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OTC DP-400 Owner's Manual

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MANUAL NO:P10355
OWNER'S
MANUAL
FOR
CO
/MAG/MIG
DIGITAL INVERTER
2
DP400
MODEL: DP-400 P10355
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
June 1, 2004
Upon contact, advise MODEL and MANUAL NO.

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Questions and answers

Eli Yoder
March 3, 2025

OTC PD-400 how do you change in put voltage 480v to 240v

0
1 comments:
Mr. Anderson
March 3, 2025

The OTC DP-400 welding power source automatically links to the primary voltage. To change the input voltage from 480V to 240V, ensure that the power supply voltage falls within the supported range (208/230/460V ±10%). No manual switching is required as the machine adjusts automatically. However, verify that the installed capacity is at least 24kVA and use the appropriate circuit breaker (70A for 208/230V, 50A for 460V) for safe operation.

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Summary of Contents for OTC DP-400

  • Page 1 MANUAL NO:P10355 OWNER'S MANUAL /MAG/MIG DIGITAL INVERTER DP400 MODEL: DP-400 P10355 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.
  • Page 2 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 1, 1995. Please make sure that this product is not allowed to bring into the EU after January 1, 1995 as it is.

  • Page 3: Table Of Contents

    No. P10355 TABLE OF CONTENTS 1. SAFETY INFORMATION…………………………………………………………… 2 2. ARC WELDING SAFETY PRECAUTIONS……………………………………… 3. GENERAL NOTICE OF OPERATION…………………………………………….. 8 4. STANDARD COMPOSITION AND ACCESSORIES…………………………… 5. FUNCTION OF EQUIPMENT……………………………………………………… 11 6. NECESSARY POWER SOURCE EQUIPMENT………………………………… 12 7. TRANSPORT AND INSTALLATION……………………………………………… 13 8.

  • Page 4: Safety Information

    No. P10355 1. SAFETY INFORMATION The following safety alert symbols and signal words are used throughout this manual to identify various hazards and special instructions. WARNING gives information regarding possible personal injury WARNING or loss of life. CAUTION refers to minor personal injury or possible equipment CAUTION damage.
  • Page 5 No. P10355 2. ARC WELDING SAFETY PRECAUTIONS (continued) 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.
  • Page 6 No. P10355 2. ARC WELDING SAFETY PRECAUTIONS (continued) 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.
  • Page 7 No. P10355 2. ARC WELDING SAFETY PRECAUTIONS (continued) 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. Use only correct shielding gas cylinders, pressure regulators for gas cylinders, hoses, and fittings designed for the specific application;...
  • Page 8 No. P10355 2. ARC WELDING SAFETY PRECAUTIONS (continued) ARC WELDING work areas are potentially hazardous. FALLING or MOVING machine can cause serious injury. When hanging the welding power source by a crane, do not use the carrying handle. 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.
  • Page 9 No. P10355 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro technical Commission 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.

  • Page 10: General Notice Of Operation

    No. P10355 3. GENERAL NOTICE OF OPERATION 3.1 Rated Duty Cycle CAUTION Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle limitation may result in damage to the welding machine. The rated duty cycle of the welding power source is the following: 400A 50% (for pulse mode) 400A 60% (for DC mode) The duty cycle of 60% means the way the machine is rested for 4 minutes after 6...

  • Page 11: Standard Composition And Accessories

    No. P10355 4. STANDARD COMPOSITION AND ACCESSORIES 4.1 Standard Composition The parts names indicated in the boxes are standard parts. They are not supplied with this welding machine. Preparation of the standard parts except the welding power source is required to use the welding power source. Input cable and grounding cable For a switch box, the 2m input and grounding cables are from the back panel of welding power source.
  • Page 12 No. P10355 4. STANDARD COMPOSITION AND ACCESSORIES (continued) 4.2 Accessory Make sure you have the item below before you start using the welding power source. Description Specification Q’ty Part number Remarks For the power cable to welding Power cable connector DIX SKK 70 4734-025 power source...

  • Page 13: Function Of Equipment

    No. P10355 5. FUNCTION OF EQUIPMENT 5.1 Welding Power Source | 1 1 |...

  • Page 14: Necessary Power Source Equipment

    Be sure to install a switch with fuse or a circuit breaker (for motor) to the input sides of each welding machine. Capacity of Necessary Power Source Utility DIGITAL INVERTER MODEL DP-400 Power supply voltage 208/230/460V, Three phase The welding power source links the primary voltage automatically.

