MANUAL NO:E2235-8

OWNER'S MANUAL
FOR

INTERFACE BOX
MODEL: IFR-101 E2235

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

December 20, 2005

Upon contact, advise MODEL and MANUAL NO.

 Notice : Machine export to Europe

This product does not meet the requirements specified in the EC Directives which are the EU safety
ordinance that was enforced starting 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.
 No.E2235
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CONTENTS

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

2. ARC WELDING SAFETY PRECAUTIONS ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2

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

4. COMPONENT AND OPTIONAL ACCESSORIES ‥‥‥‥‥‥‥‥‥‥‥ 9

5. INSTALLATON AND GROUNDING FOR SAFETY ‥‥‥‥‥‥‥‥‥‥‥ 10

6. MAINTENANCE AND TROUBLESHOOTING ‥‥‥‥‥‥‥‥‥‥‥‥‥ 20

7. PARTS LIST ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 20

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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 gives information regarding possible personal injury

WARNING or loss of life.

CAUTION refers to minor personal injury or possible equipment

CAUTION damage.

2. ARC WELDING SAFETY PRECAUTIONS

WARNING
ARC 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 installation, operation, and
maintenance of this equipment.

4. Use only well maintained equipment. Repair or replace damaged parts at once.
ARC WELDING is safe when precautions are taken.
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2. ARC WELDING SAFETY PRECAUTIONS (continued)

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 disconnect 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.
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2. ARC WELDING SAFETY PRECAUTIONS (continued)

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 10m (33ft) 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 power cable for base metal 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. 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 reel stand, are may be generated and cause damage by a fire if the wire contacts
the frame or the work piece.

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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2. ARC WELDING SAFETY PRECAUTIONS (continued)

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, gas regulator, 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.
9. Do not disassemble or repair the gas regulator except for the person authorized by the
manufacturer of them.

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.
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2. ARC WELDING SAFETY PRECAUTIONS (continued)

ARC WELDING work areas are potentially hazardous.

FALLING or MOVING machine can cause serious injury.

1. When hanging the welding power source by a crane, do not use the carrying handle.
2. Put the welding power source 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 body, other people, or any metal when threading
welding wire.
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PRINCIPAL SAFETY STANDARDS

Arc welding equipment – Installation and use, Technical Specification

IEC 62081, from International Electro technical Commission

Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro
technical 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.

NOTE: The codes listed above may be improved or eliminated. Always refer to the updated codes.

M050906
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3. NOTICE AT OPERATION
Thank you for buying IFR-101 type Interface box.
This is the interface box for using by combing Daihen’s CO2/MAG/MIG welding and
Yasukawa Electrical machine’s arc welding robot. Read this manual throughout before
using.

3.1 .For combining machines

The welding machines that can combine to this interface box are as follows.
Model Type Remarks
Inverter auto 180 CPV-180
Inverter auto 350 CPV-350
Inverter auto 500 CPV-500
Inverter auto 600 CPV-600
Micro 180 CPVMB-180
Fuzzy auto 200 CPD-200
Fuzzy auto 350 CPD-350
Fuzzy auto 350 EX CPDB-350
Fuzzy auto 500 CPD-500
Digital pulse 350 CPDP-350 ※1
Digital pulse 500 CPDP-500 ※1
Digital pulse auto 350 CPDPA-350 ※1
Digital pulse auto 500 CPDPA-500 ※1
Digital wave pulse 350 CPDWP-350 ※1
Digital wave pulse 500 CPDWP-500 ※1
Digital auto 350 CPDR-350 ※1 ※2
Digital auto 500 CPDR-500 ※1 ※2
Digital AC wave 200 CPDACR-200 ※2
Inverter auto 350 TB CPVB-350 ※3 ※4
Turbo pulse 350 CPVP-350 ※3 ※4
Turbo pulse 500 CPVP-500 ※3 ※4
Inverter MIG pulse auto 350 CPVPA-350 ※3
Inverter MIG wave pulse 350 CPVWP-350 ※5
Inverter MIG wave pulse 500 CPVWP-500 ※5

