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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 December 18, 2003 Upon contact, advise MODEL and MANUAL NO.
No. P10322 P. 1/71 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……………………………………………………… 10 6. NECESSARY POWER SOURCE EQUIPMENT………………………………… 12 7. TRANSPORT AND INSTALLATION……………………………………………… 13 8.
No. P10322 P. 2/71 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.
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No. P10322 P. 3/71 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.
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No. P10322 P. 4/71 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.
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No. P10322 P. 5/71 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, regulators, hoses, and fittings designed for the specific application;...
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No. P10322 P. 6/71 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.
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No. P10322 P. 7/71 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electrotechnical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, 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.
No. P10322 P. 8/71 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. •...
No. P10322 P. 9/71 4. STANDARD COMPOSITION AND ACCESSORIES 4.1 Standard Composition • This welding power source is not included the accessories indicated in the boxes. Preparation of the Accessories for welding. Gas flow rate regulator Digital remote control ( Optionally available )...
No. P10322 P. 10/71 5. FUNCTION OF EQUIPMENT 5.1 Welding Power Source...
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No. P10322 P. 11/71 5. FUNCTION OF EQUIPMENT (continued) 5.2 Gas Flow Rate Regulator WARNING ● Use a proper gas regulator for type of gas. ● Argon gas regulator should be used only for argon gas (Ar). Never use any other high pressure gas.
No. P10322 P. 12/71 6. NECESSARY POWER SOURCE EQUIPMENT 6.1 Welding Power Source Equipment (for commercial use) 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) to the input sides of each welding machine.
No. P10322 P. 13/71 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.
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● Add a noise filter to the input cables. ● Mount an input cable in the grounded metallic conduit. ● Shield the whole welding places from electromagnetic trouble. If electromagnetic troubles are still not solved after following the above instructions, consult your nearest DAIHEN dealer. CAUTION Follow the instructions below when selecting an installation place of the welding power source.
No. P10322 P. 15/71 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.
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No. P10322 P. 16/71 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.
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No. P10322 P. 17/71 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.
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No. P10322 P. 18/71 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.
No. P10322 P. 19/71 9. WELDING PREPARATION 9.2 Operating the Switches and Controlling the Gas Flow Rate Regulator 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.
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No. P10322 P. 20/71 9. 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.
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No. P10322 P. 21/71 9. WELDING PREPARATION (continued) The data in the tables below is only for reference. Please find the optimum welding conditions for weldment shape and welding position. 9.4.1 Example CO Welding Conditions (1) Example Welding Conditions of Horizontal Fillet Plate Length Wire...
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No. P10322 P. 22/71 9. WELDING PREPARATION (continued) (3) Example Welding Conditions of I Shape Butt without Backing Plate Plate Root Wire Welding Welding Number flow rate Thickness (t) Gap (g) size current voltage speed cfh.( ℓ /min) in.(mm) in.(mm) in.
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No. P10322 P. 23/71 (4) Example Welding Conditions of Single and Double Grooves Plate CO 2 gas Root Root Wire Welding Welding Number thickness Bevel Gap (g) face(h) diameter current voltage speed flow rate shape In. (mm) in.(mm) in.(mm) IPM(cm/min) layers cfh.(ℓ/min) in.
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No. P10322 P. 24/71 9. WELDING PREPARATION (continued) 9.4.2 Example Welding Conditions of Wire CO with Flux (1)Example Welding Conditions of Horizontal Fillet Length of leg Wire size Current Voltage Speed in.(mm) in.(mm) in./min.(cm/min) .045 (1.2) 19.7 (50) 0.16 (4) .052 (1.4) 39.3 (100) 1/16 (1.6)
No. P10322 P. 25/71 10. OPERATION 10. Front Panel [16] [11] [18] [17] J O B W AR N IN G DIGITAL INVERTER M EM O R Y LO AD IP M ± S e c J O B N O . A R C SAVE M AIN...
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No. P10322 P. 26/71 10. OPERATION (continued) CAUTION ● This welding machine should be operated by persons only after reading and understanding contents of this owner’s manual and having knowledge and skills for handling the welding machine safely. ● 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.
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No. P10322 P. 27/71 10. OPERATION (continued) 10.1.2 Setting the Parameter Pressing the key while the A/IPM lamp (located Pressing the key while the V/± lamp (located at at the upper left of the A/IPM selector key [3]) is the upper left of the V/± selector [3] key) is lit lit changes over displays of current setting and changes over displays of voltage setting and wire feed rate.
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No. P10322 P. 28/71 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 the pre-flow time while turning the parameter adjusting knob [5].
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No. P10322 P. 29/71 10. OPERATION (continued) 10.1.3 Setting of the CRATER-FILL Functions Crater Crater is a depression left at the termination Bead of the weld. As it may cause cracks and poor welding, a crater treatment called crater-filler is used to fill in the depression. Pool When giving a crater treatment, set the CRATER-FILL key [6] to "ON"...
