YASKAWA MOTOWELD-EH500 Instruction Manual

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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

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

1-2

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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

14mm φ27.0～φ30.0mm *1

60mm 80mm

～22mm

or more (cable length:5m or less)

or more (cable length:5m or more ) *2

Grounding Cable

14 mm

2-2

or more

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2.4 Combination with Earth Leakage Breaker

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

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

2.7.1 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

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

, MAG, Ar Meter: Indicates primary pressure and

and flow amount

Heater: 100 VAC*

float-type flow amount Heater: 100 VAC*

, 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

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

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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2. Transporting with Using a Crane When using the crane, be sure to confirm the following points before transporting.

1) Confirme the mass of the welding source by referring to " 1 Basic Specifications ". Select the wire rope suitable for the mass and angle.

2) Use eyebolts for transporting and confirm that the eyebolts are tightened firmly before transporting.

3) Lift the welding source using the crane after the above confirmation.

2.9 Precautions on Transporting

3. Transporting with Using a Forklift Observe the following points to use the forklift for transporting.

1) Con firm availability of safe operations site, and transfer the weldin g source to the installing site.

2) After determining the operation site, warnings must be placed on transport path to prevent accidents.

3) Put the welding source on the transporting pallet and fix firmly to prevent falling or shifting. Employ a stopper on the casters to fix the welding source. Over-tightening the cover may cause it to deform.

4) Do not raise the lift excessively.

5) Avoid excessive shock or vibration while transporting since the system consists of precision component.

6) Transport the welding source at yield speed when using the forklift.

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4. Others

1) Do not climb up on the welding source or place anything on it.

2) Do not p a ss a rope directly arou nd the welding source case durin g transporting . Failure to observe this caution may deform the shape of the case or cause malfunction.

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3 Welding Preparation

The following table describes the preparation procedure to start actual welding.

Table. 3 Welding Preparation Procedure

Step Item Details

Setting welding wire Set a wire suitable to the welding method. Make sure

Checking torch Confirm that a contact tip suitable to the diameter of

that the diameter of the roller of wire feeder matches the wire diameter.

the wire is installed on the torch.

Turning ON the switch in the

switch gear Turning ON switches for the weld-

ing source

Setting feeding motor The feeding motor type can be set by the parameter

Confirm that connections are correct, then turn ON the switch of the switch gear of the welding source.

Turn ON the power switch. The power indicator lamp lights and the built-in cooling fan starts. The fan stops after fifteen minutes unless the arc starts. The fan automatically restarts when the arc starts.

C09. 0: Print servomotor (default setting) 1: Minertia servomotor for servo torch 2: 4-roller servomotor (YWE-WF340MELC) Incorrect setting of the feeding motor precludes proper welding because the wire cannot be fed at wire feeding speed as directed by the set value. When the parameter was changed, follow the instructions as follows:

1. Keep on pressing the "Record" button for more than three seconds to save changes. Do not turn OFF the welding source while saving.

2. Confirm that the 7-segment LED indicators light again, then turn OFF the welding source once and ON again.

For details, refer to " 4.2.8 Selecting Feeding Motor ".

Setting welding source voltage control

Setting at the robot side Set the welding source condition files (including “Syn-

Set the welding source voltage control: either "Synergic (auto adjustment)" or "Independent (individual)". When "Synergic" is set, the LED indicator lamp above "Auto Adjustment/Individual" button will light up. "Synergic (auto adjustment)" is set before shipping.

ergic (auto adjustment)” or “Independent (individual)”). For details, refer to " 16 Welding Source Condition File of the Robot Controller ".

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Table. 3 Welding Preparation Procedure

Step Item Details

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Selecting welding type Before Setting;

the type of shielding gas and wire, or short-circuit/

Checking the indicated value on the welding source panel

Wire inching Adjust the welding wire by wire inching so that it can

pulse. Selectable types are written on the nameplate on the front face of the panel. Set the welding type number to the Type on the welding source panel.

Check the settings for the voltage, current, wire feeding speed, and welding type of the digital meter on the welding source panel. Check the indicated value on the panel by changing command value from the robot controller.

be used for welding as follows:

1. Output the inching command from the robot controller.

Select the welding type according to

2. Inch the wire until it comes out from the end of the torch.

Adjusting gas flow Adjust the gas flow as follows:

1. Press the "Gas" button on the panel of welding source. The LED indicator lights and the gas flows for 20 seconds. The gas automatically stops after the 20 seconds. (The gas flow time can be set by the parameter C00. Refer to " 4.2.7 Checking the Flow Amount of

Shielding Gas ".)

2. Turn the valve of the gas cylinder counterclockwise to open.

3. Turn the knob of the gas regulator to adjust the flow according to welding conditions. Proper gas flow rate is 10 to 25 liters per minute. The flow rate must be increased in proportion to the welding current (the higher the current, the larger the flow rate).

Saving welding conditions Save the conditions before turning OFF the welding

source as follows:

1. Keep on pressing the "Record" button for more than three seconds to save changes.

Do not turn OFF the welding source while saving.

2. The 7-segment LED indicators light up again at the completion of the saving. Confirm that the 7-segment LED indicators light again.

End

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4.1 Explanation of Welding Source Panel

4 Operations on Panel

4.1 Explanation of Welding Source Panel

NOTE

Pressing the panel buttons during welding does not change any oper ation othe r than user file selection. Be sure to stop welding before starting the panel operations.

PRM Select

Common PRM Select

Record

Auto Adj.

Auto Adjustment

/Individual

Gas

Wire m/min

PRM Set

Type

Weld.Type

File No.1 File No.2

File No.3

User File Select

Power Warning

Fig. 9 Welding Source Panel

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The following table explains the display of the meters c, d, e, and f. The content of the display differs according to the status as follows:

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Status

During standb y

During welding During wire inching

When Parameter C32=0, Displays Setting Conditions.

When Parameter C32=1, Displays Stanby

c Welding Volt-

age Indicator Displays the set

welding voltage value (V).

Displays 0.0V Displays 0A Displays 0.0m/min Displays the weld-

Displays the welding voltage value (V) that is fedback.

d Welding Cur-

rent Indicator Displays the set

welding current value (A).

Displays the welding current value (A) that is fedback.

Wire m/min

e Wire Feeding

Speed Indi cator Displays the feed-

ing amount (m/ min) of the set welding current value.

Displays the feeding amount (m/ min) of the motor that is fed-back, or the motor current. (Can be switched by the parameter D1-5.)

Type

f Welding Type

Indicator Displays the weld-

ing type (Type).

Displays the welding type (Type).

During setting parameter

Displays the parameter number.

Normally displays "---". When the arc touch start is selected, displays "-" in the parameter P01.

Display Lamps

Item Content Explanation

Power Lamp Lights when the power supply is turned ON.

Warning Lamp Lights or blinks when an error occurs. The error number is dis-

played on the digital meter.

Search Lamp Lights while the starting point detecting function is used. High

voltage is being generated while the lamp is turned ON. ( E ffective only when the starting point detecting unit is installed.)

Displays

-P parameter: ratio (%)

-C parameter: value (in decimal)

-D parameter ON/OFF

Displays the welding type (Type).

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4.1 Explanation of Welding Source Panel

Setting Buttons

Item Content Explanation

Parameter Select (P parameter)

Common Parameter Select (C parameter)

Auto Adjustment/Individual (synergic/independent) Switch

Parameters Setting When setting parameters or common pa rameters, the numbers and

Selecting of Welding Type

When the "PRM Select" button is pressed during standby status, the display changes to the P parameter setting display. The 7-seg-

ment LED indicator

e displays the parameter set value. (Effective only when the

cator user file is selected.) Press this button again to return to the standby display.

When the "Common PRM Select" button is pressed during standby status, the display changes to the common para meter setting dis-

play. The indicator the common parameter set value. Press this button again to return to the standby display.

Switches the control type of welding voltage.

-Auto adjustment: LED indicator lamp lights. (Output voltage is set at % from the robot controller.)

-Individual: LED indicator lamp turns OFF. (Output voltage is set by welding voltage command from the robot controller.)

the parameter set values can be switched. The blinking 7-segment LED indicator is the selected item.

Press the button "Weld Type" button during standby status to change the welding type (Type), and the 7-segment LED indicator

c displays "P.00", and the 7-segment LED indi-

c displays "C.00", and the indicator e displays

f blinks. The welding type setting is confirmed with pressing of this

button again, and the 7-segment LED indicator

f stops blinking.

Right to Left or Up and Down Move Button

Saving Conditions Used to save the setting. The LED indicator lamp blinks when the

Checking Gas Checks the gas. The LED indicator lamp lights when pressing the

Selecting of the User File

Used to change the settings. Press "L" or "R" to move the digit. Press "+" or "-" to increase or decrease the value.

setting is changed. To save the changed setting, keep pressing the "Record" button for three seconds or more. If the welding source is turned OFF when the 7-segment LED indicators go out, the changed setting cannot be saved successfully. Wait until the 7-segment LED indicators are lit again. If the welding source is turned OFF and back ON af ter the 7-segment LED indicators are lit again (the conditions are saved), the settings return to the status where the conditions were saved. Turn the welding source OFF and back ON without pressing this button so as not to save the changed settings.

"Gas" button, and the gas flows for 20 seconds. (The default setting for the gas flow time is 20 seconds. This time can be changed by C00 parameter.) When this button is pressed again during the gas check, the gas stops flowing.

Selects the file to save the contents of the changed settings. Each time the "User File Select" button is pressed, the LED indic ator lamp for the file number is changed.

(No File→ File No.1→ File No.2→File No.3) P parameters cannot be changed or saved without a file: "No File".

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4.2 Settings on Welding Source Panel

4.2.1 Changing Welding Type

The following describes how to change the welding type.

(1) Press the button "Weld. Type", and the 7-segment LED indicator

blinks.

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f "Type"

(2) Use the button "+" or "-" to increase or decrease the value. Use t he button "L"

or "R" to move the digit.

(3) After changing the value, press the button "Weld. Type" or leave it without doing

anything for 10 seconds, and the 7-segment LED indicator

Press the button "Record" for 3 seconds or more to save the changed value. Do not turn OFF the welding source while pressing this button. The saving of conditions is completed when the 7-segment LED indicators are lit again.

Wire m/min

Type

f "Type" lights.

Type

The welding types available for software version 3.20-000-6 (CPU) are listed on the nameplate attached to the front panel of the welding source.

Welding types other than listed on the nameplate are not available. Using improper welding type will result in unstable welding, which causes excessive spatters or imperfect bead appearance. Before starting welding, confirm that the welding type has been correctly selected.

