MANUAL NO:P10224

OWNER'S MANUAL
FOR
MIG/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. 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

Upon contact, advise MODEL and MANUAL

NO.
 No.P10224
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CONTENTS

1. SAFETY INFORMATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2

2. ARC WELDING SAFETY PRECAUTION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2

3. GENERAL NOTICE OF OPERATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 8

4. STANDARD ACCESSORIES‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 9

5. LOCATION AND FUNCTION OF CONTROL‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 10

6. NECESSARY POWER SOURCE EQUIPMENT ‥‥‥‥‥‥‥‥‥‥‥‥‥ 13

7. TRANSPORT AND INSTALLATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 14

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE‥‥‥‥‥‥ 16

9. WELDING PREPARATION ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 20

10. WELDING OPERATION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 22

11. APPLIED FUNCTION‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 26

12. MAINTENANCE AND TROUBLESHOOTING‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 35

13. PARTS LIST‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 42

14. SPECIFICATIONS‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 45

15. SERVICE AND SUPPORT‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 47

No.P10224
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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 CAUTION refers to minor personal injury or possible

equipment damage.

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.

Have only trained and experienced persons perform installation, operation, and
maintenance of this equipment.

Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
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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.
1. Do not touch live electrical parts.
2. Wear dry insulating gloves and other body protection that are free of holes.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Be sure to turn off the line disconnect switch before installing, changing torch parts or
maintaining this equipment.
5. Properly install and ground this equipment according to its Owner’s Manual and
national, state, and local codes.
6. Keep all panels and covers of this equipment securely in place.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not touch electrode and any metal object if POWER switch is ON.
9. Do not wrap cables around your body.
10. Turn off POWER switch when not in use.

ARC RAYS can burn eyes and skin: FLYING SPARKS AND HOT
METAL can cause injury. NOISE can damage hearing.

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can
burn eyes and skin.
Noise from some arc welding can damage hearing.
1. Wear face shield with a proper shade of filter ( See ANSI Z 49.1 listed in PRINCIPAL
SAFETY STANDARDS) to protect your face and eyes when welding or watching a
welder work.
2. Wear approved safety goggles. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare: warn others not
to look at the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs if noise level is high.
Chipping and grinding can cause flying metal. As welds cool, they can throw off slag.
6. Wear approved face shield or safety goggles. Side shields recommended.
7. Wear proper body protection to protect skin
No.P10224
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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.
1. Protect yourself and others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 33ft. (10m) of the welding arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easily pass through cracks and
openings into adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can ignite a hidden fire.
7. Do not weld on closed containers such as tanks or drums.
8. Connect base metal side cable as close to the welding area as possible to prevent the
welding current from traveling along unknown paths and causing electric shock and fire
hazards.
9. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
10. Do not use the welding power source for other than arc welding.
11. Wear oil-free protective garments such as leather gloves, a heavy shirt, cuffless trousers,
boots, and a cap.
12. A loose cable connection can cause sparks and excessive heating.
13. Tighten all cable connections.

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.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. Ventilate the area and / or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturer’s instructions on
metals, consumables, coatings, and cleaners.
5. Do not weld or cut in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
6. Work in a confined space only if it is well ventilated, or while wearing an air-supplied
respirator. Shielding gases used for welding can displace air causing injury or death.
Be sure the breathing air is safe.
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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; maintain them in good condition.
2. Protect compressed gas cylinders from excessive heat, mechanical shock, and arcs.
3. Keep the cylinder upright and securely chained to a stationary support or a rack to prevent
falling or tipping.
4. Keep cylinders away from any welding or other electrical circuit.
5. Never touch cylinder with welding electrode.
6. Read and follow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-1 listed in PRINCIPAL SAFETY STANDARDS.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when gas cylinder is in use or connected for
use.

Rotating parts may cause injuries. Be sure to observe the following.

If hands, fingers, hair or clothes are put near the fan’s rotating parts or wire feeder’s feed roll,
injuries may occur.
1. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, certified or experienced
operators must perform the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, fingers, hair or clothes near the rotating fans or wire feed roll.
No.P10224
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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.
Do not put wire feeder on the welding power source.
Do not put the welding power source and wire feeder where they will pit or fall.

WELDING WIRE can cause puncture wounds.

Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other people, or any metal when threading
welding wire.
 No.P10224
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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.

Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, from
American Welding Society.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association,
Standards Sales.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from
American National Standards Institute.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.
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 Hard aluminum 0.040/ 3/64
Soft aluminum 3/64
Stainless 0.030 / 0.035 / 0.040 / 0.045
Mild steel solid 0.030 / 0.035 / 0.040 / 0.045
AC pulsed MIG Hard aluminum 0.040 / 3/64
Soft aluminum 3/64
Stainless 0.030 / 0.035 / 0.040 / 0.045
Mild steel solid* 0.030 / 0.035 / 0.040 / 0.045
Note:
*Using M2 gas (a mixture of 98% argon and 2% oxygen) is recommended when welding process is AC pulsed MIG.

3.2 Rated duty cycle

CAUTION
●Use this welding power source at or under the rated duty cycle. If exceeding the rated duty
cycle, the welding machine may be damaged.

●Rated duty cycle of the welding power source: 80% (200A, 27V). When the welding power source is
operated on higher voltage than the rated voltage, the rated duty cycle must be lowered.
●The duty cycle of 80% means the way the machine is rested for 2 minutes after 8 minutes of continuous
welding at the rated current.

ON OFF
8 min. 2 min.

10 min.

●Failure to observe duty cycle limitations may result in temperature inside the welding machine
exceeding the tolerance, which may contribute to premature welding machine failure or product
damage.
●The figures shown below indicate the relation between welding current and duty cycle. Use the welding
machine within its usable range, following the duty cycle for the welding current.
●The duty cycle of the welding power source is also limited by the duty cycles of accessories combined
with, such as welding torches. Use the welding machine within the lowest rated duty cycle of the
accessories.
100 ％(Less than 178A) 100 ％(Less than 167A)
100 100

80 ％(200A, 27V)
70 ％(200A,36V)

Duty Usable range Duty Usable range

cycle( ％) 50 cycle( ％) 50

When the welding power source is used on

0
the higher voltage than the rated voltage.
40 100 200 0 40 100 200
(The left chart)
Welding current(A) Welding current(A)
 No.P10224
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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. STANDARD ACCESSORIES
4.1 Accessory kit
●Your package contains the accessory kit listed below.

