Daihen OTC Welbee M350L Owner'S Manual Download | Manualshive

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8-5

Maintenance and Inspection

Chapter 8

P

ERIODICAL

R

EPLACEMENT

P

ARTS

M

AINTENANCE

AND

I

NSPECTION

C

HAPTER

8

8.4 Periodical Replacement Parts

This section explains the parts to be replaced periodically.

•

Printed circuit board PCB7 (

The printed circuit board PCB7 inside the welding power source has a high voltage electrolysis capacitor.
The high voltage electrolysis capacitor supplies stable direct current to the inverter circuit, but its
performance will degrade year by year.

If the printed circuit board PCB7 is used for an extended period without being replaced, it may result in
performance degradation of the welding power source and damage of the high voltage electrolysis
capacitor or other parts.
It is recommended to replace the printed circuit board PCB7 every five years.

For replacement of the printed circuit board PCB7, contact your dealer.

•

Others
Fan, relay, and rated power supply has a certain lifetime; they are recommended to be replaced once in
approximately five years.
When replacement of fan, relay, and rated power supply is necessary, please contact your dealer.

8.5 Insulation Resistance Measurement and Withstand

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 steps below.
Refer to the schematic diagram, parts layout, and parts list for maintenance.

–

Disconnect the input power cable and grounding cable from the disconnect switch and short-circuit
the input terminal.

• Even if the part is replaced by the user, please contact your dealer.

• When inserting the connector to the printed circuit board, check that the number

printed on the printed circuit board is the same as the number indicated on the
connector, and insert firmly to the end.

• Do not turn on the power switch of welding power source when the connector of printed

circuit board is disconnected.

• The customer MUST NOT perform the withstand voltage test. If withstand voltage test

is necessary, ensure to contact your dealer.

• Insulation resistance measurement should be conducted by qualified persons or

persons familiar with the welding machine. Also, fence and other neccessary measures
should be taken around the welding machine to prevent other people from getting in
the nearby area.

• Conducting insulation resistance measurement by customer may result in injury or

equipment failure. For insulation resistance measurement, be sure to ask your dealer.

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Summary of Contents for OTC Welbee M350L

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 November 2015 Manual No 1P30200 1 Model WB M350L Welbee Inverter M350L OWNER S MANUAL DAIHEN Corporation CO MAG Welding power source 2 ...

Page 2: ......

Page 3: ...anual 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 Troubleshooting Store this manual in a safe place so that it can be referred whenever necessary ...

Page 4: ...tallation 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 immediately contact your dealer Copyright This manual is copyrighted and all rights are reserved by OTC Any part of the manual shall not be copied photocopied or reproduced without the prior consent of OTC When ...

Page 5: ...el 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 purchased product Example Attachment location of the nameplate No Serial No 1 Same number as the nameplate in the rear X X 2 Product model Manufacture year Serial number XX X X year X X 3 Software version number X Ve...

Page 6: ...Manual transportation with carts 3 6 CHAPTER 4 CONNECTION 4 1 Precautions for 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 4 5 4 2 4 Connection of voltage detection cable Voltage detection cable is used 4 6 4 2 5 Connection at TIG welding 4 7 4 2 ...

Page 7: ... 7 4 7 2 1 Setting welding result control function 7 4 7 2 2 Details of welding control items 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 13 7 3 5 Importing backup data 7 14 7 4 Initializing Welding Conditions and Internal Functions 7 15 7 5 C...

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

Page 9: ...rstand 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 Safety Precaution This section explains the safety precautions regarding operation of the welding power source Symbols Explanation Gives information regarding possible personal injury or loss of lif...

Page 10: ...achine 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 attach a safety belt when working at high locations For those with pacemaker avoid being close to the machine during operation or work area until obtaining physician s approval Machine at operation wi...

Page 11: ...source 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 gloves for protection Do not use damaged or wet gloves Tighten all cable connections and insulate them Do not wrap cables around the body Perform periodical maintenance and repair damaged parts if any bef...

Page 12: ...For 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 inspect the ventilation equipment to ensure correct and proper performance of ventilation To reduce the dust concentration install a partial exhaust facility such as fume suction device or install the coll...

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 pipes may cause burst Watch for fire and keep a fire extinguisher near the welding area Periodically blow the parts of welding power source with dry compressed air to remove dust Powder dust accumulating...

Page 14: ...way 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 gas cylinders from excessive heat mechanical shock and arcs Do not set welding torch to the cylinder or touch the cylinder with welding electrode For the gas regulator make sure to use a device for co...

Page 15: ...ng 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 face and eyes Wear safety goggles in the work area and the surrounding Ignoring the above may cause injury in the eye or burn from spatter and spattering dross Wear protective equipment such as protecti...

Page 16: ...n Welding Society Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society National Electrical Code NFPA Standard 70 from National Fire Protection Association Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Code for...

Page 17: ...08 230 V 10 460 V 10 208 230 V 10 460 V 10 Rated input 15 6 kVA 13 4 kW 15 6 kVA 13 8 kW 12 1 kVA 8 9 kW 11 5 kVA 8 6 kW Rated input current 38 5 A 19 6 A 51 3 A 25 0 A Rated output current 350 A 250 A Rated load voltage 31 5 V 26 5 V Rated output current range 30 to 350 A 30 to 250 A Rated output voltage range 12 to 31 5 V 12 to 26 5 V Maximum no load voltage 79 V 70 V 78 V 70 V Rated duty cycle ...

