No.

COO25
CONTENTS
I. SAFETY INFORMATION ... . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. .. I
2. ARC WELDING SAFETY PRECAUTIONS ........... ......... ... ....
3. GENERAL NOTICE AT OPERATION ............... . ........ .. ........ 7
4. CHECK OF STANDARD COMPOSITION AND ACCESSORIES
........ 8
5. DESCRIPTION AND OPERATION OF EACH PART
....... ............. IO
6. REQUIREMENT OF INPUT POWER ............... -. . . . .. .. . .. . . . . .. 12
7. TRANSPORTATION AND INSTALLATION ........ ... ................. 13
8. EXTERNAL CONNECTION .. ... .... ... .... .......... ... . . ........... 14
9. WELDING PREPARATION ........ . . . ... . .... . .... . .... . . . .. . . ...... 20
10. WELDING OPERATION ...... ..... ................................. 22
I I. APPLIED FUNCTION .............................. .. . . . . ... ... .... 38
12. MAINTENANCE AND TROUBLESHOOTING .... .. ......... . .......... 48
13. PARTS LIST ... .......................... .. . ........... . . . . ....... 59
14. SPECIFICATIONS ...... ... ................................... .. . ... 61
IS. AFTER SERVICE ....... . .................... . ... . ........... ... . .. 63
I. SAFETY INFORMATION
No.C0025
P. 1/63
The following safety alert symbols and signal words are used throughout thi s manual to
identi fy variolls hazards and special instructions.




Lh WARNING
CAUTION
WARNING gives infonnati on regarding possible personal
injury or loss of life.
CAUTION refers to minor personal injury or possible
equipment damage.
2. ARC WELDfNG SAFETY PRECAUTIONS
Lh WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS fNJURY OR
DEATH.
Be sure to:
. Keep children away_
. Keep pacemaker wearers away until consulting a doctor.
Read and understand the summari zed safety information given below and the
origi nal principal infonnati on that will be found in the PRINCIPAL SAFETY
STANDARDS.
Have only trained and experienced persons perfonn installation, operation, and
maintenance of this equipment.
Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDfNG is safe when precautions are taken.
No.C0025
P. 2 / 63
ELECTRIC SHOCK can kill.
Jive electrical parts can cause fatal shocks or severe bums. The electrode and work
ICI"cullilsare electricall y live whenever the output is on. The power line and internal circuits
equipment are also li ve when the line disconnect switch is on. When arc wel ding all
Im"tal components in the torch and work circuits are electrically live.
o.
Do not touch live electrical parts.
Wear dry insulating gloves and other body protection that are free of holes.
Insulate yourself from work and ground using dry insulating mats or covers.
Be sure to tum off the line di sconnect switch before installing, changing torch parts or
maintaining thi s equipment .
Properly install and ground thi s equipment according to its Owner' s Manual and
national, state, and local codes.
Keep all panels and covers of this equipment securely in place.
Do not use worn, damaged, unders ized, or poorly spliced cables.
Do not touch electrode and any metal obj ect if POWER switch is ON.
Do not wrap cables around your body.
~ 4 f )
ARC RAYS can bum eyes and skin: FL YrNG 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.
I. Wear face shield with a proper shade of filter (See ANSI Z 49. 1 li sted in PRrNCIPAL
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 fl ash and glare: warn others not
to look at the arc.
4. Wear protective clothi ng made from durable, flame-resistant materi al (wool and leather)
and foot protection.
5. Use approved earplugs or earmuffs ifnoise level is high.
Chipping and grinding can cause !l ying metal. As welds cool. they can throw orr slag.
6. Wear approved face shi eld or safety goggles. Si de shi elds recommended.
7. Wear proper body protection to protect skin.
WELDING can cause fire and explosion.
No.C0025
P. 3/63
Sparks and spatter fly oft' from the welding arc. The flying sparks and hot metal. spatter. hot base
metal, and hot equipment can cause fi re and explosion. Accidental contact of electrode or
welding wire to metal object can cause sparks, overheating, or fire.
I. Protect yourself and olhers from flying sparks and hot metals.
2. Do not weld where flying sparks can strike fl ammable material.
3. Remove all flammabl es within 10m (35ft.) orthe weldi ng arc. If this is not possible, tightly,
cover them with approved covers.
4. Be alert that welding sparks and hot metals from welding can easi ly 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 cei ling, floor, bulkhead, or partiti on 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 ofT welding wire at contact tip when not in use.
10. Do not use the welding power source for other than arc welding.
\ 1. Wear oil-free protecti ve garments such as leather gloves, a heavy shirt, cuffiess 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 10 your heahh.
Arc welding produce fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
I. Keep your head out of the fumes. Do not breathe the fumes.
2. Ventilate the area and I or use exhaust at the 8rc to remove welding fumes and gases.
3. lf ventilation is poor. use an approved air-suppl ied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the manufacturers instruct ions on
metal s, consumabl es. coatings. and cleaners.
5. Do not weld or cut in locations near dcgreasing. cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to fonn highly toxic and irritating gases.
6. Work in a con lined space only if it is well or while weari ng an air-supplied
respirator. Shieldi ng gases lIsed for wclding can air c;]using injury or (kath.
Dc sure breathing air is stile.
No.C0025
P. 4 / 63
ITJI
;;;; CYLI NDER can expl ode ir dmnagcd .
. , J .
" ,.
: ..
A shielding gas cylinder contains high-pressure gas. I r damaged, a cylinder C3J;! explode.
Since gas cyli nders are nonnally part of the wel ding process, be sure to trcat them carefully_
I. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the
specific application; maintain them in good condition.
2. PrOlect 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 fo llow instructions on compressed gas cylinders, associated equipment, and the
CGA publication P-I listed in PRINCIPAL SAFETY STANDARDS.
7. Tum face away from valve outlet when openi ng 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,
..
InJunes may occur.
I. Do not use this equipment if the case and the cover are removed.
2. When the case is removed for maintenance/inspection and repair, cert ified or experienced
operators must perfonn the work. Erect a fence, etc. around this equipment to keep others
away from it.
3. Do not put hands, hair or clothes near the rotating fans or wire feed roll.
~
This equi pment uses high frequency for arc starting.
No.C0025
P. 5/63
Hi gh-frequency may enter ncarby uni ts as shown below, causing electromagneti c trouble.
Input cables, signal cables, telephone cables
Radio sets, TV sets
Computers and other control equipment
Industrial detectors and safety units
,
Pacemakers, hearing-aid sets
For preventing electromagnetic trouble;
I. Make the cable as shortest as possible.
2. Install cables along the fl oor or the ground as close as possible.
3. Put the base metal side cable together with the torch side cable.
4. Do not use a common base metal ground with other machines.
5. Tight ly close all of the doors and covers of thi s equipment, and secure them.
6. Do not press the torch switch other than when ready to start the arc.
7. When electromagnetic trouble occurs, take the measures shown in thi s instruction
manual until trouble is corrected.
Please contact OTC-DAIHEN , when necessary.
8. Pacemaker wearers must not come near this equipment during operation until consulting
a doctor.
Operation of the pacemakers will be affected badly by high frequency.
ARC WELDING work areas are potentially hazardous.
FALLlNG or MOVrNG machine can cause serious injury.
Use both eyebolts, if instal led, to lift the welding power source.
Put this equipment solidly on a flat surface.
Do not pull this equipment across a floor laid with cables and hoses.
No.C0025
P.6 / 63
PRI NCIPAL SAFETY STANDARDS
Arc welding equipment - Install ation and usc, Technical Specificat ion
l Ee 62081. from Internat ional Elect rOlcchnical Commi ssion
Safety in Welding and Cutt ing, ANSI Standard 249. 1, from American Welding Society.
Safety and Health Standards, OSHA 29 CFR 1910, from Superi ntendent of Documents, U.S.
Government Printing Office.
Recommended Practices for Pl asma Arc Cuning, American Welding Society Standard A WS
C5.2, from American Welding Society.
Recommended Safe Practices for the Preparation for Welding and Cutt ing of Containers That
Have Held Hazardous Substances, American Welding Society Standard A WS 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 Pamphl et Pl , from Compressed Gas
Association.
Code for Safety in Welding and Cutting, CSA Standard WI17.2, 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 51 S, from National Fire Protection
Association.
J.GENERAL NOTICE AT OPERATION
3. 1 Rated duty cycle
& CAUTION
No.C0025
P. 7/63
. Use al the rated dUly cycle or under. Ife)(ceeding the rated dUl Y cycle. the welding power
source may be deteriorated and burned.
I) Rated dutY cycle: 40%
& CAUTI ON
. When you set to AC BALANCE is " MAX. PENETRATION" si de al AC TIG welding, lise it
wi th rated duty cycle is less than 30%. If duty cycle is over 30%, the welding power source
may be deteriorated and burned.
(2)The duty cycle is percentage of a ten mi nutes period that welding power source can be operated
at rated output wit hout causi ng overheating and damage of the welding power source. This
welding power source can be operated for four consecutive minutes. but it must operate al no
load for the remaining six minutes to allow proper COOling.
~
ON I orr
I
I:
4 min' l
6 min.
:1
..
IOmin.
(3) If exceeding the rated duty cycle, temperature rise of weldmg power source and torch exceed the
allowable value, and it causes to burn the equipment.
(4) The fol[owing figure indicates the combinat ion of welding current and dUlY cycle.
Observe the duty cycle according to welding current.
(S)The duty cycle is limited by other machines (welding lorch CIC.). Therefore, observe the lowest
rated duty cycle in the combination machines.
(Less Ihan I64A)
100 _ __ . _ __ l.!Lessthan I90A
\ \ AC BALANCE
DUlY
cycle SO
(%).
o
\ Alowllble duty cycle .t
\ AG BAlANCE ...
\ wMAX.PENETRA n ONN
,
,
,
Usable range ", 40%
,
100 200
Welding CUlTclIl{A)
.. . (30%)
I
I
300
No.C002S
P. 8 / 6J
4. CHECK OF STANDARD COMPOSITI ON AND ACCESSORIES
4.1 Standard composition
. 1 I part s are standard compositi ons. The other parts shall be prepared at yOllr side.
Remote control box, extension cable and hose are available as a optional accessory.
Single phase
380V
Shielding gas cylinder
!
-1 Argon gas regulator with flowmeter I
[nput
cables Grounding ":"
4.2 Standard accessories
Cooling water hose for water cooled torch
Remote control box
(Optional accessory)
00 I Welding torch
Base metal
Grounding cable
Welding power source
Ch k h h ec the quantity w en you receive I e
Description Speci fication Quantity Remarks
Q)Glass enclosed fuse 5A 250Y I
Glass enclosed fuse IDA 250V 2
@Bolt MIO x 25 I
For torch connection
Nut . washer MIO I set
Bolt M8 X20 I For connection of base metal side cable
@Bolt M6 x l 6 2
For input tenninal connection
CVN ut washer M6 2 set
Cartridge fuse RLI1 5 IDA I
4.3 Accessori es whi ch you shoul d prepare
(I) Argon gas: Only when TIG welding (Gas; Tungsten Arc Welding)
Use argon gas for wcld ing.( Purity should be more than 99.9%),
(2) Filler wire : Onl y when TIG welding
Use a proper fi ller wire according to materi al and thickness of base metal.
(3) Electrode: Only when stick welding (Shi elded Metal Arc Welding)
No.C0025
P. 9/63
Use proper electrode according to material of base metal, welding position and joint shape.
(4) Electrode holder
Use an insulated electrode holder to ensure operator safety.
(5) Input cables and grounding cable
Input cables Thicker than 14 mm
2
X2
Grounding cable Same in ut cable X 1
* Be sure to make a grounding to avoid electric shock.
The resistance of grounding should be less than 10 9 .
,

