Daihen OTC AC/MIG/201 CPDACA-200 User Manual (English)

Questions and Answers:

M
misty06Aug 14, 2025
Why won't shield gas generate when I turn on the torch switch on my Daihen Portable Generator?
- A
  Alicia Gordon DDSAug 14, 2025
  If shield gas isn't generated when the torch switch is activated on your Daihen Portable Generator, several factors could be responsible: * The outlet valve of the gas cylinder might be closed (open the valve). * The gas cylinder may lack sufficient pressure (check the gas pressure). * There could be a problem with the +24V power source circuit (replace P.C.B. P10153Q). * The gas electromagnetic valve SOL may be faulty (check and replace the gas electromagnetic valve SOL). * There might be an issue with the gas control circuit (check and replace P.C.B.P10153Q). * There could be a problem with the interface circuit (check and replace P.C.B.L8268M).
R
rhonda41Aug 17, 2025
What to do if the WARNING lamp PL2 lights up when I turn on the main power switch on my Daihen OTC AC/MIG/201 CPDACA-200?
- R
  Reginald DeckerAug 17, 2025
  If the WARNING lamp PL2 illuminates when you turn on the main power switch of your Daihen Portable Generator, consider these potential causes and solutions: * There may be an issue with thermostat TH1 or TH2. Check thermostat TH1 or TH2. * The heat sink might be overheated. Cool the fins after checking for the causes. * There could be an overloaded input voltage or a shortage of input voltage. Check the input voltage. * CN11 or CN14 on P.C.B.P10153Q might not be fully inserted. Completely insert CN11 or CN14. * The wiring of the external connection terminal board on P.C.B.P10153Q could be incorrect. Wire to 'OPERATION STOP'.
B
Brittany MillerAug 20, 2025
How to troubleshoot wire feeding issues on my Daihen OTC AC/MIG/201 CPDACA-200 Portable Generator?
- C
  christine44Aug 21, 2025
  If your Daihen Portable Generator is not feeding wire, and inching or retract functions are not working, consider the following: * A blown fuse F2. Replace F2 after identifying and resolving the cause. * A problem with relay CR1 and 2 on P.C.B. P1053Q. Check and replace relay CR1 and 2 on P.C.B. P10153Q. * A fault in the interface circuit. Check and replace L8268M. * A problem within the motor control circuit. Check and replace P6906P. * A fault in the filter circuit. Check and replace P.C.B.P6768T. * The wire feeder mounted with encoder may not be connected to ICN4, or the control cable (7 conductors) may be broken. Connect ICN4, check the control cable, and replace it if necessary.
B
Brian ByrdAug 25, 2025
Why can't I set the current and voltage on my Daihen Portable Generator?
- C
  Christopher WestAug 25, 2025
  If you're unable to set the current and voltage on your Daihen Portable Generator, here are a few possible reasons: * There may be a problem with the filter circuit. Check and replace P.C.B.P6768T. * The CURR. VOLT. CONTROL switch S3 might be set to PANEL. Set S3 to ROBOT. * There could be a break in the communication cable or poor contact of the socket. Replace the communication cable or check the contact of the socket. * There might be a problem with the interface circuit. Check and replace P.C.B. L8268M.
J
Jon DillonAug 27, 2025
What causes the WCR relay to keep running on my Daihen Portable Generator?
- D
  daniel90Aug 27, 2025
  If the WCR relay is continuously running on your Daihen Portable Generator, it could be due to: * A problem with the hall current detector CT2. Check and replace CT2. * An issue within the WCR circuit itself. Check and replace P.C.B.P10153Q.
R
Ronald MathewsAug 31, 2025
What to do if shield gas won't stop flowing on my Daihen OTC AC/MIG/201 CPDACA-200 Portable Generator?
- J
  Jennifer CobbAug 31, 2025
  If the shield gas won't stop flowing on your Daihen Portable Generator, it may be because the gas valve switch terminal on the terminal block of P.C.B.P10153Q is short-circuited. Open the gas valve switch terminal.
T
Thomas HillSep 3, 2025
What to do if the main power lamp PL1 will not light on my Daihen Portable Generator?
- H
  henry13Sep 3, 2025
  If the main power lamp PL1 on your Daihen Portable Generator does not light up, it could be due to: * Trouble of PL1. Check PL1. * Line disconnect switch of power box not connected. Check power box.
C
Cody BrownSep 6, 2025
Why won't the fan rotate when I connect the POWER switch on my Daihen OTC AC/MIG/201 CPDACA-200 Portable Generator?
- K
  kristenmyersSep 6, 2025
  If the fan does not rotate when you connect the POWER switch on your Daihen Portable Generator, it may be due to trouble of the fan. Checking fan.
R
Rachel AndersenSep 9, 2025
What to do if the POWER switch tripped on my Daihen OTC AC/MIG/201 CPDACA-200 Portable Generator?
- I
  ioliverSep 9, 2025
  Do not connect POWER switch again. Contact your dealer.