Page 18: ...040 045 0 8 0 9 1 0 1 2 STANDARD MAG 20 CO2 1 1 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD MIG 2 O2 1 2 STAINLESS STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD STAINLESS FERRITE 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD 1 Note that the collective voltage adjustment may not meet the appropriate condition if a mixing gas other than those with the following mixing ratios is used 1 1 MAG gas ...

Page 19: ...figuration SPECIFICATION PRODUCT SPECIFICATION AND CONFIGURATION CHAPTER 2 2 1 3 External dimensions This section explains the external dimensions of the welding power source 31 9 810 mm 15 6 395 mm 28 0 710 mm 12 6 320 mm 18 1 460 mm 3 9 100 mm ...

Page 20: ...may not only reduce the duty cycle but also result in degradation or burnout of the welding power source The rated duty cycle of the welding power source is the following Operation cycle at duty cycle of 60 350 A 60 for three phase 250 A 60 for single phase Rated duty cycle of 60 means the power source must be rested for 4 minutes after 6 minutes of continuous welding at the rated current Use the ...

Page 21: ...lding power source No Name Required component 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 118 1 3 m 1 Included in feeder 5 Control cable for wire feeder 59 0 1 5 m 1 Included in feeder 6 Power cable for torch side 1 7 Power cable for base metal side 1 8 Shielding gas To be prepared by the customer...

Page 22: ...le for wire feeder 59 0 1 5 m 1 Included in feeder 6 Power cable for torch side 1 7 Power cable for base metal side 1 8 Shielding gas To be prepared by the customer 2 2 3 Accessory not supplied 9 Digital remote control optional 2 2 4 Optional accessories 10 Analog remote control 118 1 3 m optional 1 11 Voltage detection cable 1 1 Optional extension cable and hose 196 9 393 7 590 6 787 4 5 m 10 m 1...

Page 23: ...2 3 Accessory not supplied 2 Welding torch 3 Gas hose 118 1 3 m 1 Included in feeder 4 Power cable for base metal side 1 5 Shielding gas To be prepared by the customer 2 2 3 Accessory not supplied 6 Digital remote control optional 1 7 Analog remote control 118 1 3 m optional 1 1 Optional extension cable and hose 196 9 393 7 590 6 787 4 5 m 10 m 15 m 20 m are also available 2 2 4 Optional accessori...

Page 24: ...ck for the warranty instruction manual this publication and the quantity of parts when opening the package No Name Required component Optional accessories Remarks 1 Welding electrode holder To be prepared by the customer 2 2 3 Accessory not supplied 2 Power cable AWG2 38mm2 or more 1 3 Power cable for base metal side 1 4 Digital remote control optional 1 5 Analog remote control 118 1 3 m optional ...

Page 25: ...s This section explains the optional accessories used with the welding power source 2 2 4 1 Remote control voltage detection cable and other optional items Following items are optionally available including remote control and voltage detection cable Name Remarks CO2 gas Carbon dioxide CO2 100 MAG gas Argon Ar 80 Carbon dioxide CO2 20 MIG gas stainless Argon Ar 98 Oxygen O2 2 MIG gas aluminum alumi...

Page 26: ...le may cause an unstable arc Use extension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 196 9 5 m 393 7 10 m 590 6 15 m 787 4 20 m 1 Gas hose BKGG 0605 BKGG 0610 BKGG 0615 BKGG 0620 2 Control cable for wire feeder BKCPJ 1005 BKCPJ 1010 BKCPJ 1015 BKCPJ 1020 3 Power cable torch side BKPDT 6007 BKPDT 6012 BKPDT 8017 BKPDT 8022 4 Power...

Page 27: ...of the welding power source 2 3 1 Front panel The section explains the front 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 ޓޓ 6 2 Function on Operation Panel Terminal for directly detecting voltage on the base metal side ...

Page 28: ... explains the rear section of the welding power source Blind bush for drawing externally connecting wire Cover for external connections Connector for connecting CAN Print circuit board Terminal block for external connections 㧔 ޓޓ 4 5 2 Connection of automatic machine㧕 Input cable Grounding cable ...

Page 29: ...load welding operation When the welding power source is used in a humid environment such as construction site or location with highly conducting material such as steel plate or on steel structure install a leakage breaker Otherwise electric shock 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 sour...

Page 30: ...ity This section explains the ventilation equipment 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 ventilation ensure to provide ventilation equipment Condition of ventilation equipment Oxygen concentration of 18 or more must be maintained in the weldin...

Page 31: ...of 50 or lower ambient temperature of 104 F 40 C and 90 or lower ambient temperature of 68 F 20 C Location with an altitude of less than 3280 ft 1000 m Location with an incline of 10 or less For the welding power source with wheels use chock to prevent from sliding Location with no metallic foreign body such as spatter entering the welding power source Installation distance of 11 8 30 cm or more b...

Page 32: ...y 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 source during welding other machine near the welding power source may be failed due to electromagnetic noise Follow the instructions below Do not ground the welding power source commonly with other machines Close and fix...

Page 33: ...ce and resulting accidents 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 as wire and shackle suitable for the weight of the welding power source Hoist according to the specified procedure Lift the welding power source alone with two wires using all o...

Page 34: ...ch as carriers secure the welding power source and carrier with a rope before transporting When lifting the welding power source make sure to hold the bottom of the welding power source by more than one person If attempting to lift by holding the front plastic part top cover side plates it may cause back pain deformation or damage to the welding power source When using a tool such as carriers it m...

Page 35: ... 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 sure to cut the input power with the disconnect switch in the box connected with the welding power source Do not turn on the input power before confirming the completion of connection Use a cable wi...

