Daihen OTC CM-743-U User manual

OWNER'S MANUAL
WIRE FEEDER
MODEL: CM-743-U
Ensure to read this
instruction manual
thoroughly for safe and
proper use of the product.
DAIHEN Corporation
U30104
December 16, 2015
Manual No. : U30104-1

ll Notice Machine export to Europe
This product does not meet the requirements specified in the
EC Directives which are the EU safety
ordinance that was enforced starting on January
I, 1995. Please make sure that this product is not
alfowed to bring into the EU after January 1, 1995 as it is.
The same restriction is also applied
to any country which has signed the EEA accord.
Please ask us before attempting to relocate or resell this product to or in any EU member country or
any other country which has signed the EEA accord.

TABLE OF CONTENTS
1. SAFETY INFORMATION ................,.......................................... 1
2. ARC WELDING SAFETYPRECAUTIONS...............................2
3. CHECKING OF QUANTITY OF THE ACCESSORIES............. 9
4. NAMES OF PARTS.........................,........... .. .............................9
5. CARRYING AND INSTALLING OF THE WIRE FEEDER...... 10
6. CONNECTION PROCEDURE.........,........................................ 12
7. WELDING PREP ERA TION..................................................... 17
8. MAINTENANCE AND TROUBLESHOOTING........................26
9. PARTS LIST............................................................................32
10. SPECIFICATIONS...........................,........................................ 53

SAFETY INFORMATION
The following safety alert sy mb ols and signal words are used throughout this ma nu al to
i
de ntify various hazards and special instruction s.
~WARNING
~CAUTION
WARNING gives information regarding possible
personal injury or loss of life.
CAUTION refers
to minor personal injury or possible
equipment damag e.
Prohibited: indicates " Prohibited " matters.
- 1 -

fj ARC WELDING SAFETY PRECAUTIONS
~WARNING
ARC WELDING can be hazardous.
•PROTECT YOURSELF AND OT HERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
Be sure to:
-Keep children away.
-Keep pacemakerwearers away until consulting a doctor.
• Read and understand the summarized safety information given below and the original principal
information that will befound 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.
l_lli .,._ B_e_f_o_re_ u_s_in_g_ th_is_p_r_o_d_u_c_t_,_b_e_s_u_r_e_t_o_r_e_a_d_t_h_i_s_m_a_n _u_ a_I _. _ ____,
The device is manufactured using state-of-the-arttechnology and according
to recognised safetystandards.
If used incorrectly or misused, however, it can
cause.
-injury or death to the operatorora third party,
-damage tothe device and other material assets
-belonging to the operating company,
-inefficient operation
of the device
All persons involved in commissioning, operating, maintaining and servicing
the device must:
-be suitablyqu al ified
-have sufficient knowledge of welding
-read and follow these operating instructions carefully.
The operating instriuctions must always be at hand wherever the device is
being used. In addition
to the operating instructions, attention must all so be
paid
to any general ly applicable and local regulations regarding accident
prevention and environmental protection
All safety and danger notices on the device
-must kept in a legible stake
-must not be damaged or marked
-must not be removed
-must not be covered, pasted or painted thecovers
-2 -

