pressure”.
If no cooling water is going through the water-cooled hose or shortage of water pressure is
occurred, the WARNING lamp will light up, “E-“ and “500” in the display will blink, then the welding
machine will automatically stop. In this case, check to make sure that the water-cooled hose does
not leak water and that adequate cooling water is going through the hose. When using an air­cooled torch, make sure that the TORCH lamp on the front panel is OFF (AIR).



- 59 -

11. APPLIED FUNCTION (continued)

7) E-510 Display

If "E-“ and “510" in the displays blink, it indicates the "Pump error".

As this welding power source connect the OTC water cooling unit.

If CON4 connector 1-2pin is open circuit for error signal comes from OTC water cooling unit, “E­“ and 510” are displayed. See the manual of OTC water cooling unit and checking for the solution.

8) E-600 Display

If "E-“ and “600" in the displays blink, it indicates the "Battery low (warning)".

This welding power source uses batteries so that it can hold the welding conditions in memory even

when no operation is carried out for long time. “E-“ and “600” in the displays blink when the

batteries get low. “E-“ and 600” are displayed only when the front panel and the welding power

source are temporarily not in use. To cancel the display of the error , press any key. Even when “E-

“ and “600” appear in the displays, welding can continued to be performed, but when the batteries

run down, the preset welding condition functions and the settings of functions are all erased.

The last welding conditions before power is applied to the welding machine can not be

stored. Each time power is applied to the equipment, all the parameters are reset to initial

values. Refer to Section 12.4, “ Replacement of batteries” for details.

9) E-710 Display

If "E-“ and “710" in the displays blink, it indicates the "Lack of phase".


By detecting primary input open phase, the malfunction lamp lights up and “E-710” is displayed by
flashing, and then the welding machine comes to an automatic stop. In this case, check the primary
input voltage for each phase.

10) E-751 Display

If "E-“ and “751" in the displays blink, it indicates the "Secondary side over voltage error".


In case where the secondary-side transistor surge voltage has become abnormally high, for
example since an extension cable was used, the malfunction lamp lights up, and “E-751” is
displayed by flashing, whereby the welding power source comes to an automatic stop. In this case,
take an action therefore in accordance with the description given in 10.1.5 “Notice of using AC TIG
mode”, and then turn the power switch “ON” again.

11) E-9XX Display

If “E-9XX“ in the displays blink, it indicated the “Microcomputer error”.
There could be an error in the built-in microcomputer, Please contact your dealer immediately.
When contacting your dealer, you are required to provide the details of the problem you are facing.



- 60 -

11. APPLIED FUNCTION (continued)

2

P

3

N

WARNING

٨Do not touch the live electrical parts inside or outside the welding power source.
٨Only the certified operators or the person who understand the welding machine well can

change wiring or switch setting in the welding machine.

٨Turn OFF all power switches in the switch box and wait for 3 minutes or more before

touching the inside parts of the welding machine.

٨Try to move the control cable which is pulled out from the automatic connection terminal on

the printed board father away from the welding power cable or the torch cable when making
an external connection. Otherwise, equipment failure may be caused by noise, etc., during
welding operation.

٨Do not pull out the wiring on the printed circuit board to outside except the wiring to the

external connection terminal block.

11.2 External Connection of Inside Terminal Block of Automatic Machine

When taking off the upper cover of the welding power source, you will find there is a 12P
terminal block (TM12P) on the printed board P10541T on the chassis. Use the 12P terminal
block to connect with an automatic machine. Refer to 12.7, “Parts layout” for the locations of the
terminal blocks.

Note:
* Wait more than three minutes after turning off the line disconnect switch or no-fuse
breaker and the power switch on the front panel to remove the cover.
* To pull out the external connecting wire, break the grommet with film on the rear surface
so as not to come into contact with the printed circuit board parts and sheet metal edge
or the like.

Observe the following to prevent electrical shock.

CAUTION

[12P terminal block]

ԘԙԚԛԜԝԞԟԠԡԢԣ

STO

㧙

WCR

㧗㧗㧗

EXT

EXT1

㧙

㧗

㧗

EXT

㧙

GAS

PLS I



- 61 -

㧙

㧗

11. APPLIED FUNCTION (continued)

12P terminal block (TM 12P)

Pin No. Signal name Function

+

㧙 -

Ԙ

Ԛ

Ԝ

ԝ

Ԟ



Ԡ

Ԣ

Precaution for connection with terminals on the terminal block
The wires from the terminal blocks should be twisted for each signals to avoid accidental operation.
Take care that the wires form the terminal blocks do not cross other signal wires from other welding
power source.

*1 Equivalent circuit is as the figure shown right. Maximum capacity of TR is 80V, 100mA. When
connecting such as relay to two terminals, do not exceed 80% of the maximum capacity of TR. (Figure

1)

*2 Equivalent circuit is as the figure shown right. Connect allowable contacts (10mA or more) to two
terminals. (Figure 2)

*3 Rating of the provided relay contacts is 125V AC, 0.5A, 30V DC, 1A. Do not exceed 80% of the
rating of the provided relay contacts.

*4 Be careful that no-load voltage (100V or less) is applied to between the terminals during welding.

ԙ

+

㧙 -

ԛ

+

㧙 -

ԟ

+

㧙 -

ԟ

+

㧙 -

ԡ

+

㧙 -

ԡ

+

㧙 -

ԣ

EXT1 (Output)
External output
terminal 1
EXT2 (Output)
External output
terminal 2
GAS (INPUT)
Solenoid Valve
Control
PLSIN (Input)
Pulse
synchronizing input
signal
EXT3 (INPUT)
Extra Input Signal
STOP (INPUT)
Operation Stop

WCR(OUTPUT)
Current Detection

64

From among the power source preparation, pulse
synchronizing output, EN synchronizing output and AC
synchronizing output functions, select the required one for
use. For the setup method, see 10.1.17 “Internal
Functions”.

The terminals used for controlling the gas solenoid valve by
external signals. (If the terminals are short-circuited, the
gas valve will open.)
Short-circuiting across terminals outputs pulse current. For
details, see 10.1.17 “Internal Functions”.