① ②

③ ④

Description Specifications Q’ty

2A 250V 1
①Fuse (glass tube)
10A 250V 1
②Fuse (cartridge) BLA-003 2
③Hexagon bolt (with washer) M8-20 2
④T-shape round head screw M3-8 4
No.P10224
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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 )

Arc voltage direct detection negative terminal

( to base metal)
 No.P10224
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5. LOCATION AND FUCTION OF CONTROL (continued)
5.1.1 Front panel (continued)
CAUTION
● Stop welding when using the switches on the front panel.
PROGRAM switch CURR.VOLT. CONTROL switch
To select a welding method and a wire size while pressing + or -. Set the only wire Set this switch to ROBOT for normal use. When Fuses
sizes listed in WELDING MODE AND WIRE SIZE on the next page. switching, turn off the power switch.

F1(2A) F2(10A)
NOTE:
GAS switch
WHEN SET TO "PANEL",THESE KNOBS ARE
AVALABLE,USUALLY SET TO "ROBOT." opens the gas valve to regulate
the amount of gas flow. Be sure
+24V MOTOR to set this switch to WELD after
120 -2
0
+2
regulating the amount of the gas
80
160
-4 +4 PANEL GAS flow.
CHECK
-6 +6 4 2
40
200
-8 +8 ROBOT WELD
-10 V +10
A
PROGRAM CURR.VOLT. GAS
CURRENT(A) VOLTAGE ADJ. CONTROL
CURRENT (A) / CAUTION
VOLTAGE ADJ. knob IF THIS SWITCH IS TRIPPED
DO NOT TURN ON AGAIN.
REFER TO OWNER'S MANUAL.
works when CURR.VOLT.
CONTROL switch set to PANEL.
POWER

OFF OFF OFF

WARNING TEMPERATURE
DCNO-LOADVOLTAGE
POWER switch
( AC MODE ) When turning on the line
disconnect power switch and
this switch, fan rotates and
control circuit is turned on.

NOTE: The switches/ knobs/ lamps are located inside the WARNING / TEMPERATURE lamps

P. 11/47
No. P10224
front cover of the welding power source. When light and stop outputting for abnormal condition. MAIN POWER lamp
opening the front cover, push and pull it toward you as Refer to section 11.4 for cancellation of this Lights when turning on the line
illustrated below. condition. disconnect switch. Before making an
external connection or checking the
DC NO-LOAD VOLTAGE lamp machine, make sure the line disconnect
lights when DC no-load voltage is generated switch is turned off and its lamp goes
at AC pulse mode or AC wave pulse mode. out.
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)
11 0.040
Hard aluminum
12 DC
3/64
13 Soft aluminum
WAVE PULSE
21 0.040
Hard aluminum
22 AC
3/64
23 Soft aluminum
31 0.040
Hard aluminum
32 DC
3/64
33 Soft aluminum
PULSED MIG
41 0.040
Hard aluminum
42 AC
3/64
43 Soft aluminum
51 0.030
52 0.035
DC
53 0.040
54 0.045
PULSED MIG Stainless steel
61 0.030
62 0.035
AC
63 0.040
64 0.045
71 0.030
72 0.035
DC
73 0.040
74 0.045
PULSED MIG Mild steel
81 0.030
82 0.035
AC
83 0.040
84 0.045
●Gas switch
This welding power source automatically stops flowing gas, and the warning lamp flashes, when
the gas switch is set to CHECK for more than 2 minutes. And also, if the welding power source is
started during gas checking, the warning lamp flashes and the welding power source stops
operation. To start the machine again, turn the switch back to WELD side. If it is started before
doing so, the warning lamp will keep flashing.

Pressure gauge
Flowmeter

Flow adjusting knob

 No.P10224
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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.

●Capacity of necessary power source utility

CPDACA-200
Power supply voltage and phase 460V, Three phases
Tolerance of fluctuation of power supply voltage 460V
Installed capacity 21kVA or more
Capacity of switch/circuit breaker 40 A

6.2 Precautions against the use of engine generator

CAUTION
●To prevent damage to engine generator or auxiliary power, follow the instructions below.
●Set the engine generator to within the voltage range between 460 and 483V. Setting to excessive
high output voltage may result in product damage.
●Use the engine generator with a damper winding of which capacity is more than twice as much as
the rated input of the machine. Generally, the recovery time of the engine generator’s voltage for
load change is slower than that of the commercial input power source, and if the engine generator
does not have sufficient capacity, sudden current change such as arc start may occur. This may
result in abnormal decrease in output current or arc loss. Ask a manufacturer of engine generator
for a damper winding.
●Do not combine more than two welding machines with an engine generator. The effect of each
machine may cause easy loss of arc.
●Use the auxiliary power source of engine welder whose waveform has been improved. Some
auxiliary power sources are poor at electricity conduction, which may lead to damage to the
welding machine. Contact a manufacturer of engine welder for the improvement of waveform.
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.
●When hanging the welding power source with a crane, fix a case or a cover
with eyebolts.
●Use two wires when hanging the equipment with a crane.
●When moving the welding power source with a forklift, secure the wheels to
prevent possible rolling of the power source.

7.2 Installation
WARNING
When installing the welding machine, follow the instructions below to avoid fire caused by
welding and physical damages by fume gas.
●Do not install the welding machine near combustible materials and
inflammable gas.
●Remove combustible materials to prevent dross from coming into contact
with combustible objects. If you can not do so, cover them with
noncombustible covers.
●To prevent the danger of gas poisoning and suffocation, wear a respirator or
adequately ventilate.
●To prevent disorder or poisoning caused by fume, wear a respirator for
breathing approved by the local regulation.
●Adequately ventilate or wear a respirator when using the machine in a tank,
a boiler, a hold of a ship. Because heavier gas such as carbon dioxide or
argon gases are drifting.
●When using the machine at a narrow space, comply with a trained
supervisor’s directions.
 No.P10224
P. 15/ 47
7. TRANSPORT AND INSTALLATION (continued)
CAUTION
To prevent electromagnetic troubles, read the following. Should
ＨＦ
electromagnetic troubles occur, check the following again.

