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Daihen OTC Almega AX Series, Instruction Manual

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Daihen OTC Almega AX Series Instruction Manual Download Page 5

Notice 

 
 

 
 

Notes on Safety

 

 

Before installation, operation, be sure to read "Chapter 1 Points on Safty" in INSTALLATION manual and other 

attached documents thoroughly and acquire all the knowledge of machines, safety information, and precautions.

   

Furthermore, before maintenance, inspection, and trouble scene, be sure to read CONTROLLER 

MAINTENANCE manual and MANIPULATOR manual and other attached documents thoroughly and acquire all 
the knowledge of machines, safety information, and precautions. 

If operating machines in a wrong way, the accident resulting in various ranks of injury or death, or damage may 

occur. 

In order to call attention to wrong handling, the following four ranks of safety notes (“DANGER”, “WARNING”, 

“CAUTION”, and “IMPORTANT”) are provided.

 

 

 

Cases where a mistake made in handling is likely to cause the user to be exposed to 
the danger of death or serious injury and where the degree of the urgency 
(imminence) of the warning given for the danger to occur is at the high end of the 
scale (including high-level danger). 

DANGER 

 

 

WARNING 

 

Cases where a mistake made in handling is likely to cause the user to be exposed to 
the danger of death or serious injury. 

 

 

CAUTION 

 

Cases where a mistake made in handling is likely to cause the user to be exposed to 
the danger of minor injuries or of property damage only. 

 

The following symbol is also used for particularly important checkpoints: 

 

 

IMPORTANT 

 

This is a particularly important checkpoint.

 

 

 

Note that even the matters which are described as 

CAUTION

 can result in serious accident depending on the conditions.   

Be sure to keep the safety notes since they describe very important matters.

  

 

The meanings of “Serious injury”, “Minor injury”, and “Damage” described above are as follows. 

 

Serious injury   

：

  Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low 

temperature), an electric shock, fracture, poisoning, etc. and that which requires 
hospitalization and long-term treatment as an outpatient.   

 

 

Minor injury     

： 

Injury which does not require either hospitalization or long-term treatment as an outpatient, 
a burn (high temperature, low temperature), and an electric shock.

 

 

Damage        

： 

Direct and indirect damage in connection with damage of property and equipment. 

 

 

- 4 - 

Summary of Contents for OTC Almega AX Series

Page 1: ...ANUAL WELDING INTERFACE DIGITAL Read and follow these instructions and all safety blocks carefully Have only trained and qualified persons install operate or service this unit Give this manual to the...

Page 2: ...s Service menus Details of function command list of short cut code parts replacing procedure trouble shooting etc This manual is not provided as the paper manual but is built in the robot as Help tuto...

Page 3: ...ng Do not alter or remodel our products You may get injured or have your equipment damaged because of fire failure or malfunction caused by altering or remodeling the product The warranty does not cov...

Page 4: ...pan or 2000 hours of actual working time from the date of delivery to the original user This warranty shall be invalidated by any abuse misuse misapplication or improper installation by users DAIHEN a...

Page 5: ...h level danger DANGER WARNING Cases where a mistake made in handling is likely to cause the user to be exposed to the danger of death or serious injury CAUTION Cases where a mistake made in handling i...

Page 6: ...00L 1 63 1 4 7 Welding mode list of Welbee Inverter W350 W400 1 78 Chapter 2 Connections 2 1 Connect Welding Interface Digital 2 1 2 1 1 Installation of the Welding Interface Digital Board 2 1 2 1 2 C...

Page 7: ...th DC wave pulsed welding 3 34 3 10 5 About the welding constants 3 35 3 10 6 Settgins on the Welding Power Source Side 3 36 3 11 Welding conditions of WB P350L P400L P500L 3 38 3 11 1 About the weldi...

Page 8: ...How to reset an error indication 4 6 4 4 Notes on Scope of Warranty and Liability 4 7 4 4 1 The product for a warranty target 4 7 4 4 2 Warranty period 4 7 4 4 3 Disclaimer 4 7 4 4 4 Limitation of li...

Page 9: ...2 6 External view 1 7 1 3 Standard configuration 1 8 1 3 1 Components of Robot controller Welding power source Peripherals 1 8 1 4 Welding mode lists 1 12 1 4 1 Welding mode list of Welbee Inverter M3...

Page 10: ......

Page 11: ...eful functions are available such as the real time monitoring of the welding current and voltage during welding When the interface is used D series welding power sources shown in Table 1 2 3 that are...

Page 12: ...ers 1 2 3 Connectable welding power sources When the interface is used the Welbee Inverter series welding power sources shown in Table 1 2 2 can be connected to the AXC controller Up to 4 Welbee Inver...

Page 13: ...sia DW 6 Welbee Inverter W400 specifications for Europe Europe Welbee Inverter W400 specifications for U S U S Welbee Inverter A350P A500P specifications for Japan Welbee Inverter A350P specifications...

Page 14: ...placement Welding power source Welding power source DM350 DM350 S 2 DM350 Welbee Inverter M350 M400 DM500 Welbee Inverter M500 DR350 Welbee Inverter M350 DL350 DL350 S 2 Welbee Inverter M350L 400L DP3...

Page 15: ...rol Robot RS control Stitch pulse welding Gas Saver GFC Available Not available 1 The items that can be set as welding conditions vary depending on the combination of the Welbee Inverter welding power...

Page 16: ...sk More than 5 MB of available hard disk space Disc unit CD ROM drive is mounted Personal Computer USB port Note 2 One or more Display 1024 768 dots or more Required 64 MB or more USB memory Note 2 Re...

Page 17: ...External view Install the Welding Interface Digital board Figure 1 2 1 inside the robot controller For details on the installation method see Chapter 2 Connections Unit mm Figure 1 2 1 External view o...

Page 18: ...on cable L22440E00 between Storage board and Welding Interface Digital board Power cable L22440J00 for power supply 24V 1 WB M350 WB M400 WB P350 WB P400 WB P350L WB P400L WB W350 WB W400 MV4AP MV4LAP...

Page 19: ...1 3 Standard configuration 1 9 AX C Welding Interface Digital Control cable 5 Figure 1 3 1 Components for Peripherals of Robot controller and Welding power source other than TIG welder...

