Daihen OTC AC/MIG/201 CPDACA-200 Owner's Manual
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Daihen OTC AC/MIG/201 CPDACA-200 Owner's Manual

Daihen OTC AC/MIG/201 CPDACA-200 Owner's Manual

Inverter controlled welding power source
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MI
G/MAG
MODEL: CPDACA-200 P10224
IMPORTANT:
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
OWNER'S
AC / MIG / 201
INVERTER CONTROLLED WELDING POWER SOURCE
DO NOT DESTROY
Read and understand the entire contents of this
Upon contact, advise MODEL and MANUAL
NO.
MANUAL
FOR
MANUAL NO:P10224

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Summary of Contents for Daihen OTC AC/MIG/201 CPDACA-200

  • Page 1 MANUAL NO:P10224       OWNER'S MANUAL G/MAG AC / MIG / 201 MODEL: CPDACA-200 P10224 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: Table Of Contents

    No.P10224   P. 1/ 47 CONTENTS 1. SAFETY INFORMATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2 2. ARC WELDING SAFETY PRECAUTION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 3. GENERAL NOTICE OF OPERATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 8 4. STANDARD ACCESSORIES‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 5. LOCATION AND FUNCTION OF CONTROL‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 6. NECESSARY POWER SOURCE EQUIPMENT ‥‥‥‥‥‥‥‥‥‥‥‥‥ 7. TRANSPORT AND INSTALLATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 14 8.

  • Page 3: Safety Information

    No.P10224    P. 2 /47 1. SAFETY INFORMATION The following safety alert symbols and signal words are used throughout this manual to identify various hazards and special instructions. WARNING WARNING gives information regarding possible personal injury or loss of life. CAUTION refers to minor personal injury or possible CAUTION...
  • Page 4 No.P10224   P. 3/ 47 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 5 No.P10224    P. 4 /47 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 6 No.P10224   P. 5/ 47 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. 1. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application;...
  • Page 7 No.P10224    P. 6 /47 ARC WELDING work areas are potentially hazardous. FALLING or MOVING machine can cause serious injury. Use both eyebolts, if installed, to 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.
  • Page 8 No.P10224   P. 7/ 47 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electrotechnical 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.

  • Page 9: General Notice Of Operation

    No.P10224    P. 8 /47 3. GENERAL NOTICE OF OPERATION 3.1 Welding mode and wire size Welding process Wire Wire size(in.φ) DC wave Hard aluminum 0.040/ 3/64 Pulsed MIG Soft aluminum 3/64 AC wave Hard aluminum 0.040/ 3/64 Pulsed MIG Soft aluminum 3/64 DC pulsed MIG...

  • Page 10: Standard Accessories

    No.P10224   P. 9/ 47 3. GENERAL NOTICE OF OPERATION (continued) 3.3 Combination of welding power source and other welding machines CAUTION ●When this welding power source is combined with other welding machines to use, refer to the manual of the machine. 4.

  • Page 11: Location And Function Of Control

    No.P10224    P. 10 /47 5. LOCATION AND FUCTION OF CONTROL 5.1 Welding power source   Upper cover Panel cover Right-side panel Front panel Left-side panel Front cover ICN4 receptacle (to manipulator) Terminal block (with 12 pins) Negative output terminal Positive output terminal ( to base metal ) ( to torch side )
  • Page 12 No.P10224 P. 11/ 47   5. LOCATION AND FUCTION OF CONTROL (continued) 5.1.1 Front panel (continued) CAUTION ● Stop welding when using the switches on the front panel. CURR.VOLT. CONTROL switch PROGRAM switch Set this switch to ROBOT for normal use. When Fuses To select a welding method and a wire size while pressing + or -.
  • Page 13 No.P10224 P. 12 /47 5. LOCATION AND FUCTION OF CONTROL (continued) 5.1.1 Front panel (continued) ●Program switch Program Welding method Wire Wire size. (in.φ) 0.040 Hard aluminum 3/64 Soft aluminum WAVE PULSE 0.040 Hard aluminum 3/64 Soft aluminum 0.040 Hard aluminum 3/64 Soft aluminum PULSED MIG...

