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10-1

Chapter 10 

       Reference Materials

Chapter 10 Reference Materials

This chapter contains the parts list of welding power source, and reference materials for setting the 
welding conditions.

10.1 Parts List

This section shows the parts list of welding power source.

 • When placing an order, provide your dealer with the necessary information: the model name of welding power 

source, the name of the part to be replaced, and the part number (or specifications if part has no number).

The period of supplying parts will be at the shortest approximately seven years after the welding power source
is manufactured. It may change, however, if the parts from other companies cannot be supplied.

 • The codes in the table correspond to those in the schematic diagram/parts layout drawing.

Code

Part No.

Product Name

Specifications

Q’ty

Remarks

NF

100-1568

Circuit protector

CA3-X0-19-177-41D-C

1

PL1

100-0171

Pilot lamp

N46010A7KW-01 ROHS

1

DR1

4531-716

Diode module

DFA100BA160

1

DR2 to 6,8

4531-119

Diode module

DSEI 2X101-06A

6

DR7

4531-505

Diode module

S2L60

1

DR9

4531-710

Diode module

D1N60

1

TR1 to 4

100-1999

IGBT module

CM150DUS-12F

4

SCR1

4530-412

Thyristor

SG25AA20

1

CT1

4810-030

Current transformer

W-W03029

1

CT2

100-0956

Hall current detector

CS-40GEH

1

T1

P30086B00

Inverter transformer

P30086B00

1

T2

W-W03674

Auxiliary transformer

W-W03674

1

LF1

100-2233

EMI FILLTER

TAC-30-683

1

L1

P30086L00

Input reactor

P30086L00

1

L2

P30086C00

DC reactor

P30086C00

1

L3

4739-497

Ferrite core

E04RA400270150

1

L4,5

4739-543

Ferrite core

E04RA310190100

2

L6

100-0620

Ferrite core

SN-20 OR23.5×9.5×12.6

2

L7 4739-497

Ferrite 

core

E04RA400270150

2

L8 

100-0620

Ferrite core

SN-20 OR23.5×9.5×12.6

3

L9

100-0618

Ferrite core

HM2AT4815

1

L10

4739-497

Ferrite core

E04RA400270150

2

L11

100-0618

Ferrite core

HM2AT4815

2

L12

100-0618

Ferrite core

HM2AT4815

2

THP2

100-0123

Thermostat

US-602SXTTAS 130

℃

1

FM1,2

100-1429

FAN

9WV1224P1H003

2

FM4

100-1825

FAN

9G1224E1D07

1

CR1

4341-139

Relay

G2R-1-T DC24V

1

SH

4403-116

Meter shunt

SH 400A/60mV

1

R1 to 4

6100-052

Surge absorber

TND14V-911KB0LLAA0

4

R5 to 10

100-0234

Carbon resistor

RD20S 1 K

Ω

J

6

R11,12

100-1430

Metal film resistor

RPM200Z 5

Ω

2

R16

4509-916

Cement resistor

T20SH 2.2

Ω

J

1

R17

4509-704

Carbon resistor

RD1/4W 1K

Ω

J

1

R18

100-0662

Thermistor

EC2F103A2-40113

1

R19a, b

100-1432

Winding resistor

FHN50 471J/RO

2

R20,21

100-0234

Carbon resistor

RD20S 1K

Ω

J

2

Summary of Contents for OTC WB-M400

Page 1: ...t h i s i n s t r u c t i o n m a n u a l thoroughly for safe and proper use of the product October 2013 Manual No 1P30134 1 Model WB M400 Welbee Inverter M400 OWNER S MANUAL CO MAG Welding power sour...

Page 2: ......

Page 3: ...nual hereafter referred to as this manual explains the following points for safe use of the product Caution regarding the product Welding operation setting method Daily maintenance cleaning inspection...

Page 4: ...e that installation operation maintenance of the welding power source and welding machine is performed by a qualified personnel with sufficient knowledge and skills If this manual is lost or damaged i...

Page 5: ...Product model manufacture year serial number and software version number Refer to the diagram below for product information Attachment location and content of nameplate may vary depending on the purc...

Page 6: ...or Connection Procedure and Grounding 4 1 4 2 Connecting the Welding Power Source 4 2 4 2 1 Connection of cable at output side 4 3 4 2 2 Connection of wire feeder 4 4 4 2 3 Connection of welding torch...