  • Page 15: Transport And Installation

    No. P10355 7. TRANSPORT AND INSTALLATION 7.1 Transport WARNING Follow the instructions below to avoid trouble and product damage when carrying the welding machine. Do not touch the charging parts inside or outside the welding machine. Be sure to disconnect the line disconnect switch when carrying the welding machine.
  • Page 16 No. P10355 7. TRANSPORT AND INSTALLATION (continued) CAUTION To prevent electromagnetic troubles, read the following. Also, if electromagnetic troubles occur, check the following again. Since large current abruptly flows inside the welding machine during welding, other machines near the welding power source may be troubled due to electromagnetic noise Do not ground the welding power source commonly with other machines.

  • Page 17: Connection Procedure And Ground For Safety Use

    No. P10355 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE WARNING Follow the instructions below to avoid electric shock. Do not touch the charging parts, as this will result in fatal shock and severe burn. Do not touch the charging parts of the welding machine. Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected, following a local low.
  • Page 18 No. P10355 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) Follow the steps below to attach the cables to the output connectors of the welding power source referring to the illustrations of “Connection of the Welding Power Source“ on the previous page. 1.
  • Page 19 No. P10355 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) WARNING Follow the instructions below to avoid electric shock. Touching the charging parts may result in fatal electric shock and severe burn. Do not touch the charging parts of the welding machine. Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected in accordance with a local low.
  • Page 20 No. P10355 9. WELDING PREPERATION 9.1 Preparing the Protective Equipment To protect you from gas generated from welding, fume, and lack of oxygen, wear protective equipment. To avoid gas poisoning and danger of suffocation, wear a gas mask or adequately ventilate when the welding machine is used in the place regulated by a local law.

  • Page 21: Welding Preparation

    No. P10355 9. WELDING PREPARATION (continued) 9.2 Operating the Switches and Controlling the Pressure regulators for gas cylinders CAUTION Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as burst of high-pressure gas may result in physical injuries. NOTE: Gas checking automatically stops in two minutes.
  • Page 22 No. P10355 WELDING PREPARATION (continued) 9.4 Welding Conditions When setting to the improper welding conditions, the following troubles will occur. Cause Trouble Wire extension is too long. ¥Long Arc length ¥Wide bead width ¥Poor shield Wire extension is too short. ¥Short arc length ¥Easy generation of spatter Arc voltage is too high.
  • Page 23 No. P10355 9. WELDING PREPARATION (continued) (2) Example Welding Conditions of Down Fillet Wire CO 2 gas Plate Welding Welding diameter thickness length current voltage speed flow rate t (in [mm]) l (in [mm]) (ft [cm]/min) (in [mm] ) (gal [ ]/min) 0.047 [1.2] 0.098-0.118 0.035...
  • Page 24 No. P10355 9. WELDING PREPARATION (continued) (4) Example Welding Conditions of Single and Double Grooves Plate Wire CO 2 gas Root Root Welding Welding Number thickness Bevel diameter face current voltage speed flow rate shape g (in [mm]) h (in [mm]) (ft [cm]/min) layers (in [mm] )
  • Page 25 No. P10355 9. WELDING PREPARATION (continued) Example Welding Conditions of Lap Fillet Wire CO 2 gas Plate Welding Welding Welding Mark diameter Thickness current voltage speed flow rate position (in [mm] ) (ft [cm]/min) (in [mm]) (gal [ ]/min) 0.047 0.035 1.5-1.8 2.6-4.0...
  • Page 26 No. P10355 9. WELDING PREPARATION (continued) 9.4.2 Example Welding Conditions of MAG Short Arc Material: Soft steel, Gas: Mixture gas of Ar + CO (10 | 15 /min) Plate Wire Welding Arc voltage Welding Joint thickness diameter (in [mm]) current speed Geometry (ft [cm]/min)
  • Page 27 No. P10355 9. WELDING PREPARATION (continued) (2) Example Welding Conditions of Downward Welding Plate Shape of Welding Welding Welding thickness joint weld current voltage speed Remarks (ft [cm]/min) t(in [mm]) 0.091 [2.3] butt 22-23 2.3 [70] Back bead appearance is good. Leg length: 0.157-0.197in 0.126 [3.2] fillet...
  • Page 28 No. P10355 9. WELDING PREPARATION (continued) (5) Example Welding Conditions of Single Side Welding Conditions (Automatic) Plate Number of Welding Welding Welding thickness Groove shape layers current voltage speed (ft [cm]/min) T (in [mm]) 0.126 1.64 [50] 24-25 [3.2] 23-24 0.82 [25] 0.236 [6.0]...
  • Page 29 No. P10355 9. WELDING PREPARATION (continued) (6) Single Bevel Groove Penetration Welding Conditions (Semi-automatic) Number of Welding Welding Groove shape layers current voltage Remark Flat position 20-21 26-27 26-27 Oscillation 26-27 26-27 26-27 Unit: mm 26-27 Vertical position 20-21 21-22 21-22 21-22 Oscillation...
  • Page 30 No. P10355 WELDING PREPARATION (continued) 9.4.5 Example Welding Conditions of Aluminum Pulse MIG (1) Example Welding Conditions of I Shape Butt Plate Wire dia. Welding Welding Welding Wire Gas flow thickness (in [mm]) current voltage speed extension rate (in [mm]) (ft [cm]/min) (in [mm]) (gal [ ]/min)