Since large current abruptly changing flows through the welding machine to base metal during
welding, other machines near the welding machine may be troubled due to electromagnetic
noise.
●Do not ground the base metal and welding power source commonly with other machines.
●Tightly close and fix all doors and covers of the welding machine.
●Do not use an unnecessary long grounding cable.
●Extend the torch cable and the base metal cable as straight as possible.

Countermeasures on occurrence of electromagnetic troubles are as follows.

●Change the installation place of the welding machine.
●Keep the machines which may be affected away from the welding machine, the cables and
the welding site as far as possible.
●Add a noise filter to the input cables.
●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.
●Do not place heavy objects on the welding power source.
●Do not block the vent holes of the machine.
●Fix the gas cylinder to the stand for gas cylinder only (see fig. 1).

INSTALLATION PLACE
Observe the following when selecting an installation place.
・ Be sure to keep the machine more than 1ft. (30cm) away from the wall or other welding power sources.
(see fig. 2).
・ Do not install in the place where metal material such as spatter enters the equipment.
・ Do not install in a place subject to direct sunlight, rain, excessive moisture, oil steam, or corrosive gas.
・ Install the equipment in the place where the altitude is 3300ft.(1000 m) below, the ambient temperature
is between 14F°(-10C°) and 104F°(40C°), and the relative humidity is 50% at 104 F°(40C°) or
90% at 68 F°(20C°).
・ Use a wind shield to protect the arc from wind, otherwise welding defects may occur (see fig. 3).

Welding power source

More than 1 ft. (30cm) interval

Fig. 1 Fig. 2 Fig. 3

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.

8.1 Connection of welding power source output

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.
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after disconnecting the input power switch when installing and maintain the welding
machine. Even after turning off the input power switch, capacitor may be charging. Check
no presence of charging voltage in capacitor.
●Do not use a cable with lack of capacity or a seriously damaged cable.
●Tighten and insulate the connection of cables.
●Do not remove a case or a cover of the welding machine when using the machine.

●Follow the instructions below to connect the welding power source and a robot controller.
1 Turn off the line disconnect 5 Fix flex tube flange with the
switch of the power box at tapping screws M3
input side. mounted on the rear panel.

CN31 6 Connect a communication

2 Remove 4 bolts fixing the Optical
communication
cable connector P6981X
connector to CN57 on
upper cover to open the
P.C.B.L8268M, operation
cover. P6906P
stop to CN5#7 and #8 on the
terminal board, and ground
cable to earth terminal.

3 Pull the clocking hole plug 7 Close the upper cover with the
on the rear plate of ICN and bolts.
remove it.

8 Consult the manual supplied

with a robot controller for the
4 Pass a communication cable,
details of the connection with a
an operation stop wire, and an
OSACOM robot control device.
earth wire of flex tube through
the holes on the rear plate. 2000

Note: when using the welding machine functionally extended, consult the manual of
a robot controller.
 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.
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after disconnecting the input power switch when installing and maintain the welding
machine. Even after turning off the input power switch, capacitor may be charging. Check
on no presence of charging voltage in capacitor.
●Do not use a cable with lack of capacity or a seriously damaged cable.
●Tighten firmly and insulate the connection of cables.

●Follow the instructions below to connect the welding power source with the manipulator.

Turn off the line disconnect switch of the power box at input side
and the power switch of the welding power source.

2
Remove the front cover to connect as the figure shown
left. After the connections, cover the device with the
Front cover front cover.

ICN4 (to manipulator)

Note: when using a feeding device except L-6990 and
12P terminal block
L-7160, use ICN4 only. In this case, use the arc voltage
Output terminal(-)
(to base metal)
Output terminal(+)(Torch side)
detective terminals on 12P terminal board under the
Arc voltage direct detection receptacle. Refer to 11.2.
termimal(-)(Base metal)
 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.

8.4 Connection of gas hose

WARNING
●You may suffer from danger of suffocation caused by lack of oxygen when
shield gas keep drifting at closed place. Be sure to turn off the shield gas at
the main when the welding power source is not be used.

CAUTION
●Be sure to connect the gas hose after fixing to the stand, as toppling of gas cylinder may
cause physical injuries.
Nut for cylinder

Gas cylinder Follow the instructions below to connect the gas hose.
①

Outlet of
② 1.Attach the gas cylinder nut to the gas cylinder with a monkey
gas regulator
wrench.
Gas hose
2.Connect the gas hose to the outlet coupling with a monkey
wrench.
Gas cylinder stand

8.5 Grounding and connection of input side

WARNING
Follow the instructions below to avoid electric shock.

∗ Do not touch charging parts, as this will result in fatal shock and severe burn.
●Do not touch the charging parts of the machine.
●Disconnect all input power with the line disconnect switch when checking the machine.
●Do not use the cable with lack of capacity or the seriously damaged cable.
●Tighten firmly and insulate the connection of cables.
●After connecting cables, firmly fix the case and the cover of the equipment.
●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.
 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
(electrostatic capacity naturally generated between the input conductor and the case metal).
Touching the case or the base metal may cause an electric shock. Be sure to ground the case
of the welding power source or jig.

8.3 Grounding and connection of input side

●Be sure to properly ground welding power source to avoid electric shock.
Install a line disconnect switch for each welding power source.
Input power KVA and amperage of fuse or circuit breaker are as listed below.
CPDACA-200
Input power KVA More than 20.4kVA
Amperage of fuse or circuit breaker 40A
* The circuit breaker type must be for welding power source or for motor.

3φ460V
Input terminal cover

Input terminals

Grounding Insulating
terminal sheet

Clamp
Input cable
Cable thickness: Tighten the screws for
over input cable (the Grounding cable the cables.
Grounding
use of AWG 8 cable Cable thickness: over input cable
is recommended.) (the use of AWG 8 cable is
recommended.)
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.
●When using the machine at a narrow space, comply with a trained supervisor’s directions.
And be sure to use a respirator.
●Do not use the machine near the place where degreasing, cleansing, and spraying are
performed. Poisonous gas may be generated.
●Be sure to use a respirator or adequately ventilate when welding a coating steel plate.
(poisonous gas and fume may be generated.)
● Use a wind shield to protect arc from wind when using an electric fan for ventilation
or welding outdoors. Failure to do so may result in poor welding.

CAUTION
Use a protective equipment to protect you and other workers from arc rays,
spattering dross, and noise from welding operation.