The terminals used for special specifications. These
terminals should not be used for normal use.
To stop welding externally. Release the wiring between two
terminals to run Operation Stop. Welding 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.
Contact Output of welding current relay used for detection
of welding current. The contacts close while welding current
is flowing.

8

2%

*1

*2

*2

*2

*3



4.7kΩ



Figure 1

Mǡ




Figure 2



- 62 -

11. APPLIED FUNCTION (continued)

11.3 Optional Accessories

11.3.1 Welding Torch

Model AW(P)-17 AW-18 AWD-18 AW-26 AWD-26
Rated

Current
Cooling Method Air Water Air
Duty Cycle 50% 100% 50%
Electrode Dia. 0.5 - 2.4mm 0.5 - 4.0mm 0.5 - 4.0mm
Cable Length 4 or 8m 4 or 8m 4 or 8m

When using the welding power source by combining the following torches, use the proper torch
adapter.

Torch type Torch adapter

AW(P)-17 BBAWD-1701

AW-18 BBAWD-1801
AW-26 BBAWD-2601

Connecting to the Extension Torch Cable/Hose

㧔1㧕Water-Cooled Torch

Connect the extension cables/hoses (optional accessories) as the figures shown below.
Do not confuse the water feeding hose with the condensate hose.

㧔2㧕Air-Cooled Torch

DC 150 A 300 A 200 A
AC 130 A 260 A 160 A

Extension gas hose

Extension power cable

Extension hose (for feeding water)

Taping
(three points)

Connecting cover H558M01

Extension power cable (for condensate water)

Taping
(three points)

To water cooled torch

To air cooled torch



- 63 -

Connecting cover H558M01

11. APPLIED FUNCTION (continued)

11.3.2 Optional Accessories
Description Part number Remarks
Analog Remote Control K5416T00 With 4-meter cable

Digital Remote Control E-2452

CAN communication module K5422C00
CAN communication cable BKCAN-04XX XX:10(10m),20(20m)
Foot-Operated Current Regulator K1104F00

Foot Switch 4259-004
Push-Button Torch Switch K509B00 With 4-meter cable

Push-Button Torch Switch K509C00 With 8-meter cable

11.3.3 Extension Cable/Hose

BAWH-1504
Parts for extending AW(P)­17 (cable length: 4m) to 8m

BAWH-1511
Parts for extending AW(P)­17 (cable length: 4m) to
15m

BAWH-1516
Parts for extending AW(P)­17 (cable length: 4m) to
20m㩷

BAWH-2004
Parts for extending AW(D)­26 (cable length: 4m) to 8m㩷

BAWH-2011
Parts for extending AW(D)­26 (cable length: 4m) to
15m㩷

BAWH-2016
Parts for extending AW(P)­17 (cable length: 4m) to
20m㩷

CAN Communication module and CAN

communication cable is necessary.

With 5-meter cable

Extension Torch Cable H954B00 1 4m

Extension Remote Control

Cable (4 conductors)
Control Cable for Torch Switch
(2 conductors)
Adapter P1600N02 1
Connecting Cover H558M01 1

Extension Torch Cable H955B00 1 11m
Extension Remote Control
Cable (4 conductors)
Control Cable for Torch Switch
(2 conductors)
Adapter and connecting cover is equivalent to BAWS-1504.

Extension Torch Cable H956B00 1 16m
Extension Remote Control
Cable (4 conductors)
Control Cable for Torch Switch
(2 conductors)
Adapter and connecting cover is equivalent to BAWS-1504.

Extension Torch Cable㩷 H957B00 1 4m
Extension Remote Control
Cable (4 conductors)㩷
Control Cable for Torch Switch
(2 conductors)㩷
Adapter and connecting cover
is equivalent to BAWS-1504.㩷

Extension Torch Cable
Extension Remote Control

Cable (4 conductors)
Control Cable for Torch Switch
(2 conductors)
Connecting Cover

Extension Torch Cable㩷
Extension Remote Control

Cable (4 conductors)㩷
Control Cable for Torch Switch
(2 conductors)㩷
Connecting Cover

P1043R00 1 4m

P1043S00 1 4m

K527H00 1 11m

K527K00 1 11m

K527J00 1 16m

K527L00 1 16m

P1043R00 1 4m

P1043S00 1 4m

H558M01 1

H958B00 1 11m

K527H00 1 11m

K527K00 1 11m

H558M01 1

H959B00 1 16m

K527J00 1 16m

K527L00 1 16m

H558M01 1

㩷



- 64 -

11. APPLIED FUNCTION (continued)

Extension Gas Hose
Extension Water Hose

(for feeding water)
BAWS-3004
Parts for extending AW-18

(cable length: 4m) to 8m㩷

BAWS-3011
Parts for extending AW(D)­18 (cable length: 4m) to
15m㩷

BAWS-3016
Parts for extending AW(D)­18 (cable length: 4m) to
20m㩷




٨Cable Hose

Model BKPDT-3803 BKGFF-0603 BBDW-3001 BBPU-3002



11.4 Optional parts

11.4.1 TIG BOY (Wire/torch integrated compact type TIG automatic welding machine)
TIG BOY special torch Controller

Model AWG-1501 AWGW-3001 Model HC-81
Rated current 150A 300A Rated input voltage Single phase 200V

Duty cycle 40% 40% Rated input power 200VA
Cooling type Air Water

Cable length 8m 8n

Extension Torch Cable

Extension Remote Control

(4 conductors)

Control Cable for Torch Switch

(2 conductors)

Connecting Cover

Extension Gas Hose K527B00 1 11m

Extension Water Hose

(for feeding water)

Extension Torch Cable H593J00 1 11m

Extension Remote Control

Cable (4 conductors)

Control Cable for Torch Switch

(2 conductors)

Connecting Cover H558M01 1

Extension Gas Hose K527C00 1 16m

Extension Water Hose

(for feeding water)

Extension Torch Cable H593K00 1 16m

Extension Remote Control

Cable (4 conductors)

Control Cable for Torch Switch

(2 conductors)

Connecting Cover H558M01 1

Grounding Cable㩷

3m

Gas Hose

3m

P1043K00 1 4m

P1043L00 1 4m

H593H00 1 4m

P1043R00 1 4m

P1043S00 1 4m

H558M01 1

K527D00 1 11m

K527H00 1 11m

K527K00 1 11m

K527E00 1 16m

K527J00 1 16m

K527L00 1 16m

Tap Water Kit

5m

Water Hose

2m



- 65 -

11. APPLIED FUNCTION (continued)

11.4.2 TIG filler wire feeding system

■Controller
Model

Rated input voltage Single phase 200/220V

VA at rated output 100VA
When you use HC-71D control box, CAN communication module(K5422B00) and CAN
communication cable(BKCAN-0405[5m] and BKCAN-0410[10m] ) are necessary separately.