  • Page 31: Operation

    No. P10355 10. OPERATION 10. Front Panel [21] [20] [19] [13] [9] [10] [15] J O B W ARNING DIGITAL INVERTER M EM ORY LOAD IP M S e c J O BN O . A R C SAVE M AIN CO NTROL CONDITION ENTER...
  • Page 32 [2]. Finally, set the wire diameter with the WIRE DIA (inch) key [3]. For example, for DP-400, when selecting “WAVE PULSE” while setting "DC HARD SOLID 0.035in [1.0mm] " with the WELDING METHOD key [1], the "MILD STEEL SOLID CO "...
  • Page 33 No. P10355 10. OPERATION (continued) Table of the Welding Mode Welding mode WIRE DIA. DP-400 Welding Inch.(mm) Type of wire method .030 (0.8) .035 (0.9) MILD STEEL SOLID .040 (1.0) .045 (1.2) .030 (0.8) .035 (0.9) MILD STEEL .040 (1.0)
  • Page 34 No. P10355 10. OPERATION (continued) 10.1.2 Setting the Parameter Pressing the key while the A/m/min lamp (located Pressing the key while the V/ lamp (located at the at the upper left of the A/m/min selector key) is lit upper left of the V/ selector key) is lit changes over changes over displays of current setting and wire displays of current setting and wire feed rate.
  • Page 35 No. P10355 10. OPERATION (continued) 10.1.2 Setting the Parameter (continued) (1) Pre-flow Time Setting Once the pre-flow time is chosen, the setting value is displayed in the left display and the "sec." lamp lights. At this condition, you can set pre-flow time while turning the parameter adjusting knob [6].
  • Page 36 No. P10355 10. OPERATION (continued) 10.1.3 Setting of the CRATER-FILL Functions Crater Crater is a depression left at the Bead termination of the weld. As it may cause cracks and poor welding, a crater treatment called crater-filler is used to fill in the depression.
  • Page 37 No. P10355 10. OPERATION (continued) Initial Crater Timing Chart Current Torch Switch Pre-flow time Anti-stick (Burnback) time No-load voltage Gas Flow Post-flow time Voltage Between Slow-down speed Output Terminals Welding Current Wire feedpeed Crater Current Welding current MAIN WELDING CRATER Torch Switch Pre-flow time Anti-stick (Burnback) time...
  • Page 38 No. P10355 10. OPERATION (continued) 10.1.4 Setting of Arc Spot Time i When arc spot treatment is carried out using the CRATER-FILL key [7], set to "SPOT". Then, when pressing the SPOT TIME key [11], the SPOT TIME lamp (located at the upper left of the CRATER-FILL key) lights up, the setting value is displayed in the right display, then the "sec."...
  • Page 39 No. P10355 10. OPERATION (continued) 10.1.5 Adjusting Welding Voltage Using the VOLT. CONTROL key [14] allows you to select one of the following voltage adjustment methods. (1)Making the INDIVIDUAL Adjustment The INDIVIDUAL adjustment can be achieved when the VOLT.CONTROL lamp (located at the upper left of the VOLT.
  • Page 40 No. P10355 10. OPERATION (continued) 10.1.6 CONSTANT PENETRATION Function For conventional CO /MAG welding, as the wire extension changes, welding current changes and base metal penetration depth and bead width change. By setting the constant penetration function to “ON”, wire feed speed is automatically adjusted so that constant current can be always obtained even when wire extension varies.
  • Page 41 No. P10355 10. OPERATION (continued) 10.1.8 WAVE PULSE Function (optional) In wave pulse welding, the ripple bead appearance is changed by applying two separate pulses cyclically at low frequency. This feature will also assist in welding joints that have some poor fit up or gaps. Although, the wave mode is usually most applicable for fully automatic welding, benefits are also achieved even in semi-automatic applications.
  • Page 42 No. P10355 10. OPERATION (continued) 10.1.11 TORCH WATER/AIR Selection Select WATER/AIR according to your torch by using the TORCH key [16]. When using a water-cooled torch, select “WATER” by pressing the TORCH key once. When “WATER” is selected, the TORCH lamp (located at the upper left of the TORCH key) lights up. When using an air-cooling torch, make sure that the TOCH lamp goes out.
  • Page 43 No. P10355 10. OPERATION (continued) 10.1.13 Using the Parameter Adjusting Knob When adjusting parameters using the parameter adjusting knob [6] during welding, change over the display mode to the “parameter setting value display” mode by pressing the DISPLAY CHANGE key [8]. The initial conditions, the main conditions, and the fill crater conditions can be changed during the INITIAL welding, MAIN welding, and CRATER welding respectively.
  • Page 44 No. P10355 10. OPERATION (continued) 10.1.14 Using the Analog Remote Control K5416H (optional accessory) (continued) When making the INDIVIDUAL adjustment: Selecting the "INDIVIDUAL" adjustment allows you to set welding current and welding voltage individually. NOTE: INDIVIDUAL adjustment is activated when selecting AL/PURE (SOFT ALUMINUM) or AL/MG (HARD ALUMINUM).