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4.2 Settings on Welding Source Panel

Table. 4 List of Weld Types

Shielding Gas Wire

MAG (Ar 80%, CO

20%)

MAG (Ar 80%, CO

20%)

MIG (Ar 98%, O

2%)

Soft steel Fe

Stainlesssteel SUS

Pulse or

Short-circuit

Pulse

Short-circuit

Wire

Diameter

Weld

Type No.

φ 0.9 3.21 φ 1.0 3.24

φ 1.2 3.27 φ 1.4 3.61 φ 0.9 3.19 φ 1.0 3.22 φ 1.2 3.25 φ 1.4 3.60 φ 0.9 3.35 φ 1.0 3.36 φ 1.2 3.37

φ 1.4

3.62

φ 0.9 5.29 φ1.0 5.31 φ1.2 5.33

Remarks

MIG (Ar 98%, O

2%)

MAG (Ar 80%, CO

20%) MIG

(Ar 98%, O 2%)

MIG (Ar 92%, O

8%)

Welding types other than listed on the nameplate are not ava ila ble .

SUPPLE

-MENT

Using improper welding type will result in unstable welding,which causes excessive spatters or imperfect bead appearance.Before starting welding,confirm that the welding type has been correctly selected.

Stainlesssteel

Pulse

SUS

Stainlesssteel

Pulse

SUS

SUS Pulse φ 1.2 4.43

Aluminum

Pulse φ 1.2 2.12

φ 0.9 5.46 φ 1.0 5.42 φ 1.2 5.44 φ 0.9 5.28 φ 1.0 5.30 φ 1.2 5.32

5000

Low pulse φ 1.2 2.14 Servo torch: Necessary

Mild steel

Zinc Pulse φ 1.2 3.59

Servo torch: Recommended

For galvanized sheet iron

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4.2 Settings on Welding Source Panel

4.2.2 User Files

The conditions changed by the P parameter concerning any welding type are saved in the user files: File No. 1, File No. 2, and File No. 3. Also, the user file can be called up from the manipulator controller to perform welding. The P parameters cannot be changed or saved unless the user file is selected (No File status).

1. When the content of P parameter is to be changed, confirm that the user file can be changed by the panel operation (D1 parameter D1-11=OFF), then select the user file:

file No. 1, 2, or 3. The file No. is changed each pressing of “User File Select” button,

and the LED indicator lamp of selected file lights. The file No. is changed as: No File

ÆFile No.1ÆFile No.2ÆFile No.3.

2. Press the button “Weld.Type” to change the welding type (Type).

Refer to " 4.2.1 Changing Welding Type " for details on changing of the welding type.

When conditions are changed, the LED indicator lamp for "Record" blinks.

SUPPLE

-MENT

Keep pressing the button "Record" for three seconds or more to save the changed content. Do not turn OFF the welding source while pressing this button. The saving of conditions is completed when the 7-segment LED indicators are lit again.

CAUTION

• When the welding type which is set in the user file is changed, the P parameters are initialized and everything becomes the value at 100 %.

4.2.3 Changing P Parameters

The P parameters are used for welding adjustment. The P parameters are changed by multiplying the internal set data of the selected welding type by the modification ratio. The change of the P parameters is allowed only when the user file: file No.1, No.2, or No.3 is selected. For details on the P parameter, refer to " 4.3 List of Process Parameters ".

Follow the instructions to change P parameter value as follows:

(1) Press the button

c voltmeter (V) displays "P.00" blinking, and the 7-segment LED indicator e

cator

j "PRM Select" during standby status. The 7-segment LED indi-

"Wire m/min" (WF) displays the parameter value lighting.

(2) Press the button "L" or "R" button to change the number of blinking digits to one.

Press the button "L" button to move the blinking to the left, and press the button

"R" to move the blinking to the right.

(3) Using the button “L” or “R”, move the blinking digits to the number to be

changed.

(4) Use the button “+” or “-“ to increase or decrease the value.

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4.2 Settings on Welding Source Panel

(5) Press the button “PRM Set”, and the parameter value on the 7-segment LED indi-

e “Wire m/min” blinks. The set value of parameter is ready to be changed.

cator

Change the set value in the range between 10 and 200 %.

For changing the parameter number, press the button “PRM Set” again. The blinking digits move as shown below with each pressing of the button “PRM

Set”.

(6) After changing the value, press the button

Wire m/min

j “PRM Set” or leave it without doing

Type

anything for 10 seconds to return to the standby display. Press the button "Record" for three seconds or more to save the changed values

(conditions). Do not turn OFF the welding source during saving conditions. When the 7-segment LED indicators are lit again, the saving of conditions is completed.

4.2.4 Changing Common (C) Parameters

For the details on the common parameter, refer to " 4.4 List of Common Parameters ". The C parameter is the common parameters for the welding source.

Follow the instructions to change C parameter value as follows:

(1) Press the button

LED indicator cator

e "Wire m/min" (WF) displays the parameter value lighting.

(2) Press the button "L" or "R" to change the numb er of blinking digit s to one. Press

the button "L" to move the blinking to the left, and press the button "R" to

move the blinking to the right. (3) Using the button "L" or "R", move the blinking digits to the number to be changed. (4) Use the button "+" or "-" to increase or decrease the value.

k "Common PRM Select" during standby status. The 7-segment

c voltmeter (V) displays "C.00" blinking, and the 7-segment LED indi-

(5) Press the button "PRM Set", and the parameter value on the 7-segment LED

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indicator e "Wire m/min" blinks. The set value of parameter is ready to be

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changed. If the set value is four digits or more, use the button "L" to move the cursor to the indicator

d ammeter (A). The indicator d ammeter (A) displays the

number(s) above the forth digit.

For changing the parameter number, press the button "PRM Set" again. The blinking digits move as shown below with each pressing of the button "PRM

Set".

Wire m/min

Type

(6) After changing the value, press the button

k "Common PRM Select" or leave it

without doing anything for 10 seconds to return to the standby display. Press the button "Record" for three seconds or more to save the changed values

(conditions). Do not turn OFF the welding source during saving conditions. When the 7-segment LED indicators are lit again, the saving of conditions is completed.

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4.2 Settings on Welding Source Panel

4.2.5 Changing D Parameters

For details on the D parameter, refer to " 4.5 List of D Parameters ". D parameters specify the setting or operation conditions for the welding source by ON/OFF.

The D parameters consist of D-1 parameter and D-2 parameter. The setting items for each parameter are: No.1 to No.16, altogether 32 setting items are available.

Follow the instructions to change D parameter as follows:

(1) Keep pressing the button

Select" during standby status. The 7-segment LED indicator

plays "d-1" blinking, the 7-segment LED indicator

ware switch number blinking, and the 7-segment LED indicator

(WF) displays ON or OFF lighting.

k "Common PRM Select" and press the button j "PRM

c voltmeter (V) dis-

d ammeter (A) displays the soft-

e "Wire m/min"

(2) Use the button "+" or "-" to switch "d-1" and "d-2" (3) The blinking digits move as shown below with each pressing of the button "PRM

Set".

Wire m/min

Type

Use the button "L","R", "+", or "-" to change the parameter number and the set

contents.

When the 7-segment LED indicator

d ammeter (A) is blinking, the software switch

numbers (1 to 16) can be selected.

When the 7-segment LED indicator

e "Wire m/min" is blinking, the setting of soft-

ware switch (ON/OFF) can be changed. ON and OFF are switched with each press-

ing of the button "+" or "-".

(4) After changing the setting, press the button

k "Common PRM Select" or leave it

without doing anything for 10 seconds to return to the standby display.

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<Example> When the parameter D1-11 is ON (enabled):

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Press the button "Record" for three seconds or more to save the changed values

Wire m/min

Type

(conditions). Do not turn OFF the welding source during saving conditions. When the 7-segment LED indicators are lit again, the saving of conditions is completed.

4.2.6 Saving Welding Conditions

When the parameter set value is changed by the operations on the welding source panel, the LED indicator lamp above the button "Record" blinks.

The following describe how to save the settings.

(1) Referring to " 4.2.2 User Files ", specify the file number where the data are to be

saved.

(2) Press the button "Record" for 3 seconds or more, and the 7-segment LED indica-

tors display dashes "- - -".

(3) When the saving is completed, the 7-segment LED indicators returns to the status

where the conditions were saved. If the power supply is turned OFF while saving the welding conditions, the data cannot be successfully saved. Confirm that the 7 segment LED indicators are lit again before turning OFF the power supply.

CAUTION

• For P parameters, the changed data are validated at the same time the change is made. However, when the welding type is changed or the power supply switch of the welding source is turned OFF, the changed data will be lost. The changed data are overwritten on the da ta of the file where the data are to be stored.

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4.2 Settings on Welding Source Panel

4.2.7 Checking the Flow Amount of Shielding Gas

The shielding gas flow amount can be checked. Press the button "Gas" button. The LED indicator lamp above the "GAS" button lights and the gas flows for 20 seconds.

Press the button again during gas checking to stop the gas flow.

The checking time of the gas flow amount can be adjusted by change in the numerical value of C parameter C00, while, the default setting is 20 seconds (unit: second).

Press the button "Record" for 3 seconds or more to save the changed value.

NOTE

Do not turn OFF the breaker until the 7-segment LED indicators are lit again when the “Record” button was pressed.

4.2.8 Selecting Feeding Motor

The feeding motor can be selected by change in the numerical value of C parameter C09.

C09: 0 Print servo (Default setting) C09: 1 Servo torch C09: 2 4-roller servo

Press the button "Record" button for 3 seconds or more to save the changed value. To validate the change in setting, turn OFF the welding source and ON again after saving the

conditions.

NOTE

Do not turn OFF the breaker until the 7-segment LED indicators are lit again when the “Record” button was pressed.

(YWE-WF340MELC)

CAUTION

• Welding performance will be unsatisfactory, since the wire cannot be fed at the wire feeding speed as instructed by the command value unless the feeding motor is set correctly.

• The change in the motor setting will be first reflected when the welding source is restarted (turned OFF

Æ ON) after saving the conditions.

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4.2 Settings on Welding Source Panel

4.2.9 Monitoring of Motor Current

The motor current of rotating feeding motor can be displayed in the 7-segment LED indicator "Wire m/min" by setting D parameter D1-5 to "OFF". During the standby status, the 7-segment LED indicator displays the command of wire feeding amount (m/min).

When the 7-segment LED indicator displays the motor current, "A" is indicated at the third digit of the indicator. In the figure above, the motor current is 0.5 A. When the 7-segment LED indicator does not display "A" at the third digit, D paramete r D1-5 is set to "ON" status, and the indicator shows the feedback speed of wire feeding.

