YASKAWA MOTOWELD-EH500 Instruction Manual
YASKAWA
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MOTOWELD-EH500
INSTRUCTIONS
TYPE: YWE-EH500-6N0(INPUT VOLTAGE: 480V)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
YASKAWA
180369-1CD
0
MANUAL NO.
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MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOWELD-EH500. Read
this manual carefully and understand the contents before handling the
MOTOWELD-EH500. For the wire feeder, the welding torch, and the gas
regulator, read each instruction manual carefully.
• General items related to safety are listed in the Safety Manual Section
1: Safety. To ensure correct and safe operation, carefully read the Setup
Manual before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples
and differences may exist between them and the delivered product.
• Y ASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your product’s warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of the
MOTOWELD-EH500.
In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”
“MANDATORY,” or “PROHIBITED.”
Indicates a potentially hazardous situation wh ich, if not
WARNING
CAUTION
avoided, could result in death or serious injury to personnel.
Indicates a potentially hazardous situation wh ich, if not
avoided, could result in minor or moderate injury to personnel
and damage to equipment. It may also be used to alert against
unsafe practices.
MANDATORY
PROHIBITED
“Serious injury” described above indicates loss of eyesight, injuries, burns (both due to high/
low temperature), electric shock, fractures, poisoning, etc. which may cause personnel to suffer aftereffects, hospitalization, or prolonged out-patient medical treatment.
“Moderate injury” indicates injuries, burns, or electric shock which does not require hospitalization or prolonged out-patient medical treatment.
“Damage to equipment” indicates expanded damages relating to property or equipment.
Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING.”
Always be sure to follow explicitly the items listed under this
heading.
Must never be performed.
For safe training concerning welding, utilize technical institutes held by the welding society or
association, or related societies or associations, technical courses held by the headquarters
or their branches, or qualifications examinations for welding technicians or engineers.
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WARNING
Be sure to observe the following warnings to avoid serious injury to personnel.
• Be sure to observe the precautions in this instruction manual although
this welder is designed and manufactured with sufficient consideration
given to safety.
Failure to observe this warning may result in death or serious injury to personnel.
• Observe the regulations and your own references for the construction of
the input power sources, selection of the installation site, handling of
high-pressure gases, storage and piping, storage of manufactured products after welding, disposal of wastes, etc.
• Do not let personnel to approach the welder or welding sites unnecessarily.
• Any person using a pacemaker must not approach the welder or welding
site under operation unless permitted by doctor.
The welder generates a magnetic field around it during current conduction, resulting in
bad influence on the pacemaker.
• Clean the cooling-water path once a month when using a water-cooled
torch and the cooling water circulator.
Failure to observe this warning may result in explosion or burns due to the choked path.
• In order to secure safe operations, only a trained or qualified person
who has understood the welder must perform installation, maintenance
and inspection, or repair of the welder.
• In order to secure safe operations, only a person that has understood
this instruction manual and has knowledge and techniques to handle
the welder safely must operate the welder.
• Do not use the welder for any applications other than welding.
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WARNING
Be sure to observe the following warnings to avoid an electric shock.
• Never touch the charged parts.
Touching the charged parts may result in critical electric shock or burns.
• Only a qualified person in electric construction should perform grounding construction for the welder case and base metals (to be welded) or
jigs that are electrically connected to the base metals as specified in
the electric facility technical reference.
• Be sure to perform installation or maintenance and inspection five minutes after all the input power supplies are turned OFF by using switches
in the switch box.
Even if the input power supply is turned OFF, the capacitor may still be charged. Be sure
to confirm that charged voltage is gone before starting operations.
• Do not use any cable of insufficient capacity or damaged or with its conductor exposed.
• Tighten the cable connecting sections firmly and insulate them.
• Do not use the welder with its case or cover removed.
• Do not use worn, damaged or wet gloves. Always use dry insulated
gloves.
• Use lifelines when working at hights.
• Perform maintenance and inspection periodically. Repair damaged
parts immediately.
• Turn OFF all equipment input power supplies when not being used.
• When performing AC arc welding in a small space or at hights, be sure
to use equipment to prevent critical electric shock as specified by labor
safety and sanitary regulations.
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WARNING
Be sure to observe the following warnings and use protectors to protect
yourself or other people from the fumes or gases generated at welding and
short of the oxygen.