  • Page 14: Necessary Power Source Equipment

    No.P10224   P. 13/ 47 6. NECESSARY POWER SOURCE EQUIPMENT 6.1 Power source utility (for commercial power source) WARNING ●When the welding machine is used in such a humid environment as construction site, on the steel plate, or on steel structure, install a leakage breaker. CAUTION ●Be sure to install a switch with fuse or a circuit breaker (for motor) at input side of welding machine.

  • Page 15: Transport And Installation

    No.P10224 P. 14 /47 7. TRANSPORT AND INSTALLATION 7.1 Transport WARNING Follow the instructions below to avoid trouble and product damage when transporting the machine. ●Do not touch charging parts either inside or outside the welding machine. ●With the line disconnect switch disconnected, when transporting the welding machine.
  • Page 16 ●Install input cables in the grounded metallic conduit. ●Provide electromagnetic shield to the whole welding places. If electromagnetic troubles can not be solved after trying the above measures, consult your nearest DAIHEN dealer. CAUTION ●Use a wheel stopper after installation of the welding power source.

  • Page 17: Connection Procedure And Ground For Safety Use

    No.P10224 P. 16 /47 8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE CAUTION To prevent serious physical injuries, follow the instructions below. ●When making connections, be sure to disconnect the line disconnect switch of welding power source, robot, or automatic machine for safe. ●Be sure to follow the instructions described in the manual of a robot when connecting the welding power source with a robot.
  • Page 18 No.P10224   P. 17/ 47 8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE (continued) 8.2 Connection of a manipulator CAUTION ∗ Do not touch the charging parts, as this will result in fatal shock and severe burn. ●Do not touch the charging parts of the machine. ●Have a qualified person connect the case of the welding machine and the base metal or jig grounded.
  • Page 19 No.P10224 P. 18 /47 8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE (continued) 8.3 Using an extension cable WARNING Follow the instructions below to maintain high-performance of the welding machine. ●Do not use an unnecessary long cable. ●Use an extension cable rolled out. ●Do not use an extension cable wound, as this may result in unstable arc.
  • Page 20 No.P10224   P. 19/ 47 8. CONNECTION PROCEDURE AND GROUD FOR SAFETY USE (continued) CAUTION ●Be sure to install a switch with fuse or a circuit breaker (for motor) at the input side of each welding machine. CAUTION ●Be sure to ground the welding power source. ●Grounding cable thickness: AWG 8 or more If the welding power source not grounded is used, voltage is generated in the case through the capacitor between the welding power source input circuit and the case or floating capacity...

  • Page 21: Welding Preparation

    No.P10224 P. 20 /47 9. WELDING PREPARATION 9.1 Preparation of safety protective equipment To protect you from gas generated from welding, fume, and lack of oxygen, use a protective equipment ●To avoid gas poisoning and suffocation, use respirator apparatus or adequately ventilate when the machine is used at the place regulated by a local low.
  • Page 22 No.P10224   P. 21/ 47 9. WELDING PREPARATION (continued) 9.2 Switch operation and gas flow control CAUTION ●Keep your face away from the outlet when turning on gas in the main of the gas cylinder, as burst of high-pressure gas may result in physical injuries. Follow the steps below to prepare for welding.

  • Page 23: Welding Operation

    No.P10224 P. 22 / 47 10. WELDING OPERATION CAUTION ● To ensure personal safety, the person who understands this manual and can use the welding machine safely must use the equipment. ●Failure to observe duty cycle limitations may result in premature welding machine failure or product damage ●Close the panel cover of the front panel during welding.
  • Page 24 No. P10224 P. 23 / 47  10. WELDING OPERATION (continued) 10.2 AC pulse welding For AC pulse welding, set the PROGRM switch to 21-23(wave pulse), 41-43(pulsed MIG or aluminum), 61-64(pulsed MIG or stainless steel), and 81-84(pulsed MIG or soft steel). Even when welding extremely thin plates or couplers, high quality welding can be obtained, because input heat can be controlled while welding to match the ratio of EP current (torch with positive polarity current) and EN current (torch with negative polarity current).
  • Page 25 No.P10224 P. 24 / 47 10. WELDING OPERATION (continued) 10.4 Characteristics of pulse arc The waveform of pulses current can be adjusted from a robot control device while pulse welding. Setting to HARD results in directive and deeper penetrative pulse arc. Setting to SOFT wide and shallow penetrative pulse arc.
  • Page 26 No. P10224 P. 25 / 47  10. WELDING OPERATION (continued) 10.7 WELDING CONDITIONS ●If the improper welding conditions are set, the following problems will occur. CAUSE TROUBLE Welding current too large. ･ Deep penetration. ･ Holes or brakes on welded metal when welding thin plate when welding thin plate.