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No. P10322 P. 30/71 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 Slow-down speed Welding voltage Welding current Wire Feed Speed Crater current Welding Current MAIN WELDING CRATER Torch Switch Pre-flow time...
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No. P10322 P. 31/71 10. OPERATION (continued) Initial Crater Timing Chart Current Within two seconds Torch Switch Pre-flow Time Pre-flow Time No-load voltage Gas Flow Welding Voltage Anti-stick (Burnback) Time Slow-down Speed Welding Current Wire feed speed Crater Current Wire feed speed CRATER CRATER MAIN WELDING...
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No. P10322 P. 32/71 10. OPERATION (continued) 10.1.4 Setting of Arc Spot Time( ) When arc spot treatment is carried out using the CRATER-FILL key [6], set to "SPOT". Then, when pressing the SPOT TIME key [9], 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."...
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No. P10322 P. 33/71 10. OPERATION (continued) 10.1.5 Adjusting Welding Voltage Using the VOLT. CONTROL key [12] 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.
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No. P10322 P. 34/71 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 is always obtained even when wire extension varies.
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No. P10322 P. 35/71 10. OPERATION (continued) 10.1.9 INCHING Function When pressing the INCHING key [15], the INCHING lamp (located at the upper left of the INCHING key) light up and begins feeding wire. Releasing the key stops wire feeding and the INCHING lamp to go out.
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No. P10322 P. 36/71 10. OPERATION (continued) 10.1.11 Using the Parameter Adjusting Knob When adjusting parameters using the parameter adjusting knob [5] during welding, change over the display mode to the “parameter setting value display” mode by pressing the DISPLAY CHANGE key [7]. The initial conditions, the main conditions, and the crater conditions can be changed during the INITIAL welding, MAIN welding, and CRATER welding respectively.
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No. P10322 P. 37/71 10. OPERATION (continued) 10.1.12 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. • When making the SYNERGIC adjustment: When selecting the "SYNERGIC"...
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No. P10322 P. 38/71 10. OPERATION (continued) 10.2 Applied Settings 10.2.1 Using Internal Function • How To Use Internal Functions When holding down the F key [10] for a few seconds, the function number in the ① left-side display blinks, and the status of function assigned to the function number lights up and is displayed in the right-side display.
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No. P10322 P. 39/71 10. OPERATION (continued) The following functions can be adjusted by using the F key [10]. (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. Anti-stick (Burnback) time is preset to proper conditions according to welding methods and wire diameters at shipment, but it can be finely adjusted by activating F1.
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No. P10322 P. 40/71 10. OPERATION (continued) (4) Selection of Auto/Semi-automatic: F4 Selection of Auto allow the welding power source to do the following operation. • Operation stop can be cancelled by short-circuiting on 12P terminal block “STOP” without main power reset. •...
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No. P10322 P. 41/71 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 the maximum command voltage from the robot or an automatic machine is up to 10V, activate F5 using the F key [10].
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No. P10322 P. 42/71 10. OPERATION (continued) (9) Selection of Scale Plate of Analog Remote Control: F9 When the analog remote control (optional accessory) is used, it is possible to finely adjust a low-current region where a small-diameter wire is used for weld by replacing the full-scale 350A scale plate with the full-scale 200A scale plate (supplied).
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No. P10322 P. 43/71 10. OPERATION (continued) 10.2.2 Key Lock Key lock is a function to prevent the welding conditions from being changed by accidentally operating keys and knobs on the front panel. Only the keys and parameter adjusting knob which are used for changing each parameters and modes can be protected.
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No. P10322 P. 44/71 10. OPERATION (continued) ① 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 [17], the machine enters memory mode, the SAVE lamp (located at the upper left of the SAVE key) lights up.
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No. P10322 P. 45/71 10. OPERATION (continued) ② LOAD Function The welding conditions stored in memory are read out from the memory inside welding power source. NOTE: The welding conditions currently used are overwritten with the welding conditions that are read out. When you wan to save the welding conditions that have been used until now, set the welding conditions to any condition number, then carry out readout.
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No. P10322 P. 46/71 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.
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No. P10322 P. 47/71 10. OPERATION (continued) ③ 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 [16] and SAVE key [17] pressed.
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No. P10322 P. 48/71 10. OPERATION (continued) 10.2.4 Resetting to Initial Values When resetting to the welding conditions to initial values, the welding conditions that are currently used (including the welding condition currently used) are all reset to initial values. But, even when resetting to initial values, the welding conditions held in memory are not changed.
No. P10322 P. 49/71 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.
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P. 50/71 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.
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No. P10322 P. 51/71 11. APPLIED FUNCTION (continued) 6) E-600 Display If "E-“ and “600" in the displays blink, it indicates the "Replacement of batteries (warning)". This welding power source uses batteries so that it can hold the welding conditions in memory even when no operation is carried out for long time.