• In order to prevent gas poisoning or suffocation, be
sure to ventilate sufficiently or use an inhaler, etc.
when welding at a place specified by regulations such
as labor safety and sanitary regulations or hypoxia
preventive regulations.
• In order to prevent dust trouble or gas poisoning due to the fumes or
gases, use a local air exhaust facility specified by regulations such as
labor safety and sanitary regulations or dust trouble preventive regulations or use effective protectors for breathing.
Fumes or gases generated at welding may harm your health.
• When welding within such areas as a tank, a boiler, or a ship’s hold, be
sure to ventilate sufficiently or use an inhaler, etc. in order to prevent or
offset any actual or potential oxygen shortage.
Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom.
• When welding in a small space, be sure to ventilate the site sufficiently
or use an inhaler. At the same time, operations must be done under
trained supervisor.
Welding operations at a small sp ace may result in short of the air, cau sin g a p erson to be
suffocated.
• Do not perform welding near degreasing, cleaning, or spraying operations.
Failure to observe this warning may generate extremely noxious gases.
• Before welding coated steel plates, be sure to ventilate sufficiently or
use protectors for breathing.
Welding such coated steel plates generates noxious fumes or gases.
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WARNING
Observe the following cautions to prevent fire, explosion, or rupture.
• Remov e inflammables so that they will not get spattered.
If they cannot be removed, use the inflammables with
nonflammable covers.
Spatters or hot base metal immediately after welding may result in fire.
• Do not weld near flammable gases.
If arc is generated in a container (for inflammables) in which gasoline or the like is put, the
container may explode.
• Do not make hot base metals immediately after welding close to inflammables.
• Remove inflammables at the hidden side when welding ceiling, floor, or
wall.
Failure to observe this caution may result in fire.
• Tighten and insulate the cable connections.
Imperfect cable connections or imperfect contacting section of the current path at the
base metal such as iron framework may result in fire due to heat generation by current
conduction.
• Connect the cable at the base metal as close to the welding part as possible.
• Do not weld a gas tube having gas inside or an enclosed tank or pipe.
Welding an enclosed tank or pipe may result in rupture.
• Locate fire extinguishers near the welding site.
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CAUTION
Be sure to observe the following cautions and use protectors to protect yourself
or other people from arc beams, spatters, slugs or noise generated from welding.
• Wear welding mask or shaded glasses appropriate for
welding.
• Wear protective glasses to protect your eyes from spatters or slags.
Scattered spatters or slags may damage eyes or burn the skin.
• Use such protectors as leather gloves, clothes with long sleeves, leg
covers, or leather aprons for welding.
• Install protective curtains around the welding site to protect your eyes
from arc beams.
Arc beams may irritate eyes or burn skins.
• Use noise protector when there is excessive noise.
Noise may damage hearing.
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CAUTION
Be sure to observe the following cautions to prevent a gas cylinder from falling or a gas regulator from rupturing.
• Observe the regulations and your own references for
the handling of gas cylinders.
Since a gas
pressure gas to blow up, resulting in personal injury.
• Use the attached gas regulator or our recommended one.
• Read carefully the instruction manual of the gas regulator and observe
the precautions before using it.
• Hold the gas cylinder in the exclusive-use gas cylinder stand.
A gas
• Do not expose the gas cylinder to high temperature.
• Do not bring your face close to the discharging opening when opening
the valve of the gas cylinder.
• Be sure to attach the protective cap when the gas cylinder is not used.
• Do not hang the welding torch over the gas cylinder or keep the electrode away from the gas cylinder.
cylinder is filled with high pressure gas, improper handling may cause high
cylinder falling may result in personal injury.
Observe the following cautions to prevent personal injury due to improper handling.
• Do not use the welder with the case or cover removed.
• Only a qualified person or a person who has understood the
welder must remove the welder case for maintenance and
inspection or repair. Take preventive measures not to let
other personnel approach the welder or welding sites unnecessarily by
putting up a guard fence or the like.
• Do not contact the rotating cooling fan or feeding roll of the wire feeder
with hands, fingers, hair, or clothes.
Failure to observe this caution may cause someone to be caught in the machine resulting
in personal injury.
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CAUTION
Observe the following cautions to prevent personal injury by the end tip of the welding wire.
• Do not peep through the chip hole to confirm that the wire
is being fed.