Page 36: ...source 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 Connection of wire feeder Connection of welding torch 4 2 3 Connection of welding torch Connection of shielding gas 4 2 7 Connection of shielding gas Connection of input power connectors 4 3 Groundin...

Page 37: ...tighten 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 complete Procedure is followed by 4 2 2 Connection of wire feeder Use a grounding cable for the case of welding power source and perform grounding Otherwise voltage may increase in the case or base metal wh...

Page 38: ...eder and insert the control 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 When using an analog remote control optional accessory remove the cap of socket for analog remote control and insert the control cable 6 cores Connection for wire feeder is co...

Page 39: ...at of the terminal fully insert the connector 2 When 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 disconnection hold the hose end and press the collar part to the arrow mark direction shown in the figure Connection for welding torch is complete Wire...

Page 40: ...tage detection cable for base metal side to the voltage detection terminal of the wire feeder TIPS Voltage detection cable for base metal side can also be connected to the direct voltage detection terminal for base metal of the welding power source When using the welding power source by lifting with hoisting equipment connect the voltage detection cable for base metal side to the direct voltage de...

Page 41: ...table length Wire the voltage detection cable of the base metal side close to the one at the torch side detection wire to narrow the area surrounded by the two voltage detection cables 4 2 5 Connection at TIG welding 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 connection of the welding torch to...

Page 42: ...for base metal side to the output terminal torch side and base metal Connect the connectors as same as above 4 2 6 Connection at DC STICK welding In using the welding power source for DC STICK welding prepare a welding electrode holder by the customer After five seconds have passed the safety voltage approx 15 V is automatically provided Ground a base metal if required by local law Power cable for...

Page 43: ...nnector and concave part of the output terminal for secure connection and tighten 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 Power cable for base metal side Base metal Power cable for torch side Welding power source Ground a base metal if required by local law Connector Output termi...

Page 44: ...e 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 Securely connect the gas hose and attach the gas regulator with a wrench so that there is no gas leakage For the gas regulator make sure to use a device for compressed gas cylinder that conforms to the s...

Page 45: ...he input side of each welding power source Otherwise electric shock and fire due to overcurrent or damage to the welding power source may occur If the welding power source which is not grounded is used voltage will be generated in the case through the capacitor between the welding power source input circuit and the case or floating capacity electrostatic capacity naturally generated between the in...

Page 46: ...only 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 case of the welding power source Ground terminal is properly grounded when grounding cable of the welding power source is connected to the breaker s ground terminal No tools are left or equipment a...

Page 47: ...cables see 2 2 4 2 Details on extension cables and hoses 7 Cable at torch side BKPT 8012 393 7 10 m 8 Cable at base metal side BKPT 8012 393 7 10 m 9 Gas hose BKGG 0610 393 7 10 m 10 Gas regulator To be prepared by the customer 11 Conduit Z318P50 Guide adaptor attachment part 9 16 18UNF When using the conduit 7 16 20UNF guide adaptor L7810D04 is also required 12 Voltage detection cable torch side ...

Page 48: ...tion cable for torch side Connect the other end of the voltage detection cable for torch side to the tip of the torch Use the voltage detection cable for torch side with a blind bush 4 Remove the voltage detection cable line No 309 connected to the bracket 5 Restore the plates in the right side and left side of the wire feeder Wiring for the wire feeder is complete Perform the work after turning t...

Page 49: ...the terminals stops 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 functions Setting the internal functions Function allows you to externally open and close the gas valve and perform inching operation 6 7 Setting Internal Functions 6 9 IN EXT2 External in...

Page 50: ...rk 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 work is complete Do not use damaged cable or cable without grounding Securely attach the case and cover of the welding power source after connecting the cables Use the following cable for connecting to the termina...

Page 51: ...ass 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 25 64 to 7 16 10 to 11 mm from the end while pressing the button on the terminal block and insert the cable 5 Check the wiring and place the cover for external connection back to the welding power source Strip the cable cover by 2...

Page 52: ...en 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 26 F38 Arc voltage direct detection switching 4 6 1 Wiring to wire feeder This section explains how to connect the voltage detection cable at the base metal side to the wire feeder 1 Check that input power is turned off with the disconnect switch connected to ...

Page 53: ...detection cable 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 the welding power source 2 Connect the voltage detection cable at the base metal side to the voltage direct detection terminal at the base metal side Wiring of voltage detection cable is com...

Page 54: ...h 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 detection cable check that conduction between the jig base and the base metal is stable Power cable for base metal side Voltage detection cable for base metal side Stage 1 Stage 2 Stage 3 The wire feeder ...

Page 55: ...tilation 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 welding operation in a narrow space perform the operation with the trained supervisor Periodically inspect the ventilation equipment to ensure correct and proper performance of ventilation To reduce th...

Page 56: ...from 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 Install protective screens or barriers to protect the eyes of others in the work area from arc ray Wear an ear protector when noise level is high Ignoring the above may cause hearing disorder When the w...

Page 57: ...O2 MAG gas MIG gas 21 to 53 CFH 10 to 25 L min 32 to 53 CFH 15 to 25 L min 11 When the shield gas is mixed each gas pressure should be the same Set pressures of the respective gas to the same level 12 Oil or other dirt should not be adhered on the welding wire Consider a measure to wipe off the dirt 13 In the CO2 and MAG welding the particle diameter of wire tip at the welding completion should no...

Page 58: ...ner 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 cylinder according to the related laws or regulations as well as the internal standard of the customer Note that the gas cylinder contains a high pressure gas Wrong operation may cause gas explosion resulting...

Page 59: ...s 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 cable Bent cable may cause feeding failure of the wire or wire bending 2 Press the INCHING key to feed the wire Keep pressing the INCHING key key until the wire protrudes from the end of the tip in ap...