ARC WELDING SAFETY PRECAUTIONS (Continued)
~WARNING
1~
ELECTRIC SHOCK can kill.
Touching live electrica l parts can cause fatal shocks or severe burns. The
electrode and work circuits are el ectrica lly live whenever the output is on. The
power line and internal circuits of th is equ i pment are also live when the li ne
disconnect switch is on. When arc we l ding all metal components in the torch
and work circuits are electrica lly live.
•
Do nottouch live electrical parts.
• Weardryinsulating gloves and other body protection thatare free of holes.
• Insulate yourselffrom work and ground using dry insulating mats
or covers.
• Be sureto disconnectthe line disconnect switch before installing, changing torch
parts or maintaining this equipment.
• Properly install and ground this equipment according to its Owner's Manual and
national, state, and local codes.
• Keep all panels and covers of this equipmentsecurely in place.
•
Do not use worn, damaged, undersized, or poorly spliced cables.
•
Do nottouch electrode and any metal object if POWER switch is ON.
• Do notwrap cables around your body.
• When the wire feeder is not in use orthe work is interrupted for a long time, shut off
the power of all units.
• Bl ow dry air to parts periodically to remove dust and dirt.
~f)
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 i ntense heat and strong ultraviolet
rays that can burn eyes and skin .
Noise from some arc we l ding ca n damage h earing.
• Wearface shield with a propershade of filter (SeeANSI Z 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a
we lderwork.
• Wearapproved safety goggles. Side shields recommended.
• Use protective screens or barriers to protect others from flash and glare: warn
others notto look at the arc.
• Wear protective clothing made from durable, flame-resistant material (wool and
leather)and foot protection.
• Useapproved earplugs or earmuffs if noise level is high. Chipping and grinding can
cause flying metal. As welds cool, they can throw
off slag.
• Wearapproved face shield or safety goggles. Side shields recommended.
• Wear proper body protection to protect skin.
-3-

ARC WELDING SAFETY PRECAUTIONS (Continued)
~WARNING
- ~ ~~ WELDING can cause fire and explosion.
"'9t' Sparks and spatterfly 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.
• Protectyourself and others from flying sparks and hot metals.
• Do notweld where flying sparks can strike flammable material.
• Remove all flammables within 33ft. [ 1
Om ] of the welding arc. If this is not possible,
coverthem with approved covers.
• Be alert thatwelding sparks and hot metals from welding can easily pass through
cracksand openings into adjacent areas.
• Watch forfire, and keep a fire extinguisher nearby.
• Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden
fire.
• Do notweld on closed containers such as tanks or drums.
• Connect base metal side cable as close to the welding area as possible to prevent
the
we lding currentfrom traveling along unknown paths and causing electric shock
and fire hazards.
• Remove stickelectrode from holder orcut off welding wire at contacttip when not in
use.
• Does not use the we lding power source for otherthan arc welding.
• Wear oil-free protective garments such as leathergloves, a heavyshirt, cuffless
tr ousers, boots, and a cap.
• A loose cable connection can cause sparks and excessive heating.
• Tighten all cable connections.
• When there is an el ec trical connection between a work piece and the frame of wire
feeder
or the wire reel stand, are may be generated and cause damage by a fire if
thewire contacts the frame or thework piece.
-4-

ARC WELDING SAFETY PRECAUTIONS (Continued)
~WARNING
- 1- F_U_M_E_S_ A_N_D_ G_A_S_E_S_ c_a_n_b_e_h_a_z_a_r_d_o_u_s_to_ y_o_u_r_h_e_a_lt _h_. -~
~ Arc welding produce fumes and gases. Breathing these fumes and gasescan
be hazardous to
your health.
• Keepyour head out of the fumes. Do not breathethe fumes.
• Ventilate the area and/or use exhaust at the arc to remove welding fumes and
gases.
• If ventilation is poor, use an approved air-supplied respirator.
• Read the Material Safety Data Sheets (MSDS) and the manufacturer's instructions
on metals, consumables, coatings, and cleaners.
•
Do notweld or cut in locations neardegreasing, cleaning, orspraying operations.
The heatand arc rays can reactwith vapors to form highlytoxicand irritating gases.
• Work in a confined spaceonly ifitis well ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can displace air causing injury or
death. Besurethe breathing airis safe.
CY LINDER 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.
• Useonly correct shielding gas cylinders, gas regulator, hoses, and fittings designed
for the specific application; maintain them in good condition.
• Pr otectcompressed gas cylinders from excessive heat, mechanical shock, and
arcs.
• Keepthe cylinder uprightand securely chained to a stationary support or a rack to
prevent falling ortipping.
• Keep cylinders awayfrom any welding orotherelectrical circuit.
• Nevertouch cylinder with welding electrode.
• Read and follow instructions on compressed gas cylinders, associated equipment,
and the CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
•Turn face awayfrom valve outletwhen opening cylinder valve.
• Keep protective cap in place
over valve exceptwhen gas cylinder is in use or
connected foruse.
• Do notdisassemble or repairthe gas regulator exceptfor the person authorized by
the manufacturer
of them.
- 5 -