Page 7: ...7 5 7 3 Data Backup Utilization of data 7 9 7 3 1 Setting of welding conditions internal functions 7 10 7 3 2 Simplified data log function 7 12 7 3 3 Failure log function 7 13 7 3 4 Backup operation 7...

Page 8: ...TABLE OF CONTENTS vi MEMO...

Page 9: ...stand the content before beginning operation The below symbols are categorized by the degree of possible hazard and damage The below symbols are categorized according to the content to be followed 1 2...

Page 10: ...chine or work areas Only authorized personnel or person with full understanding and experience of the welding machine must perform installation maintenance and repair of welding machine Make sure to a...

Page 11: ...ource and wait three minutes or more The capacitors may be still charged even after the input power is cut Make sure that there is no charged voltage before starting the work Wear dry insulating glove...

Page 12: ...or preventive measure from falling due to anoxia apply lifelines such as a safety belt For the welding operation in a narrow space perform the operation with the trained supervisor Periodically inspec...

Page 13: ...on gas pipe and closed containers such as tanks or drums Performing arc welding on flammable object such as fuel tank may cause explosion Furthermore welding on closed container such as tanks and pipe...

Page 14: ...ay from the gas discharge port Keep protective cap in place over valve except when gas cylinder is in use or connected for use Do not place the gas cylinder under high temperature Protect compressed g...

Page 15: ...g by customer is out of the warranty scope When welding or watching a welder work wear face shield with a proper shade of filter See ANSI Z 49 1 listed in PRINCIPAL SAFETY STANDARDS to protect the fac...

Page 16: ...Electrical Code NFPA Standard 70 from National Fire Protection Association Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Code for Safety in Welding an...

Page 17: ...ase Three phase Rated frequency 50 60 Hz Rated input voltage 400 V Input voltage range 400 V 15 Rated input 17 7kVA 15 8kW Rated input current 25 5 A Rated output current 400 A Rated load voltage 34 V...

Page 18: ...EEL 0 8 1 0 1 2 2 3 Enable STAINLESS FERRITE 0 8 1 0 1 2 2 3 Enable MIG 2 5 CO2 1 4 STAINLESS STEEL 0 8 1 0 1 2 2 3 Enable STAINLESS FERRITE 0 8 1 0 1 2 2 3 Enable MIG 100 Ar 1 5 Al PURE 1 2 1 6 2 3 A...

Page 19: ...istor and radiation fin of the diode If dust and dirt accumulate on the radiation fin it may not only reduce the duty cycle but also result in degradation or burnout of the welding power source Rated...

Page 20: ...Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Wire feeder 3 Welding torch 4 Gas hose 3 m 2 5 Control cable for wire feeder 1 5 m 2 6 Power...

Page 21: ...elding torch 3 Gas hose 3 m 2 4 Power cable for base metal side 2 m 2 5 Shielding gas To be prepared by the customer 2 2 3 Accessory not supplied 6 Digital remote control optional 2 7 Analog remote co...

Page 22: ...ssory not supplied This section explains the accessories to be prepared by the customer before operating the welding power source Prepare the following No Name Suppliedunit 1 Optional accessories Rema...

Page 23: ...ilable including remote control and voltage detection cable Name Remarks CO2 gas Carbon dioxide CO2 100 MAG gas Argon Ar 80 Carbon dioxide CO2 20 Argon Ar 90 Carbon dioxide CO2 10 MIG gas Argon Ar 97...

Page 24: ...ension cable may cause an unstable arc Use extension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 5 m 10 m 15 m 20 m 1 Gas hose BKGG 0...

Page 25: ...section of the welding power source Socket for wire feeder Socket for analog remote control Output terminal Torch side Output terminal Base metal side Power switch Main power lamp Operation panel 6 2...

Page 26: ...PART NAMES PRODUCT SPECIFICATION AND CONFIGURATION CHAPTER 2 2 10...

Page 27: ...eration Setting to an extremely high output voltage may result in damage to the welding power source When the welding power source is used in a humid environment such as construction site or location...

Page 28: ...ent and partial exhaust facility in welding work area 3 1 2 1 Ventilation equipment When welding is required in tank boiler reaction tower or hold of a ship closed space or any other places of poor ve...

Page 29: ...20 C Location with an altitude of less than 1000 m Location with an incline of 10 or less Location with no metallic foreign body such as spatter entering the welding power source Installation distance...

