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OTC CMAW-7401 Owner's Manual

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MANUAL NO: U30009
OWNER'S
MANUAL
FOR
WIRE FEEDER
MODEL: CMAW-7401 1U30009
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
January 1, 2013
Upon contact, advise MODEL and MANUAL NO.
4-1-066-4

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Summary of Contents for OTC CMAW-7401

  • Page 1 MANUAL NO: U30009 OWNER'S MANUAL WIRE FEEDER MODEL: CMAW-7401 1U30009 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.
  • 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

    TABLE OF CONTENTS 1. SAFETY INFORMATION･･････････････････････････････････････････････････････････ 2. ARC WELDING SAFETY PRECAUTIONS･･･････････････････････････････････････････ 3. CHECKING OF QUANTITY OF THE ACCESSORIES･･････････････････････････････････ 4. NAME OF PARTS･････････････････････････････････････････････････････････････････ 5. CARRYING AND INSTALLING OF THE WIRE FEEDER････････････････････････････････ 6. CONNECTION PROCEDURE･･･････････････････････････････････････････････････････ E11 7. WELDING PREPARATION･････････････････････････････････････････････････････････ 8. MAINTENANCE AND TROUBLESHOOTING･･････････････････････････････････････････ E22 9.

  • Page 4: Safety Information

    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 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 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 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, gas regulator, hoses, and fittings designed for the specific application;...
  • Page 8 2. ARC WELDING SAFETY PRECAUTIONS (continued) ARC WELDING work areas are potentially hazardous. FALLING or MOVING machine can cause serious injury. 1. When hanging the welding power source by a crane, do not use the carrying handle. 2. Put the welding power source and wire feeder solidly on a flat surface. 3.
  • Page 9 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: Checking Of Quantity Of The Accessories

    3. CHECKING OF QUANTITY OF THE ACCESSORIES Check the quantity of parts when opening the package. Wire feeder Accessory Description Specification Quantity ① Gas hose (3m) K5430A00 ② Hose cover U1997C03 ③ Water hose (1.7m) U2879J00 ④ Outlet guide (1.6) U5207J04 4.

  • Page 11: Carrying And Installing Of The Wire Feeder

    5. 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. ● Do not touch the charging parts inside or outside the wire feeder. ●...
  • Page 12 5. CARRYING AND INSTALLING OF THE WIRE FEEDER(continued) WARNING When using the wire feeder at a high place or in hung condition, observe the following precautions to prevent serious personal injury due to fallen wire feeder or wire reel. ● ● ● ● For hanging the wire feeder, use a metal hanger structured to prevent falling and hang the wire feeder in a safe and secure manner.

  • Page 13: Connection Procedure･･･････････････････････････････････････････････････････ E11

    6. CONNECTION PROCEDURE CAUTION Follow the instructions below to avoid electric shock. ∗ Do not touch the charging parts, as this may cause in fatal shock and severe burns. ● Do not touch the charging parts of the welding machine. ●...
  • Page 14 6. CONNECTION PROCEDURE (continued) 6.1 Connection to the Welding Power Source and to the Gas regulator Firmly attach the connectors by turning the connectors in Gas regulator the clockwise direction. Gas cylinder ⑥ Gas hose* Welding power source Control cable* ⑤ Power cable for wire feeder* ③④...
  • Page 15 6. CONNECTION PROCEDURE (continued) 6.2 Connecting of the Power Cable for Wire Feeder WARNING ∗ Touching the charging parts may cause in fatal electric shock and severe burns. ● 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 16 6. CONNECTION PROCEDURE (continued) 6.4 Connecting of the Gas Hose WARNING ● You may suffer from danger of suffocation caused by lack of oxygen when shield gas keeps flowing in a closed place. Be sure to turn off the shield gas at the main when the welding power source is not in use.

  • Page 17: Welding Preparation･････････････････････････････････････････････････････････ E15

    7. WELDING PREPERATION 7.1 Fitting of Wire WARNING ● ● ● ● When the wire is set on the wire reel shaft, fully tighten the cap to prevent falling. ● ● ● ● In case a breakage, crack or deformation is found in the wire reel shaft or cap, do not use but replace it.
  • Page 18 Wire size mark Confirming of the wire size marked on the feed roll Use the proper feed roll for the wire size. The feed roll ofφ1.2 wire size is mounted on the CMAW-7401 wire feeder. Replacing of the feed roll 1.
  • Page 19 7. WELDING PREPERATION (continued) 7.3 Adjusting of the wire reel hub After performing inching operation, take care to adjust the brake of the wire reel hub to prevent the wire from going too slack. The bake has been properly adjusted before shipment. Therefore, readjustment of the brake is not required for welding in standard welding conditions.
  • Page 20 7. WELDING PREPERATION (continued) 7.4 Feeding Wire Feeding by Performing Inching Operation WARNING ● Do not look into the tip hole to check for the rate of wire feeding while inching. CAUTION ● Keep away your hands, fingers, hair or clothes from the rotating parts of the feed roll, etc.
  • Page 21 7. WELDING PREPERATION (continued) 7.5 Hanging the Wire Feeder CAUTION ● When hanging the wire feeder, firmly fix the cap knob and clamp screw in position to prevent the device from dropping. ● Do not use the carrying handle of the wire feeder to hang the wire feeder. Hanging bracket (optional) Carrying handle ―E19―...
  • Page 22 7. WELDING PREPERATION (continued) How to attach the hanging bracket WARNING Observe the following precautions to prevent serious personal injury caused by fall of the wire reel at the time of wire reel hub adjustment or hanging bracket installation. ●Mount the brake pad to the wire reel shaft as illustrated below with care placed to the mounting direction.
  • Page 23 7. WELDING PREPERATION (continued) 3. Install the wire reel hub and hanging bracket on the reel bracket and tighten to the following torque so as not to loose the hexagon head bolt (M10X30), nut(M8), washer (M8) and spring washer (M8) (3 pieces for each) of the hanging bracket accessory in that order.