  • Page 27: Applied Function

    No.P10224 P. 26 / 47 11. APPLIED FUNCTION WARNING Follow the instructions below to avoid electric shock. Touching charging parts may result in critical electric shock and burn. ●Do not touch charging parts either inside or outside of the welding machine. ●Have a qualified person adjust the variable resistor.
  • Page 28 No. P10224 P. 27 / 47  11. APPLIED FUNCTION (continued) (1) Switching arc voltage detection cable Using arc voltage detection cable for the connection to base metal is recommended, when an over 60-meter extensive cable is used. In this case, set S1 on P10153Z to the DIRECT position. Note: whenever the arc voltage detection cable at a base metal side is not used, set S1 P.C.B.P6906P to the TANSI position.
  • Page 29 No.P10224 P. 28 / 47 11. APPLIED FUNCTION (continued) (8)Automatic correction of the voltage detecting circuit This welding power source precisely detects the welding voltage so that the machine can take the high-level control of the waveform. But if any error occurs in the detected welding voltage, the output voltage will become higher or lower.
  • Page 30 No. P10224 P. 29 / 47  11. APPLIED FUNCTION (continued) WARNING Follow the instructions below to avoid electric shock. Touching charging parts may result in critical electric shock and burn. ●Do not touch charging parts either inside or outside the welding machine. ●Have a qualified person adjust a variable resistor.
  • Page 31 No.P10224 P. 30 / 47 11. APPLIED FUNCTION (continued) WARNING Follow the instructions below to avoid electric shock. Touching charging parts may result in critical electric shock and burn. ●Do not touch charging parts either inside or outside of the welding machine. ●Have a qualified person change wiring of welding machine or change-over switch.
  • Page 32 No. P10224 P. 31 / 47  11. APPLIED FUNCTION (continued) 11.8 when troubles occur WARNING To avoid electric shock, follow the below instructions. ●Do not touch the charging parts of the machine. ●Have a qualified engineer or a person who is familiar with this welding power source change wiring inside the welding machine or change over the switches .
  • Page 33 No.P10224 P. 32 / 47 11. APPLIED FUNCTION (continued) ① Operation of safety circuit error When turning on the power switch while the welding staring signal is sent to avoid accidental work of the welding power source, the safety circuit functions, the welding power source keeps stopping, and the WARNING lamp flashes.
  • Page 34 No. P10224 P. 33 / 47  11. APPLIED FUNCTION (continued) ⑧ Error in primary/secondary current detection wire The WARNING lamp lights and the welding power source stops automatically due to the current detection wire error. Start the welding power source after turning off the CONTROL POWER switch and checking to make sure connector CN11 or CN14 of the P.C.B.P6906P is not removed.
  • Page 35 No.P10224 P. 34 / 47 11. APPLIED FUNCTION (continued) 11.5 AC Pulse welding (1) Precaution against the use of AC Pulse mode When performing AC pulse welding, follow the instructions below. 1. Do not use an unnecessary long extensive cable. 2.