ARC WELDING SAFETY PRECAUTIONS (Continued)
~WARNING
Be sure to observe the followings for preventing physical injuries,
a fire and electric shock.
Handling of plastic parts
Side door is made of polycarbonate.
Make sure to observe the following notice.
• Do not apply external force and a shock to side door. Otherwise it maybe broken and in trouble.
• Polycarbonate parts can be weakened ordamaged
by solvents and oils. If theside door or
covers are damaged, repair or replace immediately.
Do not alter or remodel our products.
•You mayget inijured or have your equipmentdamaged because of fire, failure or malfunction
caused byaltering or remodeling the product.
• The warranty does notcover any altered or remodeled products.
-6-

ARC WELDING SAFETY PRECAUTIONS (Continued)
~WARNING
~
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.
• Do not use this equipment ifthe case and the cover are removed.
• 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 awayfrom it.
• Before touching rotating parts for maintenance, inspection and repair, shut off the
welding power.
• Do not put hands, fingers, hair or clothes nearthe rotating fans or wire feed roll.
ARC WELDING work areas are potentially hazardous.
--
~
FALLING or MOVING machine ca n cause serious in jury .
• When hanging the welding power source by a crane, do notuse the carrying
handle.
• Placethe welding power source and wire feeder securely
on a flat surface.
• Do not pull the welding power source across obstacles.
•
Do not put wire feeder on the welding powersource.
• Do not put the welding power source and wire feeder where theywill pit or fall.
WELDING W IRE can cause puncture wou nd s.
• Do not press gun trigger until instructed to do so.
• Do not point guntoward any part of the body, other people, or any metal when
threading welding wire.
-7-

ARC WELDING SAFETY PRECAUTIONS (Continued)
PRINCIPAL SAFETY STANDARDS
Arc welding equipment- Installation and use. Technical Specification
IEC 62081, from International Electro technical Commission
Arc welding equipment Part 1: Welding powersources IEC 60974-1, 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 forthe Preparation for Welding and Cutting of Containers
Tha t 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, NFPAStandard 51 B, from National Fire Protection
Association.
NOTE: The codes listed above may be improved or eliminated. Always refer to the
updated codes.
M050114
-8-

b CHECKING OF QUANTITY OF THE ACCESSORIES
Check the quantity of parts when opening the package.
Wire feeder Accessory
Description
CD GAS HOSE (3m)
@ SW I TCH CORD
@TERMINAL
@)V IN YL CAP
@HOSE COVER
HEXAGON SOCKET
@ SCREW KEY (M4)
II NAMES OF PARTS
• Refer to the secti on indicated in D for details.
Specification
U597 1 ROO
U597 1 SOO
100-0816
100-0817
U1997C03
Feed motor [!!]
Wire reel hub
~ 1
7
--
2
-, -7.-4-I Pressure roll holder ~
Q' ty
2
2
2
Gas supply inlet ~
Pressure handl es ~
Torch socket 16.4 I
Feed rolls ~
-9-

CARRYING AND INSTALLING OF THE WIRE FEEDER
5.1. Transportation
~WARNING
Observe the following to avoid damage to the wire feeder or physical injury when
carrying the equipment.
1~
• Do nottouch the charging parts inside or outsidethe wire feeder.
• Disconnectthe wire feeder from the welding power source byturning off the line
disconnect switch in the power boxto avoid an electric shock before carrying the
equipment.
--
• Be sure to detach the wire reel from the wire feeder before lifting the equipment to
~
the high places by a crane.
5.2. Installation
~WARNING
When installing the wire fe eder , follow the instructions belowto avoid occurrence
of fires during welding and physical damage by fume gas.
It
• Do not place the welding machine nearcombustible materials and flammable gas.
• Remove combustible materials to prevent dross coming into contact with
combustible object s. If that not possible, coverthem with noncombustible covers.
~
• To avoid gas poisoning and danger of suffocation, weara gas mask or adequately
ventilate when using the welding machine in the place regulated bya local law.
•
To prevent disorder or poisoning caused by fume, weara gas mask or weld at a
partial exhaust facility approved by the local regulation.
• Adequately ventilate
or weara gasmaskwhen using the welding machine in atank,
a boiler, a hold
of a ship, because heavier gas such as carbon dioxide or argon
gases are
dr ifting there.
• When using the welding machine at a narrow space, complywith a trained
supervisor's directions. And be sure to
wear a gas mask.
• Do notoperate the welding machine near the place where degreasing, cleansing,
and spraying are performed. Otherwise, poisonous gas may be generate d.
• Be sure to wear a gas mask or adequately ventilate when welding a coating steel
plate. (Poisonous gas and fume may be generated.)
• Do not place the we lding powersource, wire feeder, torch, and control cable
(including the extensi
on cable) in an area where the equipmentcan become wet.
-10 -