  • Page 45 No. P10355 10. OPERATION (continued) 10.2 Applied Settings 10.2.1 Using Internal Function How To Use Internal Functions @ When holding down the F key [12] for a few seconds, the function number in the left-side display blinks, and the status of function assigned to the function number lights up and is displayed in the right-side display.
  • Page 46 No. P10355 10. OPERATION (continued) The following welding conditions can be adjusted by using the F key [12] and the parameter adjusting knob [6], but only the welding conditions with* next to the function numbers can be preset to the welding condition numbers. (1) Fine Adjustment of Anti-Stick (Burnback) Time: F1* Anti-stick (Burnback) time means the processing time to prevent electrode wire from fusing to base metal when welding is completed.
  • Page 47 No. P10355 10. OPERATION (continued) (4) Selection of Auto/Semi-automatic: F4 Use this function when combining with a robot or an automatic machine. Selection of Auto allow the welding power source to do the following operation. Operation Stop can be cancelled by short-circuiting Operation Stop terminals. Initial setting of this function is semi-automatic.
  • Page 48 No. P10355 10. OPERATION (continued) (5) For external setting voltage ranges between 0 and 10V: F5 When the welding machine is used by combining with a robot or an automatic machine and when the maximum command voltage from the robot is output up to 10V, set F5 using the F key [12].
  • Page 49 No. P10355 10. OPERATION (continued) (8) Setting of Result Display Holding Time: F8 After completion of welding, the average value of output current and output voltage for last one second blinks for about 20 seconds, but the result display holding time can be set by F8 using F key [12]. The setting range of result display holding time is 5 seconds to 60 seconds.
  • Page 50 No. P10355 10. OPERATION (continued) (12) Arc voltage direct detection ON/OFF selection: F12 When using an extension cable results in abnormal generation of spatter or when unstable welding is caused from malfunction of pulse weld, use a voltage detection cable (optional accessory K5416G00) for directly detecting arc voltage(-).
  • Page 51 No. P10355 10. OPERATION (continued) NOTE: When the unit pulse conditions change significantly, there may be a possibility of difference between the preset current value and the output current and an impossibility of appropriate synergic fine adjustment. (13-1) Fine adjustment of Pulse Peak Current : F13* The fine adjustment of pulse peak current can be achieved by activating F13 using the F key [8].
  • Page 52 No. P10355 10. OPERATION (continued) (14) Turbo Start ON/OFF Selection: F19 The welding power source has Turbo Start function by capacitor discharge, which enable you to obtain good welding start. At poor welding start with burnback, setting F19 to “oFF” deactivates the Turbo Start function. The function is preset to “on”...
  • Page 53 No. P10355 10. OPERATION (continued) @ SAVE Function Welding conditions being currently in use are stored in the memory inside the welding power source. Holding the welding conditions in memory (1) When pressing the SAVE key [20], the machine enters memory mode, the SAVE lamp (located at the upper left of the SAVE key) lights up.
  • Page 54 No. P10355 10. OPERATION (continued) A LOAD Function The welding conditions stored in memory are read out from the memory inside welding power source. NOTE: The welding conditions currently used can be overwritten with the welding conditions read out. When you wan to save the welding conditions that have been used until now, preset the welding conditions to any condition number, then carry out readout.
  • Page 55 No. P10355 10. OPERATION (continued) Operation flow in the memory mode Press the MEMORY key. Set the welding condition number while Discontinue turning the parameter adjusting knob. Press the ENTER key. Press the MEMORY key. Press the DISPLAY CHANGE key Discontinue to check the parameter value.
  • Page 56 No. P10355 10. OPERATION (continued) B Erasing the Welding Conditions When you erase the welding conditions stored in memory, you can select either erasing all or erasing one. Erasing the welding conditions (1) Turn off the power switch and turn on the power switch with both the LOAD key [19] and SAVE key [20] pressed.
  • Page 57 No. P10355 10. OPERATION (continued) 10.2.4 Resetting to Initial Values The welding conditions that are currently used (including the welding condition currently used) are all reset to initial values. To reset to initial values, turn off the power switch and then turn on the power switch with both the F key [12] and GAS CHECK key [14] held down.