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5.2 Welding torch (Refer to owner's manual of each welding lorch for detai ls)
Torch switch
Water
Power cabl e ho:se[= b3CCC:r'/ L
i
Torch
Tungsten electrode
5.3 Argon gas regulator
Gas hos<: I=):e:===i
_To". \' switch
.&. WARNING
No.C002S
i'. 11/ 63
{
. An argon gas regulator is designed specifical ly for argon gas. Use the regulator only for
high pressure argon gas .
0 0 not di sassemble the regulator, and never touch the screw of safcty valve, and the
pressure controll ing mechanism inside of the regulator. Disassembli ng and touching may
cause seri ous ini urv or death. Refer to the owner' s manual of the rce. ul ator.
Flowmeter
Pressure gauge
o
o
\ Flu" k"uh
(l ull e! i.;Pll pl 1t1! ,
Fixi ng nut

No.C0025
P. 12 / 63
6. REQUIREMENT OF IN PUT POWER
6. 1 Commercial input power
Lb. WARNING
. Provide a leakage circuit breaker when the weldi ng power source is used at place with high
humidity such as work site, the stcctpl alc or the steel structure,.
Lb. CAUTION
e Se sure to provide a switch(with fuse) or circuit breaker at input side of each welding
power source.
ec :apaclty 0 commercia f d mput power an amperage 0 ffi eak use or CirCUit br er
TIG Stick
DC AC DC
I
AC
InDut voltage and phase 380 V Single-phase
Input voltage range
380V+ 1O%
Input power (KVA) More than More than More than More than
19.9kVA 22.3kVA 21.2kVA 22.0kVA
Amperage of fuse or
80A
circuit breaker
6.2 Precautions for use on an engine generator
Lb. CAUTION
Observe the following to prevent troubles of the welding machine in using auxiliary power
supply of engine generator and engine welder.
e Set the voltage of engine generator to 380 ......... 399V during no- load running.
If output voltage is set too high, failure of welding machine results .
Unlike commercial power source, engine generator is slow in recovering voltage when load
variations occur. Therefore, output voltage drops excessively when current varies
suddenly due to arc start, and that may cause loss of arc.(However. a welding power source
will not fai l due to such conditions.) To prevent this, the capacity of engine generator
must
be more than twice the rated input (KV A) of a weldi ng power SOUl"e. Especially, engine
generator with a damper winding is recommended. Contact the manufacture of engine
generator whether the engine generator is provided with a damper winding .
If one engi ne generator is used for two or more welding power sources, loss of arc is likely
to occur due to the influence of recepti ve welding power source .
When use the auxiliary power source of engine welder, use only the auxiliary power source
which voltage wave form is improved.(Contact the manufacture of engine welder for
delai ls. )
NO.C002S
P.I3 / 63
7. TRANSPORTATIO AND INSTALLATION
7. 1
WARNING
the followings to preveOl troubles during transportation and damage of the
not touch live electrical parts inside and oUlside of the welding machine.
When carrying or transferring the welding machine, be sure to tum OFF i
power supply by li ne disconnect switch.
lifting the welding machine with a crane, surely lit the case and the
cover, and linnly tighten the eyebolts .
Lift the welding machine in single with two wires. Lifting the welding power
source with other equipment may cause them to drop.
carrying the welding machine with a fork lift , surely provide wheel
WARNING
installing the welding observe the lowings to prevent occurrence
and
V
fumes and
not install the welding machine near <;:ombustible materials and
innammable gas.
le Rem()ve combustible materials not to attach the spatter to them.
preventing gas-poi soning at choking, usc local exhaust equipment or use
protectors for respiration that are prescribed at safety regulations.
welding at narrow space, ventilme the place sufficiently or wear the
protectors for respiration, and work under supervision by a trained supervisor.
1.'AI:!er installing the welding machine, provide wheel stoppers.
le Do not put heavy substances on the lOp of the machine.
not cover the venti lation pan of the v,"clding machine.
stand.
if'., CAUTION
To prevent electromagnetic troubles, examine the followings.
Also, when electromagnetic troubl es actually occurs, examine the followings
agam .
Change the installati on place of the welding machine .
'nslall the input cables in Ihe grounded metalli c conduit .
Provide clcctromugncti c shield to the wholl! welding place.
No.C0025
P. 14 / 63
Lh CAUTION
When setting the weldi ng power source, examine the foll owi ngs .
Observe the fo ll owings when select ing an instal lation place .
Keep the welding power source away more than JOcm from wall or other machines .
Select the place of less humidity, dirt and dust. And do not expose welding power source to
direct sunlight, wind and rain .
The installation place should be apart from fl yi ng sparks and spatter.
. The installation place should be dry and clean with few dusts, and come on the oil steam .
No bad corrosive gas should be around the installation place .
The installation place should be below altitude of 1 DOOm and ambient temperature should be
from -10 to 40"(;. and relative humidity of the air should be up to 50% at 40"(;. 90% at 20"(; .
Install the wetdi ng power source in few vibration and rigid hori zontal place. (i nclined up to
10
.)
. Select the place that no wind blows against the arc. (Use a wi nd shield to protect the arc
from wind, otherwise welding defects may be generated.)
8 EXTERNAL CONNECTION
,1:, WARNING
~
Observe the followings to prevent the electrical shock.
In touching the live electrical parts, critical electric shock and bum may occur .
00 not touch li ve electrical part inside and outside of the welding power source .
Grounding to the case of the welding power source should be perfonned by persons
qualified in electrical work and according to the laws and regulations .
Be sure to tum off the line di sconnect switch before connecting .
00 not use cables with insuffici ent capaci ty, dan13ged or exposing the conductor.
. Securely tighten each connection .
Securely attach the case and cover after connecting cables.
8 .1 Extema f connection 0 output 51 e
Lh CAUTION
V
To prevent electromagnetic troubles, examine the followings. Also,
when electromagnetic troubles actually occur, examine the followings again .
Shorten the welding cable as much as possible .
fnslallthe \ .. -elding cable along the Iloor or the ground as close as possible .
Pl ace the cable of the base metal side and lorch side as cl ose as possi ble .
00 not ground the weldi ng power source commonl y with other machines.
8. 1. 1 TIG welding (Gas Tungsten Arc Welding)
CDRemove two screws
Torch switch c ble
o
, ,0
Remote control box
(Optional accessory)
o 0
Torch switch
No.C0025
1' . 15 / 63
II @Torch switch

control m;:::;dJ
5 Gas 1
4 Cooling water
L
_==:r @ utput terminale
@Outputterminal () @:J ,-,E
Base metal side cablcr=.L f __ ,------,
Fix securely to
. Tum off the line disconnect switch before connecting. base metal.
CDRemove two screws (M6) of the front cover, and open it.
Connect output terminal () with base metal side cable.
Connect output terminat e with torch side cable.
Connect "Cooling water" terminal with water hose of torch, in case of using water cooled
torch.
Connect "GAS" out let with gas hose of torch.
@Connecl "Torch switch" receptacle with torch swi tch or foot switch.
CVWhen usi ng remote control box , connect "Remote control" receptacle with remote control
box and change-over the switch on printed circuit board.( Refer to " II. APPLIED
FUNCTION" for detail s.)
@Close front cover and tighten the screws.
During use or the welding power source, close the front cover and screw by screws.
No.C0025
P. 16 / 63
8.1.2 Slick weldi ng (Shielded Metal Arc Welding)
COLoosc two screws.
o
, ,0
4 Remote control
Remote control box
(Optional accessory)
0 0
Electrod_\O: der
1----1-----<"113 Output terminal@ \ ====1
L ___ @Outputtcnninal e (0
Base metal side ca;:b:;:l;:e_Lf_-:--,
Fix securely to
base metal.
. Tum off the line disconnect switch before connecting.
CDRemove two screws(M6) of the front cover, and open il.
Connecr output tcnninal 8 with base metal side cable.
output tenninal wi lh holder side cable.
@When using remote comrol box, connect "Remote canlrol" receptacte with remote control box,
. and change-over the switch on printed circuit board.(Refer to " 11 . APPLIED FUNCTION" for
details).
@Close front cover and lighten the screws.
During usc of the welding power source, close the fro nt cover and screw by screws.
Connect in order to follow figure above for stick weldi ng with AC or DC Electrode Negative
Posit ive. When us ing DC Ele<:trode Pos itive polarity, change holder side cable to base
metal side cable.
8.2 Connection of 'as hose and water hose TIG weldin onl
Lh WARNING
. Choking can occur when shielding gas conti nues to fl ow in poor ve nt ilated
area. Close the main plug of the shieldi ng gas cylinder when weldi ng operation
is not perfonned.
Lh CAUTION
.If the gas cylinder overturns. physical injuries lIlay occur. Connect the gas.hose ancr fixi ng
the gas cylinder to gas cylinder stand.
Gas regulator
wi th flowmeter
Nut for cyl i nder