Page 20: ...h 6m L 7623J Cable length 10m For air cool ing 200A torch L 7633E Cable length 6m Power cable torch side L 7633J Cable length 10m For water cool ing 350A torch BBAWD 1701 For air cool ing 200A torch T...

Page 21: ...around controller and welding power source without TIG filler feeding unit 3 TIG filler controller Welding Interface Digital Torch side welding cable 2 Control cable 5 5 Comminucation cable Gas hose W...

Page 22: ...0 9 SuS High WTBD4411 1 0 350A Mig_4 DC 1 0 SuS High WTBD4412 1 2 350A Mig_4 DC 1 2 SuS High WTBD4413 CO2 Mild Steel Solid 0 8 Standard 350A Co2 DC 0 8 Low WTBD4419 0 9 350A Co2 DC 0 9 Low WTBD4420 1...

Page 23: ...High 350A Mig_4 DC 0 8 Ferrite High WTBD4449 1 0 350A Mig_4 DC 1 0 Ferrite High WTBD4450 1 2 350A Mig_4 DC 1 2 Ferrite High WTBD4451 0 8 Standard 350A Mig_4 DC 0 8 Ferrite Low WTBD4461 1 0 350A Mig_4...

Page 24: ...0 9 350A Mig_4 DC 0 9 SuS Low WTBD4578 1 0 350A Mig_4 DC 1 0 SuS Low WTBD4579 1 2 350A Mig_4 DC 1 2 SuS Low WTBD4580 MIG 2 Hard Alm 1 2 350A Mig_3 DC 1 2 Hard Al Low WTBD4586 1 6 350A Mig_3 DC 1 6 Har...

Page 25: ...446 1 0 400A Mig_2 DC 1 0 Ferrite High WTBD4447 1 2 400A Mig_2 DC 1 2 Ferrite High WTBD4448 MIG 4 0 8 400A Mig_4 DC 0 8 Ferrite High WTBD4449 1 0 400A Mig_4 DC 1 0 Ferrite High WTBD4450 1 2 400A Mig_4...

Page 26: ...o2 DC 1 2 Cored Low WTBD4518 SUS Cored 1 2 400A Co2 DC 1 2 SuS Cored Low WTBD4519 MAG Mild Steel Cored 1 2 400A Mag DC 1 2 Cored Low WTBD4520 SUS Cored 1 2 400A Mag DC 1 2 SuS Cored Low WTBD4522 MAG 1...

Page 27: ...Hard Alm 1 0 400A Mig_3 DC 1 0 Hard Al Low WTBD4585 1 2 400A Mig_3 DC 1 2 Hard Al Low WTBD4586 1 6 400A Mig_3 DC 1 6 Hard Al Low WTBD4587 Soft Alm 1 2 400A Mig_3 DC 1 2 Soft Al Low WTBD4588 1 6 400A...

Page 28: ...DC 1 2 Cored Low WTBD3016 1 4 350A Co2 DC 1 4 Cored Low WTBD3017 SUS Cored 0 9 350A Co2 DC 0 9 SuS Cored Low WTBD3018 1 2 350A Co2 DC 1 2 SuS Cored Low WTBD3019 MAG Mild Steel Solid 0 8 350A Mag DC 0...

Page 29: ...ding performance may become unstable when using the extended power cable depending on the layout condition of cables when the total length exceeds 30m or the cable is coiled In that case voltage adjus...

Page 30: ...Low WTBD3026 1 2 350A Mig_4 DC 1 2 SuS Low WTBD3027 CO2 Mild Steel Solid 0 8 Extended cable 350A Co2 DC 0 8 Low WTBD3028 0 9 350A Co2 DC 0 9 Low WTBD3029 1 0 350A Co2 DC 1 0 Low WTBD3030 1 2 350A Co2...

Page 31: ...o welding performance may become unstable when using the extended power cable depending on the layout condition of cables when the total length exceeds 30m or the cable is coiled In that case voltage...

Page 32: ...ld Steel Cored 1 2 400A Co2 DC 1 2 Cored Low WTBD3032 SUS Cored 1 2 400A Co2 DC 1 2 SuS Cored Low WTBD3035 MAG Mild Steel Solid 0 8 400A Mag DC 0 8 Low WTBD3036 1 0 400A Mag DC 1 0 Low WTBD3038 1 2 40...

Page 33: ...A Mig_3 DC 1 2 Cu Si Low WTBD3099 Cu Al 0 8 400A Mig_3 DC 0 8 Cu Al Low WTBD3100 1 0 400A Mig_3 DC 1 0 Cu Al Low WTBD3102 1 2 400A Mig_3 DC 1 2 Cu Al Low WTBD3103 MAG Mild Steel Cored 1 2 Extended cab...

Page 34: ...o welding performance may become unstable when using the extended power cable depending on the layout condition of cables when the total length exceeds 30m or the cable is coiled In that case voltage...

Page 35: ...Cored Low WTBD3224 1 4 500A Co2 DC 1 4 Cored Low WTBD3225 1 6 500A Co2 DC 1 6 Cored Low WTBD3226 SUS Cored 1 2 500A Co2 DC 1 2 SuS Cored Low WTBD3227 1 6 500A Co2 DC 1 6 SuS Cored Low WTBD3228 MAG Mi...

Page 36: ...more as a target with this condition However it will not make any differences in the welding performance whether choosing High or Standard application when using the wire of 1 4 and 1 6 Note that the...

Page 37: ...ild Steal Solid 3 64 Extended cable 500A CO2 DC 3 64i Low WTBD3240 0 052 500A CO2 DC 052i Low WTBD3241 1 16 500A CO2 DC 1 16i Low WTBD3242 MAG 3 64 500A MAG DC 3 64i Low WTBD3248 0 052 500A MAG DC 052...

Page 38: ...solid or SUS and also the wire diameter is 1 2 In addition when welding on the thick plate plate thickness would be 4 5mm or more as a target with this condition However it will not make any differenc...

Page 39: ...w WTBD3237 1 2 500A Mig_4 DC 1 2 SuS Low WTBD3238 1 6 500A Mig_4 DC 1 6 SuS Low WTBD3239 CO2 Mild Steel Solid 1 2 Extended cable 500A Co2 DC 1 2 Low WTBD3240 1 6 500A Co2 DC 1 6 Low WTBD3242 Mild Stee...