Page 60: ...hat 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 change of the welding conditions the erroneous operation prevention function is equipped for the operations other than inching gas check or reading saving of the welding condition In using the analog rem...

Page 61: ...he 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 the base metal In DC STICK welding arc start requires setting of the welding electrode in the electrode holder and contact of the electrode with the base metal 2 A series of welding operation is comple...

Page 62: ...Adjust the welding current When the LED 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 parameter adjustment knob for the remote control the welding current adjustment knob to adjust the welding current 3 Adjust the welding voltage When the LED of the V...

Page 63: ...ely 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 available only with the crater set to on and in the welding condition 6 7 Setting Internal Functions When the LED of the VOLT ADJUST key is lit CONSTANT penetration the voltage is automatically set t...

Page 64: ...charged 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 rate to zero 5 Turn OFF the power switch of the welding power supply The power LED switch lights off 6 Shut off the input power Operate the disconnect switch to shut off the input power Input power supply...

Page 65: ...g the welding Crater condition set the current and voltage value at the end of welding Voltage INDIVIDUAL 12 0 to 38 0 V 12 0 to 34 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 welding ends Arc spot time 0 1 to 10 sec 3 sec Set the welding time at arc spot Arc characteristics 99 to 99 0 Set the arc to the condition from soft to har...

Page 66: ... the crater condition F8 Welding result display time 0 to 60 20 s Sets the 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 current detection level 20 to 150 70 Sets the over current warning level for the rated current of the wire feed motor F11 Fine adjus...

Page 67: ... 0 F31 External input 3 setting 0 F32 External input 4 setting 0 F33 Inhibition ratio display for squeeze detection When F33 is selected the Squeeze detection inhibition ratio is displayed on the right digital meter This function is not configurable F34 Automatic correction of squeeze detection sensitivity OFF ON ON Sets ON OFF of the automatic correction function of the Squeeze detection sensitiv...

Page 68: ...me by single clicking of the torch switch available when ON is selected in F48 F50 Current increase and decrease by double clicking 50 to 50 0 A Sets current increase decrease volume by double clicking of the torch switch available when ON is selected in F48 F51 Special crater repeat OFF ON OFF With the setting of Crater sets whether to switch the welding condition and crater condition by the clic...

Page 69: ...dition OFF ON OFF When CRATER ON is selected sets the current value of the initial condition and crater 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 value of the initial condition in the percentage based on the current value of the welding conditi...

Page 70: ... 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 source 6 7 Setting Internal Functions Pressing this key for a second or more lights up the LED and the sequence transits to the Internal Function Setting mode 8 GAS CHECK key Discharges the shield gas 5 3 Power ON and Gas S...

Page 71: ...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 lights up For details of the crater treatment 6 6 3 Crater setting For details of arc spot 6 6 4 Arc spot time 16 SPOT TIME key Sets the welding time when ARC SPOT is selected by the CRATER FILL key 6 6 4...

Page 72: ...ng voltage are adjusted respectively 22 WELD MONITOR key Sets welding control function See Chapter 7 Administrator Functions Pressing this key for a second or more lights up the LED and the sequence transits to the welding control mode 23 LOAD key Reads the registered welding condition from the internal memory 6 5 Memory Function of Welding Conditions 24 SAVE key Registers the set welding conditio...

Page 73: ...SS CORED Welding current adjustment by torch switch 6 7 Setting Internal Functions Using the internal function F48 enables to increase or decrease the welding current set by the torch switch operation Available only with the CRATER FILL ON is selected and with welding condition 6 4 Preparing Welding Conditions This section explains the setting process of basic welding conditions Check welding mate...

Page 74: ...dition by the analog remote control optional 6 7 Setting Internal Functions Use of the internal function F11 enables to finely adjust the current voltage values read out from the memory by the analog remote control optional 6 7 Setting Internal Functions 6 5 1 Memory registration of welding conditions This section explains how to register the current welding condition set on the operation panel to...

Page 75: ...e setting value of the welding current is displayed on the left digital meter At this time the LEDs for the keys of crater or wire material also light up The LED of ENTER key flashes Pressing the DISPLAY CHANGE key enables to check the value of welding parameter registered in the JOB No to overwrite The setting values are displayed on the left right digital meters in a flashing mode To change the ...

Page 76: ...k the welding JOB No to delete When there is no registration data on the selected JOB No is displayed on the left digital meter When there is any registration data on the selected JOB No the setting value of the welding current is displayed on the left digital meter At this time the LEDs for the keys of crater or wire material also light up The LED of ENTER key flashes Pressing the DISPLAY CHANGE ...

Page 77: ...registration at the same 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 welding parameters including the internal functions return to the initial values The display dEL on the left digital meter starts flashing Pressing the DISPLAY CHANGE key ena...

Page 78: ...2 1 6 2 3 HARD ALUMINUM 045 1 16 1 2 1 6 2 3 DC LOW SPATTER 4 CO2 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD MAG 20 CO2 1 1 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD MIG 2 O2 1 2 STAINLESS STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD STAINLESS FERRITE 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD 1 Note that the collective voltage adjustment may not meet the appropriate condition i...

Page 79: ...eter gas discharge time welding current voltage The welding parameters are set according to the welding sequence 0 8 OP 0 9 1 0 1 2 1 6 1 4 F A IPM V r A V r 㧑 OP5 OP1 OP2 OP4 OP3 DC STICK DC TIG WELDING METHOD CO2 OP3 MAG MIG GAS 㧔100 Ar㧕 Hz WARNING sec IPM JOB No DISPLAY CHANGE PRE FLOW POST FLOW MAIN CONDITION INITIAL CONDITION CRATER FILL CONDITION ARC CONTROL INITIAL CONDI TION ON CONSTANT PE...