■Wire guide assembly
Torch

AW(D)-18 BHCD-7118
AW(D)-26 BHCD-7126
AW(D)-17 BHCD-7117

࡮Model CM-7471 TIG FILLER wire feeder

11.4.3 Tungsten Electrode

Use cerium-Tungsten Electrode (grey mark) or thoriated tungsten electrode (red mark). Using
DAIHEN cerium-tungsten electrode that is hardwearing realizes good arc start and better work
efficiency.

■ Cerium-Tungsten Electrode

Part No.

0870-016 1.6 150 150 130
0870-024 2.4
0870-032 3.2

■ Thoriated Tungsten Electrode

Electrode Dimension(mm) Max. Tolerance Current(A)

Dia. Length DC Straight Polarity AC

150
150

Part No.

0831-005 0.5 150 20 ­0831-010 1.0
0831-016 1.6
0831-316 1.6 75 150 130
0831-020 2.0
0831-024 2.4
0831-324 2.4 75 250 220
0831-032 3.2 150 400 290
0831-332 3.2 75 400 290
0831-040 4.0 150 500 360

Electrode Dimension(mm) Max. Tolerance Current(A)

Dia. Length DC Straight Polarity AC

HC-71D

Model of wire guide

250 220
400 290

150
150

150
150

80 -

150 130

200 180
250 220



- 66 -

12. MAINTENANCE AND TROUBLESHOOTING

٨

WARNING

٨Do not touch the live electrical parts inside or outside the welding power source.
٨Turn off all of the line disconnect switches before touching the parts inside the welding

machine.

٨Perform the maintenance checks periodically. If any damaged parts are found, only use the

welding machine after troubleshooting or repairing.

٨Only certified operators should maintain, inspect, or repair the welding machine.
٨When carrying out the maintenance, wait more than three minutes after powering off all input

power supply by turning off the line disconnect switch in the switch box. Capacitor may be
discharging even after powering off all input power supply. Check to make sure that
charging voltage does not exist before carrying out the maintenance.
This welding power source uses a high-frequency inverter system, be careful of accidental

٨

connection of the line disconnect switch at input side.
Have qualified operators or the persons familiar with this welding power source test

٨

withstand voltage. And install a protective wall around the welding machine to keep away
others from the welding machine.

٨Only certified operators should maintain, inspect, or repair the welding machine.
٨Install a fence around the welding machine to keep others away from it.
٨Do not put your hands, fingers, hair and clothes near the fans and wire feed roll rotating.

Observe the following to prevent electric shock.

CAUTION

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

CAUTION

٨Do not touch the parts for the main circuit which are located inside the power

source, such as single-phase transformer, DC inductor, heat sink, etc. immediately
after welding is performed, as the parts are extremely hot. Wait until the parts cool
down, when touching. Failure to observe the demand may result in burn.

CAUTION

The welding conditions (electronic data) stored using the JOB MEMORY keys are likely to be

٨

affected by occurrence of static electricity, and there is a possibility that the preset data
contents may be changed or erased. We recommend taking notes of important data.
We shall not assume any responsibility for any change or loss of the electronic data resulting

٨

from repair.

CAUTION

٨Do not use moisture-free compressed air for cleaning the fan. Dust may penetrate into fan

by compressed air pressure, or fan blades may be rotated at excessive rotation speed. It
causes an abnormal wear in the bearing and fan failure. Use soft cloth for removing dust.
Do not vacuum the space between main body and rotating part. Otherwise the grease may
be vacuumed up and result in damage to fan.



- 67 -

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.1 Carrying out Maintenance on the Welding Power Source

Periodically check the welding power source to ensure the safety of the equipment and the
efficiency of work.

Check the following daily:

٨

-

No strange vibration, buzzing noise, and smell are generated from the welding power source.

-

No excessive heat is generated from the cable connections.

-

Fan functions properly when the power switch is turned on.

-

The switches properly function.

-

Connection and insulation of cables are surely made.

-

There is no break in cables.

-

Fluctuation of power source voltage is not large.

-

Case Earth is surely connected. (Disconnection of the Case Earth may result in failure or
malfunction of the equipment.)

-

There is no trouble in crack and the like on the front panel.

Check the following each three to six months:

٨

-

There is no damage inside the torch.

-

There are no loose connections or no poor contacts caused from rust, on input side of the
welding power source and output side of the cables.

-

There is no trouble with insulation.

-

The welding power source is properly grounded.

-

Built-up dust on the transistor or the cold plate on the rectifier may affect the equipments.
Take off the cover of the welding power source once a half year, then remove dust by
blowing moisture-free compressed air on each part.

-

The dust protective filter located on the inlet of the fan does not clog, which may result in
damage to the welding power source. Be sure to inspect it periodically.

12.2 Precaution for Replacement of the Printed Circuit Board

Make sure that the connector number inscribed on the

٨

printed circuit board matches the number marked on the
connector.

٨Turn off the control power switch and line disconnect

switch before carrying out maintenance on the welding
power source, and wait three minutes until the capacitors
inside the welding power source discharge.

٨ This welding power source uses a high-frequency

inverter system, be careful of accidental connection of
the line disconnect switch at input side.
Surely connect the connectors until the connector clicks. Failure to do so may result in damage

٨

to the printed circuit board and to the machine.
With the connectors disconnected, do not turn on the power switch on the front panel.

