Related Manuals for Daihen OTC CM-0401-D
Summary of Contents for Daihen OTC CM-0401-D
- Page 1 OWNER'S MANUAL WIRE FEEDER CM-0401-D MODEL: Ensure to read this instruction manual thoroughly for safe and proper use of the product. MANUAL No.: 632189-1 2023.11 EN...
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION ......................... 3 ARC WELDING SAFETY PRECAUTIONS ..................4 CHECKING OF QUANTITY OF THE ACCESSORIES ..............9 NAMES OF PARTS ......................... 9 CARRYING AND INSTALLING OF THE WIRE FEEDER ............. 10 5.1 TRANSPORTATION ........................10 5.2 INSTALLATION ..........................10 CONNECTION PROCEDURE ....................... -
Page 3: Safety Information
1 SAFETY INFORMATION The following safety alert symbols and signal words are used throughout the manual to ensure proper operation of the equipment and to prevent from various hazards that cause serious injury and damages. Indication and explanation for the symbols are as follows: Symbols Explanation WARNING... -
Page 4: Arc Welding Safety Precautions
2 ARC WELDING SAFETY PRECAUTIONS WARNING ARC WELDING can be hazardous. • PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. Be sure to: - Keep children away. - Keep pacemaker wearers away until consulting a doctor. • Read and understand the summarized safety information given below and the original principal information that will be found in the PRINCIPAL SAFETY STANDARDS. - Page 5 WARNING 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. When arc welding all metal components in the torch and work circuits are electrically live.
- Page 6 WARNING 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 WARNING FUMES AND GASES can be hazardous to your health. Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to your health. • Keep your head out of the fumes. Do not breathe the fumes. •...
- Page 8 WARNING Be sure to observe the followings for preventing physical injuries, a fire and electric shock. Handling of plastic parts. Front cover is made of polycarbonate. Make sure to observe the following notice. • Do not apply external force and a shock to front cover. Otherwise it may be broken and in trouble. •...
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Page 9: Checking Of Quantity Of The Accessories
3 CHECKING OF QUANTITY OF THE ACCESSORIES Check the quantity of parts when opening the package (DV code: 632876). Wire feeder Accessory Description Specification Quantity MANUAL CM-0401-D 4 NAMES OF PARTS Wire reel hub Digital control panel Gas supply inlet Pressure Wire reel cover roll holder... -
Page 10: 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 11: Connection Procedure
6 CONNECTION PROCEDURE WARNING Follow the instructions below to avoid electric shock. Do not touch live electrical parts, as this may cause in fatal shock and severe burns. • Do not touch live electrical 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 12: Connection Flow Chart
6.1 CONNECTION FLOW CHART －12－... -
Page 13: Connecting Of The Water/Gas Hose
6.2 CONNECTING OF THE WATER/GAS HOSE WARNING You may suffer from danger of suffocation caused by lack of oxygen when shield gas keep drifting 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 14: Connecting Of The Connection Cable
6.3 CONNECTING OF THE CONNECTION CABLE CAUTION • Ensue that the torch connector is firmly attached. If the connector is not fully inserted, there may be a risk of product damage. ❖ How to connect the connection cables Connect the connection cables following the procedure shown below. Attaching control cable for wire feeder. -
Page 15: Connecting Of The Power Cable For Wire Feeder
6.4 CONNECTING OF THE POWER CABLE FOR WIRE FEEDER WARNING Touching live electrical parts may cause in fatal electric shock and severe burns. • Do not touch live electrical 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: Connecting Of The Welding Torch
6.5 CONNECTING OF THE WELDING TORCH CAUTION • Ensue that the torch connector is firmly attached. If the connector is not fully inserted, there may be a risk of fire, burns, and product damage. ❖ How to connect the welding torch Connect the welding torch following the procedure shown below. -
Page 17: Welding Preperation
7 WELDING PREPERATION 7.1 CHECKING OF WIRE SIZE / REPLACEMENT OF FEED ROLL Use feed rolls suited to the wire size. Using an improper feed roll will cause it slip to disable normal wire feed or deform the wire, resulting in improper welding. ❖... - Page 18 Lock gear carrier. －18－...
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Page 19: Fitting Of Wire
7.2 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 20 －20－...
