Daihen OTC AC/MIG/201 CPDACA-200 User manual
MANUAL NO:P10224
G/MAG
OWNER'S MANUAL
FOR
MI
MODEL: CPDACA-200 P10224
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
Upon contact, advise MODEL and MANUAL
NO.
AC / MIG / 201
No.P10224
P. 1/ 47
CONTENTS
1. SAFETY INFORMATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2
2. ARC WELDING SAFETY PRECAUTION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2
3. GENERAL NOTICE OF OPERATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 8
4. STANDARD ACCESSORIES‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 9
5. LOCATION AND FUNCTION OF CONTROL‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 10
6. NECESSARY POWER SOURCE EQUIPMENT ‥‥‥‥‥‥‥‥‥‥‥‥‥ 13
7. TRANSPORT AND INSTALLATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 14
8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE‥‥‥‥‥‥ 16
9. WELDING PREPARATION ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 20
10. WELDING OPERATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 22
11. APPLIED FUNCTION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 26
12. MAINTENANCE AND TROUBLESHOOTING‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 35
13. PARTS LIST‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 42
14. SPECIFICATIONS‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 45
15. SERVICE AND SUPPORT‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 47
No.P10224
P. 2 /47
1. SAFETY INFORMATION
The following safety alert symbols and signal words are used throughout this manual to identify
various hazards and special instructions.
WARNING WARNINGgives information regarding possible personal
injury or loss of life.
CAUTION CAUTIONrefers to minor personal injury or possible
equipment damage.
2. ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
OR DEATH.
Be sure to:
・Keep children away.
・Keep pacemaker wearers away until consulting a doctor.
Read and understand the summarized safety information given below and the
original principal information that will be found in the PRINCIPAL SAFETY
STANDARDS.
Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.
Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
No.P10224
P. 3/ 47
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.
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 turn off 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 electrode and 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.
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 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 approved face shield or safety goggles. Side shields recommended.
7. Wear proper body protection to protect skin
No.P10224
P. 4 /47
WELDING can cause fire and explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and 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.
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 33ft. (10m) 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 base metal side cable 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 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.
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 rays of the arc 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.
No.P10224
P. 5/ 47
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 treat them carefully.
1. Use only correct shielding gas cylinders, regulators, 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.
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.
No.P10224
P. 6 /47
ARC WELDING work areas are potentially hazardous.
FALLING or MOVING machine can cause serious injury.
Use both eyebolts, if installed, to lift the welding power source.
Put the welding power source and wire feeder solidly on a flat surface.
Do not pull the welding power source across a floor laid with cables and hoses.
Do not put wire feeder on the welding power source.
Do not put the welding power source and wire feeder where they will pit or fall.
WELDING WIRE can cause puncture wounds.
Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.
No.P10224
P. 7/ 47
PRINCIPAL SAFETY STANDARDS
Arc welding equipment – Installation and use, Technical Specification
IEC 62081, from International Electrotechnical 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.
No.P10224
P. 8 /47 3. GENERAL NOTICE OF OPERATION
3.1 Welding mode and wire size
Welding process Wire Wire size(in.φ)
DC wave Hard aluminum 0.040/ 3/64
Pulsed MIG Soft aluminum 3/64
AC wave Hard aluminum 0.040/ 3/64
Pulsed MIG Soft aluminum 3/64
Hard aluminum 0.040/ 3/64
Soft aluminum 3/64
Stainless 0.030 / 0.035 / 0.040 / 0.045
DC pulsed MIG
Mild steel solid 0.030 / 0.035 / 0.040 / 0.045
Hard aluminum 0.040 / 3/64
Soft aluminum 3/64
Stainless 0.030 / 0.035 / 0.040 / 0.045
AC pulsed MIG
Mild steel solid* 0.030 / 0.035 / 0.040 / 0.045
Note:
*Using M2 gas (a mixture of 98% argon and 2% oxygen) is recommended when welding process is AC pulsed MIG.
3.2 Rated duty cycle
CAUTION
●Use this welding power source at or under the rated duty cycle. If exceeding the rated duty
cycle, the welding machine may be damaged.
●Rated duty cycle of the welding power source: 80% (200A, 27V). When the welding power source is
operated on higher voltage than the rated voltage, the rated duty cycle must be lowered.