/ ' il) /> cylinder
0"," """'"'' I

COFjt the nut to gas cyli nder.
and fi rmly tighten the nut
with a monkey wrench.
Fit the gas hose to the
Oli llet cOllpling of gas
n.:gulahlf ,UlJ linn l) li ghh:!l
Ih e !lUI \I ilh :1 111lm!....:) \\ 1"":I1( h .
8 3 Grounding and connecti on of input side
Lb. WARNING
It
Observe the foll owings to prevent the electrical shock.
In touching the live electri cal parts, critical el ectric shock and bum Illay occur.
. Do not touch live electrical parts inside and outside of the welding power source .
No.C0025
P. 17 ! 63
Grounding to the case of the welding power source should be performed by persons
qualified in electrical work and according to the laws and regulat ions.
e Se sure to tum off the line disconnect switch before connecting .
Securely attach the case and cover after connecting cables .
Provide a leakage circuit breaker when the welding power source is used at pl.ace wi th hi gh
humidity such as work si te or the steel plate or the steel structure.
Lb. CAUTION
To prevent electromagnetic troubles, examine the followi ngs. Al so, when
W
electromagnetic troubles actually occur, examine the followi ngs again.
e Add noise filler to input cables.
eoo not ground the welding power source commonly with other machine.
Lb. CAUTION
Be sure to provide a switch (with fuse) or circuit breaker at the input side of each welding
power source.
Lb. CAUTION
. Be sure to make a grounding to avoid electric shock .
Use the fo ll owing cable size:
. Thicker than 14 mm
2
Thicker than input cable
No.C0025
P. 18 / 63
Input cables
ix it securely.
able size : Thicker than 14mm2
@Grounding
Provide line di sconnect switch wit h fuse or ci rcuit
breaker for each welding power source
\
_____ (DGas regulator
with flowmeter
I+----+---@Gas hose
@Drain water hose
@Cooling water hose
,1:, CAUTION
Be sure to ground the case of welding power source.
(The resistance should be less than 10 Q .)
Grounding cable thickness:Same your input cable
e lf grounding is not provided, leakage voltage may appear between input circuit and the case
of welding power source. These are the causes of electrical shock when touching them.
8.4 Connecti on of cooling water hose .( When using wmer cooled larch)
At I I r h f . d I fi bel tac 1 t l C COO I ng water ase 10 a lap 0 city water accor Ill ' to t le :Igurc ow.
No. Description Part No. Remarks
( I) Water hose 501 PI 042LOO Optional accessory
(2) Hose connector PI042M02 Optional accessory
(3) Rubber hose(for city water) 15 <p 30cm Optional accessory
(4) Feed watcr place(for water hose) PI 042MOI Opti onal accessory
No.C0025
P.19 163
(5) Nipple (1/2) Available on the market
Note) For tnslalhng (4), COI l wIth seal tape.
~ ~ - ~ ~
( I) .. , (n
(a) Direct connection
of rubber hose with
a water tap.
(b) Connection with
tap or fitting of
112 threaded.
om mallon 0 water-coo C C b
f J d lore
Model
Description Part No. Q' ty
Gas hose PI042KOO I
Welding cable PI042POO I
Water hose PI042LOO 2
Feed water place (for water hose) PI042MOI I
Hose connector PI042M02 I
Rubber hose (for city water) I
(e) Connecti on with
stop valve.
h d an cuy waler
BAB-350 1
Remarks
3m with nut at both sides
38mm
2
X3m
Sm. with nul at one side
30cm
.
No.C0025
P.20 / 63
9 WELDING PREPARATION
Lh CAUTION
To prevent electromagnetic troubles. examine the followings. Also, when
if
electromagnetic troubles actually occur. examine the foll owings again .
Close and fix securely of all doors and covers of welding power source .
Install the welding cable along the floor or the ground as close as possible .
Pl ace the cable of the base metal side and (orch side as close as possi ble .
Keep fl owing rate ofshiclding gas proper. If it is not proper, high freq uency noise will
Increase.
9 I P . f Ii rcparallon 0 sa ety protective eqUIpment
Lh CAUTION
~ 4 f )
ARC RAYS can bum eyes and skin: FLYING SPARKS AND HOT METAL
can cause of injury. NOISE can damage hearing .
. '.
-
Arc rays from the welding produce intense heat and strong ultraviolet rays that can bum eyes
and skin. Noise from some arc welding can damage hearing .
Wear a face protection with a proper shade of filter ( See ANSI Z 49. I listed in
PRrNCIPAL SAFETY STANDARDS. ) to protect your face and eyes when welding or
watching .
Wear approved safety goggles .
Use protective screens or barriers to protect others from fl ash and glare: warn others not to
watch the arc .
Wear protecti ve clothing made from durabl e, fl ame-resistant material (wool and leather)
and foot protection .
Use approved ear plugs or ear muffs if noise level is high.
,
Shielding at TIG I STICK welding
( I) Sh Id Ii T G Id ,e mg or I we Ing
Welding current Less than 100A 100-300A 300-500A
More than.500A
Shielding No. 9 or 10 11 or 12 13 or 14 150rl6
,e JOg or we mg
Welding current Less than 30A 35- 75A 75- 200A 200- 400A
More than 400A
Shielding No. S or 6 7 or 8 9 or II 12 or 13 15 or 16
No.C0025
P.2 1/ 63
9.1 s.'X\\cn tll)eT"ation and gas fl ow control
Lt. CAUTION
. 00 not put your hands, hair, and cloths near the rOlating parts of the fan motor.
. When operating the main plug of the gas cylinder. do not put your face near the out let port .
High-pressure ~ a s may blow out, causing physical ini uries.
Preparation in order of the numbers,CD (2) ....
CDSet the line di sconnect
switch for single-
hase 380V to ON.
o
o
@Pl ace
CONTROL
POWER swi tch
in "ON"
positi on.
I""'''''''' check
the flow
adjust ing
handle is
placed in
"SHUT' side,
open the
of main
@Adjust the gas @PlaceGAS
switch in
"CHECK"
sition.
Flow usting flowing by turning
After adj usting
gas fl ow, pl ace
GAS swi tch in
"WELD"
sition.
handle. gas fl ow adjusting
handle to "OPEN".
9.3 Cooling method of welding torch
Lt. CAUTION
. Using water cooled torch when "TORCH" switch on front panel in "AIR-COOLED"
_position may cause burning the torch.
AIR COOLED
n
WATt : \{ COOI.EI)
I ORCI I
. Select ..... proper cooling method .... ccording 10
the sorl of welding la rch.
No.C0025
P.22 / 63
10 WELDING OPERATION
& WARNING
It
Observe the followings to prevent the electri cal shock.
.In touching the live electrical parts, cri tical electric shock and bum may occur .
Do not touch live electrical parts inside and outside of weldi ng power source.
e Se sure to turn off the line di sconnect switch before connecting .
Securely anach the case and cover after connect ing cables .
Wear dry clothes and gloves when weldi ng.
& CAUTI ON
. This weldi ng machine must be operated by operators understanding contents of this
owner's manual and having knowledge and ski ll s for handling the weldi ng machine safely .
Use at the rated duty cycle or under. If exceeding the rated duty cycle, the welding machine
may be deteriorated and burned .
Close panel cover of the fro nt panel duri ng weldi ng.
&
CAUTI ON
~
Observe the fo llowi ngs to perform TIG welding safely .
Use "GAS" switch when adjusting shielding gas fl ow. If using torch switch to adj ust the gas
fl ow, useless high frequency generates .
Using improper electrode may cause fail ure of arc stan, and generate useless high
frequency .
Improper shielding gas fl ow may cause failure of arc start, and generate useless high
frequency.
10. I TI G welding (Gas Tungsten Arc Welding)
10. 1. 1 Operation of TIG weldi ng
STICK
TIGC
TIG SPOT
WELDING MODE
Set the WELDING MODE
change-over switch to TIG welding.
DC
.....
A C
1-
Set the mode
change-over switch.
& WARNING
No.C002S
1' .23 / 63
WELDING CURRo
Set the welding
current.
If change-over thi s switch at welding, sparks will generate,
and it mi ght be a cause of buming .
10.1.2 Pulse (ON/OFF)
. Never change-over this switch at weldi ng .
. Sct the switch surel y.
Pulse function can be used at DC TIG weldi ng and AC TIG welding. It can not be used at
stick welding.
( I) What is pulse?
Pulse is the function which change the welding current periodically to stabilize arc, control
penetrations, and control heating.
ON
(2) Setting of pulse
For pulse operation, set the pulse change-over switch on front panel.
lJ
Pulse switch Main applications
Tack welding
Repeating of short
welding.
OFF
Thin plate welding
. Preventing weldi ng bead
hnnging down on thin
platl..! welding
ON
,
Torch switch
Welding current
Torch switch
OFF
PULSE
Timing chart
ON
~
~
ON
~
L
L
L
Welding "n.,."nl ~ ~
J'Il "": ":Uffl"111 11;1-''': e llrr':111
No.C0025
P. 24 / 63
(3) cHi ng the condition of pul se
ON
iA\'
VI ..
OFF
PULSE PULSE WELDING! PULSE TIME ($!,.'(;.) BASE TlME( Sct:. }
CURR.(A) BASE
SCI PULSE
change-over switch
loON.
PULSECURR.
!
CURR.(A)
Sel PULSE CURR., WELDfNG/ BASE
CURR., PULSE TIME and BASE TIME.
BASECURR.
--!n,----------,---n,--
h -I- t 1
Pulse time Base time
. Pulse li me can be set for 1.4 seconds maxi mum. and base time can be set for 2.5 seconds
maxImum.
10. 1.3 Craler-fi ller (ON/OFF/REPEAT)
( I) Whal is craler-fill er?
Crater
JL
Bcad
" . .
,
The hollow call ed "crntcr" is generated when
fini shi ng the weldi ng. That hollow distort ion may
cause cracks or weld ing defects and should be as
small as poss ible. The function of fi lling the hollow
is called "crater-fi ller",
(2) Cratcrti ll er setting
No.C0025
P. 25 / 63
REPEAT
. This welding power source has three ki nd welding operation by
sett ing af eRA TER-FILLER switch on front panel.
OFF
Setting of
CRATER-
FILLER
switch
OFF
ON
REPEAT
Main applications
Tack welding
Repeat of short welding
Thin plate welding
Thick plate welding
. Preventing welding bead
hangi ng down on thin
plate welding
Torch switch
(TS)
Wel ding
current
Gas now
Timing chart
ON
ON
ON
f
I 1
--' .
i<E7; Pre- now !!nIt
ON
CRATER
FILLER

i LOFF
POSt now ti ntti oE-'i
Keep torch switch on during welding.
Torch switch
(TS)
Welding
current
Gas flow
ON ON
Init iol cum:n!
\,
I !
--I ;
,.1
I OFF I
Main
;

; ,
!
; !