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Page 21: Adjusting Of The Wire Pressure
7.3 ADJUSTING OF THE WIRE PRESSURE ❖ Adjusting of the wire pressure and straightener • Set to the proper wire pressure for the wire type by turning the pressure handle. • The numeral on the pressure scale set with the right pressure handle should be correspond to the one set with the left pressure handle. -
Page 22: Adjusting Of The Wire Reel Hub
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 23: Wire Feeding By Performing Inching Operation
7.5 WIRE FEEDING BY PERFORMING INCHING OPERATION WARNING • Do not look into the tip hole to check for the rate of wire feeding while inching. WARNING • Keep away your hands, fingers, hair or clothes from the rotating parts of the feed roll, etc. to prevent you from being caught into the rotating parts while inching. -
Page 24: Digital Control Panel
8 DIGITAL CONTROL PANEL 8.1 SETTING INTERNAL FUNCTIONS Check ARXIS welding power source owner’s manual (Chapter 6.2). －24－... -
Page 25: Troubleshooting
8.2 TROUBLESHOOTING 8.2.1 ACTION IN CASE OF ERROR When a communication error has occurred between the digital panel and the welding power source, a corresponding error code is displayed on the digital panel. Check the displayed error code and take an appropriate action according to the table below. -
Page 26: Maintenance And Troubleshooting
9 MAINTENANCE AND TROUBLESHOOTING 9.1 CARRYING OUT MAINTENANCE WARNING • Do not touch live electrical 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 27 < Schematic Diagram > Legend: Motor L1,L2 Ferrite core Torch switch X1-7 Connector Central connector X9,10 CAN Connector Gas valve Power cable －27－...
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Page 28: Replacing Of The Outlet Guide
9.2 REPLACING OF THE OUTLET GUIDE WARNING • Do not alter or remodel our products. • You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or remodeling the product. • The warranty does not cover any altered or remodeled products. Follow the procedures below when replacing the outlet guide. - Page 29 6. Put a new outlet guide through the torch connection port with careful attention paid to the direction of the outlet guide. 7. Reassemble the wire feeder following the reverse procedure. －29－...
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Page 30: Replacing Of The Feed Motor
9.3 REPLACING OF THE FEED MOTOR WARNING • Never attempt to disassemble the feed motor. This may result in damage to the wire feeder. • Feed motor is built with dustproof structure, in which a rotary encoder is installed. If the feed motor is disassembled, its dustproof function will be lost or the rotary encoder damaged, resulting in failure. -
Page 31: Replace The Center Guide
9.4 REPLACE THE CENTER GUIDE Replace the center guide following the procedure shown below. －31－... -
Page 32: Intermediate Cable
10 INTERMEDIATE CABLE 10.1 INTERMEDIATE CABLE – WATER COOLED INTERMEDIATE CABLE ARXIS/W 1m 632136 INTERMEDIATE CABLE ARXIS/W 5m 632137 INTERMEDIATE CABLE ARXIS/W 10m 632138 INTERMEDIATE CABLE ARXIS/W 15m 632139 10.2 INTERMEDIATE CABLE - GAS COOLED 632179 INTERMEDIATE CABLE ARXIS/G 1m 632180 INTERMEDIATE CABLE ARXIS/G 5m 632181... -
Page 33: Parts List
11 PARTS LIST Please contact your local dealer to order parts. (See the back cover for telephone and fax numbers.) 11.1 MAIN BODY Q’ty Order code Description Part no. Remarks 631853 FRAME ASSY Chapter 11.2 631894 HOUSING ASSY Chapter 11.3 631895 DRIVE MODUL Chapter 11.4... -
Page 34: Frame Assy
11.2 FRAME ASSY Q’ty Order code Description Remarks 631827.SA METAL BASE FRAME 631292 HANDLE GRIP 631291E1 HINGE ROTATING CARRIER 631851.SA SCREW M6X12 Figure 2: Frame assy －34－... -
Page 35: Module
11.3 MODULE Q’ty Order code Description Remarks 631820 FRONT FRAME 631821 SIDE DOOR 631822 631823 SIDE FRAME 631824 REAR COVER 631834 MAIN FRAME 631835 REAR FRAME 632083 LCD COVER 631289 DOOR KNOB 631290 DOOR HOOK Figure 3: Drive module －35－... -
Page 36: Drive Unit
11.4 DRIVE UNIT Q’ty Order code Description Remarks 631857.SA METAL FRAME 631968 WIRE FEEDER SF ST4 631969 FEED MOTOR 631884 TORCH CONNECTION 604826 CONNECTION BLOCK 606783 BASE FOR TIES Figure 4: Drive unit －36－... -
Page 37: 1Drive Unit - Mechanism
11.4.1 DRIVE UNIT - MECHANISM Q’ty Order code Description Remarks FEED ROLL 1,0/1,2 ˝V˝ (Fe) 632194 For steel (V type groove) 632198 PRESSURE ROLL (1.0/1.2) Flat roll 632014 WIRE GUIDE SET BLUE (0.6-1.6) Set (inlet and middle guide) 632208 DRIVE WHEEL GEAR WITH BEARING Figure 5: Wire feeder mechanism •... - Page 38 • OPTIONAL Feed roll / Pressure roll –Twin (groove all 4 roll) Q’ty Order code Description Remarks 631999 FEED ROLL (0.6/0.8) TWIN For steel (V type groove) 632000 FEED ROLL (0.8/1.0) TWIN For steel (V type groove) 632001 FEED ROLL (1.0/1.2) TWIN For steel (V type groove) 632002 FEED ROLL (1.2/1.6) TWIN...