●The duty cycle of 80% means the way the machine is rested for 2 minutes after 8 minutes of continuous
welding at the rated current.
10 min.
100
50
0100
100
％
(Less than 178A)
Usable range
Duty
cycle(
％
)
Welding current(A)
200
80
％
(200A, 27V)
40
When the welding power source is used o
n
the higher voltage than the rated voltage.
(The left chart)
2 min.
8 min.
100
50
0100
100
％
(Less than 167A)
Usable range
Duty
cycle(
％
)
Welding current(A)
200
70
％
(200A,36V)
40
Usable rangeUsable range
100
50
100
100
％
(Less than 167A)
200
70
％
(200A,36V)
40
Usable range
0
100
50
100
100
％
(Less than 167A)
200
70
％
(200A,36V)
40
Usable range
Duty
cycle(
％
)
0
100
50
100
100
％
(Less than 167A)
200
70
％
(200A,36V)
40
Usable range
ON OFF
●Failure to observe duty cycle limitations may result in temperature inside the welding machine
exceeding the tolerance, which may contribute to premature welding machine failure or product
damage.
●The figures shown below indicate the relation between welding current and duty cycle. Use the welding
machine within its usable range, following the duty cycle for the welding current.
●The duty cycle of the welding power source is also limited by the duty cycles of accessories combined
with, such as welding torches. Use the welding machine within the lowest rated duty cycle of the
accessories.
No.P10224
P. 9/ 47
3. GENERAL NOTICE OF OPERATION (continued)
3.3 Combination of welding power source and other welding machines
CAUTION
●When this welding power source is combined with other welding machines to use, refer to
the manual of the machine.
4. STANDARD ACCESSORIES
4.1 Accessory kit
●Your package contains the accessory kit listed below.
①②
③④
Description Specifications Q’ty
2A 250V 1
①Fuse (glass tube) 10A 250V 1
②Fuse (cartridge) BLA-003 2
③Hexagon bolt (with washer) M8-20 2
④T-shape round head screw M3-8 4
No.P10224
P. 10 /47 5. LOCATION AND FUCTION OF CONTROL
5.1 Welding power source
Upper cover
Panel cover Right-side panel
ICN4 receptacle (to manipulator)
Left-side panel
Negative output terminal
( to base metal ) Positive output terminal
( to torch side )
Terminal block (with 12 pins)
Front cover
Front panel
Arc voltage direct detection negative terminal
( to base metal)
No.P10224
P. 11/ 47
5. LOCATION AND FUCTION OF CONTROL (continued)
5.1.1 Front panel (continued)
CAUTION
●Stop welding when using the switches on the front panel.
0+2
‑2
+4
‑4
+6
‑6
+8
‑8
+10
‑10
WELD
GAS
CHECK
NOTE:
WHEN SET TO "PANEL",THESE KNOBS ARE
AVALABLE,USUALLY SET TO "ROBOT."
OFF OFF OFF
IF THIS SWITCH IS TRIPPED
DO NOT TURN ON AGAIN
.
REFER TO OWNER'S MANUAL
.
4 2
WARNING
DCNO-LOADVOLTAGE
(ACMODE)
POWER
TEMPERATURE
PROGRAM
PANEL
CURR.VOLT.
CONTROL
GAS
ROBOT
VOLTAGE ADJ.
V
200
160
80 120
40
CURRENT(A)
A
F2
(
10A
)
F1
(
2A
)
MOTOR+24V
CAUTION
N
OTE: The switches/ knobs/ lamps are located inside the
front cover of the welding power source. When
opening the front cover, push and pull it toward you a
s
illustrated below.
CURR.VOLT. CONTROL switch
Set this switch to ROBOT for normal use. When
switching, turn off the power switch.
PROGRAM switch
To select a welding method and a wire size while pressing + or -. Set the only wire
sizes listed in WELDING MODE AND WIRE SIZE on the next page. Fuses
CURRENT (A)
/
VOLTAGE ADJ. knob
works when CURR.VOLT.
CONTROL switch set to PANEL.
GAS switch
opens the gas valve to regulate
the amount of gas flow. Be sure
to set this switch to WELD afte
r
regulating the amount of the gas
flow.