If the wire is projected from the end tip of the welding torch, it may poke
you in the eyes or face.
• Do not bring the welding torch end close to eyes, face, or body to perform inching or pulling the torch switch.
If the wire is projected from the end tip of the welding torch, it may poke you in the eyes,
face, or body.
• When hanging the wire feeder, remove the anti-fall fastening
from the spool shaft and tighten.
Failure to observe this caution may cause the wire to
be removed from the spool shaft, resulting in personal injury.
Observe the following cautions to prevent burns due to the plasma arc.
If body parts such as hands and fingers directly touch the plasma arc,
burns will result.
• Do not put your hands and fingers near the chip and
the electrodes of the torch end during cutting operation.
• Do not grasp near the base metal during cutting operation.
• Turn OFF the power supply before replacing the chip or the electrodes
of the torch.
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CAUTION
Observe the following cautions to prevent a fire accident caused by deterioration of
welder insulation.
• Perform all welding and grinding away from welder to protect welder from spattering and metal powder.
Spatter and metal powder inside the welder may cause a deterioration of
insulation resulting in accidental fire.
• Be sure to perform maintenance and inspection periodically to prevent
deterioration of insulation caused by accumulation of dust and dirt.
• If spatter or metal powder enters the inside of the welder, remove it by
forced air spray after turning OFF the welder and switch in the switch
box.
Sp atter a nd met al powder in side th e welder may cause a deterio ration of insulation resulting in accidental fire.
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1 Basic Specifications
2 Installation and Connection
2.1 Installation Site and Welding Source Environment .2-1
2.2 Precautions on Grounding. . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Power Supply Installed Capacity and Connection
Cables
2.4 Combination with Earth Leakage Breaker . . . . . . . . . .2-3
2.5 Connection of Electrical System. . . . . . . . . . . . . . . . . . . .2-3
2.6 Connection of Welding Voltage Detecting Line . . . . .2-7
2.7 Connection of Shielding Gas System. . . . . . . . . . . . . .2-10
2.7.1 For Mixed Gas or Carbon Dioxide Gas Welding. . . . . . . . . . . 2-10
2.7.2 Installation Site and Gas Cylinder Environment . . . . . . . . . . . 2-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
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2.8 Ambient Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.9 Precautions on Transporting . . . . . . . . . . . . . . . . . . . . . .2-13
3 Welding Preparation
4 Operations on Panel
4.1 Explanation of Welding Source Panel . . . . . . . . . . . . .4-1
4.2 Settings on Welding Source Panel . . . . . . . . . . . . . . . . .4-4
4.2.1 Changing Welding Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.2.2 User Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.3 Changing P Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.2.4 Changing Common (C) Parameters. . . . . . . . . . . . . . . . . . . . . 4-7
4.2.5 Changing D Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2.6 Saving Welding Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.2.7 Checking the Flow Amount of Shielding Gas . . . . . . . . . . . . .4-11
4.2.8 Selecting Feeding Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.2.9 Monitoring of Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.10 System Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.2.11 Lock Of Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.3 List of Process Parameters. . . . . . . . . . . . . . . . . . . . . . . .4-16
4.4 List of Common Parameters. . . . . . . . . . . . . . . . . . . . . . .4-19
4.5 List of D Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
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5 Welding Operation
5.1 Checking the Welding Conditions. . . . . . . . . . . . . . . . . . 5-1
5.2 Wire Stickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Direction of Welding and Torch Angle. . . . . . . . . . . . . . 5-1
5.4 Precautions on Using Extension Cable . . . . . . . . . . . . 5-2
6 Precautions on Welding
6.1 Error Detection Function. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Tripped Power Supply Switch. . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Precautions on Welding Operation. . . . . . . . . . . . . . . . . 6-4
7 Built-in Functions
7.1 Internal Selecting Switches . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Location of Printed Boards. . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2.1 DIP Switch Settings for Pr(MB)-021 Board . . . . . . . . . . . . . . . .7-4
7.2.2 Jumper-pin Settings of the Pr(MB)-021 Board . . . . . . . . . . . . .7-4
8 Maintenance and Inspection