※1 Adapter connector K5076B is needed if it is necessary for CMR-231’s plug to use wire
feeder 4P.
※2 If using CMRE-231, control cable for CMRE-231 (optional accessory) is necessary.
※3 Optional accessory E1984G01 is necessary for connection.
※4 It is necessary to use special item’s power source if using of arc generated detection
signal for robot connection canon plug (M) and (N).
※5 Optional accessories E1984M00 or E1984J00 is needed for connection.
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4.COMPONENT AND OPTIONAL ACCESSORIES

4.1 Interface box
Model IFR-101
Input voltage / phase AC208 / 230 / 460±10%, single phase
Rating cycle 50 / 60 Hz
Rating input 1A
100×330×192 (W×D×H) mm
External dimension (Attachment metal, screw and projection
nuts are not included.)

4.2 Standard accessories

●Check for quantity at open.
Description Specification Q’ty Remarks
Wire harness (1) E1984K01 1 Connection for CMH type wire feeder
Wire harness (2) E1984K02 1 Connection for CMH type wire feeder
Cable VSF 1.25 G 1 Grounding
Pressure terminal R 1.25 – 4 1 For grounding
Pressure terminal R 1.25 – 6 1 For grounding
Glass enclosed fuse 1A 250V 1
Cartridge fuse element C-3 1

4.3 Optional accessories

Description Specification Q’ty Remarks
Adapter cable K5076B00 1 set Connection for CPDP
Arc voltage detection wire K2809B00 1 set Connection for CPDP
Adapter for CPVP(A), CPVB E1984M00 1 set Connection for CPVP(A), CPVB
Adapter for CPVWP E1984J00 1 set Connection for CPVWP

Adapter component for CPVWP

Description Specification Q’ty
Wire harness (1) E1984J01 1
Wire harness (2) E1984J02 1
Relay assembly E1984J03 1

Adapter component for CPP(A), CPVB

Description Specification Q’ty
Wire harness E1984G01 1
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5. INSTALLATION AND GROUNDING FOR SAFETY

5.1 Installation
WARNING
Observe the following to prevent the electrical shock.

In touching the live electrical part, critical electric shock and burn may occur.
●Do not touch live electrical part inside and outside of the welding power source.
●Have a qualified electric engineer ground the case of the welding power source and the
base metal or jig electrically connected, following a local low.
●Be sure to turn off the line disconnect switch before connecting.
●Do not use cables with insufficient capacity, damaged or exposing the conductor.
●Securely tighten each connection.
●Securely attach the case and cover after connecting cables.

①Take off the upper cover of welding power source.

②Pull interface box over to right side board of welding power source.
③Close the upper cover of welding power source finally.

Welding power source

Interface box
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5.2 Connection of control cable

5.2.1 Connection with CPV-180, 350, 500 and 600

For welding power source

inside terminal
Welding power source

Wire feeder

Interface box

For “Remote control”

receptacle (6P)
For “Wire feeder”
receptacle (4P)

・Connect 6P plug from the interface box to “Remote control” receptacle of welding power
source.
・Connect 4P plug from the interface box to “Wire feeder” receptacle of welding power
source.
・Connect 4P plug from wire feeder, such as CMR-231 to “Wire feeder” receptacle of the
interface box back part.
・Connect control wires (No. 8, 9, 25, and 59) from the interface box to the inside terminal
(on P.C.B.P6768Q) of welding power source.
12P terminal block

GAS SOLENOID
VALVE WELD.CURR. OPERATION STOP POWER FOR
RELAY (WCR) AMMETER VOLTMETER
CONTROL (Normally closed. PREP.RELAY
(Gas purge when CONTACT Stop when open.) (DC 24V)
h i i d)
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5.2.2 Connection with CPD-200, 350, 500 and CPDB-350

Welding power source

Wire feeder

Interface box

For “external
connection terminal”

For “remote control”

receptacle (6P)
For “wire feeder”
receptacle (4P)

・Connect 6P plug from the interface box to “Remote control” receptacle of welding power
source.
・Connect 4P plug from the interface box to “Wire feeder” receptacle of welding power
source.
・Connect 4P plug from wire feeder, such asCMR-231 to “Wire feeder” receptacle of the
interface box back part.
・Follow the diagram below and connect control wires (No. 8, 9, 25, and 59) from the
interface box to the outside terminal (on P.C.B.P6768Q) of welding power source inside
the front door.