Page 80: ...er adjustment knob to set the gas discharge time The set parameter is displayed on the left digital meter Process Description PRE FLOW It is the sequence to discharge gas before the welding starts INITIAL CONDITION The welding is carried out in this sequence during when the torch switch is ON MAIN CONDITION It is the welding sequence CRATER FILL CONDITION It is the sequence processing the crater p...

Page 81: ...d on the welding voltage automatically set according to the welding current At INDIVIDUAL mode voltage setting is made in regardless of the welding current Switch the mode by the VOLT ADJUST key 6 6 5 Welding voltage adjustment The mode set by the VOLT ADJUST key is applied all of the conditions INITIAL CONDITION MAIN CONDITION CRATER FILL CONDITION 4 Register to the memory as necessary 6 5 Memory...

Page 82: ... condition before the main welding and the welding process in the Crater condition after the main welding 6 7 2 31 F45 F46 F47 Special crater sequence effective initial standard time setting crater standard time setting 6 6 3 1 Crater OFF 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...

Page 83: ...the welding operation In the second ON operation the welding sequence is carried out by the crater current Even 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 CRATER phrases ON OFF Crater fil㫃 ON OFF Crater fill current ON OFF ON OFF Torch switch Gas flow Output voltage Wire feeding speed Welding current ...

Page 84: ... the second ON operation enables the welding by the crater current Even 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 Welding method in the initial condition is the same with the main welding ON OFF ON OFF Initial condition Initial current ON OFF ON OFF Crater fil㫃 Crater fill ...

Page 85: ... on again within 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 Within 2 sec ON ON OFF OFF OFF Torch switch Gas flow Output voltage Wire feeding speed Welding current Welding current Slow down speed Slow down speed Anti stick time Anti stick time Ant...

Page 86: ...ls 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 voltage can be carried out either by the SYNERGIC mode or INDIVIDUAL mode TIPS Some conditions such as synergic condition does not meet the appropriate level if a mixing gas ratio of shield gas is not the specified ...

Page 87: ...itive value soft arc condition 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 the base material side torch side or using an extended torch cable it is likely that good welding can be performed by adjusting it to hard 6 6 7 Penetration control adjustment...

Page 88: ...ons 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 No as well as in the function setting 1 Depress the F Function key for one second or more 2 Turn the parameter adjustment knob to display the function No to set 3 Press the F Function key again The display on the r...

Page 89: ...mode Set to ON for the length of extension cable longer than 1181 1 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 OFF and cannot be changed When the status is not improved even by setting of this function to ON combined use of the voltage detection cable is recommended Whe...

Page 90: ... the cause of error the power is restored After removing the cause of error the power is restored Or open short circuit the deactivated terminal pins 3 4 of the external connection terminal block TM3 4 1 In the Auto mode voltage to release welding is output for approx 0 2 seconds after the anti stick process This voltage is output even if the wire is not welded 2 If an external command voltage is ...

Page 91: ... If you want to use Automatic machine 3 conditions will change for the following functions F5 Maximum external command voltage Fixed to 10 0V F24 Wire feeding speed setting Fixed to ON E 800 and 801 encoder error of the Error code are invalid GAS CHECK key INCHING key and TRAVEL SPEED key are invalid Welding current A External command voltage V 5 0 10 15 10V 15V 0 5 10 15 20 25 30 35 14V Command v...

Page 92: ...lay time 0 to 60 sec 6 7 2 7 F9 Analog remote control scale Change the setting of the scale plate of analog remote control when using the optional analog remote control Scale plate is available separately for 500 A 350 A and 200 A According to the selected scale of analog remote control replace the scale plate as necessary 6 8 Operation of Analog Remote Control Optional When using the remote contr...

Page 93: ...rent or voltage turn the knob clockwise In the following cases this function cannot be used Welding conditions are not registered to the memory Analog remote control optional is not connected to the welding power source Internal function F44 Reading welding condition with remote control is set to ON enabled Internal function F45 Special crater sequence is set to ON enabled Internal function F48 Ad...

Page 94: ...djustment 6 7 2 12 F16 Slowdown speed adjustment Slow down speed is the speed to slowly feed the wire from the time of the machine start to the time of arc start The slowdown speed is automatically set to an appropriate speed depending on the welding method and wire diameter meanwhile it can be adjusted through this function if manual setting is preferred The setting range is 39 IPM 1 0 m min yet ...

Page 95: ...ource can be stopped Yet for some alarm codes it is possible to continue welding even if the alarm level is detected which may sometimes cause the alarm display to be ignored Using the alarm setting switch function ensures to stop the output from the welding power source ON any alarm detection stops the output of welding power source OFF alarm detection does not stop the output of welding power so...

Page 96: ...time When the welding power source is not operated for a fixed period of time it can be turned into the sleep mode 0 disables the function 1 to 10 enables the function Set the transition time to the sleep mode in the range of 1 to 10 During the sleep mode power consumption is reduced In the sleep mode the dot at the first digit on the left right digital meters flashes All the other displays on the...

Page 97: ...mum command voltage is 866 IPM 22 m min Depending on the welding mode the wire feed speed does not always reach 866 IPM 22 m min The minimum wire feed speed is approximately 24 to 79 IPM 0 6 to 2 0 m min This depends on the welding mode Even when a low command voltage is input it is not possible to set to a value below this OFF disables the function The wire feed speed is automatically set based o...