8.1 Daily Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Bimonthly to Semiannual Inspection Items. . . . . . . . . 8-2
8.3 Annual Overhaul and Repair. . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 Guideline for Service Lifetime and Replacement of
Components Used
8.5 Replace Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 Failure Analyses
9.1 Confirming Setting conditions. . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Cause and Remedy of Welding Section Failure. . . . 9-3
9.3 Cause and Remedy of Failure at Electrical Circuit
Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
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10 Robot Interface Signals
10.1 Specifications of Robot Interface Signals. . . . . . . . .10-1
10.2 Meaning and Function of Pr(RC2)-001 Terminal .10-4
10.2.1 TB2 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
10.2.2 TB3 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
10.3 Meaning and Function of Signal for Starting Point
Detecting Function (Optional board Pr(OP)-003
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6
11 Connection System Diagram
12 Diagnosis Function
12.1 Starting up Welding Source in Diagnosis Mode . .12-1
12.2 Confirmation of DIP Switch Set Status . . . . . . . . . . .12-3
12.3 Confirmation of Software Version . . . . . . . . . . . . . . . .12-4
12.4 Confirmation of the Number of Welding Source Errors
12-5
12.5 Clear of Error Record. . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
12.6 End of Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
13 Process Parameters
(Adjustment of Welding Characteristics)
13.1 Adjustable Welding Characteristics . . . . . . . . . . . . . .13-1
13.2 Adjustment of Arc Start Characteristics . . . . . . . . . .13-2
13.2.1 Adjustment of Start Pulse. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 -2
13.2.2 Adjustment of Hot Characteristics . . . . . . . . . . . . . . . . . . . .13-3
13.3 Adjustment of Arc End Characteristics . . . . . . . . . . .13-4
13.4 Adjustment of Short-circuit Welding Characteristics. .
13-6
13.5 Adjustment of Pulse Welding Characteristics. . . . .13-7
13.5.1 Adjustment of MAG/MIG Pulse Welding Characteristics . . . 13-7
13.5.2 Adjustment of MIG Pulse Welding Characteristics. . . . . . . . 13-8
13.6 Adjustment of Other Pulse Welding Characteristics .
13-9
13.7 Adjustment of Current Output Characteristics . . .13-10
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14 Calibration for External Resistance
14.1 Outline of External Resistance Calibration. . . . . . . 14-1
14.2 Procedure of External Resistance Calibration . . . 14-2
14.2.1 Connecting the Cable for Resistance Measurement. . . . . . .14-2
14.2.2 Measuring the External Resistance Value . . . . . . . . . . . . . .14-4
14.2.3 Display of External Resistance Setting Parameter . . . . . . . .14-6
14.2.4 Setting the D Parameter for Calibration of External Resistance to
"Enabled". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-6
15 Calibration Function of Welding Current
15.1 Overview of the Welding Current Calibration Function
15-1
15.2 Procedure of Welding Current Calibration. . . . . . . 15-2
15.3 Parameters for Welding Current Calibration Function
15-6
16 Welding Source Condition File of the Robot
Controller
17 Setting of Arc Monitoring Function
18 Operation by External Remote Mode
18.1 Gas Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.2 Switch of User Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
19 List of Service Parts
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1 Basic Specifications
Item Specifications
Model MOTOWELD-EH500
Type YWE-EH500-6N0
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Number of Phases,
Rated Input Voltage
Rated Frequency 50/60 Hz common
Rated Input 27.5kVA
Welding Current Adjustment Range
Welding Voltage Adjustment Range
Rated Operational Ratio 100 % (for 10 minutes)
Welding Type CO
Welding Object Material Iron, stainless steel, aluminium (Refer to the “Type” on the panel for
Feeding Motor Types of feeding motors can be selected among;
Three-phase, 480 V
24.3 kW
30 to 500 A (depends on the wire diameter)
12 to 45 V (depends on the wire diameter)
short-circuit welding, MAG/MIG short-circuit welding, pulse welding
2
details.)
0: Print servomotor (default setting)
1: Minertia servomotor for servo torch
2: 4-roller servomotor (YWE-WF-340MELC)
±10 %
Wire Feeding speed 1.5 to 18 m/min
Wire Feeding
Slow-down Speed
Encoder cable 5 m (standard), 7m max.
Gas Running-in Time Approx. 20 seconds (Can be adjusted by panel operation: 60000 sec-
Gas Pre-flow Time Approx. 0.06 seconds (Can be adjusted by panel operation)
Gas After-flow Time Approx. 0.5 seconds (Can be adjusted by panel operation)
Wire-stick Prevention
Time
CO2 short-circuit welding: Approx. 3 m/min
MAG/MIG short-circuit welding and pulse welding: Approx. 2 m/min
(adjustable range by panel operation: 1 to 4m/min)
(Optional: 25 m max with a cable extender)
onds max.)