There are two levels for monitoring the motor current: the warning level and the error level.

• Motor current warning Outputs a warning signal when the motor current exceeds the warning level which has been set by C parameter C25. Wire feeding and welding will be continued although the motor current exceeds the warning level. The warning signal will be output through the terminals 524 and 525 on the Pr(RC2)-001 board.

• Motor current error Outputs Err502 "motor overcurrent" and ends wire feeding and welding when the motor current is passed more than the rated current.

Wire m/min

Type

4.2.10 System Reset

System Reset initializes all the setting data in the welding source. Reset the system only when the software is updated or initialization or when Memory Error (Error 205 to 299) occurs.

CAUTION

• Be sure that executing System Reset initializes all the internal data. If some parameters must be retained, write them down on a sheet of paper before System Reset. The data cannot be restored after the system reset operation.

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The following describes how to reset the system.

(1) Press the button

LED indicator cator

e "Wire m/min" (WF) displays the parameter value lighting.

k "Common PRM Select" during standby status. The 7-segment

c voltmeter (V) displays "C.00" blinking, and the 7-segment LED indi-

4.2 Settings on Welding Source Panel

(2) Use the button "+", "-", "L" or "R" to display the parameter "C23".

(3) Press the button "PRM Set", and the parameter value on the 7-segment LED

indicator

e "Wire m/min" blinks. Change the setting value of parameter "C23" to

Wire m/min

"2004". When the setting value is four digits or more , use the button "L" to move the cursor to the 7-segment LED indicator

d ammeter (A). The indicator d amme-

Type

ter (A) displays the number(s) above the forth digit. The system reset will be executed at C23=2004.

Wait until "sys rst" starts blinking.

Wire m/min

Type

(4) Turn OFF the welding source when "sys rst" is displayed. This is end of the initial-

ization.

Wire m/min

Type

(5) Turn ON the power supply and the parameters retu rn to the de fault setting. Set the

recorded parameters again if necessary.

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4.2 Settings on Welding Source Panel

4.2.11 Lock Of Panel Operation

"Lock of panel operation" is a function to invalidate the button operation so as not to operate the button of a front panel of the welding power supply by mistake. The button that can be operated with the panel operation locked is only a gas check button.

 Method of setting "lock of panel operation"

R button is pushed continuousness three times while pushing L button.

PRM Select

Common PRM Select

Record

Auto Adj.

Auto Adjustment

/Individual

Gas

Wire m/min

After the condition is stored, HOLd is displayed.

Type

PRM Set

Weld, Type

File No.1 File No.2

File No.3

User File Select

Wire m/min Type

Power Warning

If "HOLd" is displayed, "lock of panel operation" is set. In the state of "lock of panel operation", only the gas check button can be operated. HOLd "is displayed when buttons other than the gas check button are pushed, and the button operation is not accepted.

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4.2 Settings on Welding Source Panel

 Method of releasing "lock of panel operation"

L button is pushed continuousness three times while pushing R button with the panel operation locked.

PRM Select

Common PRM Select

Record

Auto Adj.

Auto Adjustment

/Individual

Gas

Wire m/min

PRM Set

Type

Weld, Type

File No.1 File No.2

File No.3

User File Select

Power

Warning Search

After the condition is memorized, and 7- Segment LED lights again, "lock o f panel operation" has been released. All the button operations of a front panel become possible.

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4.3 List of Process Parameters

The welding characteristics (start/main conditions/end) that are specified by database in the welding source can be adjusted according to your environmental conditions by changing the set values of the process parameters (P parameters). All the values are set to "100% = Operating as the characteristics in the database" before shipping. If the adjustment of welding characteristics is required, refer to " 13 Process Parameters (Adjustment of Welding Characteristics) "

Display

No.

P00

C Wire slow-down speed

P01

C Wire speed at start

P02

C Starting pulse peak current

P03

- Reserved for system Do not change.

P04

C Starting pulse peak time

P05

C Average value of hot current

P06

C Average value of hot voltage

P07

CHot time

P08

P Pulse current

P09

P Base current

P10

P Pulse time

Items Description

P11

C Average current at ending VALID when the parameter D1-4=ON

P12

C Average voltage at ending VALID when the parameter D1-4=ON

P13

C End time VALID when the parameter D1-4=ON

P14

C Average current value at burning

P15

C Average voltage value at burning

P16

C Burning time

P17

C Droplet pulse peak current

P18

C Droplet pulse peak time

P19

- Reserved for system Do not change.

P20

C Wire-stick prevention time

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4.3 List of Process Parameters

Display

No.

P21

- Reserved for system Do not change. to P30

P31

P MAG/MIG pulse current increas-

ing speed

P32

- Reserved for system Do not change. P33

P MAG/MIG pulse current decreas-

ing speed

P34

- Reserved for system Do not change. P35

A Aluminum MIG pulse current

increasing ratio

P36

A Aluminum MIG pulse current

decreasing ratio

P37

S Short-circuit current increasing

speed 1

Items Description

P38

S Short-circuit current decreasing

speed 2

P39

- Reserved for system Do not change. P40

- Reserved for system Do not change. P41

- Reserved for system Do not change. P42

- Reserved for system Do not change. P43

C Hot slope time

P44

C Ending slope time

P45

- Reserved for system Do not change. P46

- Reserved for system Do not change. P47

- Reserved for system Do not change. P48

- Reserved for system Do not change. P49

S Arc control 1

P50

S Arc control 2

P51

S Arc control 3

P52

- Reserved for system Do not change. to P54

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Display

No.

P55

A Low-pulse frequency ratio

(for welding type 2.14, aluminum)

P56

A Low-pulse wire feeding speed

ratio (for welding type 2.14, aluminum)

P57

- Reserved for system Do not change. to P59

P60

C Synergic voltage adjustment

(automatic adjustment)

P61

P Arc length control gain

P62

C Current output characteristic 1 Wire feeding speed compensation ratio 1 (unit: %)

P63

C Current output characteristic 2 Wire feeding speed compensation ratio 2 (unit: %)

P64

- Reserved for system Do not change. to P67

Items Description

Changes the frequency based on C parameter C03. E.g.) When C03=100 and P55=50%, 5.0Hz

Changes the amplitude based on C parameter C04. E.g.) When C04=10 and P55=200%, C04*200%=20%

Compensates the voltage by 1V with

±10%.

*1 P: For pulse welding (including aluminum pulse)

A: For aluminum welding S: For short-circuit welding C: Common for all the welding types

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4.4 List of Common Parameters

Common parameters (C parameters) specify the operations of the welding source. Set the parameters according to the operation conditions. Save the changed common parameters to enable common parameters. Then turn OFF the power and ON again.

Display

No.

C00 C01

C02

C03

C04

C05

C06

C07

C08

C09

C10 C11 C12

C13

C14

C15

C16

C17

Contents

Gas check time Gas pre-flow time

Gas after-flow time

Low-pulse frequency (for welding type 2.14, aluminum)

Low-pulse amplitude (for welding type 2.14, aluminum) Current at low-pulse acceleration (for welding type 2.14, aluminum)

Current at low-pulse deceleration (for welding type 2.14, aluminum)

Digital meter displayed speed

External resistance set value

Motor setting

Reserved for system Reserved for system Reserved for system Current calibration reference

current 1 (File 1) Current calibration reference

current 2 (File 1) Current calibration reference current 1 (File 2) Current calibration reference current 2 (File 2) Current calibration reference current 1 (File 3)

Default Setting

20 s 56 ms

500 ms

100 0.1Hz

20 %

120 %

100 %

1000 ms

505

50 100 200

150 A

250 A

150 A

250 A

150 A

Unit Description

×10

−

Gas flowing time before welding output starts (minimum: 56 ms) Gas flowing time after welding output completes

Low-pulse frequency

Low-pulse wire feeding speed amplitude Current at low-pulse acceleration

Current at low-pulse deceleration

Time for average moving for display of current/voltage digital meter Electric resistance value of weld-

ing current path such as power cable, jig stand connected to welding source

Motor selection 0: Print-type servomotor (default

setting)

1: Minertia servomotor for servo

torch

2: 4-roller servomotor (YWE-

WF340MELC)

Do not change. Do not change. Do not change. Reference current 1 for the user

file No.1 Reference current 2 for the user

file No.1 Reference current 1 for the user file No.2 Reference current 2 for the user file No.2 Reference current 1 for the user file No.3

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4.4 List of Common Parameters

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Display

No. C18 C19

C20 C21 C22

C23

C24

C25

C26 C27

C28

C29

C30 C31

C32

Contents

Current calibration reference current 2 (File 3)

Reserved for system Reserved for system Reserved for system Reserved for system System Reset

Reserved for system Motor current warning value

Reserved for system Reserved for system Error: outside the range of out-

put current

Setting range of the error: outside the range of output current

Reserved for system running time of Cooling Fan

after welding Digital Meter Display during

stanby

Default Setting

250 A

0 0

600

70 A

900 s

Unit Description

Reference current 2 for the user file No.3

Do not change. Do not change. Do not change. Do not change. When the C parameter C23 is set

to "2004", System Reset is executed to initialize all parameters (default setting). Before executing System Reset, record the modified parameters. After executing System Reset, turn OFF the welding source and turn ON again. When the power supply is turned OFF, the C parameter C23 is back to "0".

Do not change.

% (for motor

rated

current

The value at which the warning is output for the excess current of feeding motor

)

Do not change. Do not change. 0: If the output current is outside

the range, the error (Err790, Err791) is issued after welding.

1: If the output current is outside

the range, the error (Err790, Err791) is issued during welding and the welding stops.

2: If the output current is outside

the range, the error is not issued.

Sets the range of the error: out side the range of output current (Err790, Err791). If the output current is within the range of welding current command ±C29, the error is not issued. If it exceeds the range, the error: Err790, Err791 is issued.

Do not change. When setting 30000(max

value),Cooling Fan always runs. Set Digital meter display during

stanby. 0: Displays setting conditions. 1: Displays stanby status (0.0V,0A,0.0m/min)

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4.5 List of D Parameters

Display

No.

C33

Contents

Reserved for system

Default Setting

Unit Description

Do not change.

*1 The initial value of the external resistance set value is the value measured under the

environment for the MOTOWELD-EH500 database creation. For measurement of the external resistance value under your operation conditions, refer to " 14 Calibration for External Resistance ".

4.5 List of D Parameters

D parameters specify the operation conditions for the welding source. Set the parameters according to the operation conditions. The D parameters are displayed by following the instructions as follows: Keep pressing the button

k "Common PRM Select" and press the button j "PRM Select" during standby status.

D-1

Display

No.