٨

Do not use organic solvent such as thinner, trichloroethylene, gasoline, etc., to clean the plastic

٨

cover and carrying handle of the welding machine. Deformation and flaw may result from the
adherence of the organic solvent.

NOTE: Match the number on the printed

circuit board with that on the connector.

㧝



0

%



- 68 -

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.3 Insulation Resistance Test

WARNING

Observe the following to prevent an electrical shock.

٨Have qualified operators or the persons familiar with this welding power source measure

insulation resistance and test withstand voltage. And install a protective wall around the
welding machine to keep away others from the welding machine. Check to make sure that
charging voltage does not exist before carrying out the maintenance before carrying out
measurement of insulation resistance and withstand voltage test.

When measuring insulation resistance and testing withstand voltage, follow the steps below. And,
refer to the schematic diagram, parts layout, and parts list for maintenance.

1. Disconnect the grounding cable (wiring number: 80) from the earth.

2. Short-circuit on AC side and commutation side of DR1.
Short-circuit between TR1 (C1) and (E1), TR2 (C2) and (E2), TR3 (C1) and (E1), TR4 (C2)
and (E2), TR5㨯6 (C1) and (E1), TR5㨯6(C2) and (E2).

3. Short-circuit between anode and cathode of DR2,DR4,DR5 and DR6.

4. Disconnect CN2,CN4,CN11,CN13 and CN18 of PCB P10535U,CN5 of PCB P10535T.

Be sure to reconnect the cables after carrying out measurement of insulation resistance and
withstand voltage test.

12.4 Replacement of Batteries

Observe the following precautions listed below without fail, in order

to prevent fire, explosion and rupture.

WARNING

٨Do not charge, short-circuit, disassemble, heat, deform and/or solder batteries. Do

not throw batteries into a fire.

٨Make sure the positive and negative polarity is correctly connected.
٨Make sure battery terminals are insulated with insulation tapes when disposing

batteries. Otherwise, if batteries come in contact with other metal or batteries,
generation of heat, rupture or ignition may occur.

٨Batteries must be replaced by an experienced repairman or engineer.

This welding power source uses lithium batteries to hold welding conditions in memory. The life of
the batteries differs depending on the environments. “E-“ and “600” shown in the displays on the
front panel blinks when the batteries gets low. Replacement of the batteries every 5 years or so
are recommended even when “E-“ and “600” do not blink. Replace the batteries following the
steps:

1. Turn off the line disconnect switch in the switch box or the no-fuse breaker, and the power
switch of the welding power source.

2. After more than three minutes, remove six screws that secure the front panel, and then pull
the front panel out. Do not pull it forcibly. With the wiring inside the equipment disconnected,
do not turn on the power switch. Failure to do so may result in damage to the welding power
source.

3. Remove the connectors on the PCB P10533R to replace the printed circuit board. Refer to
the position for “Rear side of the front panel” in Section 12.7, “ Parts Layout”.

4. Insert the disconnected connectors into the PCB P10533R.

5. Screw the front panel in position.



- 69 -

12. MAINTENANCE AND TROUBLESHOOTING (continued)

12.5 Troubleshooting

When an error code is displayed, refer to Section 11.1, “How To Solve an Error”.

٨Check the troubleshooting information listed below before contacting your dealer for service.

No. Trouble Cause Solution

The power
switch on the

1

front panel is
tripped.
The main
power lamp
PL does not
light.

2

When turning
on the power
switch,
nothing

3

appears in the
display.

When turning on the power switch, the

WARNING and temperature lamp (

4

light up and an error code appears in
the display.
Shield gas is
not generated
when the torch
switch is
pressed.

5

Shield gas does not stop. The GAS CHECK lamp lights

6

When the torch
switch is pressed,
no high frequency
spark is not
generated

7

between electrode
and base metal.

Never turn it on again. Contact your dealer.

When turning on the
power switch, the
displays light.
When turning on the
power switch, nothing
appears in the
display.

The main power lamp
PL does not light.

PL lights.

Gas is not generated
when the GAS
CHECK key is
pressed.

Gas is generated
when the GAS
CHECK key is
pressed.

The sound of
spark discharge
can be heard.

The sound of
spark discharge
can not be heard.

Trouble with PL. Inspect PL.

The line disconnect switch in
the switch box is not turned
on.
The input cables are not
surely attached.

Refer to No.2 in this list.

Shortage of the input voltage Check for proper

Trouble with the power
circuit.

Refer to Section 11.1, “How
To Solve an Error”.

)

The discharge valve of the
gas cylinder is closed.
Lack of gas pressure of the
gas cylinder.

Trouble with the gas
electromagnetic valve SOL.

Disconnection of the torch
switch cable or incomplete
insertion to receptacle.

up.

Trouble with the gas solenoid
valve SOL

Electrode gets whiten. Polish electrode.

Base metal cable is
connected to the negative (-)
terminal output. (High
frequency voltage is leaking.)
The connectors on the high
frequency generating circuit
are not firmly inserted.

Inspect the power
box.

Inspect the input
cables.

input voltage.
After inspecting
PCB P10532Q,
replace it if
necessary.

Open the gas valve.

Check for proper
gas pressure.

Inspect the gas
electromagnetic
valve SOL.
Check the wiring
numbers 160, 161,
168, 169, 258 and

259.

Stop gas checking
by pressing the
GAS CHECK key.
Check for operation
of the gas solenoid
valve of wire
feeder.

Properly connect
the torch and the
base metal cable.

Check for proper
insertion of the
connectors on PCB
P10536X.



- 70 -

12. MAINTENANCE AND TROUBLESHOOTING (continued)

No. Trouble Cause Solution

When pressing
the torch
switch, high
frequency is
generated but
no arc is output.

8

WCR keeps working. Trouble with the hole current

9

When electrode
touches on the
base metal, arc
is output.

When
measuring
output voltage
in STICK mode,
no –load
voltage is
generated.
No-load voltage
is generated.

Electrode gets white. Polish electrode.

Electrode is too thick. Current
setting is too low.

Trouble with the main circuit of
inverter.