Page 40: ...Soft Al Low WTBD3299 Cu Si 0 8 500A Mig_3 DC 0 8 Cu Si Low WTBD3300 1 0 500A Mig_3 DC 1 0 Cu Si Low WTBD3302 1 2 500A Mig_3 DC 1 2 Cu Si Low WTBD3303 Cu Al 0 8 500A Mig_3 DC 0 8 Cu Al Low WTBD3304 1...

Page 41: ...more as a target with this condition However it will not make any differences in the welding performance whether choosing High or Standard application when using the wire of 1 4 and 1 6 Note that the...

Page 42: ...uS High WTBD3526 MIG 2 Hard Alm 1 0 350A Mig_3 DC Pulse 1 0 Hard Al High WTBD3527 1 2 350A Mig_3 DC Pulse 1 2 Hard Al High WTBD3528 1 6 350A Mig_3 DC Pulse 1 6 Hard Al High WTBD3529 Soft Alm 1 2 350A...

Page 43: ...g_3 DC 1 0 Hard Al Low WTBD3580 1 2 350A Mig_3 DC 1 2 Hard Al Low WTBD3581 1 6 350A Mig_3 DC 1 6 Hard Al Low WTBD3582 Soft Alm 1 2 350A Mig_3 DC 1 2 Soft Al Low WTBD3583 1 6 350A Mig_3 DC 1 6 Soft Al...

Page 44: ...o welding performance may become unstable when using the extended power cable depending on the layout condition of cables when the total length exceeds 30m or the cable is coiled In that case voltage...

Page 45: ...Low WTBD3533 1 0 400A Co2 DC 1 0 Low WTBD3534 1 2 400A Co2 DC 1 2 Low WTBD3535 MAG 0 8 400A Mag DC 0 8 Low WTBD3540 0 9 400A Mag DC 0 9 Low WTBD3541 1 0 400A Mag DC 1 0 Low WTBD3542 1 2 400A Mag DC 1...

Page 46: ...Mig_3 DC 0 9 Cu Si Low WTBD3606 1 2 400A Mig_3 DC 1 2 Cu Si Low WTBD3608 Cu Al 0 8 400A Mig_3 DC 0 8 Cu Al Low WTBD3609 0 9 400A Mig_3 DC 0 9 Cu Al Low WTBD3610 1 2 400A Mig_3 DC 1 2 Cu Al Low WTBD36...

Page 47: ...WTBD3762 SUS Cored 1 2 400A Mag DC 1 2 SuS Cored Low WTBD3763 MIG 2 Ferrite 1 0 400A Mig_4 DC 1 0 Ferrite Low WTBD3774 1 2 400A Mig_4 DC 1 2 Ferrite Low WTBD3775 DC pulse MAG Mild Steel Solid 1 4 Hig...

Page 48: ...WTBD3539 MAG Mild Steel Solid 0 8 400A Mag DC 0 8 Low WTBD3540 1 0 400A Mag DC 1 0 Low WTBD3542 1 2 400A Mag DC 1 2 Low WTBD3543 MIG 4 SUS 0 8 400A Mig_4 DC 0 8 SuS Low WTBD3544 1 0 400A Mig_4 DC 1 0...

Page 49: ...C 1 0 Cu Al Low WTBD3611 1 2 400A Mig_3 DC 1 2 Cu Al Low WTBD3612 DC pulse Cu Si 0 8 400A Mig_3 DC Pulse 0 8 Cu Si Low WTBD3617 1 0 400A Mig_3 DC Pulse 1 0 Cu Si Low WTBD3619 1 2 400A Mig_3 DC Pulse 1...

Page 50: ...8 High 400A Mig_2 DC Wave 0 8 Ferrite High WTBD3682 1 0 400A Mig_2 DC Wave 1 0 Ferrite High WTBD3684 1 2 400A Mig_2 DC Wave 1 2 Ferrite High WTBD3685 MIG 4 SUS 0 8 400A Mig_4 DC Wave 0 8 SuS High WTB...

Page 51: ...8 400A Mig_2 DC Wave 0 8 SuS Low WTBD3745 1 0 400A Mig_2 DC Wave 1 0 SuS Low WTBD3747 1 2 400A Mig_2 DC Wave 1 2 SuS Low WTBD3748 Ferrite 0 8 400A Mig_2 DC Wave 0 8 Ferrite Low WTBD3749 1 0 400A Mig_2...

Page 52: ...tion when welding on the thick plate plate thickness would be 4 5mm or more as a target with this condition Note that the welding performance may become unstable when using the extended power cable de...

Page 53: ...WTBD3522 1 2 400A Mag DC Pulse 1 2 High WTBD3523 MIG 1 SUS 0 9 400A Mig_4 DC Pulse 0 9 SuS High WTBD3524 1 0 400A Mig_4 DC Pulse 1 0 SuS High WTBD3525 1 2 400A Mig_4 DC Pulse 1 2 SuS High WTBD3526 MIG...

Page 54: ...0A Mig_4 DC 0 8 SuS Low WTBD3576 0 9 400A Mig_4 DC 0 9 SuS Low WTBD3577 1 0 400A Mig_4 DC 1 0 SuS Low WTBD3578 1 2 400A Mig_4 DC 1 2 SuS Low WTBD3579 MIG 2 Hard Alm 1 0 400A Mig_3 DC 1 0 Hard Al Low W...

Page 55: ...50cm min or lower in general which causes unstable welding performance When the wire material is a mild steel solid or SUS and also the wire diameter is 1 2 In addition when welding on the thick plate...

Page 56: ...WTBD10037 0 9 350A Mag DC Pulse 0 9 High WTBD10038 1 0 350A Mag DC Pulse 1 0 High WTBD10039 1 2 350A Mag DC Pulse 1 2 High WTBD10040 MIG 1 SUS 0 8 350A Mig_4 DC Pulse 0 8 SuS High WTBD10041 0 9 350A M...

Page 57: ...1 2 Ferrite Low WTBD10095 DC pulse MAG Mild Steel Solid 0 8 350A Mag DC Pulse 0 8 Low WTBD10096 0 9 350A Mag DC Pulse 0 9 Low WTBD10097 1 0 350A Mag DC Pulse 1 0 Low WTBD10098 1 2 350A Mag DC Pulse 1...

