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OTC DP-400 User Manual

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MANUAL NO:P10355
OWNER'S MANUAL
FOR
DIGITAL INVERTER
DP400
MODEL: DP-400 P10355
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
June 1, 2004
Upon contact, advise MODEL and MANUAL NO.
CO
2
/MAG/MIG

Table of Contents

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OTC DP-400 Specifications

General IconGeneral
Rated Input Frequency50/60 Hz
Rated Output Current400A
Output Current Range (TIG)10-400A
Duty Cycle (MIG/MAG at 400A)60%
Duty Cycle (TIG at 400A)60%
Duty Cycle (MMA at 400A)60%
Efficiency85%
Protection ClassIP21S
Wire Diameter (MIG/MAG)0.8-1.6mm
Cooling MethodForced Air
Welding ProcessMIG/MAG, TIG, MMA

Summary

Safety Information

Safety Alert Symbols and Signal Words

Explains the meaning of WARNING and CAUTION signal words used in the manual.

General Arc Welding Safety Precautions

General safety precautions for arc welding to protect yourself and others.

Specific Arc Welding Hazards and Protections

Covers electric shock, arc rays, sparks, noise, fire, fumes, gases, and cylinder safety.

Principal Safety Standards

Relevant Safety Standards and Codes

Lists relevant safety standards and codes for welding equipment and practices.

General Notice of Operation

Rated Duty Cycle Explanation

Explains the concept of duty cycle and its importance for machine longevity.

Use Limitations

Specifies a limitation for pipe thawing.

Standard Composition and Accessories

Standard Parts and Required Preparations

Lists standard parts and required preparations for using the welding power source.

Accessories and Consumables Preparation

Lists accessories and details about shield gases and welding wire preparation.

Necessary Power Source Equipment

Power Supply Requirements and Engine Generator Precautions

Specifies power supply needs and guidelines for using engine generators.

Transport and Installation

Safe Transport Procedures

Instructions to avoid damage and hazards when carrying the welding machine.

Installation Safety and Location Guidelines

Safety warnings for installation, including fire, ventilation, and location selection.

Preventing Electromagnetic Interference

Measures to prevent or resolve electromagnetic interference issues.

Connection Procedure and Ground for Safety Use

Electrical Safety During Connections

Critical safety instructions regarding electric shock prevention during connections.

Welding Power Source Connection Steps

Step-by-step instructions for connecting torches and ground.

Shield Gas and Hose Connection Safety

Safety warnings for shield gas in confined spaces and gas hose connections.

Grounding the Welding Power Source

Importance of grounding the welding power source case for safety.

Welding Preparation

Preparing Personal Protective Equipment (PPE)

Guidance on selecting and using personal protective equipment (PPE) for welding.

Control Panel and Gas Regulator Operation

Step-by-step guide for operating controls and gas cylinder regulators.

Wire Feeding (Inching) and Condition Settings

Instructions for wire feeding, and an overview of welding condition settings.

Example Welding Conditions

Tables detailing example welding parameters for various scenarios.

Operation

Front Panel Controls and Indicators

Identifies and explains the function of each control and indicator on the front panel.

Basic Settings and Mode Selection

Explains how to set up basic welding parameters and select modes.

Parameter Adjustment Procedures

Instructions on how to adjust parameters like current, voltage, and wire feed speed.

Crater-Fill, Arc Spot, and Voltage Adjustment

Settings for crater fill, arc spot, and voltage adjustment methods.

Advanced Functions: Penetration, Arc Characteristics, Wave Pulse

How to use functions for penetration, arc characteristics, and wave pulse welding.

Using Control Knobs, Remote Control, and Memory

How to use the parameter knob, remote control, and JOB MEMORY function.

Resetting and Erasing Welding Conditions

How to reset conditions to default and erase stored welding data.

Applied Function

Error Codes and Troubleshooting Steps

Table of error codes displayed on the front panel and their classifications.

Terminal Block Connections and Optional Accessories

Pin assignments for terminal blocks and list of optional accessories.

Extension Cable/Hose Usage

Guidelines for using extension cables and hoses to extend the work space.

Maintenance and Troubleshooting

Safety Precautions for Maintenance

General electrical shock precautions and warnings for maintenance activities.

Periodic Maintenance and Component Checks

Daily and periodic checks for ensuring safety and efficiency of the equipment.

Component Replacement and Testing Procedures

Precautions for replacement, insulation testing, and battery replacement.

Comprehensive Troubleshooting Guide

A table listing common troubles, their causes, and solutions.

Technical Diagrams and Parts Layout

Provides schematic diagrams and parts layout illustrations for technical reference.

Specifications

Detailed Technical Specifications

Detailed technical specifications of the DP400 welding power source.

External Views, Dimensions, and Parameter Ranges

Provides external views, dimensions, and initial parameter setting ranges.

Quick Manual

Initial Setup and Operation Guide

Quick guide for initial setup, operation, and troubleshooting before using the welder.

Welding Parameter and Condition Management

Quick steps for setting welding parameters, conditions, and memory management.

Error Troubleshooting Flowchart

A flowchart illustrating common error displays and their troubleshooting.

Service and Support

Service Contact Information and Notes

Important notes regarding service and required information for contacting the dealer.

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