Daihen OTC TURBO PULSE CPDP-350 User manual
No. P6972
P. 1/ 64
CONTENTS
1. SAFETY INFORMATION ------------------------------------------------------------------
- 2
2. ARC WELDING SAFETY PRECAUTIONS
---------------------------------------------
- 2
3. GENERAL NOTICE OF OPERATION
8
4. STANDARD COMPOSITION AND ACCESSORIES 10
5. FUNCTION OF EQUIPMENT
11
6. REQUIREMENT FOR INPUT POWER 15
7. TRANSPORTATION AND INSTALLATION 16
8. EXTERNAL CONNECTION 19
9. WELDING PREPARATION 23
10.
WELDING OPERATION
25
11.
APPLIED FUNCTION 34
12.
MAINTENANCE AND TROUBLESHOOTING 44
13.
PARTS LIST 59
14.
SPECIFICATIONS
62
15.
AFTER SERVICE 64
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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 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 your doctor.
Read and understand the summarized safety information given below and the
original principal information that will be found in the PRINCIPAL SAFETY
TANDARDS.
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.
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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. In semiautomatic or
automatic wire welding, wire reel, drive assembly, and all metal parts touching the welding
wire are electrically live.
1. Do not touch live electrical parts.
2. Wear dry insulatinggloves 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. Ground the base metal to a good electrical earth ground.
7. Keep all panels and covers of this equipment securely in place.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not touch electrode and any metal object if POWER switch is ON.
10. Do not wrap cables around your body.
11. 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 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.
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Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
6.
Wear approved face shield or safety goggles. Side shield recommended.
7. Wear proper body protection to protect skin
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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 35ft. (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 use 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.
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CYLINDER can explode if damaged.
A shieldinggas 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 shieldinggas 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 the welding machine 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 the welding machine to keep
others away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
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ARC WELDING WORKSHOP is potentially hazardous.
FALLING, FALLING DOWN and MOVING machine can cause serious injury.
Use two eyebolts not oneto 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.
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PRINCIPAL SAFETY STANDARDS
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.
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3. GENERAL NOTICE OF OPERATION
3.1 Rated duty cycle
CAUTION
Use at the rated duty cycle or under. If exceeding the rated duty cycle, the welding machine
may be damaged.
•TURBO PULSE 350 (CPDP-350) Rated duty cycle is 60% at 350 A.
TURBO PULSE 500 (CPDP-500) Rated duty cycle is 100% at 500 A for CO2, MAG, & MIG;
60 % at 500 A for Pulsed MAG, & Pulsed MIG
•The duty cycle is the percentage of a ten-minute period that the welding power source can be
operated at the rated output without causing overheating and damaging the welding power
source. This welding power source can be operated for six consecutive minutes, but it must
rest at no load for the remaining four minutes to allow for proper cooling.
ON OFF
6 min. 4 min.
10 min.
•If exceeding the rated duty cycle, temperature rise of the welding power source and torch can
exceed the allowable limit, and will damage the equipment.
•The following figure indicates the combination of welding current and duty cycle.
Observe the duty cycle in accordance with welding current.
•The duty cycle is affected by other equipment such as the welding torch, etc.
Therefore, observe the lowest rated duty cycle of combined products.
3.2 Limitation of use
100
50
0 100 200 300 400
100(Less than 350A)
68(420A)
Pulsed MAG/
Pulsed MIG
usable range
100
50
0 100 200 300 400 500
60(500A)
Non-pulse
usable range
Duty
cycle()
Duty
cycle()
Welding current(A) Welding current(A)
100(Less than 387A)
100
50
0 100
100(Less than 270A)
60(350A)
Usable range
Duty
cycle()
Welding current(A)
300200
82(300A)
CPDP-350
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•
This welding power source is not suitable for use in the rain.
•
Do not use this welding power source for pipe thawing.
3.3 Applicable welding process and wire size
This welding power source is suitable for the following welding processes.
(1)Standard Wire size ( in.)