Page 98: ...memory can be read out by combination of signals 4 6 No function is allocated 7 No function is allocated 8 JOB shift Causing short circuit between terminals shifts to the following JOB No 5 7 9 JOB shift Causing short circuit between terminals shifts to the previous JOB No 6 7 1 When the gas valve is opened by the signal from the external input terminal the gas valve will not close when welding co...

Page 99: ... out the welding condition of the JOB No 7 Setting F30 and F31 to 5 and turning the two signals of the external input terminal IN EXT2 IN EXT3 to ON enable to read out the JOB No 7 For F29 and F32 other functions can be set 5 The JOB No shifts to the following number and read out the condition by causing short circuit between terminals for 300msec during JOB shift mode If the JOB No shifts to the ...

Page 100: ...ratio on the right digital meter Welding operation is available with F33 selected When the welding is unstable the inhabitation ratio may accordingly become unstable When this happens review the welding condition first Even when the welding is stable adjust the detection sensitivity of Squeeze using the internal functions F36 F37 Spatter adjustment when the inhabitation ratio is 70 or less 6 7 2 2...

Page 101: ...ection sensitivity Sets whether to automatically correct the detection sensitivity of Squeeze ON enables to automatically set the detection sensitivity of Squeeze OFF disables to automatically set the detection sensitivity of Squeeze Using the internal function F36 F37 Spatter adjustment the detection sensitivity can be manually set 6 7 2 25 F36 F37 Spatter adjustment P1P P2P TIPS Although the sen...

Page 102: ...n and welding conditions greatly vary by welding section it is recommended to use the machine with this function set to OFF 6 7 2 25 F36 F37 Spatter adjustment P1P P2P Use this function to manually set the detection sensitivity of Squeeze This function is available when the internal function F34 Automatic correction of Squeeze detection sensitivity is set to OFF Follow the step below for setting t...

Page 103: ...stment Gain offset Set the adjustment 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 processing of the average value of outputs therefore it may not be consistent with the value indicated on a needle meter etc When this happens using this function enables ...

Page 104: ...welding voltage setting knob To 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 function In the following cases this function cannot be used Welding conditions are not registered to the memory Analog remote control optional is not connected to the welding...

Page 105: ...PS 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 is the same as that of main welding In the following cases this function cannot be used Internal function F11 Fine adjustment of welding conditions memory is set to 1 to 30 enabled Internal function F44 ...

Page 106: ...r 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 main welding Example In the setting examples of Crater setting ON Initial condition OFF Welding current 100 A Crater current 60 A F48 ON F49 10 and F50 20 the following diagram is available In the foll...

Page 107: ... 50 A 6 7 2 35 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 repeatedly as many time as needed ON Setting of CRATER FILL ON REPEATED is applied and transits to the crater treatment by single clicking of the torch switch during the welding sequence start input...

Page 108: ...g welding condition 6 7 2 36 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 the below table For data log function 7 3 Data Backup Utilization of data Setting Welding current Welding current Welding voltage Welding voltage Wire feed speed Wire feed speed Command value Detected v...

Page 109: ...Used in connection with the automatic machines of other manufacturers 6 7 2 40 F67 Setting change of current value initial condition crater condition When CRATER ON is selected the current value of the initial condition and the crater condition can be set in percentage based on the current value of the welding condition ON enables the function Set the current value of the initial condition with F6...

Page 110: ...he 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 position as the standard INDIVIDUAL adjustment The welding voltage can be individually adjusted without being influenced by the welding current 3 Inching button Feeds the wire 5 4 Wire Inching During when t...

Page 111: ...ible 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 password is set and the erroneous operation prevention function is enabled the erroneous operation prevention function will not be disabled even if the power is turned off and on or if the welding co...

Page 112: ...d 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 already been set Loc will flash To change the password delete the password with the operation from the step 2 of 7 1 2 Disabling erroneous operation prevention and go to the next step 7 1 2 Disabling erroneo...

Page 113: ...d 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 hundreds place flashes on the right digital meter Display the number specified as the password and press the DISPLAY CHANGE key Then the tens place will flash on the right digital meter When the number m...

Page 114: ...oints is achieved Wire consumption P20 0 00 Cumulative wire consumption used in welding lbs kg P21 0 0 to 999 0 to 453 Target wire consumption lbs kg P22 0 0 to 5 Operation at the time when the target wire consumption is achieved Total welding time P30 0 Cumulative total welding time minute P31 0 0 to 999 Target total welding time minute P32 0 0 to 5 Operation at the time when the target total wel...

Page 115: ...alue 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 value of welding points in the range from 0 to 999 When the P10 count value reaches the number of welding points specified here an alarm appears indicating that the target is achieved 7 2 2 5 Alarm ind...

Page 116: ...onsumption in the range from 0 to 999 lbs 0 to 453 kg When the P20 count value reaches the wire consumption specified here an alarm appears indicating that the target is achieved 7 2 2 5 Alarm indication when target is achieved P22 Operation at the time when the target wire consumption is achieved Select the operation from 0 to 5 for the time when the target specified for P21 is achieved The set v...

Page 117: ...oints 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 stops P40 Max fluctuation value of average range monitor If the average current voltage per second becomes out of the allowable tolerance range specified in P41 to P44 an alarm is displayed indicating...

Page 118: ...tion ０ 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 operation panel is pressed Continuous operation is not possible 2 Welding stops immediately Next welding cannot start until any key of the operation panel is pressed Continuous operation is not possible In...

Page 119: ... 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 lighting In case of voltage error the difference between the average voltage and specified voltage is displayed in one decimal place The display returns to the normal state when any key of the operat...