●When operating or monitoring the welding operation, use an eye protector with a good light
blocking effect or face shield.
●Wear protective glasses to protect your eyes from the spattering dross.
●Wear protective equipment such as protective gloves, long-sleeve clothes, a leg cover,
leather apron, and so on.
●When using protective screens or barriers to protect the eyes of others in the work area from
arc ray.
●Use an ear protector when noise level is high.
 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.

③
①

②⑥ ④
⑤

① Turn on the power switch.( 460V, 3φ)

② Turn on POWER switch.
③ Set the gas check switch to CHECK.
④ Set the gas regulator to SHUT and turn on gas at the main.
⑤ Turn gas flow regulator to OPEN to adjust the amount of gas flow.
⑥ After adjusting the amount of gas flow, set the switch back to WELDING.

9.3 Inching operation

CAUTION
●Do not look into the tip to check on the wire feeding while inching.
Wire may fly out and stick your face and eyes.
●Keep away your hands, fingers, hair or clothes from the rotating parts of the
feed roll, etc. while inching. Biting may result in injuries.
 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.

10.1 Welding sequence

●Control welding conditions or start and stop welding by using the control device.
●If CURR. VOLT CONTROL switch is set to PANEL, pre-flow period will be 0.08 sec. and
post-flow time 0.35 sec.

ON
Starting signal
OFF

Gas flow Slowing down

Crater-filler period

Wire feeding
Pre-flow period
Anti-stick period

When current stops during

Post-flow period

welding monitor period.

Welding current
Welding monitor period

No-load voltage
Input terminal voltage Anti-stick voltage

WCR
Movement of robot

When current does not stop during

Welding current
Welding monitor period
welding monitor period.

Welding cancellation period

Output terminal voltage Anti-stick voltage

Welding cancellation voltage

WCR
 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).

EP

EN

10.3 Adjusting penetration

The amount of penetration can be adjusted by changing EN current time during AC pulse
welding. Adjust the voltage exactly after adjusting pulse arc due to the slight change of
welding. In this case, the melting amount of wire will not change, unless current settings are
always the same. Refer to the manual of a robot control device.

Deep Shallow
Standard
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. After changing the characteristics of pulse arc,
adjust the voltage exactly due to the slight change of welding current. In this case, if the
current setting is invariable, melting amount of wire will not change. Refer to the manual of a
robot control device for details.

Hard Standard Soft

Note: Changing the characteristics of pulse arc may result in more spatters and dusts.

10.5 Wave pulse welding

When the PROGRAM switch is set to 11-13(DC) or 21-23(AC), wave pulse welding can be
performed. During wave pulse welding, bead appearance with beautiful scale patterns can be
obtained by periodically superimposing two different pulse conditions. Therefore, ALMINUM
welding will be effective in welding parts or couple, of which bead appearance is regarded as
important. Refer to the manual of a robot control device for details.

Note 1: Wave patterns of welding bead may not clearly appear according to input heat during
welding.
Note 2: When using soft wire, frequent short-circuit during welding may blacken the surface of
bead.

Wave patterns
At low frequency

At high frequenc y

10.6 Display of welding current and arc voltage

Use the arc monitor function of a robot to check welding current, arc voltage. Refer to the
manual of the robot for details.
 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.
･ Wide bead width.
･Increase in excess metal length.
･Increase in leg length.
･Easy overlapping.
･Bead dropping or undercut at some welding positions.
Arc voltage too high. ･Long arc length.
･Wide bead width.
･Decrease in excess metal length.
･Easy occurrence of blowhole.
Arc voltage too low. ･Sticking through base metal and spatter.
･Narrow bead width.
･Shallow penetration.
･High excess metal.
Welding speed too fast. ･Narrow bead width.
･Shallow penetration.
･Low excess metal.
･Easy undercut.
･Easy occurrence of poor gas shield.
Wire extension too long. ･Long arc length.
･Large potential drop and output voltage decrease caused by
resistance heat generated from wire extension part.
･Shallow penetration.
･Easy generation of poor gas shield.
Wire extension too short. ･Short arc length.
･Deep penetration.
･Spatter.
Torch angle too large. ･Wide bead width and shallow penetration at angle of advance.
･Easy occurrence of convex bead width and deep penetration
at angle of sweep back.
Penetration too shallow ･Narrow bead width.
･Shallow penetration.
･Easy overlapping.
Penetration too deep. ･Wide bead width.
･Deep penetration.
･Easy occurrence of hole or break (when welding a thin plate).
Rate of gas flow too high. ･Easy lacking of lack of arc at low current.
Rate of gas flow too low. ･Easy generation of poor gas shield at large current.
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.
●With the line disconnect switch of the power box disconnected, when touching parts inside
of the machine.

CAUTION
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after the disconnection of the input power switch, when switching the short socket or the
dip switch.
●Never touch the resistor painted white.

11.1 Function of the switches and their adjustments

With the line disconnect switch of the power

box turned off, adjust internal functions.

●Set S201, S202, S203 (except 7) on P.C.B. P6906P to OFF.

S201 Chassis (UP)

EPROM
ON Front side Rear side

OFF R126
1 2 3 4
R125
S203
R124
S202
S201
S202 Set to OFF.
ON P.C.B
P6906P
OFF 8
1 2 3 4 5 6 7
Location of Switches and EPROM
on P.C.B P6906P
Set to OFF.
S203
ON

OFF
1 2 3 4 5 6 7 8

Set to ON.
Set to OFF.
 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.

(2) Wire feeding device

This welding power source is normally used with L-6990 or L-7160 mounted an encoder. When
the machine is used with a wire feeder not including an encoder, set SW2 on P10153Q to
ENCODER 無(OFF). It is factory-set to ENCODER 有(ON). When using a typical wire feeder,
make no connection to ICN5 .

(3) Change of anti-stick period and welding release period

Anti-stick period or welding release period is the processing time to prevent an electrode wire
from welding on a base metal at welding termination. Anti-stick period, or welding cancellation
period is factory-set to the proper conditions. The condition, however, can be exactly adjusted
from the robot control device. Refer to the manual of the robot control device for details.

(4) Adjusting anti-stick voltage

Anti-stick is a voltage or welding cancellation period which is output at the end of weld to
prevent an electrode wire from welding on a base metal. Anti-stick voltage is factory-set to the
proper conditions. But the robot control device can adjust the condition. Refer to the manual of
a robot control device for details.