Page 58: ...g_4 DC Wave 0 8 Ferrite High WTBD10147 0 9 350A Mig_4 DC Wave 0 9 Ferrite High WTBD10148 1 0 350A Mig_4 DC Wave 1 0 Ferrite High WTBD10149 1 2 350A Mig_4 DC Wave 1 2 Ferrite High WTBD10150 MIG 2 Hard...

Page 59: ...ding performance may become unstable when using the extended power cable depending on the layout condition of cables when the total length exceeds 30m or the cable is coiled In that case voltage adjus...

Page 60: ...A Mig_4 DC Pulse 0 8 SuS High WTBD10041 0 9 400A Mig_4 DC Pulse 0 9 SuS High WTBD10042 1 2 400A Mig_4 DC Pulse 1 2 SuS High WTBD10044 Ferrite 0 8 400A Mig_4 DC Pulse 0 8 Ferrite High WTBD10045 0 9 400...

Page 61: ...ig_3 DC Pulse 1 2 Soft Al Low WTBD10111 1 6 400A Mig_3 DC Pulse 1 6 Soft Al Low WTBD10112 DC CO2 Mild Steel Solid 0 8 Extended cable 400A Co2 DC 0 8 Low WTBD10113 0 9 400A Co2 DC 0 9 Low WTBD10114 1 0...

Page 62: ...D10188 1 2 400A Mig_3 DC 1 2 Cu Al High WTBD10190 DC pulse Silicon Bronze 0 8 400A Mig_3 DC Pulse 0 8 Cu Si High WTBD10215 0 9 400A Mig_3 DC Pulse 0 9 Cu Si High WTBD10216 1 2 400A Mig_3 DC Pulse 1 2...

Page 63: ...6 400A Mag DC Pulse 1 6 M Crd High WTBD10328 DC wave 1 2 400A Mag DC Wave 1 2 M Crd High WTBD10329 pulse 1 4 400A Mag DC Wave 1 4 M Crd High WTBD10330 1 6 400A Mag DC Wave 1 6 M Crd High WTBD10331 1...

Page 64: ...400A Mig_4 DC Pulse 0 8 Ferrite High WTBD10045 1 0 400A Mig_4 DC Pulse 1 0 Ferrite High WTBD10047 1 2 400A Mig_4 DC Pulse 1 2 Ferrite High WTBD10048 Mig 5 Hard Alm 1 0 400A Mig_3 DC Pulse 1 0 Hard Al...

Page 65: ...Cored 1 2 400A Co2 DC 1 2 Cored Low WTBD10118 SUS CORED 1 2 400A Co2 DC 1 2 SuS Cored Low WTBD10121 Mag 1 Mild Steel Solid 0 8 400A Mag DC 0 8 Low WTBD10122 1 0 400A Mag DC 1 0 Low WTBD10124 1 2 400A...

Page 66: ...1 2 400A Mig_3 DC 1 2 Cu Si High WTBD10186 Aluminum Bronze 0 8 400A Mig_3 DC 0 8 Cu Al High WTBD10187 1 0 400A Mig_3 DC 1 0 Cu Al High WTBD10189 1 2 400A Mig_3 DC 1 2 Cu Al High WTBD10190 DC pulse Mag...

Page 67: ...D10252 1 2 400A Mig_3 DC 1 2 Cu Si Low WTBD10253 Aluminum Bronze 0 8 400A Mig_3 DC 0 8 Cu Al Low WTBD10254 1 0 400A Mig_3 DC 1 0 Cu Al Low WTBD10256 1 2 400A Mig_3 DC 1 2 Cu Al Low WTBD10257 DC APCS M...

Page 68: ...Mag_1 DC 0 8 Low WTBD10306 1 0 400A Mag_1 DC 1 0 Low WTBD10307 1 2 400A Mag_1 DC 1 2 Low WTBD10308 Mig 3 SUS 0 8 400A Mig_2 DC 0 8 SuS Low WTBD10309 1 0 400A Mig_2 DC 1 0 SuS Low WTBD10310 1 2 400A Mi...

Page 69: ...1 4 Welding mode lists 1 59...

Page 70: ...1 2 High WTBD10040 MIG 1 SUS 0 8 400A Mig_4 DC Pulse 0 8 SuS High WTBD10041 0 9 400A Mig_4 DC Pulse 0 9 SuS High WTBD10042 1 0 400A Mig_4 DC Pulse 1 0 SuS High WTBD10043 1 2 400A Mig_4 DC Pulse 1 2 S...

Page 71: ...098 1 2 400A Mag DC Pulse 1 2 Low WTBD10099 MIG 1 SUS 0 8 400A Mig_4 DC Pulse 0 8 SuS Low WTBD10100 0 9 400A Mig_4 DC Pulse 0 9 SuS Low WTBD10101 1 0 400A Mig_4 DC Pulse 1 0 SuS Low WTBD10102 1 2 400A...

Page 72: ...155 MAG Mild Steel Solid 0 8 Standard 400A Mag DC Wave 0 8 Low WTBD10156 0 9 400A Mag DC Wave 0 9 Low WTBD10157 1 0 400A Mag DC Wave 1 0 Low WTBD10158 1 2 400A Mag DC Wave 1 2 Low WTBD10159 MIG 1 SUS...

Page 73: ...30 Soft Alm 1 2 500A Mig_3 DC 1 2 Soft Al High WTBD3931 1 6 500A Mig_3 DC 1 6 Soft Al High WTBD3932 DC APCS CO2 Mild Steel Solid 0 8 500A Co2 DC 0 8 High WTBD3933 0 9 500A Co2 DC 0 9 High WTBD3934 1 0...

Page 74: ...w WTBD3986 1 2 500A Mag DC 1 2 Low WTBD3987 1 4 500A Mag DC 1 4 Low WTBD3988 1 6 500A Mag DC 1 6 Low WTBD3989 MIG 1 SUS 0 8 500A Mig_4 DC 0 8 SuS Low WTBD3990 0 9 500A Mig_4 DC 0 9 SuS Low WTBD3991 1...