Welding
process Applicable wire CPDP-350 CPDP-500
CO2Solid (Mild steel) 0.035, 0.045 0.045, 0.052, 1/16
Solid (Mild steel) 0.035, 0.045 0.045, 0.052
MAG Cored (Mild steel) 0.035, 0.045 0.045, 1/16
Pulsed MAG Solid (Mild steel) 0.035, 0.045 0.045, 0.052, 1/16
Stainless steel 0.035, 0.045 0.045, 1/16
Soft aluminum 3/64, 1/16 3/64, 1/16
MIG Hard aluminum 3/64, 1/16 3/64, 1/16
Stainless steel 0.035, 0.045 0.045, 1/16
Soft aluminum 3/64, 1/16 3/64, 1/16
Pulsed MIG Hard aluminum 3/64, 1/16 3/64, 1/16
(2)Optional Wire size (in.)Welding
process Applicable wire CPDP-350 CPDP-500
Pulsed MIG Inconel 0.035, 0.045 0.035, 0.045
Soft aluminum 3/64, 1/16 3/64, 1/16
Wave pulse Hard aluminum 3/64, 1/16 3/64, 1/16
Soft aluminum 3/64, 1/16 3/64, 1/16
Cycle pulse Hard aluminum 3/64, 1/16 3/64, 1/16
MIG brazing SiBr 0.030, 0.035
CC(Lift start TIG)
Stick
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4. STANDARD COMPOSITION AND ACCESSORIES
4.1 Standard composition
Standard composition consists of welding power source and accessories, and
includes the following parts noted in the dialog boxes.
Air cooled torch
Water cooled torch
4.2 Standard accessories (welding power source)
Check the quantities
when
you receive the
equipment.
CPDP-350 CPDP-500
Description Specification Q’ty Specification Q’ty
Remote control box P6934K00 1 P6920K00 1
2A 250V 1 2A 250V 1
5A 250V 1 5A 250V 1
Fuse (glass tube) 10A 250V 1 10A 250V 1
Cup square neck bolt
M10-30 2
Nut M10 2
Spring washer M10 2
Washer M10 2
Hexagon bolt M820 2
Torch adapter AW-406 2 AW-406 2
feed roll U1376H16 1
3208230V
Input cables
Grounding cable
Welding
power
source
Shielding gas cylinder
Gas regulator with flowmeter
Gas hose (8ft.)
Control cable (8ft.)
Torch side cable (8ft.)
Wire feeder
(Model:CMH-231)
Welding torch
Remote control cable (10ft.) Base metal side cable (6ft.)Remote control box
(Standard accessory of
welding power source)
3208230V
Input cables
Grounding cable
Welding
power
source
Shielding gas cylinder
Gas regulator with flowmeter
Gas hose (8ft.)
Control cable (8ft.)
Water hoses (8ft.)
Wire feeder
(Model:CMWH-231)
Welding torch
Base metal side cable (6ft.)
Remote control box
(Standard accessory of
welding power source)
Water cooler
Torch side cable (8ft.)
Remote control cable (10ft.)
: Standard accessory of wire feeder.
: Standard accessory of wire feeder.
( 4 6 0 V )
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5. FUNCTION OF EQUIPMENT
5.1 Operation of front panel
CAUTION
When operating switches on the front panel, be sure to stop welding.
If you open the panel cover (gray), you can see
each switch and knob.
Close the panel cover during welding.
Refer to of next page.
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CRATER FILL current and voltage control knob
These are for the crater current and crater voltage control. Set them to the optimum crater fill
conditions.
PULSE ARC CONTROL knob
Normally, use in the “” position (standard). It adjusts the pulse arc stability. If it is adjusted to
the “RIGID” side for low current operation or the “SOFT” for high current operation, the best
result will be obtained. In case of using extended welding cable (if total length is more than 60ft.
(20mm)), adjust to the “RIGID” side to obtain the best result in normal operation.
Cooling method of torch (“”
Set to proper position according to torch type.
Gas switch (“”
Set it in “GAS CHECK” position to check gas.
Set it in “WELD” position to weld.
Even when welding with the gas switch set to “GAS CHECK” side, the gas solenoid valve is still
controlled according to the welding procedure. This ensures that even if switch is left in “GAS
CHECK” side, no wasteful gas flows when welding is stopped.
After welding with the gas switch set to “GAS CHECK” side and then performing gas check
again, return the gas switch to “WELD” side and then set to “GAS CHECK” side.
CONSTANT PENETRATION switch
Set to “ ” position when using penetration control.
The penetration control functions only during main welding. Note that even if setting the switch
for penetration control to “”, the penetration control does not function during crater fill.