  • Page 58: Applied Function

    No. P10355 11. APPLIED FUNCTION 11.1 How to Solve an Error WARNING Observe the following to prevent electrical shock. When touching charging parts, critical electric shock and burn may occur. Do not touch charging parts inside or outside the welding machine. Grounding to the case of the welding power source should be performed by persons qualified electric work and according to the laws and regulations in your area.
  • Page 59 No. P10355 11. APPLIED FUNCTION (continued) 1) dAIHEn Display If “dAI” and “HEn” in the displays blink, it indicates the “Torch switch off state waiting“. When turning on the power switch, the displays on the front panel shows “dAI” and “Hen” for one second, then the welding power source becomes operable.
  • Page 60 No. P10355 11. APPLIED FUNCTION (continued) 7) E-510 Display |In the case of connecting the water pressure switch | If “E-“ and “510” in the displays blink, it indicates the “Abnormal water pressure”. Then the welding machine will automatically stop. In this case, check to make sure that the water- cooled hose does not leak water and that adequate cooling water is going through the hose.
  • Page 61 No. P10355 11. APPLIED FUNCTION (continued) 13) E-820 Display If “E-“ and “820” blink in the displays, it indicates the “Motor overcurrent warning”. Contact resistance to the feeding parts causes motor current to increase. If the motor current exceeds 70% of the rated duty cycle, “E-“ and “820” in the displays will blink only while no operation at the front panel is carried out.
  • Page 62 No. P 10355 11. AP P LIE D F UNC T ION (continued) WA R NING Obs erve the following to prevent elec tric al s hoc k. •œ Do not touc h c harging parts ins ide or outs ide the welding mac hine. •œ...
  • Page 63 No. P 10355 11. AP P LIE D F UNC T ION (continued) 12P terminal block (T M 12P ) P in No. S ignal name F unction R E ADY T he terminals us ed for ready power for prep. relay. When •| (OUT P UT ) there is not any error s uch as open phas e, Operation S top,...
  • Page 64 No. P10355 11. APPLIED FUNCTION (continued) *4 Be careful that no-load voltage (100V or less) is applied to between the terminals during welding. 2.7k ¶ Figure 1 Figure 2 11. 3 Combining with an Automatic Machine When combining with an automatic machine, use the 12P/6P terminal block inside the welding power source, the 10P terminal block inside the wire feeder, and the receptacle for the remote control or for the wire feeder.
  • Page 65 No. P10355 11. APPLIED FUNCTION (continued) (3) Direct Detection Signal When using a power cable that is more than 30 m long, connect the base metal (-) and the connector for voltage detection of wire feeder (wiring number: 310) with voltage detection cable K5416G00.
  • Page 66 No. P10355 11. APPLIED FUNCTION (continued) 11.4.2 Extension Cable/Hose (Extension of Work Space) CAUTION Do not connect an unnecessarily long extension cable. When using an extension cable, roll it out. Failure to observe the demand may result in unstable arc. Choose a proper torch cable (separately sold) for work space.