Page 30: ...lding power source Welding cables Do not use an unnecessarily long cable Place a base metal cable and a torch side cable as closely as possible Equipotential bonding Bonding of all metallic objects in...

Page 31: ...nd floor Do not apply strong shock to the welding power source when placing it on the floor It may cause damage to the welding power source Since large current abruptly flows inside the welding power...

Page 32: ...ents be sure to observe the following For operation of a crane or hoisting make sure that a qualified personnel operate them with attention to the surrounding area for safety Use the lifting tool such...

Page 33: ...parts of the welding power source Have a qualified electrical engineer ground the case of the welding power source and base metal or jig electrically connected in accordance with local regulation Make...

Page 34: ...ource until confirming the completion of connection work Otherwise electric shock may occur Connection of cable at output side 4 2 1 Connection of cable at output side Connection of wire feeder 4 2 2...

Page 35: ...ighten them in the clockwise direction 2 Connect the power cable for torch side to the output terminal torch side Connect the connectors as same as above Connection for cable at output side is complet...

Page 36: ...ol cable 10 cores to the socket for the wire feeder Fit the concave part of the connector and convex part of the socket for secure connection and tighten the knurled screws in the clockwise direction...

Page 37: ...using the water cooled welding torch connect the water feeding hose and condensing hose of the welding torch to the wire feeder Fully insert the hose end to the connection port of wire feeder For dis...

Page 38: ...tal Connect the connectors as same as above In using the welding power source for TIG welding prepare a welding torch by the customer Contrary to the normal connection the TIG welding requires connect...

Page 39: ...n them in the clockwise direction 2 Connect the cable for welding electrode holder side to the output terminal torch side Connect the connectors as same as above In using the welding power source for...

Page 40: ...sure to observe the following points to prevent from suffocation due to gas leakage or explosion Be sure to turn off the shielding gas at the main tap when the welding power source is not in use Secur...

Page 41: ...k due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker for motor to the input side of each welding power source Otherwise electric shock and fire due to o...

Page 42: ...the cable of the welding power source to the breaker Capacity of the switch and the rating of fuse and circuit breaker are appropriate 3 1 1 Welding power source equipment Perform grounding for the ca...

Page 43: ...ol cable for wire feeder BKCPJ 1010 10 m For details on cables see 2 2 4 2 Details on extension cables and hoses 7 Cable at torch side BKPDT 6012 10 m 8 Cable at base metal side BKPDT 6012 10 m 9 Gas...

Page 44: ...ps output of the welding power source When combining switches use a push lock turn reset switch for preventing accidental reset 5 9 IN EXT1 External input 1 Reserve inputs for expanding terminal funct...

Page 45: ...ing the work make sure to cut the input power with the disconnect switch connected to the welding power source and wait three minutes or more In addition do not turn on the primary power until the wor...

Page 46: ...pass the cable through Process any given blind bush among the several available types 4 Connect the cable to the terminal for external connection Strip the cable cover by 10 to 11 mm from the end whil...

Page 47: ...rce When using the voltage detection cable set the internal function F38 to ON 6 7 1 Setting procedure Details on the internal function F38 6 7 2 23 F38 Arc voltage direct detection switching 4 6 1 Wi...

Page 48: ...able at the base metal side to the voltage direct detection terminal at the base metal side of the welding power source 1 Check that input power is turned off with the disconnect switch connected to t...

Page 49: ...with a power feeding brush to the positioner Insulate the power feeding brush from the jig base and connect the voltage detection cable base metal side to the jig base TIPS Before wiring the voltage...

Page 50: ...WIRING OF VOLTAGE DETECTION CABLE AT BASE METAL SIDE CONNECTION CHAPTER 4 4 18...

Page 51: ...ilation equipment does not give sufficient performance ensure to use respiratory protective equipment For preventive measure from falling due to anoxia apply lifelines such as a safety belt For the we...

Page 52: ...rom spatter and spattering dross Wear protective equipment such as protective leather gloves long sleeve clothes leg covers and leather apron Ignoring the above may cause electrical shock and burn Ins...

Page 53: ...re the adequate shield gas flow rate as follows CO2 MAG gas MIG gas 10 to 25L min 15 to 25L min 11 When the shield gas is mixed each gas pressure should be the same Set pressures of the respective gas...

Page 54: ...liner take care for the followings If the liner is too long feeding resistance increases resulting in shorter life of wire feeder If the liner is too short feeding failure occurs Handle the gas cylind...

