Daihen OTC ARXIS pulse P403L User manual

July, 2023
Manual No. : P30433-1
DAIHEN Corporation
ARXIS pulse P403L
P503L
OWNER'S MANUAL

Preliminaries
Forward
Thank you for your purchase of OTC's welding power source.
This Owner's Manual (hereafter referred to as "this manual") explains the following points for safe use of the product.
• Caution regarding the product
• Welding operation/setting method
• Daily maintenance (cleaning, inspection)
•Troubleshooting
Store this manual in a safe place so that it can be referred whenever necessary.
Service and Support
See the back cover for contact numbers and mailing addresses. When contacting your dealer for service,
you are required to provide the following information:
• Name, address, telephone number
• Product model, manufacture year, serial number, and software version number
(Refer to the diagram below for product information. Attachment location and content of nameplate may
vary depending on the purchased product.)
<Example> Attachment location of the nameplate
No. Serial No.
1
• Product model
• Manufacture
year
• Serial number
XX-X###X
#### year
#X#####X ###########
2• Software version number
X##### Ver ###.###.###.###
1
2
)5217 5($5

1
Important Information
Use of the Product
This product is a power supply unit designed and manufactured for use in arc welding.
Do not use the product for any other purposes.
Safe Use of the Product
For safe use of the product (hereafter referred to as welding power source), ensure to follow the
instructions below:
• This manual is intended for workers who are familiar with the listed terminologies. If this product is going
to be operated or serviced by workers who are not familiar with the terminology, the responsibility falls
on the customer to provide thorough training on operation and safety.
• This equipment and this manual are for use only by persons trained and experienced in the safety
operation of welding equipment. Untrained persons must complete the "Special workshop for arc
welding".
• For protection from possible injury or damage in the equipment, be sure to read and follow the safety
information in this manual. Do not use it for purposes not indicated in the manual.
• Make sure that installation/operation/maintenanceof the welding power source and welding machine is
performed by qualified personnel with sufficient knowledge and skills.
• If this manual is lost or damaged, immediately contact your dealer.
Copyright
This manual is copyrighted and all rights are reserved by OTC. Any part of the manual shall not be
copied, photocopied, or reproduced without the prior consent of OTC.
When Exporting the Product
The following conditions are to be observed and met when exporting the product outside of the country.
• The product is designed and manufactured according to the International Electrotechnical Commission
standards. The product may not conform to laws/specification and standards in other countries.
• When shipping or reselling the product outside of the country, make sure to contact your dealer in
advance.
Disposal of the Product
For disposal of welding equipment including the welding power source and welding material, confirm
the regulation of the country/region in which the equipment is located and follow the rules. When
disposing, arrange consignment contract for waste disposal with an authorized waste collectors and
manage the disposal processes.