(5) Change of slow-down speed

Slow-down speed is the speed to feed wire slower than normal welding for the time between
starting the welding machine and the arc start. The proper slow-down speed is factory-set to
match welding modes or wire sizes. Refer to the manual of the robot control device for details.

(6) Adjustment of pulse conditions

Proper pulse conditions are factory-set according to welding modes or wire sizes. The pulse
conditions can be exactly adjusted from the robot control device. Refer to the manual of the
robot control device for details.

(7) Change of pre-flow period and post-flow period

Change pre- and post-flow periods by using the robot control device. Refer to the manual of the
robot control device for details.
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. In the worst case, the arc may be unstable because
the power source can’t take a correct control of the waveform. Although the voltage detecting
circuit is exactly factory-set, the change of temperature for a long period, the replacement of
printed circuit board may cause an error in the detected voltage. This welding power source can
correct the error automatically. This function is factory-set to ON.

Note: the automatic correction is used for the automatic detection of the errors in the
welding voltage detecting circuit. It is not for correction of the voltage fluctuation caused by
the external factors such as the quality of base material, extension cable. The correction
function detects an error from the time of the input of the welding start signal to the time of
output of welding voltage, and corrects the detecting circuit by using the detected values.
Therefore, when the external voltage for a function such as touch sensor of automatic
machine and robot system is applied to the output terminals of the welding power source at
the welding start signal input, normally the function doesn’t work. In this case, setting the
correcting function to OFF again is needed. When resetting the function, ask your dealer.
Contact an automatic machine company or a robot manufacturer to check if the voltage is
externally applied to the output terminals of the welding power source.
 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.
●Be sure to disconnect all of the input power source with the line disconnect switch of the
power box when touching parts inside of the machine.

11.2 External connection with terminals inside of the welding power source
●12P terminal block is located inside the front cover of the welding power source.
The functions of the terminal block are as illustrated below.

Connection with terminal block for external connection

12P terminal block

Arc voltage detection Retract inching starting

positive (torch side)

1 2 3 4

1 When using a wire feeding except L-6990 and L-7160, connect the arc voltage detective wire to
this terminal. When using L-6990 and L-7160, make no connection to this terminal.
2 To retract wire by external signals. (When terminals are short-circuited, wire is retracted.)
3 To perform inching wire by external signals. (When terminals are short-circuited, wire is
inched.)
4 This terminal is used to start welding from external signals.(When terminals are short-circuited,
weld starts.)

Note: 2, 3, and 4 are available when CURRENT / VOLTAGE CONTROL knobs set to PANEL.
 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.
●Be sure to disconnect all of the input power source with the line disconnect switch of the
power box when touching parts inside of the machine.
11.3 External connection with terminals inside of the welding power source with automatic
machine
12P terminal block on P.C.B.P10153Q is located inside the upper cover of the welding power
source. The terminal block outputs the signals shown in the figure below. Break the grommet with
the filter located on the rear side of the machine to lead in the external connecting wires.

12P terminal block

− +

− + − +
INDICATION

ｶﾞ ｽ ﾊﾞ ﾙ ﾌﾞ 開閉 溶 接 電 流 ﾘ ﾚ ｰ 非 常 停 止 電 源 準 備 A V
( 閉 で ｶﾞ ｽ 放 流 ) ( W C R ) 接 点 ( 開 で 停 止 ) ﾘ ﾚ ｰ ( D C 2 4 V )

OPENING / CLOSING WELD. CURR. OPERATION STOP POWER FOR PREP. AMMETER VOLTMETER
GAS SOLENOID RELAY (WCR) (Stop when set to RELAY
MEANING

VALVE CONTACT OPEN.) (24V DC)

(Gas purges when set
to CLOSE.)
To open and close the gas To use for detection of This terminal is not Terminals for preparation To connect to an To connect to a
valve by external signal. welding current. available, because it is relay. Relay functions, when ammeter. voltmeter. Use
(opens the gas valve when Contact rating is not used for operation stop there is no abnormalities of Use the ammeter the voltmeter
short-circuiting between the more than 110V AC, from the robot. input overvoltage, output for 300A 60mV having the full
terminals.) 0.3A. Contact closes overload, thermal overload, shunt. scale of 75V.
during weld current or open phase and operation
FUNCTION

flow. stop while a 24V DC relay is

connected between the
terminals and the control
power switch is on. ( Usable
relay coil current: less than
50mA )

CAUTION
Never short-circuit power source preparation relay, ammeter, and voltmeter. This may result in damaging
the welding power source.
 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.
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after turning off the input power switch when installing and maintain the welding machine.

If errors occurred, warning lamps on the front panel and red LED on P.C.B.P6906P light and the
welding power source automatically stops. In this case, check the errors in the table below and 12.3
Troubles.
○: Light ●: Extinction ◎: Flash
Error WARNING P.C.B. P6906P
Error contents indicator on
No. the front panel PL202 PL203 PL204 PL205
① Operation of safety circuit ◎ ● ● ● ●
② Setting of welding conditions ◎ ● ● ● ●
③ Operation stop ○ ● ● ● ◎
④ Input overvoltage ○ ○ ● ● ●
⑤ Output overcurrent ○ ● ● ○ ●
⑥ Thermal overload ○ ● ● ● ○
⑦ SCR and IGBT driver ○ ○ ◎ ● ●
⑧ Primary/secondary current detection ○ ● ● ○ ◎
⑨ Control power (± 15 V)/input voltage shortage ○ ◎ ◎ ● ●
⑩ Arc voltage detection wire ○ ● ● ◎ ◎
⑪ Microcomputer ○ ● ◎ ● ◎
⑫ Communication with robot ○ ◎ ◎ ◎ ◎
⑬ Gas check ◎ ● ● ◎ ●
⑭ Encoder ○ ● ◎ ● ●
⑮ Secondary transistor ○ ◎ ○ ○ ◎
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. In this case, the machine can operate when the torch
switch is turned off and safety circuit is canceled.

② Setting error of welding conditions

The WARNING lamp lights and the welding power source automatically stops when the
PROGRAM switch is set to unavailable numbers. When setting the PROGRAM switch to
numbers other than numbers listed in “5.1.1 Front panel Program switch”, reset the switch on the
front panel to the proper numbers.