Crater filler
c rent
,
Prenow time ilo l
Up i i
slope !E-+l
time
time
POSI now
lime
Welding power source is not deenergizcd even if lorch
switch is oIT during main welding.
ON ON ON ON
Torch switch
OFF OFF OF
(TS) Initial Main welding current Crall::f-
CUrretlt
Welding -Hi '-1
i JL, "OP< .J! oj L
Prc-fl ow time .... nslope ti Rle 7 M <f- time
Welding power source is not deenergizcd even if torch
switch is ofT. For fini shing the welding. pull up the
torch from base metal and then turn the torch swit ch
oITO").
No.C0025
P.26 / 63
(3) Sett ing tile conditi on of crater-fi ller
REPEAT
OFf [0]
ON
CRATER
-FILLER
Set the crater-filler
switch to ON or
REPEAT oosition.
100(i) 'f) " 200 25' 100(i) 'f) " 200 '50 \i)f) ' " (i) ' "
50 3011 50 300 I I
,
INITIAL
CURR
CRATER UP SLOPE
-FILLER TIME
CURR
Set the INITIAL CURR., CRA TER-
FILLER CURR., UP SLOPE TIME
and DOWN SLOPE TIME.
DOWN SLOPE
TIME
Usually crater-fi ller current is 60 ......... 70%
of welding current
10. 1. 4 Crater-fi ller and pul se
By combining crater- fill er and pul se. foll owing weldi ng operat ion can be possible.
_
fONl, ~ __ JONl,
Torch switch I ~ OFF I L

Welding current
~ .
Ini tial Up slope time Pul se
current current
)
r
Base current Down slope time Crater-filler
current
10.1.5 Initial current
Initial current can be selected "ON" or "Or'T' by change-over switch (SW3)on
P. C.B. P6887T.
Refer to 11 .1.2 for detai ls .
Initial current can be sct from SA to JOOA with adjusting knob on front panel.
(Minimum val ue is 20A at AC TIG welding.)
10.1 .6 Post fl ow time
Post fl ow ti me can be adjusted from 1 to 20(sec.)
by set electrode diameter from 1.6 to 4.8(mm <!
with adjusting kllOb on front panel.
10. 1. 7 AC TIG welding
(I) Notice of using AC TIG mode
INTIAL CURR.(A)
No.C0025
P.27 / 63
When using AC TIG mode, observe the followings not to damage the welding power
source
I. Use proper length cable and use as short cable as possible.
2. When usi ng the extension cable, refer [0 f0r:-I"lo':w"i:.:n"g.:.fi"l g"' u"'re"'.--:---:-c--:-:-_:-:-___ "
Bind the torch side cable and base metal
side cable each other with tape .
o
/'
. Strai ghten the cables as much as possible.
Ifcable sett ing mentioned above cannot
be perfonned by all means, lay the torch
side cable on the base metal.
IGood exampl e I
No.C0025
P. 28 / 6J
3. IflOo long torch side cable is lIsed reluctantly, wind it according to following fi gure of
" Good exam Ie",
Bad exam Ie Good exam Ie
Do not wind the excess part of cable in the
same direction.
Refer to the figure below " How to coil a
exira cable", and make two windings in
opposi te direction each other and pile up
one on another.

Top view
Side view
Explanation
x
A B
the extra cable
A and B.
I them respectively as
Same coiling dirt:ction.
Same turns or..:oiling.
SaHlI.: di:tlll l'll..'r ( If
2
A B
over A in the
lo,."".s; Ie di rcelion.
o
J
10. 1.8 Cleaning width
No.COOlS
P.29 / 63
The cleaning power of arc which is necessary for AC TIG welding (Aluminum, etc.) is
adjustable by the AC BALANCE setting knob.
The relation between the setting position of the AC BALANCE setting knob and weld ing
result s is as follows.
Cleaning width
Penetration
Electrode
consumption
It
Nmow ""pSm.II 30% CJ 40% Lo'''Sh.II, w Wid,
Ma:c .. pcntrat ion Max. cteaning
,
ACBALANCE
Example of cleaning action
wide "f--- standard --.. . narrow
it. CAUTION
.The rated duty cycl e is 40%, but in case of sett ing AC BALANCE knob " Max. penetration"
at AC TIG welding, the rated duty cycle should be less than 30%. If exceedi ng 30%, the
welding power source might burned.
No.C0025
P.30 / 63
10. 1.9 TIG welding conditi ons for reference
(I) General TI G welding conditi ons for DC without pulse welding
Plate Electrode Filler wire Welding Ar. gas
Material thickness diameter Diameter current now rate
(mm) (mill cP) (mm ~ ) (A) (C Imin.)
0.6 1.0, 1.6 - 1.6 20- 40 4
1.0 1.0, 1.6 - 1.6 30- 60 4
Stainless 1.6 1.6,2.4 - 1.6 60-90 4
steel 2.4 1.6,2.4 1.6- 2.4 80- 120 4
(DC, 3.2 2.4,3.2 2.4- 3.2 110- 150 5
Electrode 4.0 2.4, 3.2 2.4- 3.2 130- 180 5
Negative) 4.8 2.4, 3.2,4.0 2.4-4.0 150- 220 5
6.4 3.2, 4.0, 4.8 3.2- 4.8 180- 250 5
0.6 1.0, 1.6 - 1.6 50-70 3-4
Deoxidized 1.0 1.6 - 1.6 60-90 3-4
Copper 1.6 2.4 1.6- 2.4 80- 120 3-4
(DC. 2.4
2.4,3.2 2.4- 3.2 110- 150 4
Electrode 3.2 3.2, 4.0 3.2- 4.8 140- 200 4-5
Negative) 4.0 3.2, 4.0, 4.8 4.0-4.8 180- 250 4- 5
4.8 4.0,4.8 4.8-6.4 250- 300 5- 6
6.4 4.0.4.8. 6.4 4.8-6.4 300-400 5- 6
1.0 1.6 - 1.6 50-60 5-6
1.6 1.6,2.4 - 1.6 60- 90 5- 6
2.4 1.6, 2.4
1.6-2.4 80- 100 6-7
Aluminum 3.2 2.4, 3.2
2.4- 4.0 100- 140 6- 7
(AC) 4.0 3.2, 4.0
3.2- 4.8 140- 180 7- 8
4.8 3.2,4.0.4.8
4.0- 6.4 170- 220 7- 8
6.4 4.0, 4.8
4.0- 6.4 200-270 8-12
1.0 1.6 - 1.6 30- 40 3-4
1.6
1.6, 2.4 1.6-2.4 40-70 4-5
2.4 1.6, 2.4 1.6-2.4 60-90 4-5
Magnesium 3.2 1.6, 2.4
2.4- 3.2 75- 110 5-6
(AC) 4.0 2.4, 3.2
3.2-4.0 90- 120 5- 6
4.8 3.2, 4.0
3.2- 4.8 110- 150 5- 6
6.4 3.2, 4.0
4.0- 4.8 130- 170 6- 7
I ~
I
c:f=3E
I I
C ~ t 1 3
( :I ) ( II ) (c)
Groove
Layers shape
I (a). (b)
I (a), (b)
I (b)
I (h)
I (b)
I (e), (d)
I (e), (d)
1-2 (a), (e)
I (a), (b)
I (a), (b)
I (b)
I (b)
I (e)
I (e), (d)
I (e), (d)
1- 2 (e), (d)
I (a), (b)
I (a), (b)
I (h)
I (b)
I (b)
I (b)
1-2 (e), (d)
I (a)
I (h)
I (b)
I (b)
I (e), (d)
I (e), (d)
1- 2 (e), (d)
y !/Oy
\/
( cl)
(2) Welding condit ions for DC pul se welding
In case of nat position bUll welding .
Oap
Material Joint geometry