Approx. 0.2 seconds (Can be adjusted by panel operation: 0.02 to 0.4
seconds)
(adjustable range by panel operation: 1.5 to 6 m/min)
1-1
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Item Specifications
Volt age for St arting Point
Detecting Function
(Optional)
External Dimensions
[mm]
Mass Approx. 70kg
Welding V oltage Setting
Method
Arc Touch Start Function This function can be used by the parameters D2-2, D2-3, and D2-4.
User File Number of files: 3
Adjustment of Voltage
and Current Waveform
Control
Interface for Robot Controller
Output Setting Analog
Input
Peak value: 220 V
371 x 810 x 641 (width x depth x height)
(excluding the projections such as screws or eyebolts)
Can be switched by "Auto Adjustment/Individual" (Synergic/Independent) button on the welding source panel.
"Panel" or "robot" can be switched by the parameter D1-11.
Can be changed by P parameters in the user file.
Refer to " 10 Robot Interface Signals ".
0 to 14 V (The set voltage, current, and wire feeding speed are displayed
on the welding source panel.)
±20 % (full-wave rectification)
Error Output Outputs the arc failure signal to the robot side. (Error contents are indi-
cated on the welding source panel.)
Output for Arc
Monitoring
Power Supply of the
Heater for the Gas
Regulator
Standard Accessory Fuse contained in glass tube of 5A (2 fuse)
Remarks Front panel: Written in English
Outputs the signal corresponding to current or voltage to the robot side.
The output terminal stand for analog indicator is also available.
None
Fuse contained in glass tube of 10 A (1 fuse) for Pr(SD)-006 board
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2.1 Installation Site and Welding Source Environment
2 Installation and Connection
2.1 Installation Site and Welding Source Environment
CAUTION
• The welding source can be moved easily by using the caster. After
installation, use the stopper to fix the welding source before starting
operations.
For precautions on transporting, see
" 2.9 Precautions on Transporting ".
The welding source can be used under the following environmental conditions:
• Dry, indoor and at least 30 cm from the wall or peripheral devices
• Free from direct sunlight, wind, and rain
• Ambient temperature of 0 to 40
• Altitude less than 1000 m
• Free from direct splash of welding spatter or metallic fine powder at grinding
°C
2.2 Precautions on Grounding
CAUTION
• Be sure to turn OFF the main switch of the switchboard before performing the grounding work.
• If the welding source is used with rated input voltage: 480 V(6N0), the
ground resistance must be 100
by authorized or certified personnel.
Ω or less. Grounding must be performed
1. Be sure to perform secure grounding work (ground resistance must be 100 Ω or less)
on the welding source so as not to charge its case or lead to unstable operation.
2. Connect a grounding cable of 14 mm2 or thicker to the terminal marked "GROUND" or
"EARTH".
3. Be sure to ground the base metal (ground resistance must be 100
when or any other non-conductive material is placed under the base metal.
2-1
Ω or less) as well
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2.3 Power Supply Installed Capacity and Connection Cables
4. If there is a pool or pond between the grounding of the power supply switchboard and
the welding source, the leak current is concentrated in the pool or pond. In such a
case, connect the grounding with a cable to escape the leak current through the cable.
2.3 Power Supply Installed Capacity and Connection
Cables
The following table " Table. 1 Power Supply Installed Capacity and Cables " shows the power
supply installed capacity and connection cables which are required for using the welding
source.
The rated input voltage for the welding source is three-phase, 480V(6N0). The welding
source supports a voltage compensation circuit so that the equipment can operate at a power
voltage within
power supply as stable as possible. If fluctuations in power supply voltage exceed
welding source conditions cannot be guaranteed and problems may occur.
±10 % fluctuations of the rated value. All the same, it is recommended to use a
±10 %,
Diameter of the input cable and the fuse capacity must be in compliance with the t able " Table.
1 Power Supply Installed Capacity and Cables ". Insta ll a non-fuse breaker (NF B) or a switch
with fuse for each welding source.