GAS SOLENOID
VALVE WELD.CURR.
AMMETER VOLTMETER POWER FOR
CONTROL RELAY (WCR)
PREP.RELAY
OPERATION STOP (Gas purge when CONTACT
(DC 24V)
(Normally closed. h i i d)
Stop when open.)

12 terminal block
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5.2.3 Connection with CPDP-350, 500, CPDPA-350, 500, CPDWP-350, 500

(1) In case of using plug 4P wire feeder

Adapter connector K5076B is needed if using 4P plug wire feeder, such as CMR-231.

Welding power source

inside terminal
Welding power source

Wire feeder

Interface box

Connection with arc

For “remote control”
voltage detective wire
receptacle (6P)
torch (or wire feeder)
For “wire feeder”
receptacle (7P)
Adapter cable
K5076B

・Connect 6P plug from the interface box to “Remote control” receptacle of welding power
source.
・Connect 4P plug from the interface box to adapter cable K5076B and “Wire feeder”
receptacle (7P) of welding power source.
Make sure connect arc voltage detection wire from K5076B to torch or wire feeder that can
be detected arc voltage. (Extend with arc voltage detection wires K2809K if arc voltage
detection wire length is no long enough.)
・Connect 4P plug from wire feeder, such as CMR-231 to “Wire feeder” receptacle of the
interface box back part.
・Connect control wires (No. 8, 9, 25, and 59) from the interface box to the inside terminal
(P.C.B.P6768Q top) of welding power source.
・Since feeding speed is different, change wire feeder by change-over switch if using
CMR-231, CM-2301. (Refer to the manual on the welding power source to change-over
wire feeder.)
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(2) In case of using plug 7P wire feeder

If using plug 7P wire feeder, such as CMH-2301, CMH-1405, it is necessary to use accessory
wires (E1984K01, E1984K02) that exchange 4P receptacle for 7P receptacle of wire feeder.
Refer to schematic diagram 2 for connection.

Connection of E1984K01, 02
①Take off 4P plug and 4P receptacle of interface box.
②Install wire harness (1) (E1984K01) instead of 4P plug and connect it to CN5 on
P.C.B.E1984D.
③Install wire harness (2) (E1984K02) instead of 4P receptacle and connect it to CN7 on
P.C.B.E1984D.
④Connect L connector of wire harness (1) and (2).

Wire harness (2)

Replace with E1984K02

P.C.B.
E1984D L connector

Wire harness (1)

Replace with E1984K01

Refer to 5.2.1 about the following connection.

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5.2.4 Connection with CPDR-350, 500 and CPDACR-200

(1) In case of using plug 4P wire feeder
If using plug 4P wire feeder, such as CMR-231, adapter connector is needed.
Refer to 5.2.3 (1) for connection.
In addition, it is necessary to change over to “wire feeder no-encoder” inside welding
power source. Refer to the manual about welding power source for change-over.

(2) In case of using CMH type wire feeder

If using plug 7P wire feeder, such as CMH-2301 and CMH-1405, it is necessary to use
optional wires (E1984K01, E1984K02). Refer to 5.2.3 (2) for connection.
In addition, it is necessary to change over to “wire feeder no-encoder” inside welding power
source. Refer to the manual about welding power source for change-over.

(3) In case of using CMRE-231 type wire feeder

If wire feeder CMRE-231, it is necessary to use optional wires (E1984K01, E1984K02).
Refer to 5.2.3 (2) for connection.
In addition, it is necessary to use an optional accessory “CMRE control cable” that connects
welding power source and wire feeder directly without connecting the interface box.

Control cable (7P)

For terminal block
CPDACR-200 on P.C.B.P6981Q Control cable for CMRE-231
CPDR-350/500 Wire feeder
CMRE-231
Robot controller

Interface for robot

Control cable (6P)

Base metal

Control cable (7P) Base metal cable

Torch side cable

5.2.5 Connection with CPVP-350, 500, CPVB-350 and CPVPA-350

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If combining with CPVP-350, 500, CPVB-350 and CPVPA-350, it is necessary to use adapter
for CPVP (A), CPVB (E1984M00). Refer to schematic diagram 3 for connection.