③ Operation stop (compulsory stop from a robot) error

When releasing the external terminal board between operation stop terminals (line gauge: 165)
on P.C.B.P10153Q, the WARNING lamp lights and the welding power source stops. In this case,
short-circuit between the terminals after solving a cause of the operation stop. After the power
switch is turned on, the lamp may keep lighting for approximately 10 sec. until the robot control
device becomes stable, it goes out in a short period of time.

④ Operation error of input overvoltage circuit

If the input voltage exceeds 529V, the WARNING lamp will light and the welding power source
will stop automatically. In this case, turn off the POWER switch and measure the input voltage
with a tester, etc. to make sure excessively high voltage is not output. To cancel the error,
connect the POWER switch again after solving the error.

⑤ Output overcurrent error

When an overcurrent continues for more than one second during welding, the WARNING lamp
lights and the welding power source stops automatically. In this case, turn off the CONTROL
POWER switch and make sure the welding current does not exceed the rated output value, or
there are no short-circuits at the output side such as contacts between the tip and the base metal,
or short-circuits in the output cables. In this case, turn on the POWER switch again to solve the
error.

⑥Thermal overload
The rated duty cycle of this welding power source is 80% (refer to DUTY CYCLE in this manual
for details). When the duty cycle exceeds rated duty cycle, or ambient temperature exceeds
104F° (40C°), the WARNING lamp lights and the welding power source stops automatically. In
this case, wait for more than ten minutes with the POWER switch set to ON and the fan rotated.
When starting the welding operation again, turn on or off the POWER switch after lowering the
duty cycle or the welding current. Be sure to rest the welding power source for more than ten
minutes, when turning on the POWER switch again. Failure to do so may result in damaging the
welding machine.

⑦ SCR and IGBT driver error

When any error is detected in SCR and IGBT driver, the WARNING indicator will light and the
welding power source automatically. The error will be canceled by turning the control power
switch off, then turning on again, or resetting the system by receiving control signals.
 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.

⑨ Control power ± 15 V error/input voltage shortage

When control power ± 15 V drops, or the input voltage becomes under 414V, the WARNING
lamp lights and the welding power source stops automatically. To cancel the error, start the
welding machine again after turning off CONTROL POWER switch and checking the
nonpresence of error in the welding power source.

⑩ Arc voltage detection wire error

The WARNING lamp lights and the welding power source stops automatically for arc voltage
detection wire error. In this case, turn on the POWER switch after turning off the POWER
switch and checking to make sure if there is no error arc voltage detection wire or electrode.

⑪ Microcomputer error
When any microcomputer error is detected, the WARNING lamp lights and the welding
machine stops automatically.

⑫ Communication error with robot

When communication between the welding machine and the robot control device has failed, the
WARNING lamp lights and the welding machine stops automatically. In this case, turn off the
POWER switch and connect again.

⑬ Gas check error

The WARNING lamp flashes and the welding power machine stops automatically, when
starting the equipment by pressing the GAS switch on the front panel set to CHECK, or when
more than two minutes has passed after GAS switch was set to CHECK. Set the GAS switch to
WELD to cancel the error.

⑭ Encoder error
The WARNING lamp lights and the welding power source stops automatically, if the signals
from encoder are disconnected by breaking while using the only wire feeder mounted an encoder.
In this case, solve any cause of the error before connecting the POWER switch. The error is
canceled by receiving control signals from a robot.

⑮ Secondary transistor error

The WARNING lamp lights and the welding power source stops automatically when surge
voltage of the secondary transistor is excessively high. In this case, after canceling the error,
following the instructions described in 11.5, turn on the POWER switch again.
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. When using an extension cable, abide by the notice below.
NOTICE:
・ Bind the torch cable and the base metal
cable and tape them.
・Try to layout the torch cable as straight as
possible. If it is impossible to do so,
layout the cable on the base metal.

3. In case where the torch cable is coiled, follow the instructions below.
CORRECT WRONG
Cable coiled in two directions. Cable coiled in one direction.
Refer to “How to coil the torch cable for
details”.

How to coil the torch cable

Step 1 Step 2 Step 3

Top view

Side view

Coil a torch cable one way Place B on A as After placing B on A,

and check if number of illustrated above. bind the coil of a cable
Instructions turns and diameter of A are with ropes to avoid
equal to those of B. getting loose.
 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. Do not use a damaged machine unless it is repaired.
●Have the welding power source maintained and repaired by a qualified engineer or a person
who is familiar with welding machines and can handle the machine safely.
●Be sure to turn off all of the line disconnect switches and that more than 3 min. has passed
after turning off the input power switch when installing and maintain the welding machine.
Even after turning off the input power switch, capacitor may be charging. Make sure no
presence of charging voltage in capacitor.
●This welding power source uses high-frequency inverter system, be careful of accidental
connection of input line disconnect switch.
●Have a qualified engineer or the person having a thorough knowledge of this welding
power source test withstand voltage. And install a protective wall around the welding
machine to keep away others from the welding machine.

CAUTION
Follow the instructions below, as rotating parts may be the cause of injury.

●Have a qualified engineer or a skilled worker of the welding machine remove the case of
the welding machine for repair. To keep away others from the welding machine.
●Keep away your hands, fingers, hair, and clothes from a rotating wheel.

12.1 Maintenance
(1) Periodical checking
Periodically check the welding machine to ensure the safety of the machine and the efficiency of
work.
●Daily check if
− vibration, buzzing noise, or smell is not strange.
− cable connection does not generate excessive heat.
− fan rotate smoothly when the power is turned on.
− switches function properly.
− connection and insulation of cables are complete.
− there are no breaks in cables.
− vibration of power source voltage is not large.
− inside of the machine is cleaned at least once every 6 months.
− grounding cable is completely connected and insulated.
− cables from the line disconnect switch, input side and output side of welding power source are
connected and insulate completely.
●Yearly check if the control rely contacts on P.C.B.P10153Q are not damaged after removing the
upper cover. Replace the seriously damaged contacts.
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. And the life of the capacitor is limited, since it is impossible to stop leaking
the battery electrolyte completely. Therefore, the replacement of the high-pressure electrolytic
capacitor C2 is recommended every 5 years. Failure to do so may result in damaging the high-
pressure electrolytic capacitor, as well as other parts of the welding machine.