POWER switch
When turning on the line
disconnect power switch an
d
this switch, fan rotates an
d
control circuit is turned on.
MAIN POWER lamp
Lights when turning on the line
disconnect switch. Before making an
external connection or checking the
machine, make sure the line disconnec
t
switch is turned off and its lamp goes
out.
DC NO-LOAD VOLTAGE lamp
lights when DC no-load voltage is generate
d
at AC pulse mode or AC wave pulse mode.
WARNING / TEMPERATURE lamps
light and stop outputting for abnormal condition.
Refer to section 11.4 for cancellation of this
condition.
No. P10224
P. 11/47
No.P10224
P. 12 /47 5. LOCATION AND FUCTION OF CONTROL (continued)
5.1.1 Front panel (continued)
●Program switch
Program Welding method Wire Wire size. (in.φ)
11 0.040
12 Hard aluminum
13 DC Soft aluminum 3/64
21 0.040
22 Hard aluminum
23 AC
WAVE PULSE
Soft aluminum 3/64
31 0.040
32 Hard aluminum
33 DC Soft aluminum 3/64
41 0.040
42 Hard aluminum
43 AC
PULSED MIG
Soft aluminum 3/64
51 0.030
52 0.035
53 0.040
54
DC
0.045
61 0.030
62 0.035
63 0.040
64
AC
PULSED MIG Stainless steel
0.045
71 0.030
72 0.035
73 0.040
74
DC
0.045
81 0.030
82 0.035
83 0.040
84
AC
PULSED MIG Mild steel
0.045
●Gas switch
This welding power source automatically stops flowing gas, and the warning lamp flashes, when
the gas switch is set to CHECK for more than 2 minutes. And also, if the welding power source is
started during gas checking, the warning lamp flashes and the welding power source stops
operation. To start the machine again, turn the switch back to WELD side. If it is started before
doing so, the warning lamp will keep flashing.
Pressure gauge
Flowmeter
Flow adjusting knob
No.P10224
P. 13/ 47
6. NECESSARY POWER SOURCE EQUIPMENT
6.1 Power source utility (for commercial power source)
WARNING
●When the welding machine is used in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
CAUTION
●Be sure to install a switch with fuse or a circuit breaker (for motor) at input side of welding
machine.
●Capacity of necessary power source utility
CPDACA-200
Power supply voltage and phase 460V, Three phases
Tolerance of fluctuation of power supply voltage 460V
Installed capacity 21kVA or more
Capacity of switch/circuit breaker 40 A
6.2 Precautions against the use of engine generator
CAUTION
●To prevent damage to engine generator or auxiliary power, follow the instructions below.
●Set the engine generator to within the voltage range between 460 and 483V. Setting to excessive
high output voltage may result in product damage.
●Use the engine generator with a damper winding of which capacity is more than twice as much as
the rated input of the machine. 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 may occur. This may
result in abnormal decrease in output current or arc loss. Ask a manufacturer of engine generator
for a damper winding.
●Do not combine more than two welding machines with an engine generator. The effect of each
machine may cause easy loss of arc.
●Use the auxiliary power source of engine welder whose waveform has been improved. Some
auxiliary power sources are poor at electricity conduction, which may lead to damage to the
welding machine. Contact a manufacturer of engine welder for the improvement of waveform.
No.P10224
P. 14 /47 7. TRANSPORT AND INSTALLATION
7.1 Transport
WARNING
Follow the instructions below to avoid trouble and product damage when transporting the
machine.
●Do not touch charging parts either inside or outside the welding machine.
●With the line disconnect switch disconnected, when transporting the welding
machine.
●When hanging the welding power source with a crane, fix a case or a cover
with eyebolts.
●Use two wires when hanging the equipment with a crane.
●When moving the welding power source with a forklift, secure the wheels to
prevent possible rolling of the power source.
7.2 Installation
WARNING
When installing the welding machine, follow the instructions below to avoid fire caused by
welding and physical damages by fume gas.
●Do not install the welding machine near combustible materials and
inflammable gas.
●Remove combustible materials to prevent dross from coming into contact
with combustible objects. If you can not do so, cover them with
noncombustible covers.
●To prevent the danger of gas poisoning and suffocation, wear a respirator or
adequately ventilate.