Installation E1984M00
①Take off 4P cable (No.8, 9, 25 and 59)
those are connected to 10P terminal 10P terminal block
block of the interface box.
②Follow the drawing below and connect
wire harness (E1984G01).

Wire harness
(optional accessory)
E1984G01 8P plug

・Connect 6P plug from the interface box to “remote control” receptacle of welding
power source.
・Connect 4P plug from the interface box to “wire feeder” receptacle of welding power
source.
・Connect 4P plug from wire feeder, such as CMR-231 to “wire feeder” receptacle of the
interface box back part.
・Connect 8P plug (wire harness E1984G01) from the interface box to “automatic machine”
of welding power source.

For “automatic
machine” receptacle (8P)
Welding power source

Wire feeder

Interface box

For “remote control”

receptacle (6P)
For “wire feeder”
receptacle (4P)
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5.2.6 Connection with CPVWP-350, 500

If combining with CPVWP-350, 500, it is necessary to use optional adapter for CPVP (A),
CPVB (E1984M00) and adapter for CPVWP (E1984J00) that exchange 4P for 5P receptacle
of wire feeder. Refer to schematic diagram 4 for connection.

Installation E1984J00
①Take off 4P plug and 4P receptacle.
②Install wire harness 1 (E1984J01) instead of 4P plug and connect CN5 of P.C.B.E1984D.
③Install wire harness 2 (E1984J02) instead of 4P plug and connect CN7 of P.C.B.E1984D.
④Install relay assembly (E1984J03).
⑤Connect plug connections that are from relay assembly (E1984J03) and canon receptacle
together.
⑥Connect wire No.12 from relay assembly (E1984J03) with 12 on 10P terminal block.
⑦Connect L connectors of wire harness 1, 2 and relay assembly together.

Plug
connection
Relay assembly
E1984J03
L connector

10P terminal
block

P.C.B. 10P terminal

E1984D
block

Wire harness 2
(optional accessory)
E1984J02

Wire harness Canon

Wire harness 1 (optional accessory) receptacle
(optional accessory) E1984G01
E1984J01
5P plug 8P plug

Refer to 5.2.5 about the other connection.

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5.3 Connection with Yasukawa Electrical robot

Connect connector from Yasukawa Electrical robot with canon receptacle of robot controller.
Connect each connector to detect lack of gas and lack of wire.

The relationship between Yasukawa Electrical robot canon receptacle pin No. and signal is as
follows:
(1) (A) – (B)
Output terminal voltage of welding power source will be set by inputting current setting
signal between DC 0 ~ 12.5V.
(2) (C) – (D)
Wire feeding speed (welding current) of welding power source will be set by inputting
current setting signal between DC 0 ~ 12.5V.
(3) (F) – (G)
Wire feeds if short-circuit between (F) and (G) by inputting wire inching signal (contact
signal).
(4) (L) – (K)
Welding starts if short-circuit between (L) and (K) by inputting start command signal
(contact signal).
(5) (H) – (J)
Wire retracts if short-circuit between (H) and (J) by inputting wire retract signal (contact
signal).
(6) (M) – (N)
Output terminal voltage of welding power source shows. (M) is + and (N) is 0 V.
(7) (S) – (E)
Between (S) and (E) will be closed by outputting lack of gas detection signal when
flowmeter contact signal with pressure contact detection input is connected to gas pressure
detection input.
(8) (P) – (E)
Between (P) and (E) will be closed if arc generates and welding current flows by outputting
arc generated detection signal.
(9) (R) – (E)
Between (R) and (E) will be closed if start command signal stays to close and arc generated
detection signal stays to open for a while by lack of arc detection signal. TDR built on
P.C.B. can set the interval period of warning.
(10) (T) – (E)
If lack of wire detection signal is connected to lack of wire connector, between (T) and (E)
will be closed by outputting wire residual detection signal.
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5.4 If using of primary input voltage 208, 230, 460V

CAUTION
●Change-over to input voltage 208, 230V before connecting to input voltage when 460V is
set.
①Take off the cover of the interface box.
②Connect the wire (No.4) to 230V side from 208V side in the 3P terminal block.
③And then, close the cover.

5.5 Connection with input voltage side

WARNING
Observe the following to prevent the electrical shock.