  • Page 24: Maintenance And Troubleshooting･･････････････････････････････････････････ E22

    8. MAINTENANCE AND TROUBLESHOOTING 8.1 Carrying Out Maintenance WARNING ● Do not touch the charging parts inside or outside the wire feeder. ● Disconnect the wire feeder from the welding power source by turning off the line disconnect switch in the power box to avoid an electric shock before carrying the equipment.
  • Page 25 8. MAINTENANCE AND TROUBLESHOOTING (continued) < Schematic Diagram> 8.2 Replacing of the Outlet Guide Pressure handle Follow the procedures below when replacing the outlet guide. 1. Bring down the pressure handle first, and then lift the Torch socket pressure roll holder. 2.
  • Page 26 8. MAINTENANCE AND TROUBLESHOOTING (continued) 8.3 Welding wire other than aluminum ･ This wire feeder is for an aluminum wire. But mild steel wire is also applicable by exchanging parts. ･ Please rearrange to mild steel specification according to the wire to use. Please refer to the following table for the correspondence of wire and the specification.
  • Page 27 9. PARTS LIST • Please contact your local dealer to order parts. (See the back cover for telephone and fax numbers, and mailing addresses.) 9.1 Main body and wiring (Fig.1) Ref. Part number Description Q’ty Remarks U30000U00 Frame Assembly K970H90 Strike 4739-013 Support...
  • Page 28 9. PARTS LIST (continued) Fig. 1 Main Body and Wiring Assembly ―E26―...
  • Page 29 9. PARTS LIST (continued) 9.2 Wire feeding part (Fig.2) Ref. Part number Description Q’ty Remarks U5185B01 Bracket none Cap screw M6 x 30 U5185B08 Coil spring U5185B02 Pressure roll holder pin U5185S00 Pressure roll holder (R) Assembly U5185T00 Pressure roll holder (L) Assembly U5158B03 Driving roll shaft...
  • Page 30 9. PARTS LIST (continued) Fig. 2 Wire Feeding Part Assembly ―E28―...
  • Page 31 9. PARTS LIST (continued) 9.3 Central adapter (Fig.3) Ref. Part number Description Q’ty Remarks U5185D01 Power metal fitting K3985E03 Block U5185D03 Power supply block Hexagon socket cap 3361-901 M8 x 25 screw U5185D04 Small nut K3985E04 Hose connector K3985E05 Sleeve U5185V00 Switch cord Assembly...
  • Page 32 9. PARTS LIST (continued) 9.5 Optional Accessory (1) Extension cable/hose Power cable Applicable current (Rated current) 200 A 350 A 500 A Cable length Cable termination Model Model Model CSRT CSRT BKPT-3802 BKPT-6002 BKPT-8002 CSRT Connector BKPDT-3802 BKPDT-6002 CSRT CSRT BKPT-3807 BKPT-6007 BKPT-8007...
  • Page 33 9. PARTS LIST (continued) (2) Feed roll･Pressure roll Part number Description Q’ty Remarks K5439B01 Feed roll ( 1.4/1.6 ) For steel K5439B04 Feed roll ( 1.2/1.4 ) For steel K5439B05 Feed roll ( 1.2/1.2 ) For steel K5439B06 Feed roll ( 1.4/1.4 ) For steel K5439B07 Feed roll ( 1.6/1.6 )
  • Page 34 10. SPECIFICATIONS 10.1 Specifications Model CMAW-7401 (Water cooling) Hard aluminum (1.0). 1.2, 1.6 AL/MG (HARD) Soft aluminum 1.2, 1.6 AL/PURE (SOFT) Applicable wire size Mild steel, (0.6)* , (0.8), (0.9), (1.0), (1.2), (1.4), (1.6) stainless steel Brazing* (0.8), (0.9), (1.0), (1.2) Wire feeding rate Max.
  • Page 35 10. SPECIFICATIONS (continued) ―E33―...
  • Page 36 Phone: +81-78-275-2006, Fax: +81-78-845-8159 DAIHEN Inc. 1400 Blauser Drive Tipp City, Ohio 45371, USA Phone: +1-937-667-0800, Fax: +1-937-667-0885 OTC DAIHEN EUROPE GmbH Krefelder Strasse 675-677, D-41066 Mönchengladbach, GERMANY Phone: +49-2161-6949710, Fax: +49-2161-6949711 OTC Industrial (Shanghai) Co.,Ltd. 17F Majesty Building, 138 Pu Dong Da Dao Shanghai The People's Republic of China...