Pul se
current
(mm) (A)
Mild steel 0 200
,
.
(SPC)
, -
1.2 150
1.2
1.6 130
_ '"I G I..
Stainless 0 150
,
' ~
steel
I.2t.
1.2 150
(SUS304)
I
1. 6 130
- 0 -
2.0 130
Copper '.I' 0 280
(Teup-I)
(4 --'
J 1.2 280
--I. -J
'1 G-
1. 6 280
Titanium
L
(Tp- I)
,
0 200 2.0
I
JOe
Shi elding gas: Argon (10C Imin.)
Filler wire : 1.2mm <b
,
Pulse conditi on
Base Pulse
current freq.
(A) ( Hz)
50 2.5
20 1. 5
20 1
50
,
J
20 I
20 0.8
20 0. 8
50 3
50 2
30 1.5
100 I
Pul se
Ratio
(%)
50
45
50
50
35
30
30
50
50
40
30
Welding
Speed.
NO.C002S
P. 31 163
Fi ller wire
feeding
speed
(emlmi n.) (emlmin.)
60 60
30 60
15 40
80 0
17 40
10 40
83 40
80 0
50 75
25 75
25 0
Electrode : Ceri ared tungsten (3.2mm cp)
Arc length: 2mm
No.C0025
P.34 / 63
(4) Appli cable tungsten electrode
Since electrode consumpti on degree in AC welding vari es depending upon setting posi ti onor
AC BALANCE knob, determine diameter of electrode to be used frol11 the next electrode
diameter chart.
I . Electrode diameter chart
,
,
...;,
,
,
,
,
,
/
,
3.2
--- - ...
150
250
300
\ - .
\ .-' I
~ > ' Y ( " i ~ '
ODC AC BALANCE Q
Setting position
For ceriated and thoriated tungsten electrode
,
,
/
--
,
,
,
,
\
For pun: tungsten l'k't; lrodc
2. How to lise electrode diameter finder chart
At AC TIG welding
\


,
"'0;. '--" J; j' \
1fj "0
f)
DC
AC
Ma;<. penetratIOn
AC BALANCE
Setting position
No.C0025
P.35 / 63
( 1) Draw a line from the dial center(point P) to welding current graduation (point Q) and
extend the line.
(2) Read electrode diameter at the positi on of". " (on circle--) cleani ng width (point R).
(3) If cleaning width sett ing is not at "e" (on ci rcl e---), determine diameter of electrode to be
used dependi ng upon the dial setting position.
(E I ) xamplc
Cleaning width setting
Welding current Electrode

MAX.CLEANING MAX.PENETRA TION
(Standard) to . to .
120A Cerium More than 3.2 <!> More than 3.2 tb More than 2.4 <!>
tungsten
At DC TlG weldi ng
Find crossing poi nt of extension line of PQ and DC ci rcl e (point T).
(Exampk)
WcldinJ,1 current Electrode Electrode diameter
120A Ceri um
Mon: Ilmil 1.6 Q
No.C0025
P.36 163
10.2 TIG arc spot welding
10.2. 1 What is arc spot welding?
Tungsten ele<:trde
I
Argon gas
Noule
Weld"'g ii i"(:
Gas removing _.......:gtJ-V UL.
TIG arc spot welding is a kind arTIG welding.
Using thi s method. two thin plates overlapped can be
jointed partiall y from one side of the plate by arc heat.
To perform the TIG arc spot welding, it is necessary
insulting bush and nozzle.
-.----I" --"---
Example) In case of A W-IS TIG welding torch
Insulating bush: H21 B70
Nozzle: H2 1 B71
Welding part
10.2.2 Sett ing and operation orTiO arc spot welding
:t,i):,
STICK
[01
TrG
TIG SPOT
WELOING MODE SPOT TIME WELDING CURRo DOWN SLOPE TIME CRATER FILLER. CURR.
Set the WELDING MODE
change-over switch to TIG
SPOT DOsi tion.
Torch switch

Set the SPOT TIME, DOWN SLOPE TIME,
WELDING CURR. and CRATER-FILL. CURR.
Timing chart
ON (ON)
1 -- OfF -------l
i Down sllope time 1
. ..!.. II i
! .