Trouble with the control circuit. Check for PCB

detector CT2

Trouble with the WCR circuit After inspecting PCB

Set to the proper
electrode and
current.
After turning off the
power switch, contact
your dealer.

P10346P and
P10535U.
Inspect the hole
current detector CT2.

P10346P, replace it if
necessary.



- 71 -

This page is intentionally left blank.



- 72 -

12.6 Schematic Diagram

12. MAINTENANCE AND TROUBLESHOOTING (continued)



(P10346P)

- 73 -

12.7 Parts Layout

)

)

)

)

Under frame

PCB12(P10533R00)

PCB8(P10535X00

THP3

12. MAINTENANCE AND TROUBLESHOOTING (continued)

PCB11(P10541R00)

PCB1(P10535U00)

PCB2(P10346P00)

ԡ

Ԟԟ

ԙԚ

CON3

C.C

R24

Bottom Chassis

R6

PCB7
(P10536X00)

TR1,2

T1

CON4

Heat sink

L1

R18a,b,c
R19a,b,c

Heat sink

Heat sink

TR5,6

THP2

PCB6(P10538M00)

TR3,4

Behind of

Front Panel

CT1

Back Side of Front Panel

Ԝ

PL

CON1

CON2

ԝ

Ԣ

Ԡ

NF

ԝ

Ԣ

Front Panel

ԛ

L2

THP1

PCB5(P10535T00

PCB4(P10538V00

Middle Chassis Top Chassis

L7

R25

PCB3

(P10532Q00)

T2

PCB10(P10535V00

LF

R2

R4

R3 R1

DR2-6DR1

R32,33

R7

PCB9

(P10535R00)



- 74 -

Ԙ

L8

PCB13
(P10541T00)

CR

DR7

FM2

Rear Panel

FM1

ԛ

13. PARTS LIST

٨Please contact your dealer to order parts. (See the back cover for telephone and fax numbers, and mailing

addresses.)

Symbol Part No. Description Specifications Q’ty Remarks

NF 4614-101 Circuit protector CB3-X0-10-072-42D-C 1

LF 4519-022 Line filter CF3030C-DJ 1

PL 100-0171 Pilot lamp N46010A7KW-01 (RoHS) 1

DR1 4531-204 DR&SCR complex module DFA75BA160 1

DR2 – 6 4531-308 High speed diode module DBA200UA60 4

DR7 100-0188 Diode D1N60-5060 1
TR1, 2 100-0198 IGBT module CM150DY-12NF-300G 2
TR3, 4 4534-407 IGBT module 2MBI150TA-060 2
TR5, 6 100-0194 IGBT module CM300DU-12F-300G 2

CT1 4810-030 CT W-W03029 1

CT2 4406-009 Hole current detector HA400S3EH 1

T1 P10535B00 Inverter transformer P10535B00 1
T2 W-W02936 Auto transformer W-W02936 1

C.C P10535C00 Coupling coil P10535C00 1

L1 P10525L00 DC reactor P10535L00 1
L2 4739-497 Ferrite core E04RA400270150 3
L3 4739-543 Ferrite core E04RA310190100 1

L4, 5, 6 4739-497 Ferrite core E04RA400270150 3

L7 4739-497 Ferrite core E04RA400270150 1

L8 4739-497 Ferrite core E04RA400270150 2
L9 – 14 4739-543 Ferrite core E04RA310190100 6
L15, 16 4739-543 Ferrite core E04RA310190100 2

L17 4739-543 Ferrite core E04RA310190100 1

L18 4739-497 Ferrite core E04RA400270150 2
THP1 4258-040 Thermostat 67L085 1 Side of DR2- 6
THP2 4614-051 Thermostat 67L090 1 Side of TR1- 4
THP3 4258-033 Thermostat 67L070 1 Side of TR5, 6

SOL 4813-046 Solenoid valve TYPE5511DC24V 1

FM1 P30016L00 Fan P30016L00 1

FM2 P10346L00 Fan P10346L00 1

CR 4341-139 Relay G2R-1-T DC24V 1

SC1 – 8 100-0199 Surge clamper 1.5KE250CA-E3/1 8

R1 – 4 100-0175 Surge absorber ENE911D-14A 4

R5 Missing number
R6 4509-819 Cement resistor 40SH 200ΩJ 1
R7 4509-825 Cement resistor 20SH 15kΩJ 1

R8 – 13 100-0189 Carbon film resistor RD1/4W 1 kΩJ(RoHS) 6

R14 – 17 100-0192 Metal film resistor RNP-50SCZ00 10ΩF 4
R18a, b, c 4504-411 Non-inductive resistor NCRF24V 30ΩJ 3
R19a, b, c 4504-411 Non-inductive resistor NCRF24V 30ΩJ 3

Lower side
(High speed type)
Upper side
(Low speed type)



- 75 -

13. PARTS LIST (continued)

Symbol Part No. Description Specifications Q’ty Remarks

R20 – 23 100-0189 Carbon film resistor RD1/4W 1kΩJ(RoHS) 4

R24 4504-503 Wire wound resistor GG80W 200ΩJ 1
R25 4509-922 Cement resistor 20SH 10ΩJA 1
R26 4509-113 Metal oxide film resistor RS3B 20kΩJ 1
R27 4509-046 Metal oxide film resistor RS1B 10kΩJ 1
R28 4536-112 Surge absorber ENC821D-14A 1

R29 100-0189 Carbon film resistor RD1/4W 1kΩJ(RoHS) 1
R30, 31 100-0189 Carbon film resistor RD1/4W 1kΩJ(RoHS) 2
R32, 33 4509-905 Cement resistor MHR20A513JI 2

C1 Missing number
C2 – 5 4518-519 Film capacitor MIC-ST3D182J 4
C6a, b 4518-526 Film capacitor EM351200D0BA1HP 2

C7 4518-526 Film capacitor EM351200D0BA1HP 1

C8 4517-458 Ceramic capacitor 2kV 0.001μF 1
C9a, b 4517-459 Ceramic capacitor DEHR32E103KA2B 2

C10 4517-459 Ceramic capacitor DEHR32E103KA2B 1
C11 4518-547 Film capacitor MIC-ST3C563J 1
C12 4518-530 Film capacitor US16X154JAASA 1

