Daihen OTC CM-7471 Owner's Manual
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Daihen OTC CM-7471 Owner's Manual

Daihen OTC CM-7471 Owner's Manual

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MANUAL NO: U30005
OWNER'S
MANUAL
FOR
WIRE FEEDER
MODEL: CM-7471 1U30005
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
August 9, 2013
Upon contact, advise MODEL and MANUAL NO.
4-1-062-5

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  • Page 1 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 August 9, 2013 Upon contact, advise MODEL and MANUAL NO.
  • 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････････････････････････････････････････････････････････････････ E8 5. CARRYING AND INSTALLING OF THE WIRE FEEDER･･････････････････････････････ 6. CONNECTION PROCEDURE･････････････････････････････････････････････････････ E11 7. WELDING PREPARATION･･･････････････････････････････････････････････････････ 8. MAINTENANCE AND TROUBLESHOOTING････････････････････････････････････････ E19 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 5: Wire feeders IEC 60974-5, 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 ① ② ③ Description Specification Quantity U69B34 Outlet guide ① for steel 0.9-1.2mm U2586G00 Conduit ② 3.4m U3567C01 Plastic liner ③ φ2.7×φ5.6×3.4m 4.

  • Page 11: Carrying And Installing Of The Wire Feeder

    5. CARRYING AND INSTALLING OF THE WIRE FEEDER 5.1 Transportation WARNING To prevent accidents and damage of the welding machine during transportation, observe the following. ● Do not touch the charging parts inside or outside the wire feeder. ● Be sure to disconnect the line disconnect switch when carrying the welding machine.
  • 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 Observe the following to prevent electric shock.  Do not touch the charged sections; otherwise, you might receive serious electric shock or get burned. ● Do not touch the charged sections. ● Have a qualified electric engineer ground the case of the welding power source. Have a qualified electric engineer ground the base metal or jig electrically connected, following a local low.

  • Page 14: Welding Preparation･･･････････････････････････････････････････････････････ E12

    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 15 7. WELDING PREPERATION (continued) Groove forφ1.2 wire size 7.2 Mounting of the Feed Roll Wire size mark Confirmation of the wire size marked on the feed roll Use the proper feed roll according to the wire size. The feed roll of φ1.2mm wire size is mounted on the CM-7471 wire feeder when it is shipping.
  • Page 16 7. WELDING PREPERATION (continued) 7.3 For aluminum welding and for brazing Parts marked with “*” are optional parts. (Refer to section 9.3.) 1. Remove the pressure roll. 2. Change the center guide and guide adapter for aluminum. 3. Attach the middle gear and feed roll for aluminum. 4.
  • Page 17 7. WELDING PREPERATION (continued) 7.4 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 brake has been properly adjusted before shipment. Therefore, readjustment of the brake is not required for welding in standard welding conditions.
  • Page 18 7.5 Connection of conduit ･ Insert the plastic liner into the conduit, fasten the insert nut to the wire guide. Fasten Insert Wire guide Conduit Plastic liner 7.6 Feeding Wire by Inching Operation WARNING ● Keep away your face, eyes and body Remote control from the top of torch while inching.
  • Page 19 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 20 7. WELDING PREPERATION (continued) 4. Adjust the wire reel hub. Recommended tightening torque 24N・m（245kgf・cm） 6N・m（61kgf・cm） Hexagon head bolt (M10X30) (with washer,spring washer) Installation hole Hanging bracket (option) Hexagon head bolt (M8X25), Reel bracket Nut (M8), washer (M8), spring washer (M8) (3 pieces for each) －E18－...

  • Page 21: Maintenance And Troubleshooting････････････････････････････････････････ E19

    8. MAINTENANCE AND TROUBLESHOOTING 8.1 Maintenance WARNING ● Do not touch the charged sections; otherwise, you might receive serious electric shock or get burned. ● Turn off all of the line disconnect switches before touching the parts inside the welding machine. Problem Cause Solution...
  • Page 22 8. MAINTENANCE AND TROUBLESHOOTING (continued) < Schematic Diagram> Pulse A Pulse B Terminal block CAUTION ● Never attempt to disassemble the feed motor. This may result in damage to the wire feeder. ● Never check the amount of brushing friction or replace the brush. Service life of the brush varies depending on ambient temperature and welding condition, etc., but normally the service life is about 4,000 hours.

  • Page 23: Parts List

    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 24 9. PARTS LIST (continued) 1１ Fig.1 Main body and wiring disassembly －E22－...
  • Page 25 9. PARTS LIST (continued) 9.2 Wire Feeder (Fig.2) Ref. Part number Description Q’ty Remarks U5209B01 Bracket 3361-892 Hexagon socket cap screw M6 x 25 U5185B08 Coil spring U5185B02 Pressure roll holder pin U5185S00 Pressure roll holder (R) Assembly U5185T00 Pressure roll holder (L) Assembly K5439C00 Pressure roll...
  • Page 26 9.PARTS LIST (continued) Fig.2 Feeding part disassembly －E24－...
  • Page 27 9. PARTS LIST (continued) 9.3 Optional parts (1) Extension cable ･ Control cable (10P) Cable length Model BKCPJ-1005 BKCPJ-1010 BKCPJ-1015 BKCPJ-1020 (2) Feed roll･Pressure roll (Fig.3) ･ For stainless steel welding, use the parts for mild steel. ･ For brazing welding, use the parts for aluminum. Part No.
  • Page 28 9. PARTS LIST (continued) (5) Other optional parts Part No. Description Q’ty Remarks U5191E00 Wire reel cover (simple) With bolts K5439E00 Wire reel cover (full cover) Assembly, with bolts U5191F00 Reel adapter With bolts For wire feeder, K5439F00 Caster with 4 wheels and bolts U30022Z00 Hanging bracket With bolts...

  • Page 29: Specifications

    10. SPECIFICATIONS 10.1 Specifications Model CM-7471 Applicable wire size Mild steel (0.8), 0.9, 1.0, 1.2, (1.4), (1.6) Stainless steel (0.8), 0.9, 1.0, 1.2, (1.6) Aluminum (1.0), (1.2), (1.6) Brazing (0.8), (0.9), (1.0), (1.2) Wire feeding speed Max. 5 m/min 50 mm Applicable wire reel Shaft diameter Max.
  • Page 30 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 200120, China Phone: +86-21-5882-8633, Fax: +86-21-5882-8846 OTC (Taiwan) Co.,Ltd.

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