T ABLE OF C ONTENTS
2
TABLE OF CONTENTS
Forward
Service and Support
Important Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Use of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safe Use of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
When Exporting the Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Disposal of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 1 SAFETY INFORMATION
1.1 Warning Symbols . . . . . . . . . . . . . . . . . . . . . .4
1.2 Safety Precaution . . . . . . . . . . . . . . . . . . . . . .5
1.2.1 Operating precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Precautions for power supply and electric shock. . . . . . 6
1.2.3 Precautions for handling of plastic parts . . . . . . . . . . . . 7
1.2.4 Precautions for disassembling and modifying the
welding power source . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.5 Precautions for air discharge and use of respiratory
protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.6 Precaution for protective equipment . . . . . . . . . . . . . . . 8
1.2.7 Precautions for flammable materials . . . . . . . . . . . . . . . 9
1.2.8 Precautions for gas cylinder and gas regulator . . . . . . 10
1.2.9 Precautions for rotating part . . . . . . . . . . . . . . . . . . . . 10
1.3 Principal Safety Standards . . . . . . . . . . . . .11
CHAPTER 2 PRODUCT SPECIFICATION
AND CONFIGURATION
2.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . .12
2.1.1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.2 Applicable welding process . . . . . . . . . . . . . . . . . . . . 13
2.1.3 External dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.4 Rated duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Product Configuration . . . . . . . . . . . . . . . . .18
2.2.1 Standard composition . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.2 Accessory (supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.3 Accessory (not supplied) . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.4 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Part Names . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.3.1 Front panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.2 Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3.3 Operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHAPTER 3 TRANSPORTATION AND
INSTALLATION
3.1 Required Equipment. . . . . . . . . . . . . . . . . . .26
3.1.1 Welding power source equipment . . . . . . . . . . . . . . . . 26
3.1.2 Ventilation equipment/partial exhaust facility. . . . . . . . 27
3.2 Installation Environment . . . . . . . . . . . . . . .28
3.2.1 Installation environment. . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.2 Electromagnetic interference . . . . . . . . . . . . . . . . . . . . 28
3.3 Transportation Procedure . . . . . . . . . . . . . .29
3.3.1 Transportation with lifting lug . . . . . . . . . . . . . . . . . . . . 30
3.3.2 Manual transportation with carts . . . . . . . . . . . . . . . . . 31
CHAPTER 4 CONNECTION
4.1 Precautions for Connection Procedure
and Grounding . . . . . . . . . . . . . . . . . . . . . . .32
4.2 Connecting the Welding Power Source . . .33
4.2.1 Connection of cable at output side . . . . . . . . . . . . . . . 34
4.2.2 Connection of wire feeder . . . . . . . . . . . . . . . . . . . . . . 35
4.2.3 Connection of welding torch . . . . . . . . . . . . . . . . . . . . . 36
4.2.4 Connection of analog remote control (optional)
(In using analog remote control). . . . . . . . . . . . . . . . . . 37
4.2.5 Connection of voltage detection cable
(In using voltage detection cable). . . . . . . . . . . . . . . . . 38
4.2.6 Connection at MMA welding. . . . . . . . . . . . . . . . . . . . . 40
4.2.7 Connection of shield gas . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.8 Connection of water hose
(In using the water welding torch) . . . . . . . . . . . . . . . . 42
4.3 Grounding and Connection of Input Power
Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.4 Confirmation of Connection . . . . . . . . . . . .44
4.5 Connection of External Equipment. . . . . . .44
4.5.1 Connection of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5.2 Connection of automatic machine . . . . . . . . . . . . . . . . 46
4.6 Wiring of Voltage Detection Cable at Base
Metal Side . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6.1 Wiring to welding power source . . . . . . . . . . . . . . . . . . 49
4.6.2 Wiring example of voltage detection cable. . . . . . . . . . 50
CHAPTER 5 WELDING OPERATION
5.1 Precaution at Welding Operation . . . . . . . . 51
5.1.1 Precautions for air discharge and use of respiratory
protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1.2 Precaution for protective equipment. . . . . . . . . . . . . . . 52
5.1.3 Precautions on welding place. . . . . . . . . . . . . . . . . . . . 52
5.2 Check before Welding . . . . . . . . . . . . . . . . .52
5.3 Power ON and Gas Supply . . . . . . . . . . . . .54
5.4 Wire Inching . . . . . . . . . . . . . . . . . . . . . . . . .55
5.5 Check and Setting of Welding
Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5.1 Reading welding condition . . . . . . . . . . . . . . . . . . . . . . 57
5.5.2 Preventing erroneous operation on operation
panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.6 Performing Welding Operation . . . . . . . . . .58
5.6.1 Operation of welding start . . . . . . . . . . . . . . . . . . . . . . 58
5.6.2 Operation during welding . . . . . . . . . . . . . . . . . . . . . . . 60
5.6.3 Operation at welding end . . . . . . . . . . . . . . . . . . . . . . . 62
CHAPTER 6 WELDING CONDITION
6.1 List of Welding JOB . . . . . . . . . . . . . . . . . . .63
6.1.1 Parameter (Welding parameter). . . . . . . . . . . . . . . . . . 63
6.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.3 Internal function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2 Function on Operation Panel. . . . . . . . . . . .69
6.2.1 Configuration of operation panel . . . . . . . . . . . . . . . . . 69
6.2.2 Basic operation of touch panel . . . . . . . . . . . . . . . . . . . 70
6.2.3 Main screen functions . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.3 Welding JOB . . . . . . . . . . . . . . . . . . . . . . . . .74
6.3.1 Basic welding JOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.3.2 Useful functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.4 Preparing Welding JOB . . . . . . . . . . . . . . . .75
6.5 Memory Function of Welding JOB . . . . . . .75
6.5.1 Basic configuration of JOB list screen . . . . . . . . . . . . . 76
6.5.2 Memory Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.5.3 Read out of welding JOB . . . . . . . . . . . . . . . . . . . . . . . 79
6.5.4 Deletion of memory registration . . . . . . . . . . . . . . . . . . 82