  • Page 67: Maintenance And Troubleshooting

    No. P10355 12. MAINTENANCE AND TROUBLESHOOTING WARNING To avoid electric shock, follow the below instructions. Do not touch live electrical parts inside or outside the welding machine. Turn off all of the line disconnect switches before touching the parts inside the welding machine.
  • Page 68 No. P10355 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.1 Carrying out Maintenance on the Welding Power Source (1) Periodical checking Periodically check the welding power source to ensure the safety of the equipment and the efficiency of work. Daily checking the followings: No strange vibration, buzzing noise, and smell are generated from the welding power source.
  • Page 69 No. P10355 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.3 Insulation Resistance Test WARNING Observe the following to prevent an electrical shock. When touching charging parts, a critical electric shock and burn may occur. Have qualified operators or the persons familiar with this welding power source measure insulation resistance and test withstand voltage .
  • Page 70 No. P10355 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.5 Troubleshooting When an error code is displayed, refer to Section 11.1, “How To Solve an Error”. Check the troubleshooting information listed below before contacting your dealer for service. Trouble Cause Solution The power Never turn it on again.
  • Page 71 No. P10355 12. MAINTENANCE AND TROUBLESHOOTING (continued) Trouble Cause Solution Current and voltage Trouble with the control After inspecting PCB P10264P or can not be set. circuit P10264U and replace it if necessary. Trouble with the filter After inspecting PCB P10264T, replace circuit it if necessary.
  • Page 72 No. P10355 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.6 Schematic Diagram (P10352M) (P10264S) (P10264X) (P10264V) (P10322X) (P10263Q) (P10264S) (P10264P) (P10352U) (P10264R) (P10263R) (P10261Q) (P10264T) | 7 0 |...
  • Page 73 No. P10355 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.7 Parts Layout F , G TR1-4 Front Panel P10263R A, B P10264R Under frame (Battery board) P10352U P10264P C12, R30 P10352M Heat sink SCR1 CON1 R18, C15 THP2 CON2 Heat sink Behind of Control Panel R16, DR18 DR2-6...

  • Page 74: Parts List

    No. P10355 13. PARTS LIST Please contact your dealer to order parts. (See the back cover for telephone and fax numbers, and mailing addresses.) Symbol Part No. Description Specifications Q’ty Remarks 4614-104 Circuit protector 119-0637(480V 75A) 4519-037 Line filter FS5681-50-99 4600-341 Pilot lamp NPA10 |2H |WS...
  • Page 75 No. P10355 13. PARTS LIST (continued) Symbol Part No. Description Specifications Q’ty Remarks 4518-528 Film capacitor US20X103JAASA 4517-455 Ceramic capacitor 0.01µF 2kV 4511-510 LWA2N601MSMAZO Aluminum electrode capacitor CON1 4730-421 Metal receptacle HS25R-10 CON2 4730-426 Metal receptacle 25-6BK PCB1 P10352U00 Printed circuit board P10352U00 PCB2* P10264P00 Printed circuit board...

  • Page 76: Specifications

    No. P10355 14. SPECIFICATIONS 14.1 Specifications i1 jWelding power source Model Digital Inverter DP400 Specificaitons Model DP-400 Pulse Pulse Number of phase Rated frequency 50 / 60 Hz Rated input voltage 208 / 230 V 460 V Input voltage range 208 / 230 V ±...
  • Page 77 No. P10355 14. SPECIFICATIONS (continued) 14.2 External View 20.4 (524) 21.4 (544) 22.7 (577) | 7 5 |...
  • Page 78 No. P10355 14. SPECIFICATIONS (continued) Front Panel Initial Values and Setting Range of Parameter [21] [20] [19] [13] [15] [9] [10] Initial value Setting range Pre-flow time 0.1 second 0 – 10 seconds J O B W ARNING DIGITAL INVERTER Current 20 A 20 –...
  • Page 79 No. P10355 14. SPECIFICATIONS (continued) QUICK MANUAL Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”. Before Using the Welding Power Source Parameter adjusting knob Settings of Parameter Inching the Wire Settings of Welding Method W AR NING Loading the Welding Conditions After pressurizing the wire mounted on the TO RCH Set a welding method,...

  • Page 80: Service And Support

    2) When contacting your dealer for service, you are required to provide the following information: Address Name Telephone number Product model Manufacture year Serial number Software version number Details of troubles ¥ MODEL: DP-400 ¥ DATE: 20XX ¥ SERIAL NO.: P10355YXXXXXXXXXXX P10355 Ver ###.###.000 |78 |...

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