●To prevent disorder or poisoning caused by fume, wear a respirator for
breathing approved by the local regulation.
●Adequately ventilate or wear a respirator when using the machine in a tank,
a boiler, a hold of a ship. Because heavier gas such as carbon dioxide or
argon gases are drifting.
●When using the machine at a narrow space, comply with a trained
supervisor’s directions.
No.P10224
P. 15/ 47
7. TRANSPORT AND INSTALLATION (continued)
CAUTION
To prevent electromagnetic troubles, read the following. Should
electromagnetic troubles occur, check the following again.
Since large current abruptly changing flows through the welding machine to base metal during
welding, other machines near the welding machine may be troubled due to electromagnetic
noise.
●Do not ground the base metal and welding power source commonly with other machines.
●Tightly close and fix all doors and covers of the welding machine.
●Do not use an unnecessary long grounding cable.
●Extend the torch cable and the base metal cable as straight as possible.
Countermeasures on occurrence of electromagnetic troubles are as follows.
●Change the installation place of the welding machine.
●Keep the machines which may be affected away from the welding machine, the cables and
the welding site as far as possible.
●Add a noise filter to the input cables.
●Install input cables in the grounded metallic conduit.
●Provide electromagnetic shield to the whole welding places.
If electromagnetic troubles can not be solved after trying the above measures, consult your
nearest DAIHEN dealer.
ＨＦ
CAUTION
●Use a wheel stopper after installation of the welding power source.
●Do not place heavy objects on the welding power source.
●Do not block the vent holes of the machine.
●Fix the gas cylinder to the stand for gas cylinder only (see fig. 1).
INSTALLATION PLACE
Observe the following when selecting an installation place.
・
・
・
・
・
Be sure to keep the machine more than 1ft. (30cm) away from the wall or other welding power sources.
(see fig. 2).
Do not install in the place where metal material such as spatter enters the equipment.
Do not install in a place subject to direct sunlight, rain, excessive moisture, oil steam, or corrosive gas.
Install the equipment in the place where the altitude is 3300ft.(1000 m) below, the ambient temperature
is between 14F°(-10C°) and 104F°(40C°), and the relative humidity is 50% at 104 F°(40C°) or
90% at 68 F°(20C°).
Use a wind shield to protect the arc from wind, otherwise welding defects may occur (see fig. 3).
More than 1 ft. (30cm) interval
Welding power source
Fig. 2
Fig. 1 Fig. 3
No.P10224
P. 16 /47 8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE
CAUTION
To prevent serious physical injuries, follow the instructions below.
●When making connections, be sure to disconnect the line disconnect switch of welding
power source, robot, or automatic machine for safe.
●Be sure to follow the instructions described in the manual of a robot when connecting the
welding power source with a robot.
8.1 Connection of welding power source output
CAUTION
Do not touch the charging parts, as this will result in fatal shock and severe burn.
●Do not touch the charging parts of the machine.
●Have a qualified person connect the case of the welding machine and the base metal or jig
grounded.
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after disconnecting the input power switch when installing and maintain the welding
machine. Even after turning off the input power switch, capacitor may be charging. Check
no presence of charging voltage in capacitor.
●Do not use a cable with lack of capacity or a seriously damaged cable.
●Tighten and insulate the connection of cables.
●Do not remove a case or a cover of the welding machine when using the machine.
∗
●Follow the instructions below to connect the welding power source and a robot controller.
5Fix flex tube flange with the
tapping screws M3
mounted on the rear panel.
1Turn off the line disconnec
t
switch of the power box a
t
input side.
6Connect a communicatio
n
connector to CN57 o
n
P.C.B.L8268M, operatio
n
stop to CN5#7 and #8 on the
terminal board, and groun
d
cable to earth terminal.
CN31
Optical
communication
cable connector
P6981X
P6906P
2Remove 4 bolts fixing the
upper cover to open the
cover.
3Pull the clocking hole plug
on the rear plate of ICN an
d
remove it.
8Consult the manual supplie
d
with a robot controller for the
details of the connection with
a
robot control device.
7Close the upper cover with the
bolts.
OSACOM
2000
4Pass a communication cable,
an operation stop wire, and a
n
earth wire of flex tube through
the holes on the rear plate.