C13 100-0227 Film capacitor QYX1H474JTP 1 50V 0.47μF
CON1 100-0095 Metal consent socket DPC25-2BP-Z 1 2P
CON2 100-0094 Metal consent socket DPC25-4BP-Z 1 4P
CON3 P10464X02 Cable with 3P connector P10464X02 1

CON4

PCB1 P10535U00 Printed circuit board P10535U00 1

PCB2* P10346P00 Printed circuit board P10346P00 1

PCB3 P10532Q00 Printed circuit board P10532Q00 1
PCB4 P10538V00 Printed circuit board P10538V00 1
PCB5 P10535T00 Printed circuit board P10535T00 1
PCB6 P10538M00 Printed circuit board P10538M00 1
PCB7 P10536X00 Printed circuit board P10536X00 1
PCB8 P10535X00 Printed circuit board P10535X00 1

PCB9 P10535R00 Printed circuit board P10535R00 1
PCB10 P10535V00 Printed circuit board P10535V00 1
PCB11 P10541R00 Printed circuit board P10541R00 1
PCB12 P10533R00 Printed circuit board P10533R00 1
PCB13 P10541T00 Printed circuit board P10541T00 1

P10541X04 Cable with 6P connector P10541X04 1
P10464X08 Jumper plug P10464X08 1

Refer to “NOTE”
below.

*NOTE: When ordering a printed circuit board P10346P00, provide the software version on a

label below a nameplate attached to the rear side of the welding power source.

P10464 Ver. ###.###

Replace the ###.### with software version.

.000



- 76 -

13. PARTS LIST (continued)

Symbol Part No. Description Specifications Q’ty Remarks

Ԙ
ԙ
Ԛ
ԛ
Ԝ
ԝ
Ԟ
ԟ
Ԡ
ԡ

Ԣ








4739-474 Grommet with film W-W02805 4
4735-038 Knob K-100 22RSB 1
4735-039 Cap K-100 22CSBL 1
4739-475 Rubber foot C-30-RK-3220 4

P10464W02 Control panel sheet P10464W02 1

4739-476 Cap W-W02814 2

P5801G03 Carrying handle P5801G03 2

P10263G12 Bush P10263G12 4

P10263J01 Front cover P10263J01 1
P10263J02 Control panel cover P10263J02 1

4734-007 Machine socket DIX BE 50 / 70 2

4734-016 Power cable connector DIX SK 50 1

4519-030 Filter kit 109-1000F13 1
4519-031 Dust filter 109-1000M13 1
4730-001 Plug DPC25-2A (1) For CON1
4730-005 Plug DPC25-4A (1) For CON2

Adjusting knob

Output
terminal
For base metal
and holder



- 77 -

14. SPECIFICATIONS

14.1 Specifications
㧔1㧕Welding power source

㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷Model
Specifications

Model DA – 300P
Welding method DC TIG AC TIG AC – DC TIG DC STICK
Number of phase Three
Rated frequency 50 / 60 Hz
Rated input voltage 400 V
Input voltage range 400 V ±15 %

Rated input power

Rated input current 17.3 A 18.1 A 19.1 A
Rated output current 300 A 300 A 250 A
Rated output current range 4 A ~ 300 A 10 A ~ 300 A 10 A ~ 250 A
Rated load voltage 22 V 22 V 30 V
Max. no-load voltage 58 V
Rated duty cycle 40 %
Pre flow time 0.1 ~ 20 sec.
Post flow time 0.1 ~ 30 sec.
Up slope time 0.1 ~ 10 sec.
Down slope time 0.1 ~ 10 sec.
Arc spot time 0.1 ~ 10 sec.
Crater-fill operation ON / OFF / REPEAT
Pulse frequency 0.1 ~ 500 Hz
Pulse peak ratio 50 % ( Changing with F(function)key from 5 % to 95 % )
AC frequency 50 ~ 200 Hz
AC balance – 20 ~ 20 ( EP ratio : 5 ~ 50 % )
AC-DC frequency 0.1 ~ 50 Hz
Number of JOB MEMORY

( welding condition )
Temperature rise + 160˚C
Operating temperature range – 10˚C ~ + 40˚C
Operating humidity range 20 % ~ 80 % ( without dew condensation )
Strange temperature range – 10˚C ~ + 60˚C
Storage humidity range 20 % ~ 80 % ( without dew condensation )
External dimension

( W × D × H )
Mass 45 kg
Degree of protection IP 21 S
Torch cooling method Water / Air
Start method High frequency start / Lift start

*The welding power source complies with the requirements of IEC 60974-1, IEC 60974-10 and
directive 2002/95/EC (RoHS).

11.9 kVA

8.9 kW

Digital Inverter DA300P

12.5 kVA

9.4 kW

100

250 mm × 640 mm × 545 mm

( without carrying handle )

13.2 kVA

10.0 kW



- 78 -

14.2 External View

398

14. SPECIFICATIONS (continued)



- 79 -

This page is intentionally left blank.



- 80 -

14. SPECIFICATIONS (continued)

㧙

٨Initial Values and Setting Range of Parameters

Initial value Setting range

Pre flow time 0.3 sec. 0 – 20 sec.
Up slope time 1 sec. 0 – 10 sec.
Welding current for stick welding 10 A

䊶 Initial current
䊶 Welding current
䊶 Pulse current
䊶 Crater current

Pulse frequency 2 Hz 0.1 – 500 Hz
Down slope time 1 sec. 0 – 10 sec.
Post flow time 7 sec. 0 – 30 sec.
Arc spot time 3 sec. 0.1 – 10 sec.
AC frequency 70 Hz 50 – 200 Hz
AC balance 0 -20 – 20
AC-DC change frequency 1 Hz 0.1 – 50 Hz
Condition number 1 1 – 100

DC TIG

AC TIG

AC-DC 䌔䌉䌇

10 A

STANDARD

HARD

SOFT 10 – 200 A


٨Function

Initial value Setting range

Crater OFF OFF / ON / REPEAT / ARC SPOT

Welding method AC TIG

AC wave form STANDARD STANDARD / SOFT / HARD
Initial current OFF ON / OFF
Pulse OFF ON / OFF
Lift start OFF Lift start / High frequency start
Slope OFF ON / OFF
Torch AIR Water / Air

DC TIG / DC STICK welding


٨Internal function <Refer to 10.1.17 Internal Functions for detail.>
What can and cannot be stored in memory by each welding conditions memory number are
discriminated by “٤” and “” given in the table below.