12.2 Welding error table

●Check the error table below before requesting repair.
Error Cause Checkpoint
No arc generated. No difference in voltage Connection of base metal and torch cable.
between torch and base Fuse of input power disconnect switch. Connection
metal. of input cables.
No WARNING lamp lights.
Control cable and socket.
Wire will not be fed. Fuse of input power disconnect switch. Connection
of input cable.
No WARNING lamps light.
Control cable and socket.
Pressure lever of wire feeder.
Bad arc start Improper welding conditions Settings of current and voltage.
Settings of welding mode and wire size set.
Distance between torch and base metal.
Incomplete feed No insulator on surface of base metal.
Connection of base metal and torch cable.
Tip worn.
Unstable arc and dirty welding bead Incomplete feed Connection of base metal and torch cable.
Tip worn.
Improper welding conditions Current, voltage, and amount of gas flow.
Welding mode and wire size properly set.
Wire not smoothly fed. Pressure adjustment of wire.
Parts matching wire size used.
Opening of tip not damaged.
No built-up dusts in liner.
Conduit not too bent.
Dirty wire and base metal No oil on base metal.
No rust on wire.
Air in shield gas Gas nut not loosen.
No holes in gas hose.
Arc blow occurs. Taking measures to prevent arc blow
 No. P10224
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12. MAINTENANCE AND TROUBLESHOOTING (continued)

2.3Welding troubleshooting
No. Trouble Cause Solution
POWER switch Do not connect POWER switch again. Contact your dealer.
1
tripped.
Main power lamp Fan rotates when Trouble of PL1. Check PL1.
PL1 will not light. POWER switch
connected.
2
Fan will not rotate Line disconnect switch of power Check power box.
when POWER switch box not connected.
connected.
Fan will not rotate PL1 will not light. Refer to No.2.
3 when POWER Breaking of F1 Replace it after checking causes.
switch connected. PL1 lights.
Trouble of fan. Checking fan.
WARNING lamp PL2 lights when main Trouble of thermostat TH1 and Check thermostat TH1 or TH2.
power switch is turned on. TH2.
Overheated heat sink. Cool fins after checking causes.
Input overloaded voltage or Check input voltage.
shortage of input voltage.
4
Incomplete insertion of CN11 or Completely insert CN11 or CN14.
CN14 on P.C.B.P10153Q.
Wiring of external connection Wire to “OPERATION STOP”.
terminal board on P.C.B.P10153Q.

Shield gas will not Gas will not be Outlet valve of gas cylinder Open valve.
be generated when generated when GAS closed.
torch switch is switch S4 is set to Lack of gas pressure of gas Check gas pressure.
turned on. CHECK. cylinder.
Trouble of +24V power source Replace P.C.B. P10153Q.
circuit.
Trouble of gas electromagnetic Check and replace gas
5 valve SOL. electromagnetic valve SOL.
Gas generated when S4 Trouble of gas control circuit. Check and replace
set to CHECK. P.C.B.P10153Q.
Trouble of interface circuit. Check and replace
P.C.B.L8268M.
WARNING lamp Refer to No.4.
lights.
Shield gas will not stop. S4 set to CHECK. Set S4 to WELD.
Gas valve switch terminal on Open gas valve switch terminal.
terminal block of P.C.B.P10153Q
short-circuited.
Trouble of gas control circuit. Check and replace P.C.B.
6 P10153Q.
Trouble of gas electromagnetic Check gas electromagnetic valve
valve SOL. SOL.
Trouble of interface circuit. Check and replace
P.C.B.L8268M.
 No.P10224
P. 38 / 47
12. MAINTENANCE AND TROUBLESHOOTING (continued)
No. 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. P1053Q. 2 on P.C.B. P10153Q.
Trouble of interface circuit. Check and replace L8268M.
Trouble of motor control circuit. Check and replace P6906P.
7 Trouble of filter circuit. Check and replace P.C.B.P6768T
Combination of wire feeder Connect ICN4.
mounted with encoder not Checking control cable and
connected to ICN4. replace it.
Breaking of control cable (7
conductors).
Shield gas generated when pulling torch Trouble of control circuit. Check and replace P.C.B.P6906P .
switch pulled but no no-load voltage.
8
Operation stop of external Short-circuit operation stop.
connection terminal board on
P.C.B. P10153Q not short-circuit.
Due to being out of control of welding Trouble of control / filter circuit. Check and replace P.C.B.P6768T .
machine, too large current flows.
9 Breaking of arc voltage detective Check voltage switch S1 on
wire. P.C.B.P10153Z and arc voltage
detective wire.
Current and voltage can not be set. Trouble of filter circuit. Check and replace P.C.B.P6768T.

CURR. VOLT. CONTROL switch Set S3 to ROBOT

S3 set to PANEL.
10
Breaking of communication cable Replace communication cable or
or poor contact of socket. check contact of socket.
Trouble of interface circuit. Check and replace P.C.B.
L8268M.
WCR relay keeps working. Trouble of hall current detector Check and replace CT2.
CT2
11
Trouble of WCR circuit. Check and replace
P.C.B.P10153Q.
 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
Failure to do so may result in damage of P.C.B and the
machine.
●P.C.B.P6906P does not include EPROM. When
CN1
replacing P.C.B., install the EPROM on the original
P.C.B.
NOTE: match the connector numbers when connecting.
12.5 Insulation resistance test
WARNING

Follow the instructions below to prevent electrical shock.

When touching charging parts, critical electric shock and burn may occur.
●Have a qualified person measure insulation resistance or test withstand voltage test.
●Install a fence around the welding machine to keep others away from it.
No.P10224
P. 40 / 47
12.6 Schematic diagram of CPDACR-200
 No. P10224
P. 41 / 47