Page 75: ...43 1 4 500A Co2 DC 1 4 Low WTBD4044 1 6 500A Co2 DC 1 6 Low WTBD4045 Mild Steel Cored 1 0 500A Co2 DC 1 0 Cored Low WTBD4046 1 2 500A Co2 DC 1 2 Cored Low WTBD4047 1 4 500A Co2 DC 1 4 Cored Low WTBD40...

Page 76: ...SuS Low WTBD4103 Ferrite 0 8 500A Mig_4 DC Wave 0 8 Ferrite Low WTBD4104 0 9 500A Mig_4 DC Wave 0 9 Ferrite Low WTBD4105 1 0 500A Mig_4 DC Wave 1 0 Ferrite Low WTBD4106 1 2 500A Mig_4 DC Wave 1 2 Ferr...

Page 77: ...WTBD3938 1 0 500A Mag DC 1 0 High WTBD3939 1 2 500A Mag DC 1 2 High WTBD3940 MIG 4 SUS 0 8 500A Mig_4 DC 0 8 SuS High WTBD3941 0 9 500A Mig_4 DC 0 9 SuS High WTBD3942 1 0 500A Mig_4 DC 1 0 SuS High WT...

Page 78: ...D4007 MAG 0 8 500A Mag DC 0 8 Low WTBD4008 0 9 500A Mag DC 0 9 Low WTBD4009 1 0 500A Mag DC 1 0 Low WTBD4010 1 2 500A Mag DC 1 2 Low WTBD4011 MIG 4 SUS 0 8 500A Mig_4 DC 0 8 SuS Low WTBD4012 0 9 500A...

Page 79: ...DC Wave 0 8 SuS High WTBD4079 0 9 500A Mig_4 DC Wave 0 9 SuS High WTBD4080 1 2 500A Mig_4 DC Wave 1 2 SuS High WTBD4082 1 6 500A Mig_4 DC Wave 1 6 SuS High WTBD4083 Ferrite 0 8 500A Mig_4 DC Wave 0 8...

Page 80: ...g DC 1 2 Cored Low WTBD4205 1 6 500A Mag DC 1 6 Cored Low WTBD4206 SUS 1 2 500A Mag DC 1 2 SuS Cored Low WTBD4207 1 6 500A Mag DC 1 6 SuS Cored Low WTBD4208 DC pulse MIG 3 INCONEL 0 9 500A Mig_3 DC Pu...

Page 81: ...ding performance may become unstable when using the extended power cable depending on the layout condition of cables when the total length exceeds 30m or the cable is coiled In that case voltage adjus...

Page 82: ...1 2 500A Mig_4 DC 1 2 Ferrite High WTBD3948 DC pulse MAG Mild Steel Solid 0 8 500A Mag DC Pulse 0 8 High WTBD3949 1 0 500A Mag DC Pulse 1 0 High WTBD3951 1 2 500A Mag DC Pulse 1 2 High WTBD3952 1 6 50...

Page 83: ...ow WTBD4022 1 2 500A Mag DC Pulse 1 2 Low WTBD4023 1 6 500A Mag DC Pulse 1 6 Low WTBD4025 MIG 4 SUS 0 8 500A Mig_4 DC Pulse 0 8 SuS Low WTBD4026 1 0 500A Mig_4 DC Pulse 1 0 SuS Low WTBD4028 1 2 500A M...

Page 84: ...500A Mag DC Wave 1 6 Low WTBD4098 MIG 4 SUS 0 8 500A Mig_4 DC Wave 0 8 SuS Low WTBD4099 1 0 500A Mig_4 DC Wave 1 0 SuS Low WTBD4101 1 2 500A Mig_4 DC Wave 1 2 SuS Low WTBD4102 1 6 500A Mig_4 DC Wave...

Page 85: ...g_3 DC Pulse 1 2 SuS High WTBD4176 Ferrite 1 0 500A Mig_3 DC Pulse 1 0 Ferrite High WTBD4177 1 2 500A Mig_3 DC Pulse 1 2 Ferrite High WTBD4178 Cu Si 0 8 500A Mig_3 DC Pulse 0 8 Cu Si High WTBD4179 1 0...

Page 86: ...ow WTBD4249 1 2 500A Mig_2 DC Pulse 1 2 Ferrite Low WTBD4250 MIG 3 SUS 1 0 500A Mig_3 DC Pulse 1 0 SuS Low WTBD4251 1 2 500A Mig_3 DC Pulse 1 2 SuS Low WTBD4252 Ferrite 1 0 500A Mig_3 DC Pulse 1 0 Fer...

Page 87: ...98 Ar 2 O2 POINT Normally use the welding characteristic data given in Table 1 4 20 dedicated to High application The ones for Standard application must be used only when the welding speed is low 50cm...

Page 88: ...Hard Alm 1 0 High 350A Mig_3 AC Pulse 1 0 Hard Al High WBTD5924 ACP 1 2 350A Mig_3 AC Pulse 1 2 Hard Al High WBTD5925 ACP 1 6 350A Mig_3 AC Pulse 1 6 Hard Al High WBTD5926 ACWP 1 0 350A Mig_3 AC Wave...

Page 89: ...CP 1 2 350A Mag DC Pulse 1 2 Low WBTD6007 DCWP 0 9 350A Mag DC Wave 0 9 Low WBTD6009 DCWP 1 0 350A Mag DC Wave 1 0 Low WBTD6010 DCWP 1 2 350A Mag DC Wave 1 2 Low WBTD6011 ACP MIG 4 Stainless steel sol...

Page 90: ...2 Ferrite Low WBTD6147 ACWP MIG 4 Ferrite 0 9 Standard 350A Mig_4 AC Wave 0 9 Ferrite Low WBTD6149 ACWP 1 0 350A Mig_4 AC Wave 1 0 Ferrite Low WBTD6150 ACWP 1 2 350A Mig_4 AC Wave 1 2 Ferrite Low WBTD...

Page 91: ...2 400A Mig_3 AC Pulse 1 2 Hard Al High WBTD5925 ACP 1 6 400A Mig_3 AC Pulse 1 6 Hard Al High WBTD5926 ACWP 1 0 400A Mig_3 AC Wave 1 0 Hard Al High WBTD5927 ACWP 1 2 400A Mig_3 AC Wave 1 2 Hard Al Hig...