Daihen OTC AC/MIG/201 CPDACA-200 Specifications

General

Brand	Daihen
Model	OTC AC/MIG/201 CPDACA-200
Category	Portable Generator
Language	English

Summary

1. SAFETY INFORMATION

Safety Signal Words

Explains WARNING and CAUTION signal words for hazard identification.

Arc Welding Safety Precautions

General precautions for arc welding, including personal protection.

2. ARC WELDING SAFETY PRECAUTIONS

Electric Shock Hazard Details

Precautions and risks related to electric shock during welding operations.

Arc Rays, Sparks, and Noise Hazards

Hazards from arc rays, flying sparks, hot metal, and noise.

Welding Fire, Fumes, and Gas Hazards

Fire and Explosion Hazards

Sparks and spatter can cause fire and explosion. Protect yourself and others.

Fumes and Gases Hazards

Breathing welding fumes and gases can be hazardous to your health.

Cylinder and Rotating Parts Hazards

Cylinder Explosion Hazard

High-pressure gas cylinders can explode if damaged. Handle with care.

Rotating Parts Hazard

Rotating parts can cause injuries. Keep hands, hair, and clothes away.

Work Area and Welding Wire Hazards

Work Area Hazards

Welding work areas are hazardous. Secure machines to prevent falling or moving.

Welding Wire Hazard

Welding wire can cause puncture wounds. Handle with care.

3. GENERAL NOTICE OF OPERATION

Welding Mode and Wire Size

Table listing welding modes and corresponding wire sizes for different materials.

Rated Duty Cycle

Explains the duty cycle of the welding power source and its limitations.

4. STANDARD ACCESSORIES

Accessory Kit Contents

Lists the items included in the accessory kit with their specifications and quantity.

5. LOCATION AND FUNCTION OF CONTROL

Welding Power Source Component Layout

Diagram showing the location of covers, panels, and terminals on the welding power source.

5. LOCATION AND FUNCTION OF CONTROL (continued)

Front Panel Controls and Indicators

Details functions of switches, knobs, and lamps on the front panel.

5. LOCATION AND FUNCTION OF CONTROL (continued)

Program Switch Settings

Table detailing program switch settings for various welding modes and wire sizes.

6. NECESSARY POWER SOURCE EQUIPMENT

Power Source Utility Requirements

Specifies voltage, phase, capacity, and breaker requirements for commercial power.

Engine Generator Usage Precautions

Provides precautions for using engine generators as auxiliary power sources.

7. TRANSPORT AND INSTALLATION

Machine Transport Safety

Instructions to avoid damage and injury when transporting the welding machine.

Installation Safety Precautions

Safety guidelines for installing the welding machine to prevent fire and fume hazards.

7. TRANSPORT AND INSTALLATION (continued)

Electromagnetic Trouble Prevention

Measures to prevent electromagnetic interference from the welding machine.