1 2 3

5 6

7 8

9 10 11

12 13 14 15 16

Reserved for system Do not change. OFF Reserved for system Do not change. ON Wire slow-down Enabled Disabled ON End event End condition process-

Display of feeding speed/ motor current Reserved for system Do not change. OFF

Reserved for system Do not change. ON Reserved for system Do not change. ON Reserved for system Do not change. ON Data communication

mode User file switching Switched at robot side Switched on panel OFF

Reserved for system Do not change. OFF Reserved for system Do not change. OFF Reserved for system Do not change. ON Reserved for system Do not change. OFF Reserved for system Do not change. ON

Contents ON OFF

End condition process-

ing enabled Displays feeding speed Displays motor current ON

Enabled Disabled OFF

ing disabled

Default Setting

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D-2

Display

No.

2 3 4 5 6 7 8

9 10 11 12 13 14

15 16

External resistance calibration

Touch start User File1 Enabled Disabled (normal start) OFF Touch start User File2 Enabled Disabled (normal start) OFF Touch start User File3 Enabled Disabled (normal start) OFF Reserved for system Do not change. ON Reserved for system Do not change. ON Reserved for system Do not change. ON Reserved for system Do not change. ON Reserved for system Do not change. OFF Reserved for system Do not change. OFF Reserved for system Do not change. OFF Reserved for system Do not change. OFF Reserved for system Do not change. ON Reserved for system Do not change. ON Error Latch Error Latch until the

Reserved for system Do not change. OFF

Contents ON OFF

Compensates by external resistance value set in the parameter C08

power is turned OFF

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Default Setting

Disabled OFF

Automatic error reset OFF

*1 To enable the calibration for the external resistance value, the external resist ance value

must be measured. For measurement of the external resistance value under your operation conditions, refer to " 14 Calibration for External Resistance ".

• Always set the parameter "D1-10" to "disabled" (OFF) at times other than data communications.

• For aluminum welding, it is recommended to set the parameter for the end event "D1- 4" to "enabled" (ON) since automatic crater processing is effective. The crater processing requires approx. two seconds after ARCOF instruction. Set additionally the Timer instruction so that the manipulator stops for two seconds at the welding end point.

• For synergic voltage, the voltage that Yaskawa assumes adequate is specified as 100%. Changing the synergic voltage by 10%, voltage varies by approx.about 1V. (Example: In case of 20V at 100%, it becomes 19V and 21V at 90% and 110%, respectively. The percentage (%) can be changed in the range between 50% and 150% (±5V).) The percentage (%) that is set at robot synergic voltage is displayed on the welding source in the unit of V.

• For the welding type: CO

short-circuit arc welding, do not use the touch start but select

the normal start.

• When aluminum welding is selected, the touch start arc becomes enabled (default set-

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ting) with the parameters "D2-2", "D2-3", and "D2-4" set to "OFF".

4.5 List of D Parameters

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5.1 Checking the Welding Conditions

5 Welding Operation

5.1 Checking the Welding Conditions

Before starting actual welding operation, perform the test welding for welding conditions to check if the welding performance is satisfactory. Remove oil, rust, oil paint, water, and foreign matter generated by gas-cutting to prevent the surface pore and blowhole.

5.2 Wire Stickout

The wire length from the torch tip to the arc point is called wire stickout. Keep this length constant during welding.

The following table shows the length ( ) of wire stickout as standard.

Length ( ) of wire stickout

Wire Diameter

(1.2 mm)

15 mm 10 to 15 mm 20 mm

Wire Diameter

(0.9 mm)

Wire Diameter

(1.4 mm)

5.3 Direction of Welding and Torch Angle

There are two welding types: backhand welding (same as manual welding), in which the torch is tilted by 0° to 10° in the direction of welding, and forward welding, in which welding is carried out in the same state but in the opposite direction. The forward welding is more popular in robot welding because it results in better gas shielding and the welding can be performed viewing the welding line.

0°

10°

Torch

Wire stickout

Forward

welding

Gas

Forward welding is preferred in CO2/MAG welding.

Nozzle

Backhand welding

Base metal

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5.4 Precautions on Using Extension Cable

Fig. 10 Direction of Welding and Torch Angle

5.4 Precautions on Using Extension Cable

When an extension cable is used, actual output between the torch and the base metal decreases because of voltage drop in the cable. To prevent this, set the command value of welding voltage adjustment higher than the target voltage value to compensate for the output voltage drop. " Fig. 11 Reference for Voltage Drop along Extension Cable " shows a reference for the voltage drop along an extension cable. Use the one-class thicker extension cable to keep stable welding voltage.

Voltage drop (V)

100 200 300 500

Welding current (A)

100 200 300 500

Welding current (A)

Extension cable length (one way)

25m

15m

Extension cable length (one way)

Fig. 11 Reference for Voltage Drop

along Extension Cable

20m

10m

25m

15m

10m

20m

This graph indicates the relationship between voltage drop and welding current when an extension cable of 60

is used. If extension cables are used for both ways, the voltage drop becomes twice as much as the value indicated in this graph.

This graph indicates the relationship between voltage drop and welding current when an extension cable of 80

is used. If extension cables are used for both ways, the voltage drop is twice as much as the value indicated in this graph.

SUPPLE

-MENT

• If an extension cable is used for pulse welding, the response for the pulse waveform control may be delayed, which may prevent the spatter-less pulse welding. Use a cable as short as possible for high quality welding.

• In order to compensate for the voltage drop due to extension cables, etc., perform automatic correction by the calibration of the external resistance value which is described in " 14 Calibration for External Resistance ".

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6.1 Error Detection Function

6 Precautions on Welding

6.1 Error Detection Function

Error detection is performed for the following items, and the welding source is automatically stopped when an error is detected. If an error occurs, the "Warning" lamp lig hts or blinks and the error number is displayed in the digital meter on the panel face. For the contents of errors, refer to the following table. At error detection, an arc failure signal is output at the robot side.

Table. 5 List of Error Display Contents

Error No. Item Contents Remedy

Err001 Input over-

voltage

Err002 Input under-

voltage

Err102 Excessive

temperature

Err107 Input/output

overcurrent

Err110 Voltage

detector error

Primary input voltage exceeding 550 V is applied continuously for two seconds.

Primary input voltage is lower than 390 V continuously for two seconds.

The temperature in the primary or secondary control circuit exceeds the specified value of the welding source.

Overcurrent flows in the primary control circuit.

The welding voltage is not detected.

Check the input voltage.

• Check the ambient temperature

°C or less) and operational

(40 ratio (100 %).

• Check if there are dust, dirt, and clogging on the dust protective filter. Clean or replace the dust protective filter if necessary.

• Check if the output cable is short-circuited or grounded.

• The power circuit may be broken. Contact your Yaskawa representative.

Contact your Yaskawa representative.

Err111 Auxiliary cir-

cuit overcurrent

Err203 and 204

CPU error A commu nications error betwee n

Overcurrent flows in the auxiliary circuit.

the CPU1 and the CPU2 occurs.

6-1

The board may be broken. Contact your Yaskawa representative.

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6.1 Error Detection Function

Table. 5 List of Error Display Contents

Error No. Item Contents Remedy

Err205 to 299

Err303 Panel switch

Err304 to 309

Err501 Improper

Memory error An error occurs in the data in the

setting error

Improper model setting

feeding amount

welding source internal memory .

The DIP switch of PR(CR)-008 board is not correctly set.

Nonconformity in the model setting of hardware and software

The welding wire was not fed as instructed by the feeding amount command value. There is a certain difference between the feeding amount command value and the feedback from the encoder.

The data may not have been correctly saved when the welding conditions are recorded because of a power failure, etc. Reset the system after saving the changed parameters. (See " 4.2.10 System Reset ") If the error occurs again, the board may be broken. Contact your Yaskawa representative.

• Check the DIP switch setting of PR(CR)-008 board.

• PR(CR)-008 board may be broken. Contact your Yaskawa representative.

The setting of hardware or software may not be performed correctly. Contact your Yaskawa representative.

Check the following.

• Check that the encoder cable is not damaged.

• Check if the screws of the connector terminal block are securely fastened. If the encoder cable is disconnected or the screws are loosened, the wire feeding speed becomes excessively fast and an error occurs in the wire feeding amount. Replace the encoder cable or fasten the screws of the connector terminal block.

• Check if the wire load becomes heavy . Make sure that th e torch cable and conduit cable are not bent excessively.

Err502 Motor over-

current

Err601 Starting sig-

nal error

Overcurrent above the rated current flows in the motor circuit.

Arc starting signal is input before the welding source’s main power supply starts up.

6-2

Check if the wire load becomes heavy. Make sure that the torch cable and conduit cable are not bent excessively.

Check again the operation timing or signal cable connections. The same error may occur at momentary power failure.

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Table. 5 List of Error Display Contents

Error No. Item Contents Remedy

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Err701 Output over-

current

Err702 Voltage

detection wire error

Overcurrent flows in the secondary control circuit.

The welding voltage is not detected.

Confirm the following.

• Check that the torch cable or power cable is not grounded.

• Check that the contact tip does not contact the workpiece to be welded. Set the contact tip so as not to contact the workpiece, then perform welding.

• Check that the encoder cable is not damaged.

• Check if the voltage detection wire is connected. Check if the voltage detection line or the short-circuit cap is connected to the connector CON7.

• Check that the contact tip does not contact the workpiece to be welded. Set the contact tip so as not to contact the workpiece.

• Temporary power failure may have occurred.

Err790 Outside of

output current setting (Over the upper limit)

Err791 Outside of

output current setting (Over the lower limit)

The actual welding current becomes far removed from the welding current command value.

6-3

• Check if the selection of motor is correct, or confirm the settings of C parameter C09.

• Check that the welding wire does not slip, or the wire is fed as instructed by the feeding command.

• Check that the wire stickout is not excessively short or long.

• Check that the range set in C parameter C29 is not too narrow.

• Check if the wire, shielding gas, welding type, earthing, etc. are correctly set.

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6.2 Tripped Power Supply Switch

If the power supply switch is tripped, do not turn it ON again. Contact your Yaskawa representative. If the power is turned ON again with the power supply switch tripped, the problem may be compounded and may affect the welding.

6.3 Precautions on Welding Operation

Check the following precautions before starting welding.

1. The welding wire is electrically charged during welding. Be careful that the welding voltage still remains for two seconds after the welding ends due to the two-second delay set for the welding source. Also, do not touch the welding wire during the st arting point detection (optional function) since the voltage of approx. 300 V is applied to the wire.

2. If a conduit cable is extremely bent, the welding wire cannot be smoothly fed, and thus the set welding conditions may be altered. To prevent this, place conduit as straight as possible.