Page 55: ...6 Press the GAS CHECK key The LED of the GAS CHECK key lights off to stop gas check 5 4 Wire Inching This section explains the inching operation feeding operation of the wire 1 Straighten the torch c...

Page 56: ...that the welding conditions are correct 5 5 2 Preventing erroneous operation on operation panel This section explains how to prevent erroneous operation on the operation panel To prevent accidental ch...

Page 57: ...e right digital meter both in a real time basis This indication is the average value of the output per approximately one second In TIG welding arc start requires contact of the torch electrode with th...

Page 58: ...D of the CURRENT SETTING DISPLAY SWITCH key is off press the CURRENT SETTING DISPLAY SWITCH key to light up the LED In the adjustment by the remote control this operation is not necessary Turn the par...

Page 59: ...ly 5 seconds the display will return to the one showing current voltage in welding Using the internal function F48 enables to increase decrease the welding current by the torch switch operation It is...

Page 60: ...ischarged 3 After the shield gas is discharged press the GAS CHECK key The LED of the GAS CHECK key lights off to stop gas check 4 Set the flow adjustment knob to SHUT to adjust the shield gas flow ra...

Page 61: ...set the current and voltage value at the end of welding Voltage INDIVIDUAL 12 0 to 38 0 V 19 0 V Voltage SYNERGY 100 to 100 0 Post flow time 0 to 10 sec 0 4 sec Set the gas discharge time after the we...

Page 62: ...display time for the current voltage after completion of welding F9 Analog remote control scale 200 350 350 A Configures the settings of scale plate of the analog remote control F10 Motor over curren...

Page 63: ...g 0 to 9 0 Sets the functions of input terminal of the programmable I O F30 External input 2 setting 0 F31 External input 3 setting 0 F32 External input 4 setting 0 F33 No function OFF fixed OFF No fu...

Page 64: ...he setting of Crater sets whether to switch the welding condition and crater condition by the click operation of the torch switch OFF not to use torch switch ON uses the torch switch F52 Data type of...

Page 65: ...condition in the percentage based on the current value of the welding condition OFF invalid ON settable with percentage F68 Setting of current value initial condition 10 to 300 100 Sets the current va...

Page 66: ...es the welding sequence as the set target During the welding the display can be switched to display the value set as the welding condition 7 F function key Sets the internal function of welding power...

Page 67: ...hich cannot be used is selected the LED flashes 6 6 1 Welding mode setting 15 CRATER FILL key Select the crater treatment method or arc spot at the end of welding The LED of the parameter in selection...

Page 68: ...he welding voltage is automatically set according to the set welding current To fine tune welding voltage adjust the synergic fine adjustment knob When the LED of the VOLT ADJUST key is off INDIVIDUAL...

Page 69: ...use The number of welding conditions that are able to be registered are 100 at maximum Single welding condition can contain the following information at registration Welding mode selected by the keys...

Page 70: ...ns electronic data stored by this function are susceptible to occurrence of static electricity impact repair etc and there is a possibility that the stored contents may be changed or lost BE SURE TO M...

Page 71: ...setting values are displayed on the left right digital meters in a flashing mode To change the JOB No to register press the SAVE key The display returns to the status described in step 1 To cancel th...

Page 72: ...he SAVE key depressed together turn ON the power switch The LED of ENTER key flashes Pressing the DISPLAY CHANGE key enables to check the set values of welding conditions welding parameters to read ou...

Page 73: ...time turn the parameter adjustment knob counterclockwise to display ALL on the right digital meter When ALL is selected the current welding condition set on the operation panel is also deleted and the...

Page 74: ...3 Enable STAINLESS FERRITE 0 8 1 0 1 2 2 3 Enable MIG 100 Ar 1 5 Al PURE 1 2 1 6 2 3 Al Mg 1 0 1 2 1 6 2 3 Brazing CuSi 0 8 1 0 1 2 2 3 Brazing CuAl 0 8 1 0 1 2 2 3 1 Note that the collective voltage...

Page 75: ...l 6 6 7 Penetration control adjustment 0 8 OP 0 9 1 0 1 2 1 6 1 4 F A m min V r A V r Al PURE OP3 Al Mg OP2 OP1 DC STICK DC TIG WELDING METHOD CO2 OP MAG MIG MIG GAS 2 5 CO2 100 Ar Hz WARNING sec m mi...