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6.6 Setting Welding JOB . . . . . . . . . . . . . . . . . . 84
6.6.1 Welding mode setting . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.6.2 Setting welding mode . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.6.3 Setting welding parameter. . . . . . . . . . . . . . . . . . . . . . 87
6.6.4 Crater setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6.5 Arc spot time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.6.6 Welding voltage adjustment . . . . . . . . . . . . . . . . . . . . 96
6.6.7 Arc characteristics adjustment . . . . . . . . . . . . . . . . . . 97
6.6.8 Penetration control adjustment . . . . . . . . . . . . . . . . . . 98
6.6.9 Adjustment of wave frequency . . . . . . . . . . . . . . . . . . 98
6.6.10 Welding guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.6.11 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.7 Setting Internal Functions. . . . . . . . . . . . . 102
6.7.1 Setting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.7.2 Detailed information on internal functions . . . . . . . . . 105
6.8 Operation of Analog Remote Control
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 130
CHAPTER 7 ADMINISTRATOR
FUNCTIONS
7.1 Administer settings of welding
condition. . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.2 Protection of Welding JOB . . . . . . . . . . . . 133
7.2.1 Setting/Changing password . . . . . . . . . . . . . . . . . . . 134
7.3 Welding Result Control Function . . . . . . . 135
7.3.1 Setting welding result control function. . . . . . . . . . . . 136
7.3.2 Details of welding control items. . . . . . . . . . . . . . . . . 138
7.4 Data Backup (Utilization of data) . . . . . . . 142
7.4.1 Setting of welding JOB/internal functions . . . . . . . . . 142
7.4.2 Simplified data log function . . . . . . . . . . . . . . . . . . . . 144
7.4.3 Failure log function . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.4.4 Welding Result Control Function. . . . . . . . . . . . . . . . 146
7.4.5 Backup operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.4.6 Importing backup data. . . . . . . . . . . . . . . . . . . . . . . . 147
7.5 Initializing Welding JOB and Internal
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.6 Checking the Software Version and
Serial Number. . . . . . . . . . . . . . . . . . . . . . . 150
7.7 Calibration Mode . . . . . . . . . . . . . . . . . . . . 151
7.7.1 Adjustment of output current . . . . . . . . . . . . . . . . . . . 151
7.7.2 Adjustment of output voltage. . . . . . . . . . . . . . . . . . . 153
7.8 System Setting . . . . . . . . . . . . . . . . . . . . . . 156
7.9 Screen Layout Settings. . . . . . . . . . . . . . . 157
7.10 Language settings . . . . . . . . . . . . . . . . . . . 158
CHAPTER 8 MAINTENANCE AND
INSPECTION
8.1 Precautions for Maintenance and
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.2 Daily Inspection . . . . . . . . . . . . . . . . . . . . 160
8.3 Periodical Inspection. . . . . . . . . . . . . . . . . 161
8.4 Periodical Replacement Parts . . . . . . . . . 162
8.5 Insulation Resistance Measurement and
Withstand Voltage Test . . . . . . . . . . . . . . . 163
CHAPTER 9 TROUBLESHOOTING
9.1 Action in Case of Error . . . . . . . . . . . . . . . 164
9.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . 166
CHAPTER 10 REFERENCE MATERIALS
10.1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.1.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.1.2 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10.2 Reference Drawing . . . . . . . . . . . . . . . . . . 171
10.2.1 Schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.2.2 Parts layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.3 Materials for Setting Welding JOB. . . . . . 178
10.3.1 Guide for changing welding JOB . . . . . . . . . . . . . . . . 178
10.3.2 Samples of welding condition settings . . . . . . . . . . . . 178