Page 120: ...t 1 A ＡＤ reserve Reserved Ｅ pre_vset Initial voltage 0 1 V ＡＥ reserve Reserved Ｆ pre_uni_vset Initial voltage synergic 1 ＡＦ ant_tim_adj Anti stick time adjustment 0 01 s Ｇ wld_iset Welding current 1 A ＡＧ ant_vset_adj Anti stick voltage adjustment 0 1 V Ｈ wld_vset Welding voltage 0 1 V ＡＨ sldwn_adj Slowdown adjustment 3 9 IPM 0 1 m min Ｉ wld_uni_vset Welding voltage synergic 1 ＡＩ up_slp_tim Up slop...

Page 121: ... 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 setting data Ｖ wld_feed Welding feeding speed 3 9 IPM 0 1 m min ＡＶ CriIsetStep2 Double click adjustment value 1 A Ｗ cre_feed Crater feeding speed 3 9 IPM 0 1 m min ＡＷ reserve Reserved Ｘ reserve Reserved ＡＸ chksum Checks...

Page 122: ...F52 is set to 1 detected values of welding current welding voltage and feeding speed and F53 to 2 100 ms TIPS The length of time that can be used for recording depends on the sampling speed If the sampling speed is set to 100 ms data of approximately five hours can be recorded When the data exceeds the capacity they will be deleted in order from the oldest Also note that data will be recorded duri...

Page 123: ... 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 connector of the operation panel 3 Press the LOAD key 4 Turn the parameter adjusting knob counterclockwise to display USb on the left digital meter 5 Select the data to back up The LED of LOAD key l...

Page 124: ... 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 flashes Data backup starts During backup the display of right digital meter changes When backup is completed End will be displayed on the right digital meter The LED of SAVE key lights up LOAD ENTER 㧔3 s...

Page 125: ... 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 The display changes in order of ALL 1 2 ALL means that all the data 1 to 2 available for importing are selected Details of the numbers displayed 7 3 Data Backup Utilization of data The LED of ENTER key...

Page 126: ...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 manufacturer s management It is not necessary for the user to check it 3 After checking turn off the power switch The power LED switch lights off The status returns to normal when the power switch is turned...

Page 127: ...ven 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 Special attention is necessary because the welding power source contains many parts connected to the input side due to its high frequency inverter method Periodically blow the parts of welding power ...

Page 128: ...printed 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 air Otherwise powder dust may get inside the cooling fan Also the cooling fan may rotate at high speed due to compressed air resulting in wearing of the bearing When using a vacuum cleaner to remove...

Page 129: ...s 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 that there is no abnormal heat generation in cable connections Check that cable connections are not loose Check that there is no problem in the insulation method between the cables and base metal Check...

Page 130: ...onsumable 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 front slit ventilation hole to the back side to remove dust inside the welding power source Dust accumulating on the heat sink of transistor and rectifier may prevent heat radiation adversely affecting the transisto...

Page 131: ...tand 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 steps below Refer to the schematic diagram parts layout and parts list for maintenance Disconnect the input power cable and grounding cable from the disconnect switch and short circuit the input termi...

Page 132: ...tive output side and the AC side and negative output side respectively Short circuit between TR1 C1 E1 TR2 C2 E2 TR4 C2 E2 TR5 C1 E1 TR5 C2 E2 TR6 C1 E1 Apply NF After finishing insulation resistance measurement return the above to the original state After finishing insulation resistance measurement it is necessary to remove the shortcircuit cables and return the welding power source to the origin...

Page 133: ...ode The meanings of 1 and 2 in the table below are as follows 1 When the error occurs the welding power source stops the output 2 Even when the error occurs the welding power source does not stop the output To stop the output set the internal function F19 to ON 6 7 1 Setting procedure Details on the internal function F19 6 7 2 14 F19 Switching alarm setting Check the error code displayed and take ...

Page 134: ...pear 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 side is the range of 208 230 460 V 10 Check the set value of internal function F20 6 7 2 15 F20 Low input voltage detection level The error code will disappear when the power switch is turned off E 210 The arc voltage was not detected 1 Check t...

Page 135: ...ort circuit or other abnormalities in the 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 exceeded the allowable range 1 Check that the wires are not stuck or there are no other abnormalities in the welding torch or wire feeder The error code will disa...

Page 136: ...s is not correct Check that the setting of internal functions F29 to F32 is correct 6 7 2 21 F29 to F32 External input terminal setting The external input cables are disconnected short circuited Check that there is no abnormality in the cables connected to the external input terminal block If any repair replace the cables 6 Shielding gas does not stop flowing Setting handling of the external input...

Page 137: ...ltage 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 feeder came off Set correctly the pressure roll of wire feeder For setting see the instruction manual of the wire feeder There is an abnormality in cables of the wire feeder Check that there is no abno...

Page 138: ...TROUBLESHOOTING TROUBLESHOOTING CHAPTER 9 9 6 ...

Page 139: ... CM100DUS 12F 4 TR5 100 2219 IGBT module 1MBI300HH 120L 50 1 TR6 7 100 1428 IGBT module FZ400R12KP4 2 SCR1 4530 412 Thyristor SG25AA20 1 CT1 4810 030 Current transformer W W03029 1 CT2 100 0956 Hall current detector CS 40GEH 1 CT3 4810 030 Current transformer W W03029 1 T1 P30086B00 Inverter transformer P30086B00 1 T2 W W03830 Transformer W W03830 1 L1 P30086L00 Input reactor P30086L00 1 L2 P30086...