3. If welding is performed at a current exceeding the rated output current, internal p arts of the welding source may be burnt. Allowable operational ratio for a current under the rated value is calculated as follows:

Allowable operational ratio = Rated operational ratio

Table. 6 Allowable Operational Ratio of the Welding Source of 500 Ampere

(with Rated Operational Ratio of 100%)

Welding

Current

(A)

500 100 Continuous welding possible

Allowable

Operational Ratio

(%)

Allowable Continuous

Welding Time

× [ ]2%

Rated current

Operating current

Welding Pause Time

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6.3 Precautions on Welding Operation

4. Power switch operation The inverter welding source is the forced air-suction cooling type. Do not turn OFF the power supply switch until the cooling fan completely stops after co mpletion of the o peration. To prevent electric shock, never disconnect or connect the cables for the welding source, the wire feeder, the welding torch, etc. while the power is ON. Make sure that the power supply switch of the welding source is turned OFF after the operation.

5. Cooling fan The cooling fan starts rotating as soon as the power supply is turned ON. Then, the fan stops if approx. 15 minutes passes without arc start. However, the fan restarts rotating when welding starts, and it stops approx. 15 minutes after the welding ends. One of three fans operates at all times in sync with the power supply switch.

6. Stretch a protective curt ain around the welding ope ration space for workers and oth ers to protect from arc light, spatter, and slag.

7. Installation Environment Do not weld on a wet earth floor or metallic floor to avoid electric shock. Also avoid welding where there are inflammables to prevent fire due to scattering of heated spatter or slag.

8. The welding source cannot be used for gouging other than CO

9. Radio disturbance Noise may be generated over the radio during welding. When listening to the radio, keep the radio as far as possible from the welding source. When a radio is not on battery but on a 100 VAC power supply, do not bring the welding torch close to the 100 VAC cable.

/MAG welding.

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7.1 Internal Selecting Switches

7 Built-in Functions

7.1 Internal Selecting Switches

The internal selecting switches are set as follows before shipping. The internal switches are not allowed for change since the switches are prepared for adjustement and maintenace performed by manufacturers.

Table. 7 DIP Switch Setting for Pr (CR)-008 Board

DIP Switch (DSW) Default Setting Remarks

1-8 OFF 1-7 OFF 1-6 OFF 1-5 OFF 1-4 OFF 1-3 OFF 1-2 OFF 1-1 OFF 2-8 OFF 2-7 OFF 2-6 OFF 2-5 OFF 2-4 OFF 2-3 OFF 2-2 OFF 2-1 OFF 3-8 OFF 3-7 OFF 3-6 ON 3-5 OFF 3-4 OFF 3-3 ON 3-2 ON 3-1 OFF 4-8 OFF 4-7 OFF 4-6 OFF 4-5 OFF 4-4 OFF 4-3 OFF 4-2 OFF 4-1 OFF

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7.2 Location of Printed Boards

ON OFF

87654321

DSW1

87654321

DSW2

Fig. 13 DIP Switch Settings for Pr (CR)-008 Board

87654321

DSW3

87654321

DSW4

Pr (CR)-008

CAUTION

• Be sure not to switch the selecting switch which is designated as "switch disabled" by mistak e. Failure to observe this caution may result in a trouble.

7.2 Location of Printed Boards

Fig. 14 Top View without the Top Cover from the Welding Source

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7.2 Location of Printed Boards

Fig. 15 Location of Printed Board Pr(MB)-021 and Pr(CR)-008

To Replace Printed Board Pr(MB)-021 and Pr(CR )- 00 8 , Remove two screws at a control panel and open a control panel.

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7.2 Location of Printed Boards

7.2.1 DIP Switch Settings for Pr(MB)-021 Board

The DIP switch settings for Pr(MB)-021 board are for manintenance. Do not change these settings.

Table. 8 Settings of DIP Switches

SW1 Setting

1ON 2OFF 3ON 4OFF

7.2.2 Jumper-pin Settings of the Pr(MB)-021 Board

The settings of the Pr(MB)-021 board are for maintenance. Do not change these settings.

Table. 9 Settings of Jumper Pins

(no mark) Open Circle Side SW5 SW6 SW7 SW8

H H

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8.1 Daily Inspection Items

8 Maintenance and Inspection

WARNING

• Before maintenance or inspection, or wiring, be sure to turn OFF the switch in the switchgear on the input side and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in electric shock or injury.

• For internal inspection immediately after using the welding source, the capacitor in the welding source may be charged. Wait for approx. five minutes and remove the cover for inspection.

Failure to observe this warning may result in electric shock or injury.

CAUTION

• Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

Perform periodical maintenance and inspection for safe and efficient operations of the weld ing source.

8.1 Daily Inspection Items

Check the following:

(1) The switches operate without fail. (2) The cooling fan rotates smoothly by turning ON/OFF the power supply switch and

draws the air in from the rear face. (3) There is no abnormal vibration, beat, or odor. (4) There is no leakage of gas. (5) The cable connecting section is not excessively heated. (6) The welding cable and its connecting section is not excessively heated. (7) There is no damage on the connection cable such as a cable on the input side or on

the base metal side, resulting in imperfect insulation. (8) Each connecting section is tightened securely.

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8.2 Bimonthly to Semiannual Inspection Items

Perform the following:

(1) Removal of dust and dirt

Remove dust and dirt by spraying dry compressed air. Carefully clean spaces between the transformer and reactor windings, and semiconductors. To clean circuit boards, use the exclusive-use dust remover device.

(2) Inspection of electric connecting sections

Check that the bolts are firmly tightened and rust or the like does not deteriorate the contacts in the connecting sections with the external wiring such as input/output terminals or with the internal wiring. Retighten the bolts if necessary or use a file to remove rust, if any, so that the metallic faces contact with each other.

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(3) Inspection of ground line

Confirm that the case is grounded properly.

8.3 Annual Overhaul and Repair

Carry out the integrated repair such as replacement of defective components, case repair, and reinforcement of insulation deteriorated parts. Insulation resistance must be 1MΩ or more between the control unit circuit and the case; if it is less than 1MΩ, the insulation of the deteriorated part must be repaired.

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8.4 Guideline for Service Lifetime and Replacement of Components Used

The welding source is composed of many components. Unless all these components operate normally, the welding source cannot utilize its essential functions. Therefore, it is absolutely necessary to find any sign leading to a failure of a component or device as early as possible according to the periodical inspection and take proper corrective action. These components cannot be used continuously for ever. Even under normal operation status, they are apt to have variation of the characteristics or malfunction after the life elapses. Therefore, it is recommended that the component s be re placed periodically so th at the welder can operate at optimum performance. Normally, refer to the following guideline of the component replacement when the welding source is used in the rated specifications (8 hours a day, 250 days a year).

• Electrolytic capacitor: Approx. 5 years

• Cooling fan: Approx. 5 years

• Breakers, relays: Depends on how often they are used. It is recommended that they be

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8.5 Replace Fuse

If any fault shown below occurs,Check fuse.If Fuse blown again after replace fuse,Contact your Yaskawa representative.

Table. 10 Fuse

Item Fault

Fuse 10A blown.(purple color)

Fuse 5A blown. • Although power switch is ON,the Digital Meter does not dis-

• Although the start signal is ON or the wire inching signal is ON,Motor does not operate.

• Cooling fan does not rotate.

play .

To Replace Fuse 5A, Remove two screws at a control panel and open a control panel.

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9.1 Confirming Setting conditions

9 Failure Analyses

WARNING

• Before maintenance, inspection, or wiring, be sure to turn OFF the switch in the primary side switch gear and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in electric shock or injury.

CAUTION

• To connect a nylon connector, insert the connector after matching the connector number and confirm that it is locked. Do not apply excessive force to the printed board when inserting the connector. Never change the positions of the internal wiring or modify the connections.

Failure to observe this caution may result in device problems.

Confirm that the junctions between the metal receptacle and the cable, and the connectors on the printed boards are connected securely. Then, take corrective action by referring to " Table. 11 Check Items ", " Table. 12 Failure Analyses for Welding Section ", and " Table. 13 Fault Analyses for Electrical Circuit Section ". If the equipment does not function properly even after the corrective action, contact your Yaskawa representative to investigate the cause and to repair as soon as possible.

9.1 Confirming Setting conditions

If any fault occurs, check the following items in " Table. 11 Check Items ". Afterwards, take proper corrective actions in " Table. 12 Failure Analyses for Welding Section "."

Table. 11 Check Items

Item Contents

Welding type Check if the welding type suitable for material and the wire diameter or shielding

gas has been selected.

Parameter Check that changing of parameters does not le ad to the error in welding operation.

After recording the changed parameters , return the data to the initial values and check how welding is performed.

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Table. 11 Check Items

Item Contents

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Synergic/ Independent selection

Motor selection

Voltage detection wire

P Parameters cannot be changed.

User files cannot be selected.

Check if synergic/independent (auto adjustment/individual) se lection of the welding source is the same as that on the robot sid e. Synerg ic/Indepe ndent o f the weldin g

source can be set by the panel button ing source panel. When "synergic (auto adjustment)" is selected, the LED indicator "Auto Adj." lights. If the setting is different from that on the r obot side, incorrect welding voltage value is displayed on the pane l. Furthermore, if the welding source condition files of the robot are not correctly set, the robot command values are not correctly displayed on the welding source panel.

Confirm the set value of C parameter C09 to check if the motor is correctly selected. (0: Print servo 1: Servo torch, 2: 4-roller servo (YWE-WF340MELC)) If the motor is not correctly selected, the wire is not fed as instructed by the command value and welding performance becomes unsatisfactory.

If the voltage detection wire is disconnected, the 7-segment LED indicator for welding voltage ERR702 "Voltage detection wire error" is displayed on the 7-segment LED indica-

tors. Check if the voltage detection wire is correctly connected. P parameters are effective only when the user file is selected. Select the user file

File 1, File 2, File 3) when using P parameters.

D parameter D1-11 is used to specify whether the user file is selected from the panel or the robot. (D1-11 OFF: from panel, ON: from robot)

c on the welding source panel displays approx. 0 V. Then the error

l "Auto Adjustment/Individual" on the weld-

Record of conditions

Encoder cable

Shielding gas Check if the shielding gas suitable for the welding type is selected. For pulse weld-

Arc monitor When the arc monitoring function is used, refer to " 17 Setting of Arc Monitoring

After selecting the welding type or changing the parameter, save conditions before turning OFF the welder power supply. Before recording conditions, be sure not to select other welding type while the user file is being adjusted because the changed data on P parameters are deleted.

