Daihen OTC CM-7471, Owner'S Manual

Page 1: ...talling operating or maintaining this equipment This equipment and this manual are for use only by persons trained and experienced in the safety operation of welding equipment Do not allow untrained persons to install operate or maintain this equipment Contact your distributor if you do not fully understand this manual DAIHEN Corporation WELDING PRODUCTS DIVISION August 9 2013 Upon contact advise ...

Page 2: ...tarting on January 1 1995 Please make sure that this product is not allowed to bring into the EU after January 1 1995 as it is The same restriction is also applied to any country which has signed the EEA accord Please ask us before attempting to relocate or resell this product to or in any EU member country or any other country which has signed the EEA accord ...

Page 3: ...AFETY PRECAUTIONS E2 3 CHECKING OF QUANTITY OF THE ACCESSORIES E8 4 NAME OF PARTS E8 5 CARRYING AND INSTALLING OF THE WIRE FEEDER E9 6 CONNECTION PROCEDURE E11 7 WELDING PREPARATION E12 8 MAINTENANCE AND TROUBLESHOOTING E19 9 PARTS LIST E21 10 SPECIFICATIONS E27 ...

Page 4: ... WELDING can be hazardous 1 PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH Be sure to Keep children away Keep pacemaker wearers away until consulting a doctor 2 Read and understand the summarized safety information given below and the original principal information that will be found in the PRINCIPAL SAFETY STANDARDS 3 Have only trained and experienced persons perform installati...

Page 5: ...sized 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 fro...

Page 6: ...tip when not in use 10 Does 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 14 When there is an electrical connection between a work piece and the frame of wire feeder or the wire ...

Page 7: ... 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 9 Do not disassemble or repair the gas regulator except for the person authorized by the manufacturer of them WARNING Do not alter or remodel our products You may get injured or have your equipment damaged because of fire failur...

Page 8: ...ource and wire feeder solidly on a flat surface 3 Do not pull the welding power source across a floor laid with cables and hoses 4 Do not put wire feeder on the welding power source 5 Do not put the welding power source and wire feeder where they will pit or fall WELDING WIRE can cause puncture wounds 1 Do not press gun trigger until instructed to do so 2 Do not point gun toward any part of the bo...

Page 9: ...ctices 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 Sta...

Page 10: ...RTS Refer to the section indicated in for details No Description Specification Quantity Outlet guide U69B34 for steel 0 9 1 2mm 1 Conduit U2586G00 3 4m 1 Plastic liner U3567C01 φ2 7 φ5 6 3 4m 1 Pressure handle Wire reel hub Frame Torch socket Feed rolls Control cable 10P Feed motor Pressure roll holder 7 1 6 1 7 2 7 2 8 1 7 1 7 4 6 1 ...

Page 11: ...wear a gas mask or adequately ventilate when the welding machine is used in the place regulated by a local law To prevent disorder or poisoning caused by fume wear a gas mask or weld at a partial exhaust facility approved by the local regulation Adequately ventilate or wear a gas mask when using the welding machine in a tank in a boiler or in a hold of a ship because heavier gasses such as carbon ...

Page 12: ...et optional bracket of part number U30022Z00 Do not hang the wire feeder using the handle of the wire feeder as shown in the diagram below Do not install or hang the wire feeder in a posture resulting in falling of the reel as shown in the diagram below When installing the wire feeder at a high place be sure to install and secure it on a horizontal surface Reel installation angle is normal A force...

Page 13: ...ere the equipment can become wet 6 1 Connection to the Welding Power Source and to the Gas regulator Standard Composition 1 Remove the guide adapter from the wire feeder insert the outlet guide into the guide adapter and attach the guide adapter to the conduit of the welding torch Use proper sized outlet guide adjusted to the wire size Outlet guide for wire diameter 0 9 1 2 is attached For other d...

Page 14: ...ure to insert the stopper pin of the wire reel shaft into the wire reel stopper pin hole 4 Turn the cap counter clockwise to tighten it 5 Bring down the pressure handle then raise the pressure roll holder 6 After pulling out the wire thread it from the pilot to outlet guide through the center guide 7 Return the pressure reel holder first the pressure handle Wire reel shaft Wire reel stop pin Wire ...

Page 15: ... pressure and straightner Turn the pressure handle to set to the correct pressure force for your wire diameter Set both pressure handle gauge to same value Wire straightner is an optional part Refer to 9 3 Recommended wire pressure adjustment Pressure handle Wire straightner φ mm φ inch Gauge Gauge 1 6 1 16 2 3 2 3 1 2 3 64 1 2 3 4 1 0 0 035 1 2 4 5 1 6 1 16 2 3 2 3 1 2 3 64 1 2 4 5 1 6 1 16 3 4 2...

Page 16: ...he center guide and guide adapter for aluminum 3 Attach the middle gear and feed roll for aluminum 4 Attach the wire straightner inlet guide and pilot 5 Remove the wire reel hub 6 Attach the reel adapter 7 Attach the wire reel hub to the reel adapter Pilot Wire straightner Inlet guide Center guide Guide adapter Feed roll Pressure roll Middle gear Wire reel hub Reel adapter ...

Page 17: ...to the diagram below Brake pad Install the felt surface toward the wire reel shaft side Hexagon head bolt M10X55 Cap Wire reel shaft Strong Weak WARNING Observe the following precautions to prevent serious personal injury caused by fall of the wire reel at the time of wire reel hub adjustment or hanging bracket installation Mount the brake pad to the wire reel shaft as illustrated below with care ...