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No. P10322 P. 52/71 11. APPLIED FUNCTION (continued) 11) E-830 Display If “E-“ and “830” in the displays blink, it indicates the “Motor overcurrent”. If short circuit in the power line to the motor or motor overload happens, “E-“ and “830” in the displays will blink and the welding machine will automatically stop.
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No. P10322 P. 53/71 11. APPLIED FUNCTION (continued) WARNING Observe the following to prevent electrical shock. ● 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.
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No. P10322 P. 54/71 11. APPLIED FUNCTION (continued) 12P terminal block (TM 1) Pin No. Signal name Function Unused ① ②③ ④ READY (OUTPUT) The terminals used for ready power for prep. relay. When − ⑤ ⑥ Ready Power there is not any error such as open phase, Operation Stop, output overcurrent, and thermal overload, the terminals work, etc.
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No. P10322 P. 55/71 11. APPLIED FUNCTION (continued) 11. 3 Combining with an Automatic Machine When combining with an automatic machine, use the external receptacles and the sockets for remote control or for wire feeder. Refer to Section 11.4, “External Connection of the Inside Terminal Block of the Automatic Machine”...
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No. P10322 P. 56/71 11. APPLIED FUNCTION (continued) 11.4 Optional Accessories 11.4.1 Other Optional Accessories Description Part No. Remarks Analog remote control K5416H00 With a 10ft. (3m) cable Digital remote control E-2457 The cable is not included CAN I/F board K5422B00 Wheel kit K5416B00...
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No. P10322 P. 57/71 11. APPLIED FUNCTION (continued) 1. Power Cable (for torch and for base metal) 16ft.(5m) 33ft.(10m) 49ft.(15m) 66ft.(20m) Mode BKPDT-3807 BKPDT-3812 BKPDT-3817 BKPDT-3822 2. Gas Hose (for CO , MAG, MIG) 16ft.(5m) 33ft.(10m) 49ft.(15m) 66ft.(20m) Mode BKGG-0605 BKGG-0610 BKGG-0615 BKGG-0620...
No. P10322 P. 58/71 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.
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No. P10322 P. 59/71 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. • Check the following daily: No strange vibration, buzzing noise, and smell are generated from the welding power source.
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No. P10322 P. 60/71 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 .
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No. P10322 P. 61/71 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...
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No. P10322 P. 62/71 12. MAINTENANCE AND TROUBLESHOOTING (continued) Trouble Cause Solution Current and voltage can not be Trouble with the control circuit After inspecting PCB set. P10260P or P10322U and replace it if necessary. Trouble with the filter circuit After inspecting PCB P10264T, replace it if necessary.
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No. P10322 P. 63/71 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.6 Schematic Diagram (P10322M) Main Power Supply ( P10264T ) (P10263V) (P10322X) ( P10260P ) (P10263Q) ( P10327U ) ( P10263R ) ( P10261Q ) ( P10264T ) ...
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No. P10322 P. 64/71 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.7 Parts Layout Right Side Around DR Rear Side C10,C11 Chassis R1-4 ① 12P terminal block for automatic machine C8,C9 C7,R17 R27,R28 C5, R15 ...
No. P10322 P. 65/71 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 4614-101 Circuit protector CB3-XO-10-072-42D-C 4519-036 Line filter FS5681-33-99 4600-341 Pilot lamp...
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No. P10322 P. 66/71 13. PARTS LIST (continued) Symbol Part No. Description Specifications Q’ty Remarks PCB1 P10322U00 Printed circuit board P10322U00 Refer to “NOTE” PCB2* P10260P00 Printed circuit board P10260P00 below. PCB3 P10263Q00 Printed circuit board P10263Q00 PCB4 P10263V00 Printed circuit board P10263V00 PCB5 P10264T00 Printed circuit board...
No. P10322 P. 67/71 14. SPECIFICATIONS (1)Welding power source Model Digital Inverter DM350 Specifications Model DM-350 Static characteristic Constant voltage characteristic Number of phase Three phase Single phase Rated frequency 50 / 60 Hz Rated input voltage 208 V / 230 V / 460 V 230 V / 460 V Input voltage range 187 - 253V, 414 - 506 V...
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No. P10322 P. 69/71 14. SPECIFICATIONS (continued) 10. Front Panel [18] [17] [16] [11] ● Initial Values and Setting Range of Parameter Initial value Setting range Pre-flow time 0.1 second 0 – 10 seconds J O B 30 – 400 A W AR N IN G DIGITAL INVERTER M EM O R Y...
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No. P10322 P. 70/71 14. SPECIFICATIONS (continued) QUICK MANUAL Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”. Now you have completed the preparations that are required to Before Using the Welding Power Source Parameter adjusting knob ① Settings of Parameter start welding.
No.P10322 P. 71 / 71 15. SERVICE AND SUPPORT Please contact your local dealer for service. (See the back cover for telephone numbers, fax numbers, and mailing addresses.) NOTE: 1) See Section 12, “MAINTENANCE AND TROUBLESHOOTING” before contacting your dealer for service. 2) When contacting your dealer for service, you are required to provide the following information: •...
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