Page 92: ...lse 0 9 Low WBTD5997 ACP 1 0 400A Mag AC Pulse 1 0 Low WBTD5998 ACP 1 2 400A Mag AC Pulse 1 2 Low WBTD5999 ACWP 0 9 400A Mag AC Wave 0 9 Low WBTD6001 ACWP 1 0 400A Mag AC Wave 1 0 Low WBTD6002 ACWP 1...

Page 93: ..._2 AC Pulse 1 2 Ferrite Low WBTD6179 ACWP 0 9 400A Mig_2 AC Wave 0 9 Ferrite Low WBTD6181 ACWP 1 0 400A Mig_2 AC Wave 1 0 Ferrite Low WBTD6182 ACWP 1 2 400A Mig_2 AC Wave 1 2 Ferrite Low WBTD6183 DCP...

Page 94: ...High WBTD5931 DCP 1 6 400A Mig_3 DC Pulse 1 6 Hard Al High WBTD5932 DCWP 1 0 400A Mig_3 DC Wave 1 0 Hard Al High WBTD5933 DCWP 1 2 400A Mig_3 DC Wave 1 2 Hard Al High WBTD5934 DCWP 1 6 400A Mig_3 DC W...

Page 95: ...400A Mig_2 AC Pulse 1 0 SuS High WBTD6082 1 2 400A Mig_2 AC Pulse 1 2 SuS High WBTD6083 ACWP 1 0 400A Mig_2 AC Wave 1 0 SuS High WBTD6086 1 2 400A Mig_2 AC Wave 1 2 SuS High WBTD6087 DCP 1 0 400A Mig_...

Page 96: ..._3 AC Pulse 1 2 Inconel High WBTD6212 DCP 400A Mig_3 DC Pulse 1 2 Inconel High WBTD6213 ACP Standard 400A Mig_3 AC Pulse 1 2 Inconel Low WBTD6214 DCP 400A Mig_3 DC Pulse 1 2 Inconel Low WBTD6215 ACWP...

Page 97: ...DC Pulse 1 6 Hard Al High WBTD5932 DCWP 1 0 400A Mig_3 DC Wave 1 0 Hard Al High WBTD5933 DCWP 1 2 400A Mig_3 DC Wave 1 2 Hard Al High WBTD5934 DCWP 1 6 400A Mig_3 DC Wave 1 6 Hard Al High WBTD5935 AC...

Page 98: ...1 0 400A Mig_4 AC Pulse 1 0 SuS Low WBTD6066 ACP 1 2 400A Mig_4 AC Pulse 1 2 SuS Low WBTD6067 ACWP 0 9 400A Mig_4 AC Wave 0 9 SuS Low WBTD6069 ACWP 1 0 400A Mig_4 AC Wave 1 0 SuS Low WBTD6070 ACWP 1...

Page 99: ...ion of Control cable 5 Robot controller side 2 3 2 1 3 Connection of Control cable 5 Welding power source side 2 4 2 1 4 Connection of Control cable 4 2 5 2 1 5 Connection of Workpiece side welding ca...

Page 100: ...on the robot controller 2 The Welding Interface digital board is fixed to the position shown in Figure 2 1 1 of the robot controller by the plate and the locking card spacer Figure 2 1 1 Installation...

Page 101: ...e Storage Board CNCAN 4 Wire the 24V power supply cable and connect the Welding interface Digital Board CNP24V and the Sequence board TBEX3 P1 M1 If the terminal block on the Sequence Board is used fo...

Page 102: ...e 2 1 4 Connection of control cable 5 Pull cable through 3 Fix the shield section of the cables to the shield fixing fixtures on the left side of the service entrance as shown in Figure 2 1 5 Control...

Page 103: ...l cable 5 to the connector CN17 on the printed circuit board PCB1 5 Connect the grounding cable to the grounding terminal 6 Remove the STOP jumper wire connected to the terminal block TM3 on the print...

Page 104: ...tion forcedly for wiring it may cause damage of the connector Good example Wrong example In case of installation on the floor Provide some margin in wiring so as to avoid any force applied to the conn...

Page 105: ...cting the voltage detecting cable workpiece side Connect voltage detection cable workpiece side to a place near to workpiece as possible Wire the torch voltage detecting wire to along with the voltage...

Page 106: ...rkpiece side In case of use of 2PF 1PB series positioner Example 2 In case that the positioner which has no voltage detection terminal is combined Connect it directly to the table When connecting it s...

Page 107: ...e 2 2 1 Electrical connection diagram of WB M350L WB P400L WB P500L 1 WB M350 WB M400 WB M500 WB P350 WB P400 WB P350L 2 WB P500L 2 WB W350 WB W400 CN17 18 Com line Control cable 5 Control cable 4 CON...

Page 108: ...TIG filler feeding unit Com line Robot controller Sequence board Storage board Control cable 4 Torch Workpiece N C 4 2 CNCAN1 4 2 Welding interface Digital board CNCAN 4 2 Wire feeding motor 3 4 8 7 6...

Page 109: ...2 2 Electrical connection diagram 2 10 Robot controller Figure 2 2 5 Electrical connection diagram of AXC...

Page 110: ...Writing the setup data onto Welding Interface Digital 3 18 3 6 Check the configuration 3 20 3 7 Configuring the Welbee Inverter series welding power source 3 21 3 7 1 The welding power source operatio...

Page 111: ...ng conditions of WB W350 W400 3 48 3 12 1 About the welding condition parameters 3 48 3 12 2 Points for setting the conditions 3 49 3 12 3 To adjust the pulse conditions 3 50 3 12 4 Waveform control w...

Page 112: ...nnecting multiple welding power sources to the interface set the same number as the registration number in the next item Register the welding power source Configuring the robot controller Page 3 4 3 R...

Page 113: ...with the interface see the welding conditions for the various welding power sources from the section 3 8 Also for details on editing the welding conditions see the APPLICATION MANUAL ARC WELDING instr...

Page 114: ...elding and Mechatronics System Corporation Downloads http www daihen co jp yosetsu other download_e html 2 Unzip the Welding Interface Digital Setup tool into any folder This completes the setup tool...

Page 115: ...ontroller as the corresponding D series welding power source shown below Table 3 3 1 Recommended settings WB series welding power source to be connected D series welding power source to register in th...