The non fuse breaker used should be the same capacity of the fuse indicated in " Table. 1
Power Supply Installed Capacity and Cables ", and the tripp ing time at 600 % o f the rated current should be one second or longer (General motor breakers satisfy these requirements). If
breaker capacity is insufficient or primary voltage is too high, the breaker will be tripped when
the welding source is turned ON.
Table. 1 Power Supply Installed Capacity and Cables
Installed Capacity 30 kVA
Fuse Rated Current 75 A
(rated voltage: 480 V(6N0))
Input Cable
Outside diameter of acceptable
Input Cable
Exclusive-use base metal cable
2
14mm
φ27.0～φ30.0mm *1
60mm
80mm
～22mm
2
or more (cable length:5m or less)
2
or more (cable length:5m or more ) *2
2
Grounding Cable
14 mm
2-2
2
or more
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2.4 Combination with Earth Leakage Breaker
*1
The input cable is passed from the hole for wiring in the back of the po we r su pp ly.
NOTE
When the outside diameter of the cable exceeds φ30.0mm, match the plate to the
size of the input cable, process the hole, and use it.
*2 Be sure to use cables for welding. Also, use cables with sufficient thickness for pulse
welding or current of 250 A or more. Excessively small gauge cables may result in
poor welding and cause abnormal heating resuoting in burn or fire.
2.4 Combination with Earth Leakage Breaker
When the welding source is used in a construction site, in a place with high humidity, or on an
iron plate, iron framework, or surface plate with high conductivity , a leakage breaker should be
installed according to the proper regulations or laws. In such a case, connect a leakage
breaker of current sensitivity 30 mA for each welding source. The welding source may malfunction because of the inverter operations depending on the model or current sensitivity of
the leakage breaker. Therefore, select a proper one for inverter drives.
2.5 Connection of Electrical System
CAUTION
• Open the disconnect switch of the swtichgear before connecting wires
between welding machine and primary power supply.
Even one imperfect contact in the connections precludes proper welding. Be sure to
make perfect connection to the base metal by using jigs.
1. Connection on the Welding Source Side
See " Fig. 1 Connection Diagram of Welding Source at Re ar Face " for proper connections.
1) Input cable
Please remove the top cover and connect the cable with the input terminal of
the partition board.
Connected bolt of the input voltage terminal is M8.
2) Ground cable
2. Connection on the Welding Side
See " Fig. 2 Connection Diagram of Welding Source at Front Face " for proper connections.
1) Welding cable
The welding cable connects between the welding torch and power output termi-
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2.5 Connection of Electrical System
nal (+).
2) Exclusive-use base metal cable
The exclusive-use base metal cable connects between the base metal and
power output terminal (-).
3) Welding Voltage Detecting Line
The welding voltage detecting line connects between the base metal and connector "CON 7" at rear face of the welding source.
CAUTION
• Be sure to connect the welding voltage detecting line.
If the welding voltage detecting line is not connected, the error "Err70 2: Voltage Detection
Wire Error" may occur, and welding cannot be performed.
• Only if the length of the welding cable and exclusive-use base metal
cable is 5 m or less respectively, the welding source can be used with
connecting a short-circuiting cap for detecting voltage of output terminal (-) to the connector "CON 7" at rear face of the welding source. For
improving the welding performance, connect the base metal and connector "CON 7" with the welding voltage detecting line whenever possible.
3. Connection of Control Cable
Connect cables of every kind to connectors at rear face of the welding source. When
connecting the cables, securely tighten the plug until it stops rotating.
1) Connect the control cable of the robot controller to the connector "CON 3".
2) Connect the motor cable of the wire feeder to the connector "CON 4".
3) Connect the encoder cable of the wire feeder to the connector "CON 5".
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Acrobat 文書
Fig. 1 Connection Diagram of Welding Source at Rear Face
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2.5 Connection of Electrical System
Fig 2 Connection Diagram of Welding source at Front Face
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2.6 Connection of Welding Voltage Detecting Line
4. Grounding
Ground terminal is provided at the input voltage terminal in the partition board of the
welding source for safe operation. Connect the grounding cable of 14 mm
the crimp contact. Ground resistance must be 100
Be sure to ground the base metal at resistance of 100
in " Fig. 2 Connection Diagram of Welding Source at Front Face ". If it is not
grounded, voltage may be generated in the base metal resulting in electric shock.