Output
current
Welding current
!
,,----_.--.. ---
t Crater-filler current
10.3 Slick wdding (Shielded Metal Arc Welding)
.& CAUTI ON
. Keep the welding rod in a place wi th low humidity.
e Ory the rod sufficiently before using .
No.C0025
1' .37 / 63
When the gas burner is used for prehcating or removing moi sture of the base mewl. be sure
to heat to l OOt or above .
Slag and fume generated when lack welding will cause wetting the part of base metal to be
welded. Remove slag and fume after tack welding .
When welding is performed olltdoors and wind velocity exceeds 3m/ sec, lise a wind shi eld.
10.3. 1 Sett ing and operation of stick weldi ng
STICK
TIG
TIG SPOT
WELDING MODE
Sel WELDING MODE
change-over swi tch to
STICK position.
10.3.2 Stick welding conditions
R f Id' (D ange 0 we mg current d) [AJ ownwar
~
(mm $)
2.6 3.2
Characteri stic
of electrode
lImenite type 50- 85 80- 130
Lime titania type 50- 100 90-130
Low hydrogen type 55-85 100- 140
" o ~ "
~ \ V I ) ~ o
WELDING CURRo
Sel Ihe WELDING
CURRo
4.0 4.5
120- 180 145-200
140- 180 160- 210
140- 190
-
Range of welding current (Vertical Upward) [A] ,
~
(mm )
2.6 3.2 4.0 4.5
Characteri sti c
Of electrode
Ilmenite type
40- 70 60- 110 100- 150 120- 180
Lime titani a type
50- 90 80- 130 110-170 125-190
Low hydrogen Iype
50- 80 90- 130 120- 180
-
5.0
170-250
190- 250
190- 250
5.0
130- 200
140- 210
160- 210
No.C0025
P. 38 / 63
II APPLIED FUNCTI ON
.
&, WARNING
~
Observe the followings to prevent the electrical shock.
In touching the li ve elect ri cal parts, critical electric shock and burn may occur.
. 00 not touch live electri cal parts inside and outside of the welding power samec .
Grounding to the case of the welding power source should be perfonned by persons
quali fied in electrical work and according to the laws and regulations.
e Be sure to tum off the line disconnect switch before touching insi de of welding power
source.
6 CAUTION
. When changeover the switch on P.c.s., wait for three minutes or more after turning
off the control power switch on the front panel. Also, be sure to turn off the li ne
di sconnect switch .
Never touch the potentiometer on P.C. s. with white painting.
11 .1 Built in function and change-over switch
qff :0 Be sure to turn off the li ne di sconnect switch
~ before perfonning .
Change-over switch(bui lted on P. C. B.P6887T)
Switch function(A side/ B side)
SWI Pre-flow ON I OFF
SW2 Current control PANEL 1 REMOTE
SW3 Initial current ON I OFF
All sWItches are A sIde on the shipment.
.[ftaking off the upper cover, change-o""r switch(SWI ~ 3 ) on P.C.B. P6887T can be found
on chassis.
Pre-flow
\
'\
P6S87S
~ W I
P6SS7T
=
51"2
SW:I
n
v=
/
/ I
Illi ti :d curn.: nt
11. 1.1 Change of gas pre- now time
Gas pre-now time function is to let gas now before arc start.
then it protects the tungsten electrode and welding zone from
oxidation. Gas pre-flow time has been set to approximate
0.3 second on delivery. When restart ing during post flow,
gas pre-flow time is zero automaticall y. Gas pre- flow
time can be changed to zero second when switch SWI is set
to B side.
1 L 1.2 Init ial current
This function has been set to ON side on delivery. If
change-over switch SW3 is set to B side, thi s function is set
to OFF.
11 .1.3 Panel/ remote change-over switch for current control
Thi s funct ion has been set to A (PANEL) side on deli very.
When using the remote control box (opti onal accessory), set
change-over switch SW2 to B (REMOTE) side. When SW2
is set to B side, current control is not available at adjusting
knob on front paneL When SW2 is sct to A side, current
control is not available at remote control box.
11.2 WARNING and OVER HEAT lamps
No. C0025
P. 39/ 63
elf WARNING and OVER HEAT lamps on front panel come on in red and yell ow during
use, the welding power source stops automaticall y.
Check foll owing items and refer to 12.6.
( I) THERMAL OVERLOAD
The rated duty cycle of this' welding power source is 40%. If actual duty cycle exceeds
the rated val ue, WARNING (red) and OVER HEAT (yellow) lamps come on, and the
welding power source stops automatically. In thi s case, keep CONTROL POWER
swi tch on and wait for about 15 minutes under the condition of the cooling fan rOlated.
When resuming welding, make sure to decrease the duty cycle or welding current to
prevent from turning on OVER HEAT lamp and stopping the welding power source.
The welding power source may be damaged if welding operation is resumed immediately
after WARNING lamp is put out.
(2) SHORTAGE OF WATER PRESSURE
i f cooli ng water is not flowing or the water pressure is lower than proper level when
TORCH selection switch on fronl panel is WATER COOLED side. welding power source
stops I1 lJl ol11micl1ll y. In thi s case. check cooling water fl owing without knkagc.
e lf thl: torch switch is aln:ady ON when CONTROL POWER switch is ON. WARNI NG
lamp (n:d) COll h.'S (ll1 <lml welding pOWl.'r kl.!l: ps off state.
Turn I hl.: l(In.:h s\\ it ch orr and turn it (Ill ilgain !"{Ir starl ing thl: \\dding IIp .. -rali(ln.