CARRYING AND INSTALLING OF THE WIRE FEEDER (Continued)
~CAUTION
Followthe instructions below when selecting an installation place forthe wire
feeder.
• Do not install in areas exposed to direct sunlight and rain.
• Do notplace the welding powersource, wire feeder, torch, and contrailcable (includi ng the
extension cable) in an area wherethe equipment can becomewet.
• Install the wire feeder in the place where is altitude below 1,000m and the amb i ent temperature
is between -10°C and +40°C (
+1 4 °F and +104 °F).
• Install a wind
sh ield to protect arc from wind.
• Fix the gas cylinderto a stand specifically made for gas cylinders.
- 11 -

iijCONNECTION PROCEDURE
ihCAUTION
Follow the Instructions below to avoid electric shock.
Do not touch live electrical parts, as this may cause in fatal shock and
severe burns.
Do not touch live electrical parts, as this may cause in fatal shock and severe
burns.
• Do nottouch live electrical parts of thewelding machine.
• H ave a qualified electric engineer ground thecase of the welding power source and
the base metal or
jig electrically connected, following a local law.
• Disconnectthe wire feeder from the welding power source byturning
off the line
disconnectswitch in the power boxto avoid an electric shock before grounding the
welding power source or base metal and connecting the cables
or hoses.
• Do not use a cable with lack of capacity or a damaged cable.
• Tighten and insulate the connections of cables.
• Firmlyattach the cover
of the welding machine afterconnection of the cables.
• Do not place the welding power source, wire feeder, torch, and control cable
(including the extension cable) in an area where the equipment can become wet.
• Insulate connected part of the bolt and the nutwith the insulating tape surelyafterit
tightens enough.
-12 -

If.I CONNECTION PROCEDURE (Continued)
6.1. Connection flow chart
Firml y atta ch the conn e ct ors
by
turning th e c onn ec tor s in
the c lo ckwis e di recti on.
Gas regulator
Gascylinder
Control cabl
e* @
Wire feeder
Control cable for remote control
Analog remote control (Option) Base metal
Powercable for base metal* @ Ground a work piece
= if a local law requires. CD
NOTE:
• Standard composition consists of the parts indicated in D .
Preparation of the parts except the standard composition is required to use the wire feeder.
• F or cables and hoses marked with"*", dedicated cables and hoses having differentlength are
provided. Fordetails, refer to information in "9.14. Optional Accessory".
I CD Ground the base metal.
Connect the powercable for base
® metal betweenthe negative output
terminal and the base metal.
Connect the gas hose tothe gas
@ supply inleton the back s.ide of the
wire feeder.
Connect the powercable forthe wire
IA'\ feeder into the positive output
~ terminal on the welding power
source.
-13 -
Afterremoving the right-side plate of
the wire feeder, connectthe power
® cable forthe wire feeder to thecopper
bar
on the torch adaptor.
Connect the control cable forthe wire
@feeder (10P) i
nto the wirefeeder
socket on the w eld i ng power source .
(f) Connect the welding torch to the wire
feeder.
[[!]