Make sure that the grounding is always done individually , sep arated from grounding for
the manipulator. Also, connect the welding source and the base metal with exclusiveuse base metal cable.
Ω or less.
Ω or less individually as shown
2
or more to
2.6 Connection of Welding Voltage Detecting Line
In the connection of the welding voltage detecting line, Be sure to observe the following items
.If the following items are not observed, the amount of the spatter generation might increase.
1. Connect the welding voltage detecting line as close to the position where welding is
performed as possible.
2. The welding voltage detecting line and the welding output cable must separate as far
as possible.(The distance is required 100mm or more.)
3. When you use MOTOPOS(external welding positioner), Connect the welding voltage
detecting line with with the screw of the cover that exists in the base of MOTOPOS.
When two or more stations are used, connect the weldin g voltage detecting line with a station
as far away from the welding source as possible as indicated in " Fig. 2 Connection of Welding Voltage Detecting Line when Multiple Stations are Used ".
Fig. 2 Connection of Welding Voltage Detecting Line when Multiple Stations are Used
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2.6 Connection of Welding Voltage Detecting Line
When a rotation axis is used, connect the welding voltage detecting line with the screw of the
cover that exists in the base of MOTOPOS. Don’t connect output cable and the welding voltage detection line with the same part as indicated in " Fig. 3 Connection of Welding Voltage
Detecting Line when Rotation Axis and two welders is Used ".(Don't connect the welding voltage detection line with the route where the welding current flows).
Please confirm it has run electrically between the welding workpiece and the screw of the
cover by the tester before it wires.
-
Two voltage detect
Two voltage de
-
tecting lines
ing lines
Two welding out
-
put cables
(a) Connection of voltage detecting line (b) Connection of welding output cable
Fig. 3 Connection of Welding Voltage Detecting Line when Rotation Axis and two welders is Used
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2.6 Connection of Welding Voltage Detecting Line
When you use two or more welders, Connect the each welding output cable of the welder as
close to the position where welding is performed as possible.
Separate the welding output cable A from the welding voltage detecting line B,and separate
the welding output cable B from the welding voltage detecting line A as far as possible.(Distance between Cable A and cable B is required 100mm or more.)
Don't connect the welding voltage detection line with the route where the welding current flows
Fig. 4 Connection of Welding Voltage Detecting Line and Welding outputcable
when two or more welders are used.
CAUTION
• Be sure to connect the welding voltage detecting line.
If the welding voltage detecting line is not connected, the error "Err702: Voltage Detection
Wire Error" may occur, and welding cannot be performed.
• Only if the length of the welding cable and exclusive-use base metal
cable is 5 m at a maximum respectively, the welding source can be used
with a short-circuiting cap for detecting voltage of output terminal (-) on
the connector "CON 7" at rear face of the welding source. For improving
the welding performance, connect the base metal and connector "CON
7" with the welding voltage detecting line whenever possible.
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2.7 Connection of Shielding Gas System
2.7 Connection of Shielding Gas System
2.7.1 For Mixed Gas or Carbon Dioxide Gas Welding
The 100 VAC power supply is required for a heater of carbon dioxide gas regulator. Connect
the gas cylinder as follows:
1. Remove dust from the gas cylinder connecting port. Install the MAG/carbon dioxide
common gas regulator. Check the quality of the gas and the type of the cylinder.
2. Insert one end to the supplied rubber gas hose into the output of the gas regulator, and
the other end into the gas terminal inlet of the wire feeder. Clamp both ends securely
with hose bands.
2.7.2 Installation Site and Gas Cylinder Environment
Handle the gas cylinder with special care because it contains high pressure gas. Refer to the
instruction manual attached to the gas cylinder.
1. Installation SIte of Gas Cylinder
Place the gas cylinder in a specified gas container position that is not exposed to direct sunlight. If the gas cylinder is unavoidable placed at the welding site, it must
be fixed to post or cylinder stand in an upright position to
prevent it from falling. Also, the gas cylinder must not be
heated by a welding arc or the like.
2. Type of Gas Cylinder
Carbon dioxide gas-filled cylinders can be classified into
two types: one is the general type that is not the siphon
type, and the other is the siphon type.
Never use siphon type gas cylinders. The provided carbon dioxide gas regulator is not applicable to siphon
type cylinder. If the regulator is connected to a siphon
type gas cylinder, the contents of the cylinder are not
gaseous and enter the regulator as remaining liquefied.