Note: when using the welding machine functionally extended, consult the manual o
f
a robot controller.
No.P10224
P. 17/ 47
8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE (continued)
8.2 Connection of a manipulator
CAUTION
Do not touch the charging parts, as this will result in fatal shock and severe burn.
●Do not touch the charging parts of the machine.
●Have a qualified person connect the case of the welding machine and the base metal or jig
grounded.
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after disconnecting the input power switch when installing and maintain the welding
machine. Even after turning off the input power switch, capacitor may be charging. Check
on no presence of charging voltage in capacitor.
●Do not use a cable with lack of capacity or a seriously damaged cable.
●Tighten firmly and insulate the connection of cables.
∗
●Follow the instructions below to connect the welding power source with the manipulator.
Turn off the line disconnect switch of the power box at input side
and the power switch of the welding power source.
Output terminal(+)(Torch side)
Output terminal(‑)
(to base metal)
Arc voltage direct detection
termimal(‑)(Base metal)
Front cover
ICN4 (to manipulator)
12P terminal block
2Remove the front cover to connect as the figure show
n
left. After the connections, cover the device with the
front cover.
Note: when using a feeding device except L-6990 an
d
L-7160, use ICN4 only. In this case, use the arc voltage
detective terminals on 12P terminal board under the
receptacle. Refer to 11.2.
No.P10224
P. 18 /47
8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE (continued)
8.3 Using an extension cable
WARNING
Follow the instructions below to maintain high-performance of the welding
machine.
●Do not use an unnecessary long cable.
●Use an extension cable rolled out.
●Do not use an extension cable wound, as this may result in unstable arc.
8.4 Connection of gas hose
WARNING
●You may suffer from danger of suffocation caused by lack of oxygen when
shield gas keep drifting at closed place. Be sure to turn off the shield gas at
the main when the welding power source is not be used.
CAUTION
●Be sure to connect the gas hose after fixing to the stand, as toppling of gas cylinder may
cause physical injuries.
Nut for cylinder
Gascylinder
Gascylinderstand
Outlet of
gas regulator
②
①
Gashose
Follow the instructions below to connect the gas hose.
1.Attach the gas cylinder nut to the gas cylinder with a monkey
wrench.
2.Connect the gas hose to the outlet coupling with a monkey
wrench.
8.5 Grounding and connection of input side
WARNING
Follow the instructions below to avoid electric shock.
Do not touch charging parts, as this will result in fatal shock and severe burn.
●Do not touch the charging parts of the machine.
●Disconnect all input power with the line disconnect switch when checking the machine.
●Do not use the cable with lack of capacity or the seriously damaged cable.
●Tighten firmly and insulate the connection of cables.
●After connecting cables, firmly fix the case and the cover of the equipment.
●When the welding machine is used in such a humid environment as construction site, on the
steel plate, or on steel structure, install a leakage breaker.
∗
No.P10224
P. 19/ 47
8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE (continued)
CAUTION
●Be sure to install a switch with fuse or a circuit breaker (for motor) at the input side of each
welding machine.
CAUTION
●Be sure to ground the welding power source.
●Grounding cable thickness: AWG 8 or more
If the welding power source not grounded is used, voltage is generated in the case through the
capacitor between the welding power source input circuit and the case or floating capacity
(electrostatic capacity naturally generated between the input conductor and the case metal).
Touching the case or the base metal may cause an electric shock. Be sure to ground the case
of the welding power source or jig.
8.3 Grounding and connection of input side
●Be sure to properly ground welding power source to avoid electric shock.
Install a line disconnect switch for each welding power source.
Input power KVA and amperage of fuse or circuit breaker are as listed below.
CPDACA-200
Input power KVA More than 20.4kVA
Amperage of fuse or circuit breaker 40A
* The circuit breaker type must be for welding power source or for motor.
Input cable
Cable thickness:
over input cable (the
use of AWG 8 cable
is recommended.)
Input terminal cover
Grounding
3φ460V
Insulating
sheet
Clamp
Grounding cable
Cable thickness: over input cable
(the use of AWG 8 cable is
recommended.)
Input terminals
Grounding
terminal
Tighten the screws for
the cables.
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