When the encoder cable is disconnected, or whe n th e ph as es A and B are connected inversely, the wire feeding becomes excessively fast or the motor runs

inversely. In addition, the 7-segment LED indicator for wire feeding speed plays 0 and the error Err501 "Improper feeding amount" is issued. Check the connection of encoder cable.

ing, the argon ratio must exceed 80% to execute one pulse per drop. If short-circuit occurs excessively during pulse welding, check the argon ratio.

Function ". The parameter set value is different from the MOTOWELD-S350.

e dis-

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9.2 Cause and Remedy of Welding Sec tion Failure

9.2 Cause and Remedy of Welding Section Failure

Table. 12 Failure Analyses for Welding Section

Fault Cause Remedy

Blowholes and pits occur.

Excessive oil, rust, or paint adheres to the base metal.

Oil adheres to the welding wire. Or rust occurs.

Sufficient shielding gas does not flow.

Gas shielding in the welding section does not properly work due to wind, etc.

Spatters adhere to the nozzle and the gas does not flow out smoothly.

The quality of the shielding gas is poor.

The nozzle is too far from the arc point.

Carefully remove the adherent substances to clean the base metal.

Carefully store and handle the welding wire. Remove the oil or rust from the feeding roller or conduit.

Check for gas leakage. Also check that the gas regulator has been correctly adjusted and th e ga s cylinder is not empty.

When the wind blows hard, stop the operation or use a screen, etc. to help block the wind.

Often remove the spatters from the nozzle and apply spatter preventive agent to the interior of the nozzle.

Replace the shielding gas with one of better quality.

Keep the proper length of the wire stickout (10 mm to 25 mm) to perform welding. Increase the gas flow amount.

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Table. 12 Failure Analyses for Welding Section

Fault Cause Remedy

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Arc is unstable.

Power supply voltage excessively fluctuates.

Chip hole diameter becomes larger and worn.

Welding wire is not fed smoothly.

Voltage between phases of the 3-phase power supply is not balanced.

The welding conditions are not correct.

Unstable arc tends to occur when thin-plate or small-current welding is performed only with carbon dioxide gas.

Use a different power supply from that of other machines that cause power supply voltage fluctuation. Or increase the power supply transformer capacity.

Replace the chip. (Use a genuine chip.)

Remove the dust or iron powder choking up the feeding roller section or conduit. Check that the conduit is not excessively bent and that the liner, contact tip, and feeding roller match the wire diameter.

Use a different power supply from that of other machines that cause the imbalance. Or increase the power supply transformer capacity.

Use the test arc to increase or decrease the settings of the welding current value and voltage value.

Use gas mixed with carbon dioxide gas and argon gas to improve the arc behavior.

Excessive spatters

The connecting section is loose.

Voltage drop is excessive with the extension cable.

The polarities of the secondary terminal are inverted.

Jig current conduction is poor. Correct the contact between the jig and the base

The welding conditions are not correct.

Welding wire is not suitable for the shielding gas.

The status of the base metal is poor.

The welding section is distorted.

Check each terminal connection and the conn ec tions with the base metal. Securely re-tighten if necessary.

Shorten the extension cable’s length. Use a thicker cable. Use the extension cable without bending it.

Correct the connection of + and -.

metal. Increase or decrease the settings of the welding

voltage and current values to adjust the welding conditions.

Check if a welding wire suitable for the welding type is used.

Check the groove forms or dirt of the base metal. Replace them with one of higher accuracy .

Check each terminal connection and the conn ec tions with base metal. Polish the contacting face and tighten them securely.

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9.2 Cause and Remedy of Welding Sec tion Failure

Table. 12 Failure Analyses for Welding Section

Fault Cause Remedy

Bead form is bad and the appearance is poor.

Arc-start is poor.

Manipulation of electrode is not correct.

The shielding gas has a problem.

The welding conditions are not correct.

Welding current conduction is not perfect.

The connection cable is too thin.

The welding conditions are not correct.

The status of the base metal is poor.

Change the welding torch angle a little. Employ the forward welding method and practice so that welding torch can constantly aim at a target. Or change the welding speed.

Since the gas flow amount is not sufficient, let the gas flow 10 to 25 litters per minute, and mix argon gas if necessary. Or use a gas of better quality.

Increase or decrease the settings of the welding voltage or current value a little.

Check the connections and the current conduction contacting section of the base metal to confirm the current conduction.

Replace the cables at the 3-phase input side and base metal side with those of sufficient thickness.

Check that the welding voltage set value is not too small or that the wire feeding speed set value is not too large.

Check that dirt or insulating material does not adhere to the base metal or slugs do not remain on it.

Burnback occurs. (The welding wire sticks to the end of the contact tip.)

The welding torch operations are not correct.

The power cable is wired with the cable being winded.

The welding torch operations are not correct.

The welding conditions are not correct.

Contact tips are defective. Check that the contact tip hole is worn and its

Welding current conduction is not perfect.

The welding wire almost buckles.

The wire stickout of the welding wire is too long. Shorten it a little. Change the welding torch angle. Or slow down the welding speed.

Wire the power cable as straight as possible.

The wire stickout of the welding wire is too short. Extend it a little. Change the welding torch angle.

Check that the welding voltage set value is not too large or that the wire feeding set value is not too small.

inner diameter has become too big. Also ch eck for defect on the tip inner side.

Check the connections and the current conduction contacting section of the base metal to confirm the current conduction.

Pull the welding wire from the inside of the conduit and pass the welding wire again through the conduit.

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9.3 Cause and Remedy of Failure at Electrical Circuit Section

Table. 13 Fault Analyses for Electrical Circuit Section

No. Failure Cause Remedy

Power supply indicator lamp does

not light even if the power supply switch is turned ON.

Cooling fan does not rotate even if power supply switch is turned ON.

The welding source does not start although the start signal is turned ON.

Power supply indicator lamp lights.

Power supply indicator lamp does not light.

Power supply indicator lamp failure, improper contact

Cooling fan or control circuit failure

Fuse F1, F2 (5A) blown Investigate the cause and

Fuse (10 A) on the board Pr(SD)-006 blown

Power supply indicator lamp failure, improper contact

The start signal is not sent to the welding source.

Check contacting sections. Replace the power supply indicator lamp.

Check the cooling fan and the printed board (MB)-021 and (SD)-006.

replace the fuse. Investigate the cause and

replace the fuse (10 A) on the board Pr(SD)-006.

Check contacting sections. Replace the power supply indicator lamp.

• Check for the welding command cable.

• Check for insertion of the connector (CR4) on the printed board (CR)-

008.

Although the start signal is ON, only the motor does not operate.

Welding current (welding current

command) cannot be changed from the robot side.

Voltage is applied to the motor terminals (between #A and #B of the connector CON4)

The voltage is not applied to the motor terminals (between #A and #B of the connector CON4).

Motor failure Replace the motor.

Disconnection of the device control cable, or improper contact of the connector

Fuse (10A) on the board Pr(SD)-006 blown

Printed board (SD)-006 failure

The analog command sent from the robot side is not normal.

Replace the device control cable or check contacting sections.

Upon investigating the error cause, replace the fuse (10A) on the printed board Pr(SD)-006.

Check and replace the printed board (SD)-006.

Check the analog command output on the robot side.

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9.3 Cause and Remedy of Failure at Electrical Circuit Section

Table. 13 Fault Analyses for Electrical Circuit Section

No. Failure Cause Remedy

Welding voltage (welding voltage

command) cannot be changed from the robot side.

Error indication on the digital

meter The power supply switch is

tripped and the power is not

turned ON.

Shielding gas cannot be adjusted or stopped.

The analog command sent from the robot side is not normal.

See " Table. 5 List of Error Display Contents ".

Damage to the input diode Contact your Yaskawa Damage to the main circuit

transistor (IGBT) Failure of the gas solenoid

valve Fuse (10 A) on the board

Pr(SD)-006 blown

Failure of the printed board (SD)-006

The printed board (SD)-004 is installed by mistake. (The printed board (SD)-004 cannot be used.)

Check the analog command output on the robot side.

See " Table. 5 List of Error Display Contents ".

representative.

Investigate the gas system.

Upon investigating the error cause, replace the fuse (10 A) on the printed board Pr(SD)-006.

Check or replace the printed board (SD)-006.

Replace the board with the printed board (SD)-

006.

The starting point detection cannot be detected.

The starting point detection command is not sent to the welding source or the power supply for starting point I/F is not supplied to the welding source.

The starting point detection signal is not sent from the welding source.

Check the connection signal cable.

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10.1 Specifications of Robot Interface Signals

10Robot Interface Signals

10.1 Specifications of Robot Interface Signals

The following table shows the correspondence of the pin number and the signal of connector CON3 (26 pins). For signal systems, refer to “11. Conncetion System Diagram.”

Pin No.

No.

Correspon

ding to

Connector

Signal

Meaning

Function

Direct

ion

Signal

Form

- B

(0V side)

- D

(0V side)

- G Wire inching

- J Wire retract

- L ARCON/

- N

("-" side)

Arc voltage adjustment instruction

Welding current instruction

instruction

ARCOF instruction

Wire stick detection

Gives the compensation value of the arc voltage when set to "Synergic." (When set to "independent," the arc voltage is sent directly.)

Gives the set value of the output current (wire feeding amount) for the welding source.

Performs the wire inching.

Withdraws the wire.

Instructions to start/stop the welding.

Sends the output terminal voltage of the welding source. The wire stick detection voltage (approx.15 V) is input from the robot side.

R W

W R

→

Analog voltage input of 0V to 14V

Contact input (Valid at closed)

Welding source output voltage (Analog value)

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No.

Pin No.

Correspon

ding to

Connector

Signal

Meaning

10.1 Specifications of Robot Interface Signals

Function

Direct

ion

Signal

Form

- E

(COM)

- E

(COM)

Arc occurrence detection

Arc failure detection

1. The signal is output when the current is detected continuously for 16 ms after the gas pre-flow upon receiving the arc start signal.

2. If the current is not detected for 48 ms or more continuously after the signal is output, the signal stops being output.

3. (1) and (2) are repeated.

The signal stops being output at the same time as the wire stick prevention voltage ends.

1. The signal is output when the arc st ar t is not detected for 1.5 seconds after the gas pre-flow upon receiving the arc start signal.

2. After the arc occurrence is detected within 1.5 seconds, the signal is output when the arc occurrence is not detected for 0.6 seconds or more continuously.

3. After the arc failure is detected, the states described in (1) and (2) are selfmaintained until the start command of welding source is released.