Page 76: ...e time Press the DISPLAY CHANGE key and select the LED of PRE FLOW or POST FLOW Turn the parameter adjustment knob to set the gas discharge time The set parameter is displayed on the left digital mete...

Page 77: ...min On A Off and the value displayed on the left digital meter switches to the display of wire feed speed Pressing the CURRENT SETTING DISPLAY SWITCH key again to light on the LED of the key m min Off...

Page 78: ...ime setting Mode Initial condition Description CRATER FILL OFF In the welding process only available process is the main welding 6 6 3 1 Crater OFF CRATER FILL ON Unavailable After the main welding th...

Page 79: ...Select CRATER OFF by the CRATER FILL key In synchronous to the ON OFF operation of the torch switch the welding starts stops Torch switch Gas flow Output voltage Wire feeding speed Welding current Mai...

Page 80: ...n if the torch switch is switched off during welding the signal will be self hold The torch switch should remain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON...

Page 81: ...he torch switch is switched off during welding the signal will be self hold The torch switch should remain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON Regard...

Page 82: ...in 2 seconds the machine starts on the Crater condition and continues operation Repeating this allows crater process to be carried out as many times as needed ON ON OFF ON OFF OFF ON OFF Within 2 sec...

Page 83: ...ble For details on the nozzle for arc spot see the instruction manual of the torch 6 6 5 Welding voltage adjustment This section explains how to adjust the welding voltage The adjustment of welding vo...

Page 84: ...dition negative value hard arc condition TIPS It is likely that good weld can be obtained by adjusting it to hard in low current region and soft in high current region When using an extended cable for...

Page 85: ...ternal functions TIPS The internal function is activated at the point when the setting value is changed To change the set values of internal functions ensure that there is no mistake in the function N...

Page 86: ...xtension cable longer than 30 m The LED of STANDARD starts flashing when setting to ON OFF Standard mode TIPS In using the welding power source in the HIGH mode the setting of this function is set to...

Page 87: ...This voltage is output even if the wire is not welded 2 If an external command voltage is input it should be input to the terminal pins 1 3 1 4 of the remote control receptacle as shown in the below...

Page 88: ...10 0 sec 6 7 2 5 F7 Downslope time When the difference between the welding current and crater current is large the wire may plunge into weld pool at the change of the conditions the wire is fed by in...

Page 89: ...wer source is not stopped According to the use environment such as wires and torches and the customer s judgment criteria adjust the detection level at your discretion 6 7 2 9 F11 Fine adjustment of w...

Page 90: ...g torch as the welding ends The operation time of water cooled pump at this time can be set Setting range of water cooled pump operation time 20 to 60 min ON Water cooled pump is always ON 6 7 2 11 F1...

Page 91: ...ti stick time voltage adjustment Set the anti stick time voltage which is the anti stick processing time and voltage Optimum setting of the anti stick time voltage enables to obtain the following effe...

Page 92: ...code is displayed Set the value in the range of 260 to 400 V TIPS The factory default setting is 320 V However the specification of input voltage as welding power source is the range of 340 to 460 V I...

Page 93: ...he feed speed in the unit of 0 1 m min Switching to the welding current display can check the welding current value automatically set In using the welding power source in the automatic machine mode re...

Page 94: ...tion terminal block TM3 For the details of external connection terminal block 4 5 2 Connection of automatic machine The functions allocable to F29 to F32 are as follows Setting Function name Explanati...

Page 95: ...to 5 and turning the signal of external input terminal IN EXT2 to ON enable to read out the JOB No 3 For F29 F31 and F32 other functions can be set Example 2 In reading out the welding condition of th...

Page 96: ...h OFF start signal OFF to 100 ms after it do not change the setting of 5 Secondary condition current ON OFF 1 Primary condition current 5 2 1 OPEN CLOSE OPEN OPEN CLOSE OPEN EXT3 F31 5 EXT1 F29 5 JOB...

Page 97: ...ent value gain offset when the current display value on the left digital meter is different from the actual current value The current value displayed on the digital meter is obtained by software proce...

Page 98: ...o increase the welding voltage turn the knob clockwise and to reduce the welding voltage turn the knob counterclockwise The fine adjustment range for welding voltage is up to 20 OFF disables the funct...

Page 99: ...s TIPS When the internal function F45 is set to ON automatically the setting of No crater is selected disabling other welding modes The CRATER FILL key does not work Welding method at crater treatment...