  • Page 36: Maintenance And Troubleshooting

    No. P10224 P. 35 / 47  12. MAINTENANCE AND TROUBLESHOOTING WARNING To avoid electric shock, follow the below instructions. ●Do not touch charging parts either inside or outside the welding machine. ●Turn off all of the line disconnect switches to touch the parts inside of the machine. ●Periodically check the machine.
  • Page 37 No.P10224 P. 36 / 47 12. MAINTENANCE AND TROUBLESHOOTING (continued) ●Replacement of high-pressure electrolytic capacitor The stability of high-pressure electrolytic capacitor C2 and C4 (refer to CONNECTION DIAGRAM or PARTS ARRANGEMENT DRAWING) is maintained by supplying stable direct current to primary transistor inverter. However, an electrolytic capacitor such as battery contains battery electrolyte.
  • Page 38 No. P10224 P. 37 / 47  12. MAINTENANCE AND TROUBLESHOOTING (continued) 2.3Welding troubleshooting Trouble Cause Solution POWER switch Do not connect POWER switch again. Contact your dealer. tripped. Main power lamp Fan rotates when Trouble of PL1. Check PL1. PL1 will not light. POWER switch connected.
  • Page 39 No.P10224 P. 38 / 47 12. MAINTENANCE AND TROUBLESHOOTING (continued) Trouble Cause Solution Wire will not be fed. (Inching or retract can Breaking of fuse F2. Replace F2 after solving the cause. not be performed.) Trouble of relay CR1 and 2 on Check and replace relay CR1 and P.C.B.
  • Page 40 No. P10224 P. 39 / 47  12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.3Welding troubleshooting (continued) 12.4 Precaution against P.C.B. replacement ●Be sure that the connector number inscribed on P.C.B matches the number indicated on the connector. ●Completely connect them until the connector clicks. １...
  • Page 41 No.P10224 P. 40 / 47 12.6 Schematic diagram of CPDACR-200...
  • Page 42 No. P10224 P. 41 / 47  12.7 Parts layout of CPDACR-200...

  • Page 43: Parts List

    No.P10224 P. 42 / 47 13. PARTS LIST ●Please contact your local dealer to order parts. (see the back cover for telephone and fax numbers, and mailing address) Symbol Parts No. Description Specifications Q’ty Remark P10155B00 Inverter transformer P10155B00 4810-316 Aux. transformer W-W02614 4810-230 Aux.
  • Page 44 No. P10224 P. 43 / 47  Symbol Parts No. Description Specifications Q’ty Remark R1-4 4536-119 Surge absorber ENC911D-14A Missing number R6, 7 4509-825 Resistor 20SH 15kΩJA 4536-119 Surge absorber ENC911D-14A R9-12 4509-704 Carbon resistor RD1/4W 1kΩJ R13-16 4509-881 Resistor 40SHN 5.1ΩKA R17-18 4509-816 Resistor 20SHN 3.3ΩKA...
  • Page 45 No.P10224 P. 44 / 47 Symbol Parts No. Description Specifications Q’ty Remark PCB2 P10153Q00 Printed circuit board P10153Q00 Power source PCB3 P6848S00 Printed circuit board P6848S00 Secondary driver PCB4 P6768T00 Printed circuit board P6768T00 1 For control PCB5 L8268M00 Printed circuit board L8268M00 1 I/F PCB6...

  • Page 46: Specifications

    No. P10224 P. 45 / 47  14. SPECIFICATIONS (1) Welding power source Machine AC/MIG/200 Specifications Model CPDACA-200 Static characteristic Constant voltage Phase 3φ Input voltage 460V(±10%) Rated input power 20.6kVA, 12.0 kW Rated input current 25.6A Rated output current 200A Rated load voltage Output current range 40A −...
  • Page 47 No.P10224 P. 46 / 47 14. SPECIFICATIONS (continued) ICN1 receptacle to robot controller Bush (for external connection wire) 26.9(684) Input terminal 14.8(376) 25.7(653) 0.6(15) 4.8(122) 16.5(420 ） 12.3(312) Output terminal 23.3(592) 14.4(365) Arc voltage direct detection terminal (Base metal) External connection terminal block Output terminal ICN4 receptacle to manipulator Units: in.(mm)

  • Page 48: Service And Support

    No. P10224 P. 47 / 47  15. SERVICE AND SUPPORT ●Please contact your local dealer to request a repair of the product. (See the back cover for telephone and fax numbers, and mailing addresses.) NOTE: 1)Be sure to check section 12, “MAINTENANCE AND TROUBLESHOOTING” before requesting a repair.

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