CURR.VOLT. CONTROL switch
Select a method of curr. / volt. setting.
Refer to “5.2 Remote control box”.
PROGRAM switch for changing welding process / wire size
According to welding process / wire size used, select the appropriate number to press [] or
[] button. The assignment table for the number and the welding process / wire size is shown in
table 5.1 of next page. (Do not set a number other than those of in table 5.1).
CRATER FILL switch
Crater fill functin will work in “(W/O PULSE)” or “(W/PULSE)” position.
Power lamp
This lamp comes on when the input power to the welding power source is allowable whether
power switch is ON or OFF.
WARNING lamp and temperature lamp (“ ”)
When these lamps come on, output stops automatically.
Refer to “11.APPLIED FUNCTION” to reset the system.
Power switch
When turned on this switch, the fan starts rotating and the machine becomes ready to use.
WAVE PULSE knob (option)
When wave pulse welding (option), adjust the knob according to welding procedure to obtain
favorable bead appearance.
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PROGRAM switch Table 5.1
CPDP-350 CPDP-500
Progra
m Welding process Wire
size.
(in.) Program Welding process Wire
size.
(in.)
11 0.035 11 0.045
12 Mild steel CO2 0.045 12 0.052
21 0.035 13
Mild steel CO2 1/16
22 MAG 0.045 21 0.045
23 0.035 22
MAG 0.052
24
Mild steel Pulsed
MAG 0.045 23 0.045
24 0.052
25
Mild steel Pulsed
MAG 1/16
31 0.035 31 0.045
32 MIG 0.045 32 MIG 1/16
33 0.035 33 0.045
34
Stainless
steel Pulsed
MIG 0.045 34
Stainless
steel Pulsed
MIG 1/16
41 0.035 41 0.045
42 Cored wires MAG 0.045 42
Cored wires MAG 1/16
51 3/64 51 3/64
52 MIG 1/16 52 MIG 1/16
53 3/64 53 3/64
54
Soft
aluminum Pulsed
MIG 1/16 54
Soft
aluminum Pulsed
MIG 1/16
61 3/64 61 3/64
62 MIG 1/16 62 MIG 1/16
63 3/64 63 3/64
64
Hard
aluminum Pulsed
MIG 1/16 64
Hard
aluminum Pulsed
MIG 1/16
CRATER switch
Selecting “(W/O PULSE)” at pulse arc welding (when the PROGRAM switch is set to
23, 24, 33, 34, 53, 54, 63 or 64 CPDP-350,
2325, 33, 34, 53, 54, 63 or 64 CPDP-500)
causes welding with pulse off during crater fill.
However, selecting “(W/PULSE)” at non-pulse arc welding (when the PROGRAM switch is
set to 11,12, 21, 22, 31, 32, 41, 42, 51, 52, 61 or 62CPDP-350,
1113, 21, 22, 31, 32, 41, 42, 51, 52, 61 or 62CPDP-500),
welding with pulse off continues during crater fill, namely the same operation as selecting
“(W/O PULSE)” is performed.
PULSE ARC CONTROL knob
The knob for adjusting pulse arc characteristic is valid only for pulsed MAG arc welding and
pulsed MIG arc welding. Note that the adjustment does not function for non-pulse arc welding
such as CO2welding.
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5.2 Remote control box
CPDP-500
Knob for setting
welding current Inching switch Knob for setting welding voltage
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Used to set welding
current. Pressing this switch
causes only wire to be
fed. The wire feed
speed can be changed
by the left knob.
[ONE-KNOB]
Setting to the mark “•” causes optimum
voltage to be obtained automatically. Rotate
the knob clockwise to increase the voltage, or
counter-clockwise to decrease the voltage.
[SEPARATE]
The scale is divided into 10 equal parts toward
the maximum output voltage. Rotating
clockwise causes welding voltage to become
higher.
[FUZZY(ALUM.)]
Setting is unnecessary.
CPDP-350
Same operation as CPDP-500, but only different scale at “A” knob.
In case of using the “ONE-KNOB” mode
When the “CURR.VOLT. CONTROL” switch of the front panel is set to the “ONE-KNOB” side,
the optimum welding voltage can be set automatically according to “A” knob of the remote
control box. When a fine adjustment of welding voltage is desired, adjust the “V” knob.