Page 100: ...double clicking operation should be within 0 3 seconds At the time of transition to crater press the torch switch for at least 0 3 seconds Welding method at crater treatment is the same as that of ma...

Page 101: ...50 A 6 7 2 32 F51 Special crater repeat In the sequence of main welding of the CRATER FILL ON REPEATED during start input holding the torch switch operation can switch the welding and crater treatment...

Page 102: ...g welding condition 6 7 2 33 F52 Data type of data log function This function enables to select data to save when using the data log function The patterns of data which can be saved are as shown in th...

Page 103: ...ith the automatic machines of other manufacturers 6 7 2 37 F67 Setting change of current value initial condition crater condition When CRATER ON is selected the current value of the initial condition...

Page 104: ...e welding current is automatically set and fine adjustment is available for the set welding voltage Align the welding voltage adjustment knob to the center mark and adjust the voltage with the positio...

Page 105: ...ble if the erroneous operation prevention function is disabled NOTE Write down the password on a piece of paper and store it safely The current password will be requested also when you change it If a...

Page 106: ...ord will be requested Hold the two keys pressed down until Loc is displayed on the left digital meter PAS Loc will be displayed in order Release the keys after Loc is displayed If a password has alrea...

Page 107: ...ied as password 3 Select the tens place digit and ones place digit in the same manner as the step 2 4 Press the ENTER key Loc flashes on the left digital meter PAS Loc will be displayed in order The h...

Page 108: ...lding points is achieved Wire consumption P20 0 00 Cumulative wire consumption used in welding kg P21 0 0 to 999 Target wire consumption kg P22 0 0 to 5 Operation at the time when the target wire cons...

Page 109: ...lue will be cleared according to the P12 setting If continuous operation is enabled the value will be cleared when exceeding 999 and return to 0 P11 Target value of welding points Select the target va...

Page 110: ...d P21 Target wire consumption Select the target value of wire consumption in the range from 0 to 999 kg When the P20 count value reaches the wire consumption specified here an alarm appears indicating...

Page 111: ...ints is achieved 7 2 2 1 Number of welding point 7 2 2 4 Welding monitor Average current voltage during welding is monitored When it exceeds the range specified here an alarm displays and the output s...

Page 112: ...tion Alarm indication only Welding can continue Continuous operation is possible 1 The ongoing welding can continue After the welding is finished next welding cannot start until any key of the operati...

Page 113: ...right example shows a voltage error The control No P40 flashes on the left digital meter and the difference between the average value and specified value 1 5 on the right digital meter with the A LED...

Page 114: ...Reserved pre_iset Initial current 1 A reserve Reserved pre_vset Initial voltage 0 1 V reserve Reserved pre_uni_vset Initial voltage synergic 1 ant_tim_adj Anti stick time adjustment 0 01 s wld_iset We...

Page 115: ...oth or either of the data above can be imported at one time ALL Welding condition data recorded in memory Internal function setting data 1 Welding condition data recorded in memory 2 Internal function...

Page 116: ...52 is set to 1 detected values of welding current welding voltage and feeding speed and F53 to 1 100 ms TIPS The length of time that can be used for recording depends on the sampling speed If the samp...

Page 117: ...flash drive TIPS The USB flash drive to be used should be formatted as FAT32 If it is formatted as FAT16 or NTFS reformat it to FAT32 1 Turn on the power switch 2 Insert the USB flash drive to the USB...

Page 118: ...en by the backup data Make sure of it before overwriting 1 Turn on the power switch 2 Insert the USB flash drive to the USB connector of the operation panel 3 Press the SAVE key The LED of ENTER key f...

Page 119: ...s in memory and internal function values will return to the default initial setting Turn the parameter adjusting knob further counterclockwise to display the data to import on the right digital meter...

Page 120: ...y and turn on the power switch The Product No is displayed on the left and right digital meters The display changes every time the F function key is pressed The display order of 5 or later is for manu...

Page 121: ...en after the input power is cut Make sure that there is no charged voltage before starting the work During maintenance and inspection take an appropriate measure to prevent turning on the input power...

Page 122: ...rinted document Please note that OTC will not be liable for any alteration or loss of electronic information When cleaning the welding power source do not expose the cooling fan directly to compressed...

Page 123: ...not grounded electric shock failure malfunction may occur Status of cables Primary power cable for facility side cables for base metal side torch side torch cable voltage detection cable etc Check th...