Memory Initial value Setting range

F1

䌆2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

Start current

Change in sequence at arc spot time

Termination of repetition

Automatic/Stick

External command 12 V MAX

External command 10䌖䌍䌁䌘

Pulse peak ratio

Voltage reducing function

Result display holding time

AC ratio

Change of operation sound

Change of external output terminal 1

Change of external output terminal 2

Change of pulse synchronized input
signal
Indication change of AC balance
indication

Soft pulse













٤





٤











 OFF ON (soft pulse) / OFF (standard)

ON ON (HIGH) / OFF (LOW)

OFF ON (VALID) / OFF (INVALID)

OFF ON (VALID) / OFF (INVALID)

OFF ON (AUTOMATIC) / OFF (STICK)

OFF ON (VALID) / OFF (INVALID)

OFF ON (VALID) / OFF (INVALID)

50 % 5 – 95 %

OFF ON (VALID) / OFF (INVALID)

20 sec. 0 – 60 sec.

70 % 10 – 90 %

ON ON (VALID) / OFF (INVALID)

1

2

OFF ON (VALID) / OFF (INVALID)

OFF

* Further, F17 to F20 have the functions as well. For details, see 10.1.17 “Internal Functions”.

10 – 250 A

4 – 300 A

10 - 300 A

AC TIG / AC-DC TIG

1:Power preparation
2:Pulse synchronized output
3:EN synchronized output
4:AC synchronized output

ON (EP ratio indication) / OFF

(±indication)


٨In reading the “Operation” paragraph described in “10.1 Basic Setup” and in the subsequent paragraphs,
consult this page to check the key location or the like.

[19][18] [17] [3] [11] [13]

JOB

MEMORY

DC NO- L OAD VOLTAGEWAR NI N G



[14]

[3] [4] [6] [7]



ASec

LOAD

Hz

%

JOB NO.

SAVE

ENTER

PULSE FREQ.

UP SL OPE

WELDING CURR.

BASE CURR.

T1 T2

I NI TI AL CURR. CRATER- FI L L.

㧔

PULSE CURR.

DOWN SLOPE

㧕

CURR.

㧭㧯

FREQ.

AC BALANCE

ON ON ON ON WATER

f

AC- DC
FREQ .

GAS

CHECK

t

SPOT TIME

CRATER

㧲

OFF

ON

REPEAT

SPOT

FILL.

IN IT IAL
CURR.

㧭㧯

WAVE

PULSE

STANDARD

SOFT

HARD

LIFT

START

SLOPE

TORCH

AC- TIG

AC- DC TI G

DC- TIG

DC- STICK

WEL D I NG
METHOD



[16] [9] [5] [10] [2] [12] [1] [15] [8]

[1] WELDING METHOD change-over key [9] ARC SPOT TIME setting key [17] LOAD key
[2] AC WAVE change-over key [10] Function selection key [18] SAVE key
[3] Parameter selection key [11] INITIAL CURR. selection key [19] ENTER key
[4] Parameter adjusting knob [12] PULSE selection key
[5] CRATER FILL. key [13] LIFT START key
[6] AC FREQ. key [14] SLOPE selection key
[7] AC BALANCE key [15] TORCH change-over key
[8] AC-DC change-over frequency setup key [16] GAS CHECK key



- 81 -



٨

g

p

p

e

y

g)

p

e

p

QUICK MANUAL

For details, refer to “10. OPERATION”.

Before Using the Welding Power Source

Ԙ

1. Settings of Welding Method

Select “AC TIG”, “AC-DC TIG”, DC
TIG” or “DC STICK” by using the
WELDING METHOD key.
For DC STICK welding, skip steps
1, 2, 3, and 4.

2. AC WAVE selection

In the case of AC TIG and AC-DC
TIG welding, select “STANDARD”,
“SOFT” or “HARD” with the AC
WAVE selector key.

3. Settings of Crater/Arc Spot

Use the CRATER-FILL key to

select OFF / ON / REPEAT / SPOT.

4. Settings of Functions

٨ For using INITIAL CURRENT, press the INITIAL

CURR. key to set the function to “ON”.

[ON]: INITIAL CURR. lamp is on.

[OFF]: INITIAL CURR. lamp is off.

٨For pulse welding, set to “ON” by using the PULSE

key.

[ON]: PULSE lamp is on.

[OFF]: PULSE lamp is off.

٨ For LIFT START, set to “ON” by using the LIFT

START key. For HIGH FREQUENCY START, set to
“OFF” with this key.

[ON]: LIFT START lamp is on.

[OFF]: LIFT START lamp is off.

٨ For using SLOPE function, set to “ON” with the

SLOPE selection key.

[ON]: LIFT START lamp is on.
[OFF]: LIFT START lamp is off.

٨ For using the water-cooled torch, set to “WATER”

with the TOCH key, and then run cooling water.

[WATER]: TORCH lamp is on.
[AIR]: TORCH lamp is off.

NOTE:
There may be unavailable functions in some crater
settings. Refer to “OPERATION” for details.

14. SPECIFICATIONS (continued)

5. Settings of Parameter

Use the parameter selection keys to select the
parameter you want to set, then adjust it while
turning the parameter adjusting knob.

When the arc spot time is set up, select the
key shown in the figure on the left, and then
use the parameter adjusting knob for time
setting.

Using the parameter adjusting knob, adjust
the AC frequency after selecting the key
shown in the figure on the left in the case of
AC TIG and AC-DC TIG welding.

Using the parameter adjusting knob, set up

the EP ratio after selecting the key shown in
the figure on the left so that the required AC
balance is obtained in the case of AC TIG
and AC-DC TIG welding.