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Page 39: Torch Connection
11.4.2 TORCH CONNECTION Q’ty Order code Description Remarks 632206 WIRE GUIDE 0.6-1.6 012535 HOSE 5 X 2,5 Order unit (m) 692952 HOSE CLAMP 11,3 Figure 6: Torch connection • OPTIONAL Wire guide Q’ty Order code Description Remarks 632206 WIRE GUIDE 0.6-1.6 Standard Included 632207 WIRE GUIDE 1.6-2.4... -
Page 40: Front Panel Assy
11.5 FRONT PANEL ASSY Q’ty Order code Description Remarks 631830.SA METAL FRONT PANEL 631886.SA METAL FRONT COVER 631802 CENTRAL CONNECTOR HOUSING 631756 QUICK CONNECTOR RED NW 5-G 1/4 631757 QUICK CONNECTOR BLUE NW 5-G 1/4 631794 FITTING KQ2E08-G02A 631885 SEAL 13.0 X 18.0 X 1.5 CU Figure 7: Front Panel assy －40－... -
Page 41: Rear Panel Assy
11.6 REAR PANEL ASSY Q’ty Order code Description Remarks 631829.SA REAR PANEL - METAL 605311 PLUG CX0073 606068 GROMMET C-30-SG-26A-EP-UL 631756 QUICK CONNECTOR RED NW 5-G 1/4 631757 QUICK CONNECTOR BLUE NW 5-G 1/4 631794 FITTING KQ2E08-G02A 631885 SEAL 13.0 X 18.0 X 1.5 CU 696484 GAS SOLENOID VALVE 680820... -
Page 42: Digital Panel
11.7 DIGITAL PANEL Q’ty Order code Description Remarks 632882 LCD (T070WTRZ1) 631878 METAL PLATE 631868 FRONT FOIL 631844 KNOB 7136062 631845 KNOB COVER B7536109 632190 BACK COVER assy 631275 GROMET P30304W03 Figure 9: Digital Panel assy －42－... -
Page 43: Wire Reel Drum
11.8 WIRE REEL DRUM Q’ty Order code Description Remarks 632090 COVER A 632091 COVER B 631285 601591 WIRE REEL HUB 631289 DOOR KNOB 631290 DOOR HOOK Figure 10: Wire reel drum －43－... -
Page 44: Optional Accessory
11.9 OPTIONAL ACCESSORY 11.9.1 WIRE STRAIHTENER Q’ty Order code Description Remarks 632094 WIRE STRAIGHTENER SET- For Steel 632095 WIRE STRAIGHTENER SET- For aluminum Figure 11: Wire straightener －44－... -
Page 45: Specifications
12. SPECIFICATIONS 12.1 SPECIFICATIONS Model CM-7403DV Ø 0.6, - 2.4 mm Mild steel, stainless steel Applicable wire size Ø 0.6, - 2.4 mm Aluminum Ø1.2 mm Factory-settings of wire size 1.5 – 22 m/min Wire feeding rate Power supply DC 42 V Motor Current 2.5 A Torch connection... -
Page 46: External View (Mm)
12.3 EXTERNAL VIEW (mm) －46－... - Page 47 －47－...
- Page 48 Phone: +52-472-748-9435 OTC DAIHEN EUROPE GmbH Krefelder Strasse 677, D-41066 Mönchengladbach, Germany Phone: +49-2161-694970, Fax: +49-2161-6949761 DAIHEN VARSTROJ welding cutting and robotics d.d. Industrijska ulica 4, 9220 Lendava - Lendva, Slovenija Phone: +386-25-788-826, Fax: +386-25-751-277 OTC Industrial (Shanghai) Co., Ltd.
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