12.7 Parts layout of CPDACR-200

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
T1 P10155B00 Inverter transformer P10155B00 1
T2 4810-316 Aux. transformer W-W02614 1
T3 4810-230 Aux. transformer W-W02234A 1
T4 4810-302 Aux. transformer W-W02530A 1
L1 P10006D00 DC reactor P10006D00 1
LF 4519-022 EMI filter CM3030C-DJ 1
NF 4814-079 Circuit protector DA-3P 480V 40A 1
FM 4805-043 Fan motor BP-20S2-30C 1
CT1 4810-035 Current transformer W-W00216 1
CT2 4406-009 Hall current detector HA400S3EH 1
PL1 4600-341 Neon lamp N46010A7KW-01 1
PL2 4600-357 Neon lamp DB-41BR 1
PL3 4600-358 Neon lamp DB-41BG 1
PL4 4600-359 Neon lamp DB-41BY 1
F1 4610-003 Glass enclosed fuse 250V 2A 1 For control
F2 4610-004 Glass enclosed fuse 250V 10A 1 For feed motor
F4, 5 4612-006 Fuse BLA003 (600VAC, 3A) 2
THP1, 2 4614-051 Thermostat 67L090 2
SH 4403-062 Ammeter shunt KY300A 300A/60MV 1
S1, 2 4252-015 Rotary switch A7BS-206-1 2
S3, 4 4254-118 Switch DS-850K-F1-00 1
DR1 4531-204 Diode module DFA75BA160 1
DR2 4531-085 Diode 2FI300A-060 1
DR3 4531-710 Diode DIN60 (1) Inside of feeder
DR4, 6 4531-602 Diode S15VB60 2
DR5 4531-504 Diode module FTG25BA60 1
TR1, 2 4534-403 IGBT module CM150DU-24H 2
TR3-6 4534-404 IGBT module CM600HU-12F 4
TR7 4534-402 IGBT GT50J301 1
ICN4 4730-602 Cannon receptacle SRCN2A-21-10S 1
 No. P10224
P. 43 / 47

Symbol Parts No. Description Specifications Q’ty Remark

R1-4 4536-119 Surge absorber ENC911D-14A 4
R5 Missing number
R6, 7 4509-825 Resistor 20SH 15kΩJA 2
R8 4536-119 Surge absorber ENC911D-14A 1
R9-12 4509-704 Carbon resistor RD1/4W 1kΩJ 4
R13-16 4509-881 Resistor 40SHN 5.1ΩKA 4
R17-18 4509-816 Resistor 20SHN 3.3ΩKA 2
R19-22 4509-704 Resistor RD1/4W 1kΩJ 4
R23, 24 4501-039 Resistor EWST9AF20B53 2
RV24YN20SB 5kΩ
R25 4504-333 Resistor NCRF 23V 200ΩG 1
R26, 27 4509-819 Resistor 20SHN 3.3ΩKA 2
R32-35 4509-829 Resistor 20SHN 1ΩKA 4
R36 4504-323 Resistor NCRF 24V 5ΩJ 1
R37 4509-704 Carbon resistor RD1/4W 1kΩJ 1
R38a-
4504-412 Resistor NCRF 24V 300ΩJ 3
R38c
R39 4508-306 Resistor RD1S 200kΩJ 1
R40 4504-944 Resistor KNP1W 10Ω 1
R41a, b 4509-818 Resistor 40SH 200ΩJA 2
R42 4509-707 Resistor RD1/4W 10kΩJ 1
R43 4509-302 Resistor RS3B 100 kΩJ 1
R44, 45 4509-905 Resistor MHR20A513JI 2
C1 Missing number
C2, 4 4511-333 Capacitor 400LGSN3300MBD13 2
C3 4517-401 Ceramic capacitor 0.01μF 2kV 1
C5-8 4518-454 Capacitor ECW-H12H153JR 4
C9, 10 4517-415 Capacitor ECW-H12H333JR 2
C11-13 Missing number
C14,15 4518-454 Capacitor ECW-H12H333JR 2
C16, 19 4518-499 Capacitor PU630V334JSL 2
Capacitor DHS630V224JSL
C17, 18 4518-498 Capacitor PU630V224K 2
4518-498 Capacitor DHS630V224JSL
C20 4518-452 Capacitor ETD2G106KBA116 1
C21 4518-497 Capacitor DHS630V103JSL 1
C22, 23 4517-401 Capacitor 0.01μF 2kV 2
C24a, b 4517-401 Capacitor DKR1600V683JSL 2
C25 4518-456 Capacitor 0.1μF 50V 1
C26 4518-508 Capacitor LNR2W471MSMAWS 1
PCB1 P6906P00 Printed circuit board P6906P00 1 Control
No.P10224
P. 44 / 47

Symbol Parts No. Description Specifications Q’ty Remark

PCB2 P10153Q00 Printed circuit board P10153Q00 1 Power source
PCB3 P6848S00 Printed circuit board P6848S00 1 Secondary
driver
PCB4 P6768T00 Printed circuit board P6768T00 1 For control
PCB5 L8268M00 Printed circuit board L8268M00 1 I/F
PCB6 P6848S00 Printed circuit board P6848S00 1 Secondary
driver
PCB7 P10153Z00 Printed circuit board P10153Z00 1 Restrike
PCB8 P10153Y00 Printed circuit board P10153Y00 1
PCB9 P9943T00 Printed circuit board P9943T00 1
PCB10 P10198Z00 Printed circuit board P10198Z00 1
EPROM1 P10224V00 EPROM P10224V00 1

CAUTION
●P.C.B.P6906P does not include EPROM. When replacing P.C.B., install EPROM on the original
P.C.B.
●If using the previous versions of the EPROM, replacement with the upgraded one is necessary.
 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 27V
Output current range 40A − 200A
Output voltage range 13V − 36V
Max. no-load voltage 86V
Rated duty cycle 80%
Temperature rise 320F°(160 ℃ )
Temperature range 32 F° − 104 F° (0 C° − 40 C° )
Moisture range 20% − 80% (no condensation)
Storage temperature range -13 F° − 131 F° (-25 C° − 55 C° )
Storage moisture range 20% − 80%(no condensation)
Mass 194lbs(88kg)
External dimensions(W×D×H) 14.8in. (376mm)×26.9in. (684mm)×32.7in. (831mm)
(not including input terminals and eyebolts)
Refer to External view on the next page.
No.P10224
P. 46 / 47
14. SPECIFICATIONS (continued)

ICN1 receptacle to robot controller

Bush (for external
26.9(684)
connection wire)
Input
14.8(376) 25.7(653) terminal

0.6(15)

OFF OFF OFF

3 2 .7 (8 3 1 )
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)

EXTERNAL VIEW of CPDACA-200

 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.
2)When requesting a repair, you will need such information as your address, name, telephone
number, product model, manufacture date, serial number, details of troubles. (See the left-
side cover of the welding power source for product model, manufacture date, and serial
number)

Model: CPDACA-200
Date: 2XXX
Serial No.: P10224YXXXXXXXXXX