4. The signal is output also when an error occurs in the welder.

W R

→

Contact output (Valid at closed)

- E

(COM)

- E

(COM)

E (536) Common Common for detection line

W - X Monitoring

Reserved

output for output current

Sends the monitoring signal of the output current.

3.0V/600A

Note: When using the arc monitoring

function, refer to " 17 Setting of Arc Monitoring Function ".

W R

→

Contact output (Valid at closed)

Return line of contact output

Analog voltage

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Pin No.

No.

Correspon

ding to

Connector

Signal

Meaning

Function

Direct

ion

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Signal

Form

U - V Monitoring

b - Z User file

Y - Z User file

a - Z Gas check

Z (531) Common

output for output voltage

selection OP1

selection OP2

GAS

COM

Sends the monitoring signal of the output voltage. 3V/60V(66V for 66V or more) Note: When using the arc monitoring

function, refer to " 17 Setting of Arc Monitoring Function "

Externally switches the user file selection by connecting each signal to common (Z). Note: Connected to the pin terminals:

"OP1" and "OP2" of the standard

welding instruction cable. To externally switch the user file, set D parameter D1-11 to "ON".

Turns ON/OFF the gas solenoid valve by connecting to common (Z). Note: Connected to "GAS" pin terminal of

the standard welding instruction cable.

Common of OP1, OP2, and GAS signals Note: Connected to "COM" pin terminal of

the standard welding instruction cable.

W R

R W

→

Analog voltage

+24V ±10%, current capacity of 50mA or more

Return line of contact input

*1 "R" indicates the robot side while "W" indicates the welding source side.

The voltage for wire stick detection which is output from the robot sid e does not ap pear on the welding source panel.

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10.2 Meaning and Function of Pr(RC2)-001 Terminal

The following describe the cable number of the connection terminal block and corresponding signals.

10.2.1 TB2 Terminal

20W 10K

TB2

209

211

526

527

Connection

No.

1209

2211

3526

4527

Terminal

Block Cable

No.

−

"R" indicates the robot side while "W" indicates the welding source side.

Signal

Meaning

Ammeter

terminal

Voltmeter

terminal

Reserved

Function

Outputs 600A,

60mV.

Directly outputs

the output

voltage.

−−

Directi

→R

NOTE

The external meters connected to the TB2 terminal are analog mete rs of ammeter (600A / 60mV) and voltmeter (75V). Values of the ten's volts for wire stick or ground detection at the robot controller side may be displayed in the analog voltmeter, which is not a failure of the device.

CAUTION

• The output voltage(600A/60mv) of the ammeter terminal is different from the MOTOWELD-EL350.

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10.2.2 TB3 Terminal

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24V

524

525

539

538

537

531

TB3

Connection

Terminal

No.

Block Cable

No.

1524

2525

3539

4538Reserved

5537Reserved

Signal

Meaning

Motor

current

warning

Reserved

for

system

This signal monitors the motor current of wire feeding and alerts that the motor current exceeds the warning level.

Function

Directi

W→

Signal Form

time: Open At warning:

−−

−

OP→

input (valid

At normal

Closed

Contact

input

Contact

at closed)

Contact

at closed)

NOTE

6 531 Common

"W" indicates the welding source side while "OP" indicates the option.

The external detection signals connected to TB3 terminal are output from each external device. To use these signals, prepare external devices with a detector.

−

OP→

−

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10.3 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr(OP)-003 [EH500])

10.3

Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr(OP)-003 [EH500])

CAUTION

• The starting point detection function is an optional function. The optional board Pr(OP)-003 [EH500] is included when the starting point detection function is ordered, that is, not included in standard package.

• The optional board for EH500 is Pr(OP)-003 [EH500]. The optional board Pr(OP)-003 for MOT O WELD-EL350 cannot be used for MO T O WELD-EH500.

Read this section only when the starting point detection function is used. The following table shows the cable number of connection terminal block and corresponding signals.

Connection

No.

1520

2521

3522

4523

Terminal

Block Cable

No.

Signal

Meaning

Power supply for starting point detection I/F

Starting point detection signal

Common Power cable on 0V side of the

Starting point detection instruction

Power supply for starting point detecting instruction and sending /receiving of the starting point detection signal

The signal is output when the output "+" (torch side) of welding source drops to approx. 0V while the starting point detecting instruction is ON.

power supply for starting point detection I/F.

While this signal is ON:

1. The high voltage (full-wave rectification, peak value of 280V) for the starting point detection is applied between welding source’s output "+" (torch side) and "-" (base metal side).

2. Lights "Se arch Mode" lamp in red on the front panel.

Function

Direc-

tion

→W

→R

→W

Signal Form

+24V±10%, current capacity of 30mA or more

Transistor output (ON when 0V), sink current of 50mA or less

Contact output (Valid at closed)

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10.3 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr(OP)-003 [EH500])

Connection

No.

Terminal

Block Cable

No.

Signal

Meaning

Function

Direc-

tion

Signal Form

7COM

Monitoring output for output voltage

Monitoring output for output current

Common Common of the monitoring sig-

Monitoring signal for output voltage 5V/50V (For arc sensor)

Monitoring signal for output current 5V/500A (For arc sensor)

nal

*1 "R" indicates the robot side while "W" indicates the welding source side.

→R

Analog voltage

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11 Connection System Diagram

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12.1 Starting up Welding Source in Diagnosis Mode

12 Diagnosis Function

MOTOWELD-EH500 has a Diagnosis mode to confirm the software version, the number of occurrence of welding source error, and DIP switch set status.

12.1

Starting up Welding Source in Diagnosis Mode

To start up the welding source in the Diagnosis mode, turn OFF the main power of MOTOWELD-EH500 once, and turn ON the main power again while pressing the "Record" button. The diagnosis information is displayed in the 7-segment LED indicators on the welding source front panel once the Diagnosis mode is launched.

PRM Select

Common PRM Select

Record

Auto Adj.

Auto Adjustment

/Individual

Gas

Wire m/min

PRM Set

Type

Weld, Type

File No.1 File No.2

File No.3

User File Select

Power

Warning Search

OFF

The set status of DIP switch is displayed in the 7-segment LED indicators when the Diagnosis mode is launched.

PRM Select

Common PRM Select

Record

Auto Adjustment

OFF

/Individual

Fig. 15 Panel at Launch of MOTOEWELD-EH500 Diagnosis Mode

Auto Adj.

Gas

Wire m/min Type

PRM Set

Weld, Type

User File Select

Power

Warning Search

File No.1 File No.2 File No.3

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12.1 Starting up Welding Source in Diagnosis Mode

The information which is displayed in the 7-segment LED indicator can be changed with using the buttons "+" or "-" on the MOTOWELD-EH500 front panel.

"d-*"

: DIP switch set status

"C-*"

: Software version

"Err.*"

The number of error occurrence

At start-up of welding source in the Diagnosis mode

The displayed contents are changed with the buttons "+" or "-".

L R

Fig. 16 Diagnosis Mode Operation

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12.2 Confirmation of DIP Switch Set Status

By referring to the information: "d-1" to "d-4" which is displayed in the Diagnosis mode, the setting status of DIP switch on the PR(CR)-008 board of welding source inside can be confirmed without removing the cover of the welding source.

Fig. 19 DIP Switch of MOTOWELD-EH500

For displaying the DIP switch status, ON/OFF state of each switch is displayed with 0/1 bit data.

DSW No. : 1 to 4

ON/OFF state of each switch : 1=ON / 0=OFF

Fig. 20 Display of DIP Switch Set Status

The figure " Fig. 20 Display of DIP Switch Set St atus " shows that the switches No.2, 3, and 6 of DSW3 are ON.

NOTE

If the display of Diagnosis mode is different from the actual DIP switch setting, there may be failure on the Pr(CR) board or Pr(MB) board. Replace the board.

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12.3 Confirmation of Software Version

By referring to the information: "C-1", "C-2", and "C-3" which is displayed in the Diagnosis mode, the software version which is loaded in the welding source can be confirmed.

• C-1: Main CPU 1 Software Version

• C-2: Sub CPU 2 Software Version

• C-3: Memory Software Version

The software version is displayed as shown below.

CPU No. : 1=CPU1, 2=CPU2, 3=Memory

Software version No. : {. {{-{{

Model No. : (6 represents EH500-6N0.)

Fig. 19 Display of Software Version

The figure " Fig. 19 Display of Software V ersion " shows that the sof tware version of the main CPU is 3.20-000-6.

CAUTION

• For main circuit board: Pr(MB)-021 which is installed in MOTOWELDEH500, make sure that "6" is displayed in the model NO . of the software version display.

If welding is performed with the main circuit board: Pr(MB), whose model No. is other than "6", installed in the welding source, it may results in damage to the welding source.

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12.4 Confirmation of the Number of Welding Source Errors

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12.4

By referring to the information: "Err.001" to "Err.999" which is displayed in the Diagnosis mode, the number of errors which occurred in the welding source can be confirmed.

NOTE

The number of welding source errors which has been recorded is displayed in the Diagnosis mode as shown below. .

Confirmation of the Number of Welding Source Errors

The number of welding source errors is automatically saved.

V A Wire m/min Type

Error code

The number of errors

Fig. 20 Display of the Number of Welding Source Errors

The 7-segment LED indicator shows the number of welding source errors. The number of welding source errors is counted from when the weldin g source is delive red to when the welding source is started up in the Diagnosis mode. Once an error has occurred, the 7-segment LED indicator displays "1" for the error . From then onward, e very time the error occurs, one is added to the number of errors. In case of the figure " Fig. 20 Display of the Number of Welding Source Errors ", the 7-segment LED indicator shows that the error Err001 (Input overcurrent) has occurred once. For details on errors, see " Table. 5 List of Error Display Contents ".

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12.5 Clear of Error Record

To delete the number of welding source errors, perform the clear operation of the error record. The following explain how to clear the error record.

PRM Select

Common PRM Select

Record

Auto Adj.

Auto Adjustment

/Individual

Gas

Wire m/min

PRM Set

Type

Weld, Type

File No.1 File No.2

File No.3

User File Select

Power Warning

Press the buttons simultaneously.

Fig. 21 Error Record Clear Mode

(1) In the Diagnosis mode, press "L" button and "Record" button simultaneously to set

the welding source ready for clearing of error record ("Err CLr on" is displayed).

V A Wire m/min

Type

(2) Press "RECORD" button with "Err CLr on" displayed to clear the error record. To

cancel the operation for clearing the error record, press "L" button again.

12.6 End of Diagnosis Mode

To end the diagnosis mode, turn OFF the MOTOWELD-EH500 main power once, then start up the welding source as normal without pressing any buttons.

CAUTION

• Welding cannot be performed in the Diagnosis mode. After diagnosing, be sure to start up the welding source in the usual mode.