NOTE:
٨Turning the parameter adjusting knob clockwise

increases the parameter. To decrease the
parameter, turn the parameter adjusting knob
counter-clockwise. The parameters largely
increase or decrease by turning the parameter
adjusting knob quickly.

There may be unavailable parameters in some
crater settings and function settings. Refer to
Section 10, “OPERATION” for details.

6. Checking the Rate of Gas Flow
Open the discharge valve of the gas

cylinder, press the GAS CHECK key to
check the rate of gas flow. After

GAS

CHECK

performing GAS CHECK, stop the gas

flow by pressing the GAS CHECK key.
Now you have completed the preparations that are
required to start welding. Press the torch switch to start
welding.

ԙ

Protecting the Keys and Releasing the Key Protection

٨Protecting of the keys

Hold down the ENTER key + the F key at

ENTER

a time for a few sec. The F lamp starts
blinking. Blinking of the F lamp means the
welding machine is in the key protection
mode.

٨Releasing the key protection

Hold down the ENTER key + the F key at

㧲

a time for a few sec. When the F lamp
turns off, the key protection function is
released.

Presetting the Welding Conditions

Ԛ

JOB

MEMOR Y

1) Pressing the SAVE key enters the save
mode. The preset welding condition
number is displayed in the right display
and the welding current is displayed in

LOA D

the left display.

2) Preset the welding conditions to the
desired numbers 0 - 30 while turning the
parameter adjusting knob. When “---“ is
displayed in the left display, the number

SAVE

you selected is available. When “---” is
not displayed in the left display, the
number you selected is unavailable. In
this case, select another number.

ENTER

Otherwise, the welding conditions preset
to the number are erased and overwritten
with the welding conditions you newly set.

3) Press the ENTER key to check the parameter that is
preset to the number.

4) When pressing the ENTER key again, the welding
conditions are set.

Press the MEM ORY key.

Disc ontin ue

Discontinue

Press the LOAD key.

 Loading the Welding Conditions

ԛ

Set the welding condition number while
turning the parameter adjusting knob.

Press the ENTER key.

Press the parameter selector key
to check the parameter value.

The welding conditions are set to t he number you selected.

Press the ENTER key.

Thememorymodequits

.

Press t he MEMORY key .

Reset t he weldi ng condition number.

1) Pressing the LOAD key enters the load mode.
The preset welding condition number is displayed
in the right display and the welding current is
displayed in the left display.

2) Preset the welding conditions to the desired
numbers 0 – 30 while turning the parameter
adjusting knob. When “---“ is displayed in the left
display, no welding conditions are preset to the
number you selected.

3) Press the ENTER key to check for the parameter
preset to the number.

4) When pressing the ENTER key again, the
welding conditions preset to the welding condition
number are retrieved.

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Press the LOAD key.

Discont inue

Discont inue

Press the SAVE key.

Ԝ

Set the welding condition number while
turning the parameter adjusting knob.

Press the ENTER key.

Press the parameter selector key
to check the parameter value.

The weldi ng conditi ons are set to t he number you selected.

Press the ENTER key.

The readout mode quits

.

Settings of the (Internal) Functions

Press the LOAD key.

Reset t he welding condition number.

1) When holding down the F key for a few sec., the
function mode is activated. The function number
blinks in the left display, the function status is
displayed in the right display.

2) Set the function number while turning the
parameter adjusting knob.

3) When pressing the F key, the function number
lights up, then the function status blinks.

4) Set the function status while turning the
parameter adjusting knob.

5) To cancel the function mode, hold down the F
key for a few minutes.

ԝ

Error code table

Displa ys on the

No.

front pan el

Left Right
1 dAI HEn Torch switch off stat e wait in
2E-000
3 E- 100 Control

4E- 200

5 E- 300 The rmal overl oad
6E- 500
7E- 510Pump error
8E- 600Batter
9E- 710

10 E- 751 Seconda ry side o ver voltage error
11 E- 9XX Microcom

Operat ion stop

Primary/secondary current detection
error

Lack of water

Lack of

Classification of errors

ower supply error

ressur

low (warnin

has

uter error

When using this product with a robot of our company,
refer to “Application (arc welding)” in owner’s manual of
the robot.

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15. SERVICE AND SUPPORT

Please contact your local dealer for service. (See the back cover for telephone numbers, fax numbers,
and mailing addresses.)

NOTE:

1) See 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

• Telephone number

• Product model

• Manufacture year

• Serial number

• Software version number

• Details of troubles

㨯 MODEL: DA-300P
㨯 DATE: 20XX
㨯 SERIAL NO.: P30029YXXXXXXXXXXX

P10464 Ver.###.###.000

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DAIHEN Corporation

4-1, Koyocho-nishi,Higashinada-ku,

Kobe, Hyogo 658-0033

Phone: [phone], Fax: [phone]

DAIHEN, INC. DAYTON OFFICE

1400 Blauser Drive

Tipp City, Ohio 45371, USA

Phone: [phone], Fax: [phone]

OTC DAIHEN EUROPE GmbH.

Krefelder Strasse 675-677,

D-41066 Mönchengladbach, GERMANY

Phone: [phone], Fax: [phone]

OTC Industrial (Shanghai) Co.,Ltd.

17F Majesty Building, 138 Pu Dong Da Dao Shanghai

The People's Republic of China

Post Code: 200120

Phone: [phone], Fax: [phone]

OTC (Taiwan) Co.,Ltd.

2F No. 153, Huanbei Rd., Chung Li City,

Taoyuan Hsien, Taiwan R.O.C.

Phone: [phone], Fax: [phone]

OTC DAIHEN Asia Co.,Ltd.

23/43, 16th F1.Sorachai Building,

23 Soi 63 Sukhumvit Road,

Klongtonnua, Wattana, Bangkok 10110, Thailand

Phone: [phone], Fax: [phone]

OTC DAIHEN Korea Co.,Ltd

11B/L Hyeongok Industrial Complex, 463-1 Hyeongok-ri,

Cheongbuk-myeon, Pyeongtaek, Gyeonggi-do, 451-831, Republic of Korea

Phone: [phone], Fax: [phone]

Upon contact, advise MODEL and MANUAL NO.

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