Installation Place Requirements

Guidelines for selecting an appropriate installation location based on environment and spacing.

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

General Connection Safety

Safety precautions for making connections to prevent serious injuries.

Welding Power Source Output Connection

Instructions for connecting the welding power source output to base metal or jig.

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Connection of Manipulator (Robot)

Steps for connecting the welding power source to a robot manipulator.

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Extension Cable and Gas Hose Connection

Guidelines for extension cables, gas hose connection, and cylinder safety.

Grounding and Input Side Connection

Procedure for grounding the welding power source and connecting the input power.

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Input Fuse/Circuit Breaker and Grounding Details

Specifies input protection and details for grounding and input cable connections.

9. WELDING PREPARATION

Safety Protective Equipment

Lists essential protective equipment for welding to prevent hazards.

9. WELDING PREPARATION (continued)

Switch Operation and Gas Flow Control

Steps for operating switches and controlling gas flow for welding preparation.

Inching Operation Precautions

Safety warnings and precautions during wire inching operation.

10. WELDING OPERATION

Welding Sequence Overview

Diagram illustrating the sequence of operations during welding.

10. WELDING OPERATION (continued)

AC Pulse Welding and Penetration Adjustment

Guidelines for AC pulse welding and adjusting penetration.

10. WELDING OPERATION (continued)

Pulse Arc Characteristics and Wave Pulse Welding

Adjusting pulse arc features and performing wave pulse welding.

10. WELDING OPERATION (continued)

Troubleshooting Welding Conditions

Table of causes and troubles related to improper welding conditions.

11. APPLIED FUNCTION

Switch Function and Adjustment

Details on the function and adjustment of switches on the P.C.B. P6906P.

11. APPLIED FUNCTION (continued)

Arc Voltage Detection, Wire Feed, Anti-stick

Configuring arc voltage detection, wire feeders, and anti-stick settings.

11. APPLIED FUNCTION (continued)

Slow-Down Speed, Pulse, and Voltage Correction

Adjusting speeds, pulses, and automatic voltage correction.

11. APPLIED FUNCTION (continued)

External Connection Terminals (12P Block)

Functions of the 12-pin terminal block for external connections.

11. APPLIED FUNCTION (continued)

External Connection for Automatic Machine

Details of 12P terminal block signals for automatic machine integration.

11. APPLIED FUNCTION (continued)

Troubleshooting Error Indicators

Table of errors, warning indicators, and their meanings.

11. APPLIED FUNCTION (continued)

Error Code Explanations (1-7)

Detailed explanations for specific error codes and their resolutions.

11. APPLIED FUNCTION (continued)

Error Code Explanations (8-15)

Detailed explanations for specific error codes and their resolutions.

11. APPLIED FUNCTION (continued)

AC Pulse Welding Precautions

Precautions for AC pulse welding, including cable management and coiling.

12. MAINTENANCE AND TROUBLESHOOTING

Periodic Maintenance Checks

Guidelines for daily and yearly checks to ensure machine safety and efficiency.

12. MAINTENANCE AND TROUBLESHOOTING (continued)

Electrolytic Capacitor Replacement

Recommendation for replacing high-pressure electrolytic capacitors every 5 years.

Welding Error Table

Table listing welding errors, their causes, and checkpoints.

12. MAINTENANCE AND TROUBLESHOOTING (continued)

Troubleshooting: Power, Fan, Gas, and Warning Lamp Issues

Solutions for power, fan, gas generation, and warning lamp problems.

12. MAINTENANCE AND TROUBLESHOOTING (continued)

Troubleshooting: Wire Feed, Current, and Control Issues

Solutions for wire feed, current setting, and control circuit problems.

12. MAINTENANCE AND TROUBLESHOOTING (continued)

PCB Replacement and Insulation Test

Precautions for PCB replacement and performing insulation resistance tests.