Page 116: ...tering WB M350L as DL S 2 Welding mode used in WB M350L Welding characteristic data registered in the robot controller No File comment Characteristic 1 350A Co2 DC 1 2 Low WTBD1410 350A Co2 DC 1 2 Hig...

Page 117: ...D1546 400A Mig DC Wave 1 2 Sus Description Register a welding mode where the welding process and wire material match Independent Standard and High welding speed modes are not available for the DP 400R...

Page 118: ...aracteristic 2 350A Mig_3 AC Pulse 1 2 Soft Al Low WTBD1123 300A Mig AC Pulse 1 6 Soft Al Characteristic 3 350A Mig_4 AC Pulse 1 2 SuS High WTBD1131 300A Mig AC Pulse 1 2 Sus Description Register a we...

Page 119: ...file operation functions see 6 File operations in the BASIC OPERATIONS instruction manual of the robot controller INFO The name of the backup folder is given automatically using the following format N...

Page 120: ...controller 3 9 Backing up the folders 1 In the device selection field select Card1 for instance 2 Move to the folder selection field select the backup destination folder and press Enter 3 Press f12 E...

Page 121: ...teristic data file with the current and voltage output characteristics changed to match the welding mode of the Welbee Inverter series welding power source that will be used The Welding Interface Digi...

Page 122: ...g a backup 4 Select the backup folder The backup data of the robot controller is loaded from the selected backup folder and Welding Interface Digital Setup starts INFO The name of the backup folder is...

Page 123: ...memory preparations to the computer 2 Select Select Setup folder in the Settings menu 3 Select the UPDATE folder that you created in the USB memory INFO If you have not yet created the UPDATE folder...

Page 124: ...in the robot controller The type of the registered welding power source is displayed in Registered WPS of RC 2 In Actual WPS select the Welbee Inverter series welding power source to be used If you ca...

Page 125: ...ies welding power source of region specifications Specification Japan USA EU CCC ASIA model WB M350 M400 M500 Japan USA EU Japan Japan WB M350L M400L Japan USA EU Japan Japan WB P350 P400 Japan USA EU...

Page 126: ...A350P A500P the item of welding characteristics is not appeared 4 If multiple welding modes are registered in the robot controller select the next Register tab and repeat the operation from step 3 In...

Page 127: ...r 1 While the power of the robot controller is OFF insert the backup CF card that you created in 3 4 2 Configuring the welding mode for the Welbee Inverter series welding power source into the robot c...

Page 128: ...lect the folders in the order of Internal memory WORK A_APPLICATION and then press Enter The A_APPLICATION folder is selected POINT In step 5 select A_APPLICATION not the WELD folder you selected in s...

Page 129: ...rn ON the No 3 DIP switch on the Welding Interface Digital board Turn OFF the other DIP switches 3 Turn ON the power of the robot controller After 10 seconds the writing of the setup data onto the int...

Page 130: ...ed see Chapter 4 Maintenance When these steps are performed the setup file already written in this board is backed up automatically to a USB memory If step2 is changed Both No 2 and No 3 of a DIP swit...

Page 131: ...ectly Also perform 3 5 Writing the setup data again 4 Check that the emergency stop is not being input to the robot controller and check whether errors other than those described above have occurred I...

Page 132: ...nual Figure 3 7 1 Welbee Inverter series welding power source Front Panel Table 3 7 1 Keys that can be used when the welding power source is connected to a robot Key name Description of function LOAD...

Page 133: ...peration See the instruction manual for the welding power source 22 Keypad tone ON OFF Selection See the instruction manual for the welding power source 43 Welders ID CANID This is used to set the num...

Page 134: ...PCS parameter 2 APCS parameter 2 EP 2 Slope time Slope distance Initial current Ini wire speed Initial voltage Ini arc length Start adjust time Start voltage adj AE Welding process 1 1 Current cond We...

Page 135: ...can be used for actual welding it must be adjusted to ensure optimum welding Concerning the Arc char 1 Short The arc characteristic is expressed in the form of a numerical value which enables the arc...

Page 136: ...he necking Unless the necking is detected at the appropriate timing it will lead to the generation of spatter The sensitivity with which necking is detected can be adjusted using the APCS parameters F...

Page 137: ...s will give rise to spatter Furthermore the automatic necking sensitivity adjustment function will not work properly either If the welding is unstable and large amount of spatter are generated review...

Page 138: ...3 8 4 Welding constants not included in this table cannot be used Table 3 8 4 Welding constants of WB M350L Item Welding power source registration DL S1 DL S2 Inching Retract speed Inching Retract Key...

Page 139: ...n Welding power source registered on robot controller DM DM S 2 DR AS Welding process 1 1 1 Current cond Penetration adjustment Welding current Wire speed Welding voltage Arc length tun Welding speed...

Page 140: ...the welder and welding mode used If the standard software has been installed in the welder the minimum speed is approximately 130 cm min and the maximum speed is approximately 1800 cm min as a general...

Page 141: ...reflow time Arc outage detect time Online modification cycle Auto storing for online mod Arc start failure detect time Arc start timing adjust time Arc start retry number Wire retract time Scratch sta...

Page 142: ...tion Welding method DC DC pulsed DC wave pulsed AS Welding process Current cond Welding current Wire speed Welding voltage Arc length tun Welding speed Pulse arc characteristic Arc character Slope tim...

Page 143: ...speed is approximately 130 cm min and the maximum speed is approximately 1800 cm min as a general rule However depending on the welding mode the maximum and minimum wire feed speed may be more restri...

Page 144: ...litude will automatically be reduced If the wave frequency is over 3 Hz the speed of the wire feed will gradually be reduced If it exceeds over 5 Hz the amplitude will run out In this case the wire fe...

Page 145: ...pulse section The number of pulses in a low pulse section and high pulse section in each period depends on the wave frequency and pulse conditions Waveform control arc start welding underway crater tr...

Page 146: ...ract time Scratch start Waiting time after welding starts Arc end timing adjustment time Wire stick check Wire stick release time Torch WIF timeout check Restart retract distance Arc monitor display c...

Page 147: ...manner is as follows Hold down F key The front panel indicates F blinking on its left side Hold down Execute key switch the digital indication to A Move the kob on the front panel to align the digita...

Page 148: ...ut voltage F 19 It designates the process on the robot side when the welding power source detects the fan alarm or the shortage alarm of input voltage ON Indicates the error by Alarm OFF Not detecting...