Page 124: ...mality in consumable parts of the welding torch Abnormality in consumable parts can prevent smooth wire introduction Cleaning inside the welding power source Blow with dry compressed air from the fron...

Page 125: ...and Voltage Test If insulation resistance measurement and withstand voltage test is necessary please contact your dealer When measuring insulation resistance and testing withstand voltage follow the s...

Page 126: ...AC side and positive output side and the AC side and negative output side respectively Short circuit between TR1 C1 and E1C2 TR1 E1C2 and E2 TR3 C2 and E2 Apply NF After finishing insulation resistanc...

Page 127: ...s on the left right digital meters The welding power source may stop or may not stop output depending on the type of error code The meanings of 1 and 2 in the table below are as follows 1 When the err...

Page 128: ...een 340 to 460 V The error code will disappear when the power switch is turned off E 160 The input voltage for primary side fell below the allowable range 2 Check that the input voltage for primary si...

Page 129: ...cables connecting the wire feeder Check that there is no problem in the wire feeder The error code will disappear when the power switch is turned off E 810 The temperature of the governor circuit exc...

Page 130: ...rrect Check that the setting of internal functions F29 to F32 is correct 6 7 2 22 F29 to F32 External input terminal setting The external input cables are disconnected short circuited Check that there...

Page 131: ...tage detection cable is correct There is noise in the voltage detection cable Adjust the arc characteristics to the plus side 12 Wire is not fed no error code is displayed The pressure roll of wire fe...

Page 132: ...TROUBLESHOOTING TROUBLESHOOTING CHAPTER 9 9 6...

Page 133: ...T module CM150DUS 12F 4 SCR1 4530 412 Thyristor SG25AA20 1 CT1 4810 030 Current transformer W W03029 1 CT2 100 0956 Hall current detector CS 40GEH 1 T1 P30086B00 Inverter transformer P30086B00 1 T2 W...

Page 134: ...nted circuit board P30099P00 1 1 PCB2 P30086R00 Printed circuit board P30086R00 1 PCB3 P30086Q00 Printed circuit board P30086Q00 1 PCB4 P30087Q00 Printed circuit board P30087Q00 1 PCB5 P30086V00 Print...

Page 135: ...10 3 Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 2 1 Schematic diagram P30086Q00 P30133M00 P30086V00 PCB6 Driver P30086V00 PCB5 Driver...

Page 136: ...REFERENCE MATERIALS CHAPTER 10 10 4 P30099P00 CN1 2 6 11 13 16 18 26 31 32 36 39 43 45 48 49 51 52 54 56 60 62 Not connected CN2 to 4 8 Not connected P30086T00 CN7 Not connected P30086R00 P30086S00 P3...

Page 137: ...30133M00 P30086R00 DCV1 P30086Q00 P30133M00 P30087Q00 P30099P00 P30086S00 P30086V00 P30086V00 C8 SCR1 R17 C7 R16 DR7 PL1 FM1 FM2 TM5 NF 6 CON1 7 CON2 7 DR1 FM4 R12 DCV2 5 2 1 4 3 8 9 Upper Lower Back...

Page 138: ...ire feeding length is too short The arc length becomes short Spatter is generated The welding voltage is too high The arc length becomes long The bead width becomes wide Penetration and bead become sm...

Page 139: ...to 22 45 to 55 15 to 20 4 5 4 0 to 4 5 1 2 200 to 250 23 to 26 45 to 55 15 to 20 6 0 5 0 to 6 0 1 2 280 to 300 29 to 32 40 to 50 15 to 20 9 0 6 0 to 8 0 1 2 300 to 350 32 to 34 40 to 45 15 to 20 12 0...

Page 140: ...to 420 36 to 39 35 to 40 20 to 25 Back 19 0 5 to 7 1 6 400 to 450 36 to 42 25 to 30 20 to 25 Front 2 400 to 450 36 to 42 25 to 30 20 to 25 Back 1 6 400 to 420 36 to 39 45 to 50 20 to 25 1 Front Back...

Page 141: ...ong Da Dao Shanghai The People s Republic of China Post Code 200120 Phone 86 21 5882 8633 Fax 86 21 5882 8846 OTC Taiwan Co Ltd 2F No 153 Huanbei Rd Chung Li City Taoyuan Hsien Taiwan R O C Phone 886...

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