12. MAINTENANCE AND TROUBLESHOOTING (continued)

Schematic Diagram and Parts Layout

Provides schematic diagrams and parts layout for the CPDACR-200.

13. PARTS LIST

Component Parts List (Symbol to ICN4)

List of components with symbols, part numbers, descriptions, and specifications.

13. PARTS LIST

Component Parts List (Resistors to PCB1)

List of components including resistors, capacitors, and printed circuit boards.

13. PARTS LIST

Component Parts List (PCBs to EPROM)

List of printed circuit boards (PCBs) and EPROM, with their specifications.

14. SPECIFICATIONS

Welding Power Source Specifications

Detailed technical specifications for the AC/MIG/200 welding power source.

14. SPECIFICATIONS (continued)

External View and Dimensions

Diagram showing the external view and dimensions of the CPDACA-200.

15. SERVICE AND SUPPORT

Requesting Repair Service

Information on contacting local dealers for repair and required details.

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Daihen OTC AC/MIG/201 CPDACA-200 User Manual

Table of Contents

Questions and Answers:

Daihen OTC AC/MIG/201 CPDACA-200 Specifications

Summary

1. SAFETY INFORMATION

Safety Signal Words

Arc Welding Safety Precautions

2. ARC WELDING SAFETY PRECAUTIONS

Electric Shock Hazard Details

Arc Rays, Sparks, and Noise Hazards

Welding Fire, Fumes, and Gas Hazards

Fire and Explosion Hazards

Fumes and Gases Hazards

Cylinder and Rotating Parts Hazards

Cylinder Explosion Hazard

Rotating Parts Hazard

Work Area and Welding Wire Hazards

Work Area Hazards

Welding Wire Hazard

3. GENERAL NOTICE OF OPERATION

Welding Mode and Wire Size

Rated Duty Cycle

4. STANDARD ACCESSORIES

Accessory Kit Contents

5. LOCATION AND FUNCTION OF CONTROL

Welding Power Source Component Layout

5. LOCATION AND FUNCTION OF CONTROL (continued)

Front Panel Controls and Indicators

5. LOCATION AND FUNCTION OF CONTROL (continued)

Program Switch Settings

6. NECESSARY POWER SOURCE EQUIPMENT

Power Source Utility Requirements

Engine Generator Usage Precautions

7. TRANSPORT AND INSTALLATION

Machine Transport Safety

Installation Safety Precautions

7. TRANSPORT AND INSTALLATION (continued)

Electromagnetic Trouble Prevention

Installation Place Requirements

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE

General Connection Safety

Welding Power Source Output Connection

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Connection of Manipulator (Robot)

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Extension Cable and Gas Hose Connection

Grounding and Input Side Connection

8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued)

Input Fuse/Circuit Breaker and Grounding Details

9. WELDING PREPARATION

Safety Protective Equipment

9. WELDING PREPARATION (continued)

Switch Operation and Gas Flow Control

Inching Operation Precautions

10. WELDING OPERATION

Welding Sequence Overview

10. WELDING OPERATION (continued)

AC Pulse Welding and Penetration Adjustment

10. WELDING OPERATION (continued)

Pulse Arc Characteristics and Wave Pulse Welding

10. WELDING OPERATION (continued)

Troubleshooting Welding Conditions

11. APPLIED FUNCTION

Switch Function and Adjustment

11. APPLIED FUNCTION (continued)

Arc Voltage Detection, Wire Feed, Anti-stick

11. APPLIED FUNCTION (continued)

Slow-Down Speed, Pulse, and Voltage Correction

11. APPLIED FUNCTION (continued)

External Connection Terminals (12P Block)

11. APPLIED FUNCTION (continued)

External Connection for Automatic Machine

11. APPLIED FUNCTION (continued)

Troubleshooting Error Indicators

11. APPLIED FUNCTION (continued)

Error Code Explanations (1-7)

11. APPLIED FUNCTION (continued)

Error Code Explanations (8-15)

11. APPLIED FUNCTION (continued)