In touching the live electrical part, critical electric shock and burn may occur.
●Do not touch live electrical part inside and outside of the welding power source.
●Have a qualified electric engineer ground the case of the welding power source and the
base metal or jig electrically connected, following a local low.
●Be sure to turn off the line disconnect switch before connecting.
●Do not use cables with insufficient capacity, damaged or exposing the conductor.
●Securely tighten each connection.
●Securely attach the case and cover after connecting cables.

CAUTION
Be sure to ground the case of welding power source.
Cable size: Thicker than 0.75mm2
●If grounding is not provided, voltage is generated at the case through the
capacitor between the input circuit of the interface box and the case or through floating
capacity (electrostatic capacity naturally generated between the input side conductor and the
case metal), liable to cause electric shock if touching them.
Be sure to provide grounding to the interface box.

Welding power source

Interface box
Connect with two wires of
welding power source primary
input (3φ) or single phase
208/230/460V separately.

3φ208/230/460V
Grounding
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6. Maintenance and troubleshooting

WARNING
Observe the followings to prevent the electrical shock.

●Do not touch live electrical parts inside and outside of welding power source.
●Turn off control power switch and line disconnect switch before maintenance, and wait for
more than three minutes to discharge capacitors inside of welding power source.
●Operate the maintenance check periodically, and if any damages of the parts are found,
use the welding power source after troubleshooting or repairing.
●This welding power source must be operated by operators understanding contents of this
owner’s manual and having knowledge and skills for handling the welding power source
safely.
●For maintenance, turn off control power switch and line disconnect switch, and wait for
more than three minutes. Since capacitor may be charged after input side power source
turns off, make sure that charge voltage is off to perform the working.
6.1 Pilot lamp PL does not light
Check if control power switch S1 turns on, and fuse F1 turns off.

6.2 Signal doesn’t work properly even if inputting correctly

Replace P.C.B.E1984D since all functions of the interface box are installed in P.C.B.

6.3 It doesn’t work properly even if changing P.C.B.

Pull out connectors and clean connector pin, and then plug connectors in again.

7. PARTS LIST
●If parts are required for replacement, direct order involving Description and Part No. to our
sales agent or OTC’s office directly.
The symbols in the “Symbol” column of the following parts list are those given in the
Schematic diagram.
Symbol Part No. Description Specification Q’ty Remarks
T1 4810-313 Aux. transformer W-W01076 1
S1 4251-005 Toggle switch S-41 1
PL 4600-301 Pilot lamp 299-RK 1
4612-006 Cartridge fuse element C-3 1
F1
4610-104 Cartridge fuse holder AFAC30 1
F2 4610-008 Glass enclosed fuse 1A 250V 1
PCB1 E1984D00 Printed circuit board E1984D00 1
CON6 None Terminal board F1005-20S-3P 1
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 DAIHEN Corporation
4-1, Koyocho-nishi,Higashinada-ku,
Kobe, Hyogo 658-0033
Phone: +81-78-275-2006, Fax: +81-78-845-8159

DAIHEN, INC. DAYTON OFFICE

1400 Blauser Drive
Tipp City, Ohio 45371, USA
Phone: +1-937-667-0800, Fax: +1-937-667-0885

OTC DAIHEN EUROPE GmbH.

Krefelder Strasse 675-677,
D-41066 Mönchengladbach, GERMANY
Phone: +49-2161-6949710, Fax: +49-2161-6949711

OTC Industrial (Shanghai) Co.,Ltd.

17F Majesty Building, 138 Pu Dong Da Dao Shanghai
The People's Republic of China
Post Code: 200120
Phone: +86-21-5882-8633, Fax: +86-21-5882-8846

OTC (Taiwan) Co.,Ltd.

2F No. 153, Huanbei Rd., Chung Li City,
Taoyuan Hsien, Taiwan R.O.C.
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 Korea Co.,Ltd

11B/L Hyeongok Industrial Complex, 463-1 Hyeongok-ri,
Cheongbuk-myeon, Pyeongtaek, Gyeonggi-do, 451-831, Republic of Korea
Phone: +82-31-686-7459, Fax: +82-31-686-7465

Upon contact, advise MODEL and MANUAL NO.

080218