No.C0025
P.40/63
11 .3 Optional accessori es
11. 3. 1 Welding torch accessories
CD Air-cooled torch
4m
120A AW(P)-9
150A AW(P)- 17
Sm
120A AW(P)-9
150A A W(P)- 17
! 4m I 200A I AW-26
Extension cabl e and bose
4m BAWH- 1504
11m BAWH-1 511
16m BAWH-1 516
4m BAWH- 1504
11 m BAWH- 1511
4m BAWH-2004
11m BAWH-2011
16m BAWH-20 16

-+ 15m
--+ 20m



--+ 15m
--+ 20m
Li _ Sm_ ...... _ 2_0_0_A--' __ -i1: 1 :!: 1
@ Water-cooled torch
210A
AW-20
AW-25
4m AW-IS
300A AWG-S
(for arc spot)
210A
AW-20
AW-25
Sm AW- IS
300A AWG-S
Y
(for arc spot)
Extension cable and hose Length
4m BAWS-3004
11m BAWS-3011
16m BAWS-3016

--+ 15m
--+ 20ql
4m I
BAWS-3004 I 12m
19m
11m
I
BAWS-301 1
I
11 .3.2 Other opti onal accessori es ,
Description
Remote corll ral box
FOOl current controller
FOOl switch
Torch switch
(Push butlan type)
Part No.
P6699Z00
KI I04FOO
4259-004
K5091l00
K509COO
Remarks
wi th cable (4m)
with cable (4m)
wi lh cable (5111 ) (1V-34092)
with cable (4m)
with cable (8m)
No. C0025
P.41 / 63
No.C002S
1'.42 / 63
11. 3.3 Cables and hoses
( 1) For torch
Model
Description
Gas hose
Base mctal s ide cable
Part No.
PI042KOO
PI042POO
(2) For water cooled torch(Cooled by city water)
-
Model
Description Part No.
Gas hose PI042KOO
Base metal side cable PI 042POO
Water hose PI042LOO
Feed watcr place
PI042MOI
(for watcr hose)
Connecting metal
PI042M02
for water hose
Rubber hose (for city water)
BMRHP-l OOI
Q' ty Remarks
I 3m. nut s at both sides
I 38 mm", 3m
BAB-lSOI
Q' ty Remarks
I 3m, nuts al both sides
I 38 mm!X3m
I Sm, nut al one side
I
I
I 30 C(1l
(J) For water-cooled torch(Cooled by watcr cooler PU 30 I)
-
Model BMRHP-]OOI
Description Part No. Q'ty Remarks
Gas hose PI042KOO I ) m, nuts at both sides
Base metal side cable PI0421'00 I 38mm!X3m
\ \ :; 5 EXlension cables and hoses .
Descripti on
< I1I\WII 1501 > Extension torch sid.: cabl.:
For extending 1\'loJd Exh.:nsion cubic lor n:mOlc control
1\ WI 1' )-9 or A WI 1' )_ 17
Extension cable for torch swit ch
(cabl c length is 4 111 ) to 8 In
Adapter
Connection cover
< I3AWH15[ I > Extension torch side cable
For cxtcnding Model A W(P)-9 or Extension cable for remote control
A WIP)- 17{cablc length is 4m) Extension cable for torch switch
to 15 m Adapter
Connection cover
< BAWH1516 > Extension torch side cable
For extending Model A W(P)-9 or Extension cable for remole control
A W(P)-17 (cable length is 401) Extension cable for torch switch
t020m Adapter
Conncction cover
< I3A WJ-I-2004 > Extension torch side cabl e
For extending Model Extension cabl e for remote control
AW-26(cable length is 4 m) to 8 m Extension cable for torch switch
Conneclion cover
< SAWH-20 11 > Extension torch side cable
For extending Model Extension cable for remote control
AW-26(cable length is 4 m) to 15 m Extension cable for torch switch
Conncction cover
< BAWH-2016 > Extcnsion torch side cable
for extending Model Extension cable for remote control
AW-26(cablc length is 4 m) to 20 m Extension cable for torch switch
Connection cover
< BA WS-3004 > Extension gas hose
For extending Model Extension water hose
AW-200rAW- 18 (For water supply)
(cable length is 4 m) to
Extension lorch side cable
8m Extension cable for remote control
Extension cable for torch switch
Connection cover
< SAWS-30 1 I >
Extension gas hose
For extending Model
Extension water hose
AW-200rAW-IS (For wata supply)
(cable length is 4 m) to I Sm Extension torch side cable
Extension cable for remote cOnlrol
Extension cable fur turch switdl
Cunnection covcr
< !lAWS-lOl l! >
Extensil\n hose
Fur ext..:nJin!,; Mudd
Extension wat.:r huse
A W-211 IIf i\ W I X
(Fur lI';nef supply)
l e:II,1.,: kn,gth is ", mil" :W III
E"tensilln tureh side callI.,:
J-; " t<"Il Si,1I1 \":lhl<" ti.r r.:nHlt e o.ntf,,1
<"" hk I,.,. I"feh ileh
(\'IIII<"<"li "lI e"h"(
I'll n No.
119541300
f>1 Q.l] ROO
PIO-USOO
1'1 600N02
115581'101
H955HOO
K 5 2 71-1 ()()
K527KOO
PI600N02
H558MOI
1-1956BOO
Kj27JQO
K527LOO
P1 600N02
H558MOI
H9571300
P l043ROO
PI 043Soo
H558MOI
H9581300
K5271-1 oo
K527Koo
1-1 558MOI
11959800
K527JOO
K527LOO
H:5 58MOI
PI04)KOO
"104)LOO
1-1 59) 1-1 00
PI 04) ROO
PI043Soo
H558MOI
K527BOO
K527DOO
I-I S93JOO
K5271IQO
KS27K()O
11 55KMUI
K517CUU
t.:: 527EUU
115'HKHIJ
" ."i :! 7JIICI
K."i27l.111J
11 55:-; \ j(l 1
No. C0025
P. 43 / 63
Q" ty
Remarks
I
4 m
I
4 111
I
4m
I
1ST
I
II m
I
11m
I
11 m
I
1ST
I
16m
I
16m
I
16 In
I
1ST
I
4m
I
4m
I
4m
1ST
I
11m
I
11 m
I
11m
1ST
I
16m
I
16m
I
16m
1ST
I
4m
I 4 m
I
4m
I
4m
I
4m
1ST
I
11m
I 11 m
I
11 m
I II m
I
II m
1ST
I
16m
I 16m
I
16 III
I
16m
I I fi III
l S I
No.C0025
P. 44 / 63
11.4 Connection of optional accessories
II A.1 Extension of torch side cables
I) For wat er-cooled torch
Connect optional extension cable and hose as shown in following fi gure.
Do not connect a hose for water supply to the olltl et of ft:lurncd water.
When using water cooler PU-30 I, please refer to the Owner's Manual for waler cooler
PU-301.
To front face of
Extens ion gas hose
Extension water hose
welding power source