In such a case, the pressure reduction mechanism of
the regulator cannot be operated. The type of gas cylinder can be distinguished by cylinder color according to
the cylinder’s manufacturer. Contact the gas distributor
for details.
The safety valve operates when the pressure goes
extremely high. When the valve operates, stop operation immediately, confirm the reason, and take appropriate corrective actions to prevent that the same error
occurs again.
Gas cylinder
Fix the gas cylinder to prevent
it from falling.
Fig. 5 Installation Site of Gas
Cylinder
Gas cylinder stand
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3. Quality of Gas for Welding
Moisture or impurity in the carbon dioxide gas or argon gas used to shield welding arcs
adversely influenced welding. High purity and low moisture gas must be used.
Use MAG gas
containing 80 % argon and 20 % carbon dioxide gas for mixed gas.
The gas mixing ratio of MAG gas is content, which contributes to constant welding
quality. Especially for pulse welding, improper pulse welding will be resulted if the
argon gas ration is less than 80 %.
Use carbon dioxide gas
designated as "for welding" or what conforms to Class 3
specified in JIS-K1106 (moisture content 0.005 % or less) or the equivalent. Avoid
using carbon dioxide gas containing moisture more than 0.005 %, not only for the
adverse effect on welding, but also because it may cause clogging in the gas reg ulator
if the water content freezes.
4. Gas Regulator with Flow Meter
Use gas regulator with flow meter suitable for the gas to be used. The following table
show the examples of the gas regulator.
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Table. 2 Gas Regulator with Flow Meter
No. Type Applicable Gas Remarks
1 FCR-2505A CO
2 FCR-225 CO
*1
The power supply for the heater is not provided with the welding source. Prepare a 10 0
VAC power supply for the heater of the gas regulator.
, MAG Meter: Indicates secondary pressure
2
, MAG, Ar Meter: Indicates primary pressure and
2
and flow amount
1
Heater: 100 VAC*
float-type flow amount
Heater: 100 VAC*
, 190 W
1
, 190 W
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2.8 Ambient Environment
1. Wind Prevention
Normally, the allowable wind limit for welding using shielding gas is approx. 1.5 m/s or
less. If the wind speed is higher than this limit, stop operation or take some countermeasures such as putting up a screen.
Even for indoor operations, sufficient attention to the shield effect must be paid when
using air tools or fans around the welding.
2. Ventilation
The carbon dioxide gas used as the shielding gas is decomposed by arc heating, and a
small amount of carbon monoxide is generated.
For operations indoor or in a container or a t ank, ventilation is needed. In this case, do
not use a fan to blow the air, but ventilate the accumulated gas by providing a ventilation fan or exhaust duct.
2.8 Ambient Environment
Ventilating fan
Torch
Torch
Wind
Fig. 6 Shielding Wind for Welding
Screen
Object to be welded
Fig. 7 Ventilation Example
3. Shading Measures
For shaded glasses of helmets or hand shields, use filter numbers 8 to 10 of JIS T8141
for welding of thin plates since it has a weak arc beam and the arc must be seen easily.
Use numbers 10 to 13 for welding of medium-hick plates since the arc is bright. For
MAG welding, for which stronger arc light is required compared to CO
welding, use
2
greater filter numbers.
The welder brings in ultraviolet rays stronger than that caused by manual welding.
Periodically check protectors for eyes and the skin. Also, be sure to always wear these
protectors.
When the welding source is controlled by external control input signal or while operating the manipulator, provided proper shade around the welding torch.
Accidental arc generation may damage eyes or burn the skin of those without proper
protection.
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Jacket must be
long-sleeved.
Welding gloves
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Helmet
Handshield
Foot covers
Safety boots
Fig. 8 Protection Example
2.9 Precautions on Transporting
CAUTION
• Sling applications and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock while transporting.
The welding source consists of precision components. Failure to observe this caution
may affect its performance.
1. Transporting with Using Casters
When using the casters, move the welding source slowly so that it can be stopped
quickly at any time. Moving the welding source with casters quickly may result in an
accident due to inertia, and you cannot control the direction of movement.
Moreover, be sure to stop the welding source with casters at a ste p and move it slowly
to prevent any shock sudden. Do not move the welding source with casters up a slope,
stairs, etc.
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