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13.1 Adjustable Welding Characteristics

13Process Parameters

(Adjustment of Welding Characteristics)

Welding characteristics of the digital inverter welding source: MOTOWELD-EH500 are specified by database in the welding source. The values of welding characteristics, however, can be changed to 10 to 200 % of the database values with using proce ss parameters (P parameters). The characteristics values specified by database can be usually used without change. If the database values need to be changed in accordance with ambient environment and your convenience, change the characteristics values referring to the following description.

SUPPLE

-MENT

All the values are set to "100 (%) = Operating as specified by the characteristics in the database" before shipping.

User file (File 1, File 2, File 3) needs to be selected to change P parameters.

13.1 Adjustable Welding Characteristics

The welding characteristics that can be adjusted by P parameters are as follows:

• Arc start characteristics: Characteristics from when ARCON signal is output until the main welding condition becomes stable

• Arc end characteristics: Characteristics from when ARCOF signal is output until arc disappears

• Short-circuit welding characteris-

tics:

Characteristics while the main welding is performed at short-circuit welding (short arc)

• Pulse welding characteristics: Characteristics while the main welding is performed at pulse welding

• Other characteristics: Characteristics of arc length control and current output

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13.2 Adjustment of Arc Start Characteristics

13.2.1 Adjustment of Start Pulse

The following parameters change the characteristics related to the first arc start at ARCON signal.

Parameter

No.

P00

P01

P02

P04

Meaning Guideline of Adjustment

Wire speed until the wire contacts the base metal

Wire speed from when the wire contacts the base metal until arc starts.

Peak value of pulsed current that flows for arc start

Peak time of pulsed current that flows for arc start

ARCON signal

-When scrap of the wire tip end remains; Decrease the value.

-When arc does not start; Increase the value.

-For excessive repelling at arc start; Decrease the value.

-For arc burning at arc start; Increase the value.

-For arc burning at arc start; Decrease the value.

-For excessive repelling at arc start; Increase the value.

Hot conditions

Wire slow-down speed

P00

Start pulse peak current

P02

Wire speed at start

P01

Hot conditions

Start pulse peak time

P04

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13.2 Adjustment of Arc Start Characteristics

13.2.2 Adjustment of Hot Characteristics

The following parameters change the hot characteristics before transition to the main current after the first arc start at ARCON signal.

Parameter

No.

P05

P06

P07

P43

Meaning Guideline of Adju stment

Average current of hot characteristics to stabilize the molten pool

Average voltage of hot characteristics to stabilize the molten pool

Output time of hot characteristics to stabilize the molten pool

Transition time from hot characteristics to main welding characteristics

-For excessive arc burning; Increase the value.

-For excessive repelling; Decrease the value.

-For excessive repelling; Increase the value.

-For excessive arc burning; Decrease the value.

-When taking time to stabilize arc; Increase the value.

-For burn-through at start point; Decrease the value.

-When taking time to stabilize arc: Increase the value.

-For burn-through at start point: Decrease the value.

Starting pulse

Hot conditions

P05

Average hot current

P07

Hot time

P06

Average hot voltage

Main welding conditions

Average current under main conditions (Commanded from the robot side)

P43

Hot slope time

Average voltage under main conditions (Commanded from the robot side)

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13.3 Adjustment of Arc End Characteristics

The following parameters change the characteristics from when ARCOF signal is input until arc disappears.

Parameter

No.

P11

P12

P13

P14

P15

P16

P17

P18

Meaning Guideline of Adjustment

Average current for crater processing after ARCOF signal is input

Average voltage for crater processing after ARCOF signal is input

Crater processing time after ARCOF signal

Average current to adjust the burning after welding -When wire sticks to the

Average voltage to adjust the burning after welding

Arc time to adjust the burning after welding

Peak current to adjust the spherical diameter of wire end after welding

Peak time to adjust the spherical diameter of wire end afte r welding

VALID when D parameter D1-4=ON, however crater processing always invalid at P parameter P13=10.

-When craters are not filled; Increase the value.

-When craters make

holes; Decrease the value.

base metal; Increase the value.

-When wire sticks to the

contact tip; Decrease the value.

-When arc does not start at next ARCON signal; Increase the value.

-When the wire is repelled at next ARCON signal; Decrease the value.

P20

P44

Time to prevent the wire from sticking to the base metal after welding

Transition time from the main characte ristics to the end characteristics (VALID when D parameter D1-4=ON, however crater processing always invalid at P parameter P13=10.

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-When wire sticks to the base metal; Increase the value.

-When arc comes out to

the part other than the welded spot at air-cut; Decrease the value.

-When craters are not

filled; Increase the value.

-When craters make

holes; Decrease the value.

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13.3 Adjustment of Arc End Characteristics

Average voltage under main conditions (Instructed from the robot side)

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Main conditions

P44

End slope time

End conditions

Average current under main conditions

(Instructed from the robot side)

Average voltage

under main conditions (Instructed from the robot side)

Average burning voltage

Burning conditions Droplet pulse

Adjustment of

Wire stop

Average end current

P13

Ending time

Average end voltage

P15

sphere at end tip

P11

P12

Droplet pulse peak time

Droplet pulse peak current

P14

Average burning current

Wire-stick prevention time

P16

Burning time

Wire-stick prevention

Voltage only

P18

P17

P20

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13.4 Adjustment of Short-circuit Welding Characteristics

The following parameters change the short-circuit welding characteristics under the main welding characteristics.

Parameter

No.

P37

P38

P49 P50

P51

Meaning Guideline of Adjustment

Current increasing speed at short-circuit (first half)

-For unstable arc; Increase the value.

-For excessive spatters; Decrease the value.

Current increasing speed at short-circuit (second half)

Arc control 1 • When arc occurs for a long time without sphere-drip Arc control 2 Arc control 3

dropping; Decrease P49, increase P50 and P51.

• When arc is not stable; Increase P49, decrease P50 and P51.

• To make beads flat for stainless-steel or the like; Increase P49, P50, and P51

• When short-circuit occurs for a long time; Decrease P parameter P49, increase P p ara meter P50 and P51.

• When burn-through occurs; Decrease P parameter P49, P50, and P51.

• When weld penetration is needed; Increase P parameter P49, P50, and P51.

Droplet transition

Short-circuit

Arc

Creation of droplet

P38

Short-circuit current increasing speed 2

P37

Short-circuit current increasing speed 1

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P49

P50

P51

Arc control 1

Arc control 2

Arc control 3

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13.5 Adjustment of Pulse Welding Characteristics

13.5.1 Adjustment of MAG/MIG Pulse Welding Characteris-

tics

The following parameters change the pulse welding characteristics under the main characteristics for MAG/MIG pulse welding using mixed gas with Ar 98% or less.

Parameter

No.

P08

P09

P10

P31

P33

Meaning Guideline of Adjustment

Pulse peak current for droplet transition -For excessive spatters;

Increase the value.

Base current to keep arc

Pulse peak time for droplet transition

Pulse current increasing speed -For arc repelling;

Pulse current decreasing speed -For arc burning;

Pulsed current

Droplet transition

-For excessive burning; Decrease the value.

Increase the value.

-For arc burning;

Decrease the value.

Increase the value.

-For arc repelling;

Decrease the value.

Base current

Pulsed current increasing speed

P31

Pulsed current

P10

Pulse time

Pulsed current decreasing speed

Base current

P08

P33

P09

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YASKAWA MOTOWELD-EH500 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Basic Specifications

2.1 Installation Site and Welding Source Environment

2 Installation and Connection

2.2 Precautions on Grounding

2.3 Power Supply Installed Capacity and Connection Cables

2.4 Combination with Earth Leakage Breaker

2.5 Connection of Electrical System

2.6 Connection of Welding Voltage Detecting Line

2.7 Connection of Shielding Gas System

2.7.1 For Mixed Gas or Carbon Dioxide Gas Welding

2.7.2 Installation Site and Gas Cylinder Environment

2.8 Ambient Environment

2.9 Precautions on Transporting

3 Welding Preparation

4.1 Explanation of Welding Source Panel

4 Operations on Panel

4.2 Settings on Welding Source Panel

4.2.1 Changing Welding Type

4.2.2 User Files

4.2.3 Changing P Parameters

4.2.4 Changing Common (C) Parameters

4.2.5 Changing D Parameters

4.2.6 Saving Welding Conditions

4.2.7 Checking the Flow Amount of Shielding Gas

4.2.8 Selecting Feeding Motor

4.2.9 Monitoring of Motor Current

4.2.10 System Reset

4.2.11 Lock Of Panel Operation

 Method of setting "lock of panel operation"

 Method of releasing "lock of panel operation"

4.3 List of Process Parameters

4.4 List of Common Parameters

4.5 List of D Parameters

5.1 Checking the Welding Conditions

5 Welding Operation

5.2 Wire Stickout

5.3 Direction of Welding and Torch Angle

5.4 Precautions on Using Extension Cable

6.1 Error Detection Function

6 Precautions on Welding

6.2 Tripped Power Supply Switch

6.3 Precautions on Welding Operation

7.1 Internal Selecting Switches

7 Built-in Functions

7.2 Location of Printed Boards

7.2.1 DIP Switch Settings for Pr(MB)-021 Board

7.2.2 Jumper-pin Settings of the Pr(MB)-021 Board

8.1 Daily Inspection Items

8 Maintenance and Inspection

8.2 Bimonthly to Semiannual Inspection Items

8.3 Annual Overhaul and Repair

8.4 Guideline for Service Lifetime and Replacement of Components Used

8.5 Replace Fuse

9.1 Confirming Setting conditions

9 Failure Analyses

9.2 Cause and Remedy of Welding Sec tion Failure

9.3 Cause and Remedy of Failure at Electrical Circuit Section

10.1 Specifications of Robot Interface Signals

10Robot Interface Signals

10.2 Meaning and Function of Pr(RC2)-001 Terminal

10.2.1 TB2 Terminal

10.2.2 TB3 Terminal

11 Connection System Diagram

12.1 Starting up Welding Source in Diagnosis Mode

12 Diagnosis Function

12.2 Confirmation of DIP Switch Set Status

12.3 Confirmation of Software Version

12.4 Confirmation of the Number of Welding Source Errors

12.5 Clear of Error Record

12.6 End of Diagnosis Mode

13.1 Adjustable Welding Characteristics

13.2 Adjustment of Arc Start Characteristics

13.2.1 Adjustment of Start Pulse

13.2.2 Adjustment of Hot Characteristics

13.3 Adjustment of Arc End Characteristics

13.4 Adjustment of Short-circuit Welding Characteristics