Gas ou,l e' -[]"
-I

Water inlet -[J
:1
,,-
Torch ,erminal-cr=J!
/'
Extension torch side cable
(For condensed water)
2) For air cooled torch
/ (For fcedi ng water)
IT m1
7
I DtJ


-dO
.1
.I
inp at 3 noints
J
\
Connection cover
HSS8MOI
Extension lorch side cable
To waler-
- cooled torch
To front face of Taping al J points Connection cover
weld ing power source I
:l:Q@) (- 'occh
... , .............. ....
Power cable adapter
(torch accessori es)
Gas outlet-1: ",H 145EO I. HSOOD03
Adapter hose H 13000
(torch accessory)
Adapter P 1600N02 is necessary
in case of using model A W-9 torch
3) Extension of torch switch cable and remote control cable.
FrOll1 face o f .
\\"(.'l dill g

---'
2P Extension control cable
receptacle for torch switch
I' kF==([J\jll =c::P
Torch switch
QJl:D==:??==CdlP Q1tD==?F=( =[ 0 01
"'" \ II ' 1 ,1..:II ... j,'"l""lIlh.1 :tbl..:
,..:.!,l.Id..: 1.11 1 ... 111"(..: -:1'1111,,1 ! ""
[ 1.4.2 Optional remote control box
(I) TIG welding
Connection
Please refer to 8. 1. 1 for detail.
No. C0025
P. 45 / 63
Operation
II is same as "Welding current cont ror',
(Refcrto 5.1.)
(2) Stick welding
Connection Pl ease refer to 8. 1.2 for detail.
Operation It is same as "Welding current control", (Refer to 5. 1. )
Remote control is available when swi tch SW2 on P,C.R P6887T is changed over.
Refer to 11 .1.3 for detai l.
11 .5 Connection with autommi c machine
Lh CAUTION
. Contro[ cable which is connected to internal tcmlinal block on chassis shall be separated as
far as possible from base metal side cable and torch side cablc .
Never connect the wiring to control circuit except for intemalterminal block.
It cause trouble and malfunction.
When the upper cover is detached from the welding power source, 4P terminal block on P .C.R
on the chassis can be found. Function signals as shown in following fi gure which are
outputted to thi s ternlinal block can be used. Feed the wiring to terminal block through
bushing on rear panel of the welding power source.
When the upper cover is detached. wait for three minutes or more after turning ofT the control power
switch on the front panel. Also. be sure to tum ofTthc line di sconnect switch.
( 58)
o
Lj=-J
__ WCR
Used for detection of welding
current. Contact closes during
welding current fl owing. Contact
r a t i n ~ is less than O.3A at ACI lOY.
(78)
EiBEiB
EiBEiB
o
4P terminal block
Pluse synchronous oulput
During pulse welding. terminals
Will be closed.
Maximum allowable voltage: 24 Y DC
Maxi mlllll allowable current : lOrnA
No.C0025
P. 46 / 63
11 .6. Optional equipment ( Refer to respective owner's Ill anual for details.)
11.6.1 TIG welding with filler wire.
( I.) TIGUN
. TIGUN'S exclusive torch
Model
Rated output current
Duty cycle
Cooli ng method
Cable length
. Controller
Model
Rated input voltage
Rated input power
(2) TIG fiJl er wire feedi ng system
. Controller
Model
Rated input voltage
Rated input power
AWG - 1501
ISOA
40%
Ai r coolinl-'
8m
Adapter hook H528XOO is necessary when using HC-7 1 .
Wire guide assembly
Torch
AW - 18
AW - 26
AW -17
AW - 9
Model eM-27 1 wire feeder for TI G fi ll er
AWGW - 3001
30M
40%
Water cooling __
8m
HC - 81
200 V, single phase
200 VA
HC - 71
200 V, single phase
200VA.
Model of wire guide
BHC - 711 8
BHC - 7126
BHC-711 7
SHC - 7109
11 .6.2 Tungsten elect rode
Use ccrial cd tungsten or thoriated Hmgslcn elect rode.
No. C0025
P. 47/ 63
Select according to welding current. ( Refer to tabl es belO\v. EN: Electrode negative)
Ccriated tungsten electrode can be obtain consumpti on of elect rode come little. and good
arc start can be obtained.
Ceri aled tungsten
Part No.
Dimens ion (mOl ) Allowable welding current (A)
Diameter Lengt h DC EN AC (RMS value)
0870-016 1.6 150 150 130
0870-024 2.4 150 250 220
0870-032
' ?
>.- ISO 400 290
. Thori ated tungsten
Part No.
Dimension (rnm) All owable wel ding current (A)
Diameter Length DC EN AC (RMS value)
0831-005 0.5 150 20 10
083 1-01 0 1.0 150 80 40
0831-0 16 1.6 150 150 100
0831-316 1.6 75 150 100
-
083 1-020 2.0 150 200 120
0831 -024 2.4 150 250 135
0831-324 2.4 75 250 135
0831-032 3.2 150 400 175
083 1-332 3.2 75 400 175
083 1-040 4.0 150 - 300
Pure tungsten
Part No.
Dimensi on (mm) Allowable welding CUlTent (A)
Diameter Length AC ( RMS value)
0830-005 0.5 150 15
0830-010 1.0 150 50
0830-016 1.6 150 100
0830-024
2.4 150 130
0830-032 3.2 150 160
0830-040 4.0 150 240
0830-048 4.8 150
330
0830-064 6.4 150 430