In case of using the “SEPARATE” mode
Set the “CURR.VOLT. CONTROL” switch provided on the front panel to the “SEPARATE”
side, and the welding current and voltage can be adjusted separately.
In case of using the “FUZZY(ALUM.)” mode
When the “CURR.VOLT. CONTROL” switch of the front panel is set to the “FUZZY(ALUM.)”
side, the optimum welding voltage can be set automatically according to “A” knob of remote
control box in fuzzy theory. In this case, the right knob of the remote control box does not work.
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6. REQUIREMENT FOR INPUT POWER
6.1 Commercial input power
WARNING
Provide a leakage circuit breaker, when the welding power source is used at a place with
high humidity.
CAUTION
Be sure to provide a switch (with fuse) or the circuit breaker at the input side of each
welding power source.
If a leakage circuit breaker (ground fault circuit breaker) is used, select one that is protected
from high frequency.
Capacity of commercial input power and amperage of fuse or circuit breaker
CPDP-350 CPDP-500
input power voltage and phase 208230V, 3-phase
Input voltage range 187229V207253V
Input power (KVA) More than 24kVA More than 29kVA
Amperage of fuse or circuit breaker 80A 100A
+: DAIHEN recommends the amperage value of fuse or circuit breaker written above.
However, the value that is prescribed by safety regulations in user’s own country and
district takes priority.
6.2 Precautions for use on an engine generator
CAUTION
Observe the following to prevent problems with the welding machine when using the
auxiliary power supply on an engine generator or engine welder.
Set the voltage of the engine generator to208 218V in no-load running.
If output voltage is set too high, the welding machine may fail.
The engine generator’s voltage response is slower than the commercial input power when
the engine generator’s load suddenly changes. Therefore, the output voltage drops
excessively when the load current varies suddenly due to arc start, and that may cause a loss
of arc. However, the welding machine will not be out of order due to such conditions. To
prevent loosing the arc, the engine generator’s capacity must be more than twice the rated
input power (KVA) of the welding machine.
An engine generator with a damper winding is highly recommended. Contact the engine
generator’s manufacturer whether a damper winding is provided or not.
Don’t use more than two welding machines with one engine generator. Loosing the arc may
occur by interference of the other welding machine.
When using an engine welder’s auxiliary power supply, use only the power supply with an
approved voltage waveform. (Contact an engine welder’s manufacturer for details.)
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7. TRANSPORTATION AND INSTALLATION
7.1 Transportation
WARNING
Observe the following to prevent damage while transporting the welding machine.
Do not touch live electrical parts inside or outside of the welding machine.
When moving the welding machine, use the line disconnect switch to turn off
the input power.
When lifting the welding power source with a crane, secure the case and the
cover, and firmly tighten the eyebolts
Lift only one welding power source at a time with two wires. Lifting the
welding power source with other equipment may cause it to fall.
When carrying 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, observe the following to prevent possibility of fires
caused by welding and physical damage caused by fumes and gases.
Do not install the welding machine near combustible materials and
flammable gas.
Remove combustible materials to prevent the possibilities of being struck by
the spatter.
If can not be removed, cover them with a noncombustible cover.
To prevent gas-poisoning or choking, use exhaust equipment or protective
respirators that are prescribed by safety regulations.
To welding in a narrow space, ventilate the space sufficiently or wear
protective respirators, and work only under proper supervision.
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CAUTION
To prevent electromagnetic problems read the following.
Also, when electromagnetic problems occur, read the following again.
Since high current abruptly changed flows through the welding machine to base metal during
welding, nearby machines 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 welding machine.
Shorten the welding cable as much as possible.
Place the cable of the base metal side and the torch side as close as possible.
Countermeasures on occurrence of electromagnetic troubles are as follows.
Change the installation place of the welding machine.
Keep machines liable to be affected away from welding machine, cables and welding site as
much as possible.
Add the noise filter to the input cables.
Install the input cables in the grounded metallic conduit.
Provide electromagnetic shield to the whole welding place.
If electromagnetic troubles are not solved after performing the above measures, consult our
company.
CAUTION
After installing the welding power source, provide wheel stoppers.
Do not put any heavy substances on the top of the welding power source.
Do not cover the ventilation port of the welding power source.
Fix the gas cylinder to the special gas cylinder stand.
This manual suits for next models
1
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