4
Chapter 1 Safety Information
This chapter explains the precautions on the welding power source and welding operation.
1.1 Warning Symbols
The following safety warning symbols and signs are used throughout the manual to ensure proper operation of the
product and to prevent from various hazards that cause serious injury and damages. Indication and explanation for the
symbols are as follows:
Make sure to fully understand the content before beginning operation.
The below symbols are categorized by the degree of possible hazard and damage.
The below symbols are categorized according to the content to be followed.
Symbols Explanation
Gives information regarding possible personal injury or loss of life if the product is used
improperly.
Refers to minor personal injury or possible equipment damage if the product is used improperly.
Symbols Explanation
Instruction: indicates "Instruction" matters to be followed.
Prohibited: indicates "Prohibited" matters.
CAUTION

5
Chapter 1 Safety Information
S AFETY P RECAUTION
S AFETY I NFORMATION
C HAPTER 1
1.2 Safety Precaution
This section explains the safety precautions regarding operation of the welding power source.
1.2.1 Operating precautions
To prevent serious injury or accidents, ensure to follow the instructions below:
• Be sure to read and understand the information in the manual before operating the
product. Have only trained and experienced personnel perform operation of welding
power source or welding power source.
• Perform construction work on primary power source in the facility, selection of
installation space, operation/storage/piping of high pressure gas, storage of welded
products, and disposal of waste in accordance with local law and/or regulation at the
customer's facility.
• Be sure to take appropriate measures during welding so that no person is allowed
unauthorized access near the welding power source or work areas.
• Only authorized personnel or person with full understanding and experience of the
welding power source must perform installation, maintenance and repair of welding
power source.
• Make sure to attach a safety belt when working at high locations.
• For those with pacemaker, avoid being close to the machine during operation or work
area until obtaining physician's approval. Machine at operation will generate magnetic
field nearby that may cause influence upon the working of pacemaker.
• Do not use the welding power source for purpose other than welding such as thawing a
frozen pipe.
• Do not use the welding power source when the case and the cover are removed.
• Removing the cases for maintenance, inspection and repair should be performed by
qualified persons or persons familiar with the welding power source. Also put up a
barrier around the welding power source or take other necessary measure to prevent
other people from getting in the nearby area.

S AFETY P RECAUTION
S AFETY I NFORMATION
C HAPTER 1
6
1.2.2 Precautions for power supply and electric shock
To prevent electric shock or burn injury, ensure to follow the instructions below:
• Do not touch the input and output terminals and the internal live electrical parts of the
welding power source.
• Have a qualified electrical engineer ground the case of the welding power source and
base metal or jig electrically connected in accordance with local regulation.
• Before starting maintenance and inspection, make sure to cut the input power with the
disconnect switch in the box connected with the welding power source and wait three
minutes or more.
The capacitors may be still charged even after the input power is cut. Make sure that
there is no charged voltage before starting the work.
• Wear dry insulating gloves for protection. Do not use damaged or wet gloves.
• Tighten all cable connections and insulate them.
• Do not wrap cables around the body.
• Perform periodical maintenance and repair damaged parts if any before use.
• Turn off POWER switch of all the related equipment when not in use.
• Periodically blow the parts of welding power source with dry compressed air to remove
dust.
Powder dust accumulating inside may cause insulation deterioration, resulting in
electric shock or fire.
• Do not use a cable with insufficient capacity, serious damage or cable without
grounding.
CAUTION
• When the power switch is tripped, never turn it on again and contact your dealer.