Page 18: ...parts while inching After straightening the conduit feed the wire by pressing the INCHING key When the wire appears from the end of the wire guide press the INCHING key again Cut the wire at about 10mm from the end of the tip Wire feed speed can be adjusted by turning the adjusting knob 7 7 Hanging the Wire Feeder CAUTION When hanging the wire feeder firmly fix the cap knob and clamp screw to prev...

Page 19: ...o as not to loose the hexagon head bolt M10X30 nut M8 washer M8 and spring washer M8 3 pieces for each of the hanging bracket accessory in that order WARNING Observe the following precautions to prevent serious personal injury caused by fall of the wire reel at the time of wire reel hub adjustment or hanging bracket installation Mount the brake pad to the wire reel shaft as illustrated below with ...

Page 20: ...el hub M10 24N m 245kgf cm M8 6N m 61kgf cm Recommended tightening torque Reel bracket Cap Hexagon head bolt M8X25 Nut M8 washer M8 spring washer M8 3 pieces for each Hexagon head bolt M10X30 with washer spring washer Installation hole Hanging bracket option ...

Page 21: ...le with the motor Replace the motor Wire pressure is too weak Refer to Recommended wire pressure adjustment in Section 7 2 Dust and chip are accumulated on the outlet guide and on the feed roll Remove the dust and chip 3 Pressure roll does not rotate smoothly Failure of the pressure roll holder Replace it if necessary 4 Shield gas is not supplied when pressing the torch switch The discharge valve ...

Page 22: ... amount of brushing friction or replace the brush Service life of the brush varies depending on ambient temperature and welding condition etc but normally the service life is about 4 000 hours If the machine is operated for six hours a day the service life of the brush will be about two years Periodical replacement of the feed motor is recommended Terminal block Pulse A Pulse B ...

Page 23: ...g and a screen 7 U5623C04 Rear cover 1 With coating 7 1 U5374J02 Grommet with film 1 7 2 4739 489 Grommet with film 1 8 U5281C05 Panel 1 With coating and a screen 8 1 4739 507 Grommet 1 9 U5281B00 Wire feeder 1 With a feed motor 10 U5209J01 Guide adapter 1 11 U5185J04 Terminal block bracket 1 With coating 12 4739 492 Terminal block 1 13 U5185X00 Encoder cable 1 Assembly 14 U5185F00 Motor cable 1 A...

Page 24: ... E22 9 PARTS LIST continued 4 5 3 2 1 8 6 18 17 7 19 1１ 12 15 14 13 9 10 16 Fig 1 Main body and wiring disassembly ...

Page 25: ...5439B12 Feed roll 0 9 1 0 1 2 2 9 1 3361 880 Hexagon socket cap screw 4 M4 x 16 9 2 3361 893 Bolt 4 M4 x 10 10 U5185B04 Guide block 1 11 U5185B05 Center guide 1 12 4802 207 Feed motor 1 13 U5185B06 Insulating board 1 14 U3971B04 Insulating bush 3 14 1 3361 895 Flat head screw 3 M6 x 20 15 U5185Q00 Drive gear 1 16 U5185B09 Pressure spring holder 2 17 U5185B12 Compression spring 2 18 U5185B10 Pressu...

Page 26: ... E24 9 PARTS LIST continued 6 5 3 2 4 20 11 10 18 17 16 19 12 13 1 14 22 21 15 7 8 9 23 Fig 2 Feeding part disassembly ...

Page 27: ...2 Feed roll 1 0 1 2 4 For aluminum V type groove K5463V03 Feed roll 1 2 1 6 4 For aluminum V type groove K5463R06 Feed roll 0 8 0 9 4 For brazing 3 Center guide Outlet guide Guide adapter Fig 3 Outlet guides include E type snap ring Part No Description Q ty Remarks U5185B05 Center guide 0 6 1 6 1 For steel U5204B02 Center guide 0 8 1 0 1 For aluminum U5204B03 Center guide 1 0 1 6 1 For aluminum U2...

Page 28: ...1 With bolts K5439E00 Wire reel cover full cover 1 Assembly with bolts U5191F00 Reel adapter 1 With bolts K5439F00 Caster 1 For wire feeder with 4 wheels and bolts U30022Z00 Hanging bracket 1 With bolts Fig 3 Optional parts assembly Pilot Inlet guide Wire straightner Center guide Feed roll Guide adapter Outlet guide ...

Page 29: ...13 kg For using wire optional parts are necessary 10 2 Available TIG welding torch and wire guide TIG welding torch Wire guide AW D 17 150A air cooled BHCD 7117 AW D 26 200A air cooled BHCD 7126 AW D 18 300A water cooled BHCD 7118 10 3 Available TIG filler controller HC 71D type TIG filler controller 10 4 Standard accessories Part number Description Quantity Remarks K5439B12 Feed roll 0 9 1 0 1 2 ...

Page 30: ...City Taoyuan Hsien Taiwan Phone 886 3 461 3962 Fax 886 3 434 2394 OTC DAIHEN Asia Co Ltd 23 43 16th F1 Sorachai Building 23 Soi 63 Sukhumvit Road Klongtonnua Wattana Bangkok 10110 Thailand Phone 66 2 714 3201 Fax 66 2 714 3204 OTC DAIHEN INDIA Pvt Ltd 2nd FI D 45 Udyog Vihar Phase 5 Gurgaon 122016 Haryana India Phone 91 124 4300821 Fax 91 124 4300820 PT OTC DAIHEN INDONESIA Blok G1A 20 Jl Kenari l...