Page 149: ...Current cond Welding current Wire speed Welding voltage Arc length tun Welding speed Pulse arc characteristic Arc character Slope time Slope distance Initial current Ini wire speed Initial voltage In...

Page 150: ...999 cm min can be set as the welding speed the maximum speed is actually 600 cm min or so Since this is also the maximum operable speed and not a speed which can be used for actual welding it must be...

Page 151: ...time it enables to adjust the amount of wire retracting after the arc end The retract time before adjustment depends on the type of wire feeding unit as given in Table 3 11 2 Even if setting the retra...

Page 152: ...or this reason the preset necking detection sensitivity is not necessarily optimal and the generation of spatter may not be reduced satisfactorily WB P350L P400L P500L function for automatically adjus...

Page 153: ...vibration and tolerance of welding cracks will also be improved For steel and stainless welding the melted metal takes time to solidify Therefore in this welding there are cases where clear beads shap...

Page 154: ...elationship between the reduction of blowholes and the measure of the melted metal s vibration The bigger the extent of the molten pool the bigger the vibrations as well reducing more blowholes On the...

Page 155: ...poses can be achieved The amplitude rate is meant for adjusting the shift value of the wire feed Having 50 as its standard measurement adjustments can be made within the range from 0 to 100 The minimu...

Page 156: ...Wire retract time Scratch start Waiting time after welding starts Arc end timing adjustment time Wire stick check Wire stick release time Torch Penetration adjustment WIF timeout check Restart retract...

Page 157: ...ange the function type from Normal to Almega The setting manner is as follows Hold down F key The front panel indicates F blinking on its left side Hold down Execute key switch the digital indication...

Page 158: ...input voltage F 19 It designates the process on the robot side when the welding power source detects the fan alarm or the shortage alarm of input voltage ON Indicates the error by Alarm OFF Not detec...

Page 159: ...speed Welding voltage Arc length tun Welding speed Pulse arc characteristic EN adjust Slope time Slope distance Initial current Ini wire speed Initial voltage Ini arc length Wave frequency Start adju...

Page 160: ...ed speed The wire feed speeds which are actually valid as welding conditions differ according to the welder and welding mode used If the standard software has been installed in the welder the minimum...

Page 161: ...oint The correlation between the EN adjust and welding result is as below Table 3 12 2 Correlation between the EN adjust and welding result EN adjust EN ratio Wire melting speed Gap tolerance Depth of...

Page 162: ...lloy welding where the beads can be formed in shapes of fish scales it is possible to adjust the ripple pitches freely depending on the combinations between the welding speed and wave frequency The wi...

Page 163: ...high pulse section The number of pulses in a low pulse section and high pulse section in each period depends on the wave frequency and pulse conditions Waveform control arc start welding underway crat...

Page 164: ...tart failure detect time Arc start timing adjust time Arc start retry number Wire retract time Scratch start Waiting time after welding starts Arc end timing adjustment time Wire stick check Wire stic...

Page 165: ...ows Hold down F key The front panel indicates F blinking on its left side Hold down Execute key switch the digital indication to A Move the kob on the front panel to align the digital indication on th...

Page 166: ...adjustment function of the welding power source ON Available OFF Not available OFF Process in the fan failure Process in the shortage of input voltage F 19 It designates the process on the robot side...

Page 167: ...3 1 Table 3 13 2 Welding condition parameters not included in this table cannot be used Table 3 13 1 Arc start conditions of WB A350 P A400P Welding condition Welding condition DC DC pulse AC AC pulse...

Page 168: ...sed has been selected for the welding mode Pulse frequency 0 1 to 500 Hz Pulse width ratio 5 to 95 The pulse width ratio is the ratio of the peak current duration to one period expressed as a percenta...

Page 169: ...rent and DC direct current alternately Set the following conditions when AC DC hybrid has been selected as the current output waveform AC DC switching frequency AC ratio The AC ratio is the ratio of t...

Page 170: ...ct Key operation Gas check operation Preflow time Arc outage detect time Online modification cycle Auto storing for online mod Arc start failure detect time Arc start timing adjust time Scratch start...

Page 171: ...ollows Hold down F key The front panel indicates F blinking on its left side Hold down Execute key switch the digital indication to A Move the kob on the front panel to align the digital indication on...

Page 172: ...the fan failure Process in the shortage of input voltage F 19 It designates the process on the robot side when the welding power source detects the fan alarm or the shortage alarm of input voltage ON...

Page 173: ...Interface Digital error codes 4 2 4 3 Errors of Welbee Inverter series welding power source 4 4 4 3 1 Error code list 4 4 4 3 2 How to reset an error indication 4 6 4 4 Notes on Scope of Warranty and...

Page 174: ...wer source connected to the interface is ON R RESET 3 In the top screen of the teach or playback mode press Reset R The Shortcut R code Entry screen is displayed OFF 2 8 6 Enter 4 Press 2 8 6 Enter in...

Page 175: ...see Chapter 2 Check that the communication cable that connects the interface to the storage board of the robot controller is connected correctly see Chapter 2 Check that control cable 5 on the welding...

Page 176: ...mended by us Create the setup data again and write it onto the interface see Chapter 3 E 106 Setup file data error The setup file stored on the USB memory contains an error Create the setup data again...

Page 177: ...y error A5039 3 E 150 Input over voltage A5023 3 E 160 Shortage of input voltage A5023 3 E 200 Primary current detection error A5040 3 E 210 Error in the arc voltage detection A5030 1 E 215 Error in t...

Page 178: ...heck the connection of control cable 5 2 A5096 is displayed when operating Welding power sources during non operation 3 For details refer to Table 4 3 2 4 May be displayed as a different error code de...

Page 179: ...g f12 Gas on the teach pendant When inching has been performed using the inching ON OFF dedicated arc input signal When retract has been performed using the retract ON OFF dedicated arc input signal W...

Page 180: ...by third party and the failure that has a roots in that damage 8 Failure caused by movement after delivery and defective storage 9 Sound vibration bleeding of oil color degradation of coated surface r...

Page 181: ...is attributed to manufacturing If we deem it necessary to repair the equipment on site domestic location only within above warranty period we will dispatch engineer for repair work without charge B In...

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