7
Chapter 1 Safety Information
S AFETY P RECAUTION
S AFETY I NFORMATION
C HAPTER 1
1.2.3 Precautions for handling of plastic parts
Front panel, rear panel and fan of the welding power source is made from polycarbonate resin. To prevent from electric
shock or fire caused by the damage on polycarbonate resin, ensure to follow the instructions below.
1.2.4 Precautions for disassembling and modifying the welding power source
To prevent electrical shock, fire, injury from malfunction and error in the welding power source, ensure to follow the
instructions below:
1.2.5 Precautions for air discharge and use of respiratory protective equipment
To prevent suffocation or gas poisoning in the welding operation, ensure to follow the instructions below:
To prevent any health damage due to poisonous gas or particle substances (fume) emitted in thewelding operation, ensure
to follow the instructions below:
• Do not apply external force or shock to the front and rear panels.
Otherwise, damage and malfunction may occur.
• If there is dirt on plastic parts, soak a soft cloth in water, alcohol or neutral detergent,
wring it well and wipe off the dirt.
Do not use organic detergent or chemical agent. Doing so may cause crack (breaking)
and degrade the strength.
• If there is any abnormality in the plastic parts such as front panel, rear panel and fan,
immediately stop the use and contact your dealer.
• Do not use the welding power source at location in which organic solvent, chemicals,
cutting oil and composition oil adhere or atmosphere containing the above.
Doing so may cause crack (breaking) and deterioration in the plastic part.
• Do not disassemble/modify the welding power source.
Disassembling/modifying by customer is out of the warranty scope.
• When welding is required in tank, boiler, reaction tower, or hold of a ship, closed space,
or any other places of poor ventilation, ensure to provide ventilation equipment.
• Gas of larger gravity than that of oxygen, such as carbon dioxide gas or argon gas,
retains at the bottom part.
To prevent anoxia due to the retention gas, provide ventilation equipment.
• When it is difficult to provide ventilation equipment or the ventilation equipment does
not give sufficient performance, ensure to use respiratory protective equipment.
For preventive measure from falling due to anoxia, apply lifelines such as a safety belt.
• For the welding operation in a narrow space, perform the operation with the trained
supervisor.
• Periodically inspect the ventilation equipment to ensure correct and proper
performance of ventilation.

S AFETY P RECAUTION
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8
1.2.6 Precaution for protective equipment
For protection from arc ray generated from welding, spattering dross and hearing disorder from noise, observe the
following:
• To reduce the dust concentration, install a partial exhaust facility such as fume suction
device, or install the collective ventilation equipment.
• When it is difficult to provide a partial exhaust facility or the ventilation or exhaust
facility does not give sufficient performance, ensure to use the respiratory protective
equipment. It is recommended to use a respiratory protective device with an electric fan
that provides higher protection performance.
• In performing welding or cutting the coating steel plate or galvanized steel sheet,
provide a partial exhaust facility or let the welding operator as well as the surrounding
operators use respiratory protective equipment. (Welding or cutting the coating steel
plate or galvanized steel sheet will cause toxic gas or fume.)
• Do not perform welding operation in the vicinity of degreasing, cleansing, or spraying
operation. Performing the welding operation in such places may generate poisonous
gas.
• When welding or watching a welder work, wear face shield with a proper shade of filter
(See ANSI Z 49.1 listed in PRINCIPAL SAFETY STANDARDS) to protect the face and
eyes.
• Wear safety goggles in the work area and the surrounding.
Ignoring the above may cause injury in the eye or burn from spatter and spattering
dross.
• Wear protective equipment such as protective leather gloves, long-sleeve clothes, leg
covers, and leather apron.
Ignoring the above may cause electrical shock and burn.
• Install protective screens or barriers to protect the eyes of others in the work area from
arc ray.
• Wear an ear protector when noise level is high.
Ignoring the above may cause hearing disorder.