If.I CONNECTION PROCEDURE(Continued)
6.2. Connecting of the Gas Hose
~WARNING
• You may suffer fr om danger of suffocation caused bylack of oxygen when shield
gas keeps drifting in a closed place. Besure to turn off the shield gas at the main
when the
we lding powersource is not in use.
• Besure to connectthe gas hoseafter fixing to thestand, as physical inj ur ies mayresultfrom the
gas cylinder falling down.
• Attach a propergas regulator to thegas cylinder. Failure to observe thisrequirement may result
in physical injuries. The gas regulatorfor high pressure gas must be used.
•How to connect the gas ho , se
Connect the gas hosefollowing the procedure shown below.
" Gas regulator
Gas hose
Firmly tighten the nuts using a wr ench, et c. to connect
the gas hose and gas regulator .
-14 -
of
C@.
Gas hose~

If.I CONNECTION PROCEDURE (Continued)
6.3. Connecting of the PowerCable
~WARNING
Touching liveelectrical parts may cause in fatal electric shock and severe burns .
• Do nottouch live electrical parts of the welding machine.
• Have a qualified electric engineer ground the case of the welding powersource and the base
metal
or jig electricallyconnected in accordance with a local law.
• Disconnect the wire feeder from the welding powersource by turning off the li ne di sco n nect
sw itch in the power box to avoid an electric shock before the welding powersource or base
metal and connecting the cables
or hoses.
• Afterconnecting the cables, cover the powersource with the cover or case.
• When using the welding machine in such a humid environment as construction site, on the steel
plate,
or on steel structure, install a leakage breaker.
~CAUTION
• Use the proper power cable that matches the welding current.
We lding curr e nt Ca ble thickn e ss
0 200A AWG 1 [38mm2) or more
200 350A AWG 2/0 [60mm2 ]or mor e
350 SOOA AWG 3/0 [80mm2] or mor e
*W hen performing pulse welding using a 56ft. [17m] or morecable, usethe thickercable by one rank.
• How to connect the pow er cable
Connectthe power cable following the procedure shown below.
• When installi ng
the sideframe,
insertthe overlapping
part, first.
-15 -
Stopper Nut
P
ower cable for wire feeder
Recommended tightening t orqu e
M10: 24 N•m

If.I CONNECTION PROCEDURE(Continued)
6.4. Connecting of the Welding Torch
We ld in g torch is co nnected with the part torch adaptorof Wire feeder, fi xing bolt is t ig htened,
and welding torch is fixed.
~CAUTION
• Please tighten fixing bolt securelyto fix Torch. Otheiwise, it causes the electric shockand a fire
by feeding pow er the defect.
., Wire feeder Torch adaptor
Welding torch
''WT •• •• -S(M)(L)UT" series
Fitting bolt
[Note]
This product can connect the following welding torch per the standard spec ifications.
-OTC
C0
2
/MAG Welding torch
"WT3510- S(M)(L)U T' ser ies ., "WT 4000-S(M)(L )UT' series
When following welding torch is conn ec ted, it is necessa ry to prepare optional parts a nd
o ptional kit separately.
• OTC C0
2/MAG Weldi
ng torch
"WT5000-S(M)(L)UT' series
Option kit: To r ch adaptor k it (K 5975 K OO)
• OTC MIG Welding torch
"WTA200-SUT", "WTA300-SU T" ,"WTAW400-SU T' "1
Option kit: Aluminum kit (K5975E OO)
*1: When using this torch, the Water Cooling kit (K5975LOO) is required.
Please use the fol lowing torches if volt age de tection is re quir ed.
• OTC C0
2/MAG Welding torch
"WT3500-S(M)(L)D" series
"WT3510-S(M)(L)D" series
"WT3520-S(M)(L)D" series
Option kit: Voltage detection adaptor kit (K 5975VOO)
-16 -

d WELDING PREPERATION
7.1. Checking of wire size I Replacement of feed roll
Check wheth er t he feed ro ll s suitable to the wire being used are installed.
r
\..
Use feed rolls suited to the wire siz e.
Using an improperfeed roll will cause it slip to disable normal wire feed or deform the wire,
resulting in improperwelding.
• Procedure for checking feed roll
Checkwhetherfeed rolls suitable for the wire sizeare mounted following the procedure show n below.
-17 -