Page 140: ...0 Printed circuit board P30099P00 1 CHASSIS 1 4341 206 Relay G6A 274P DC24V 1 With PCB1 PCB2 P30086R00 Printed circuit board P30086R00 1 100 1421 Encoder EVEGA1F2524B 1 With PCB2 PCB3 P30086Q00 Printed circuit board P30086Q00 1 PCB4 P30087Q00 Printed circuit board P30087Q00 1 PCB5 P30086V00 Printed circuit board P30086V00 1 PCB6 P30087V00 Printed circuit board P30087V00 1 PCB7 P30138M00 Printed ci...

Page 141: ... 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 2 1 Schematic diagram P30139H00 P30087V00 P30086V00 P30138M00 P30088V00 CN3 Not connected CN1 Not connected P30086Q00 CN1 3 Not connected ...

Page 142: ...RENCE MATERIALS CHAPTER 10 10 4 PCB1 Control PCB9 Filter 2 P30099P00 CN1 16 18 26 31 36 39 43 45 47 49 51 52 54 57 59 62 Not connected P30086T00 CN7 Not connected P30086R00 P30086S00 P30087T00 P30087Q00 CN5 7 9 Not connected ...

Page 143: ...Lower 㸸P30086Q00 P30138M00 P30087Q00 P30099P00 P30086S00 P30087V00 CT1 P30086V00 P30087T00 P30086T00 SH TM6 PL1 FM1 FM2 FM3 TM5 NF 6 CON1 7 CON2 7 FM4 DCV2 5 2 L1 1 4 3 8 9 Top Back When the cover is opened Front Right side When the fan frame is removed Left side TR1 to 4 R18 㸦Back of P30138M00㸧 C8 R19a b T2 10 10 10 P30139H00 R12 DR2 to 5 CT2 CT3 L2 L7 C11 C12 T1 P30088V00 10 R28 F1 R11 TR6 7 DR1...

Page 144: ...omes poor The wire 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 small The welding voltage is too low The wire contacts the base metal and spatter is generated The bead width becomes narrow The welding current is too high The bead width becomes wide Pe...

Page 145: ... rate CFH L min 18 ga 1 2 3 32 to 1 8 2 5 to 3 0 035 040 0 9 1 0 70 to 100 18 to 19 20 to 24 50 to 60 21 to 32 10 to 15 16 ga 1 6 3 32 to 1 8 2 5 to 3 0 035 to 045 0 9 to 1 2 90 to 120 18 to 20 20 to 24 50 to 60 21 to 32 10 to 15 14 ga 2 0 1 8 to 9 64 3 0 to 3 5 035 to 045 0 9 to 1 2 100 to 130 19 to 20 20 to 24 50 to 60 32 to 42 15 to 20 12 ga 2 3 1 8 to 9 64 3 0 to 3 5 035 to 045 0 9 to 1 2 120 ...

Page 146: ...0 21 to 23 16 to 20 40 to 50 21 to 32 10 to 15 1 15 64 6 0 3 64 to 1 16 1 2 to 1 5 045 1 2 220 to 260 24 to 26 16 to 20 40 to 50 32 to 42 15 to 20 Front 1 2 Back 1 23 64 9 0 3 64 to 1 16 1 2 to 1 5 045 1 2 320 to 340 32 to 34 18 to 22 45 to 55 32 to 42 15 to 20 Front 1 2 Back 1 Plate thickness t in mm Bevel shape Root opening g in mm Root face h in mm Wire diameter in mm Φ Current A Voltage V Trav...

Page 147: ...0 to 420 36 to 39 16 to 18 40 to 45 42 to 53 20 to 25 1 Front Back 4 420 to 450 39 to 42 12 to 14 30 to 35 42 to 53 20 to 25 2 Plate thickness t in mm Wire diameter in mm Φ Current A Voltage V Travel speed IPM cm min Aim position CO2 gas flow rate CFH L min 18 ga 1 2 030 to 040 0 8 to 1 0 80 to 100 18 to 19 18 to 22 45 to 55 Ａ 21 to 32 10 to 15 16 ga 1 6 030 to 045 0 8 to 1 2 100 to 120 18 to 20 1...

Page 148: ...1 2 280 30 16 40 052 1 4 350 32 20 50 1 16 1 6 380 34 26 65 5 16 8 045 1 2 300 31 12 30 052 1 4 350 33 18 45 1 16 1 6 380 34 20 52 23 64 9 045 1 2 320 32 12 30 052 1 4 350 34 16 40 1 16 1 6 380 34 16 40 Joint shape Plate thickness t in mm Wire diameter in mm Φ Gap in mm Current A Voltage V Travel speed IPM cm min Butt joint 19 5 ga 1 0 030 to 040 0 8 to 1 0 0 50 to 55 13 to 15 16 to 22 40 to 55 18...

Page 149: ... to 140 20 to 22 24 to 31 60 to 80 0 6 15 42 20 5 32 4 0 045 1 2 150 to 170 22 to 24 24 to 31 60 to 80 0 6 to 0 7 15 to 18 42 20 15 64 6 0 1 16 1 6 180 to 210 23 to 25 16 to 24 40 to 60 0 7 to 0 8 17 to 20 42 to 53 20 to 25 Plate thickness t in mm Wire diameter in mm Φ Current A Voltage V Travel speed IPM cm min Wire feeding length in mm Gas flow rate CFH L min 1 8 3 0 045 1 2 140 to 160 21 to 22 ...

Page 150: ...MATERIALS FOR SETTING WELDING CONDITIONS REFERENCE MATERIALS CHAPTER 10 10 12 ...

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