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10-1

Chapter 10

Reference Materials

Chapter 10 Reference Materials

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

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

4614-101

Circuit protector

IELK111-34459-1-V

1

PL1

100-0171

Pilot lamp

N46010A7KW-01 ROHS

1

DR1

100-1938

Diode module

PGH150N16

1

DR2 to 5,

8 to 11

4531-119

Diode module

DSEI 2X101-06A

8

DR12,13

4531-119

Diode module

DSEI 2X101-06A

2

DR14

100-0188

Diode module

DIN60

1

TR1 to 4

100-1750

IGBT module

CM300DU-12NFH

4

TR5 to 7

100-2033

IGBT module

FZ600R12KP4

3

CT1

4810-030

Current transformer

W-W03029A ROHS

1

CT2

100-0956

Hall current detector

CS-40GEH

1

T1,T2

P30125B00

Inverter transformer

P30125B00

2

T3

W-W03674

Auxiliary transformer

W-W03674

1

L1

P30125L00

Input reactor

P30125L00

1

L2

P30137C00

DC reactor

P30137C00

1

L3 100-1950

Ferrite

core

HM2AT4815

1

L4 to 7

4739-543

Ferrite core

E04RA310190100

4

L8,9

100-0618

Ferrite core

HM2AT4815

2

L10

100-0620

Ferrite core

SN-20 OR23.5×9.5×12.6

2

L11

4739-543

Ferrite core

E04RA310190100

2

L12

4739-543

Ferrite core

E04RA310190100

2

L13

4739-543

Ferrite core

E04RA310190100

1

L14

100-1950

Ferrite core

HM2AT4815

1

L15

4739-543

Ferrite core

E04RA310190100

2

L16

100-1950

Ferrite core

HM2AT4815

2

L17

100-1950

Ferrite core

HM2AT4815

1

L18

4739-543

Ferrite core

E04RA310190100

2

LF1

4519-026

EMI FILLTER

NF3050C-RQ2

1

THP1

4614-051

Thermostat

67L090

1

THP2

4258-046

Thermostat

US-602SXTTAS 120

℃

1

L2

FM1 to 3

100-1429

FAN

9WV1224P1H003

3

FM1

、

FM2

、

FM3

FM4

100-1825

FAN

9G1224E1D07

1

Internal fan

SH

4403-132

Meter shunt

SH 600A/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

TR1 to 4

R11 to 14

100-1430

Metal film resistor

RPM200Z

5

Ω

4

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Summary of Contents for OTC Welbee P500L

Page 1: ...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 1P30137 1 Model WB P500L Welbee Inverter P500L OWNER S MANUAL Pulse MAG MIG Welding powe...

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: ...ifting lug 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...

Page 7: ...Control Function 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...

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: ...ted frequency 50 60 Hz Rated input voltage 400 V Input voltage range 400 V 15 Rated input 25 kVA 22 9 kW Rated input current 36A Rated output current DC 500 A Pulse 400 A Rated load voltage DC 39 V Pu...

Page 18: ...5 Al PURE 1 2 1 6 STANDARD 3 Al Mg 1 0 1 2 1 6 STANDARD 3 Brazing CuSi 0 8 1 0 1 2 STANDARD 3 Brazing CuAl 0 8 1 0 1 2 STANDARD 3 DC LOW SPATTER 4 CO2 MILD STEEL 0 8 1 0 1 2 STANDARD MAG 20 CO2 1 1 M...

Page 19: ...an those with the following mixing ratios is used 1 1 MAG gas Argon Ar 80 Carbon dioxide CO2 20 1 2 MAG gas Argon Ar 90 Carbon dioxide CO2 10 1 3 MIG gas stainless steel Argon Ar 98 Oxygen O2 2 1 4 MI...

Page 20: ...it 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 c...

Page 21: ...ce No Name Suppliedunit 1 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 wi...

Page 22: ...torch side 2 m 2 7 Power cable for base metal side 2 m 2 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 An...

Page 23: ...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 24: ...by the customer before operating the welding power source Prepare the following No Name Suppliedunit 1 Optional accessories Remarks 1 Welding electrode holder To be prepared by the customer 2 2 3 Acce...

Page 25: ...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 Argon Ar 90 Carbon dioxide CO2 10 MIG gas Argon Ar...

Page 26: ...tension 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...

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 Outp...

Page 28: ...on 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 bloc...

Page 29: ...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 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 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...

Page 36: ...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 37: ...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 38: ...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 39: ...re connection and tighten the knurled screws in the clockwise direction 2 When using the water cooled welding torch connect the water feeding hose and condensing hose of the welding torch to the wire...

Page 40: ...eeder 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...

Page 41: ...r reducing the influence of inductance noise Wire the voltage detection cable for the base metal away from the cable of base metal For easier handling cut the voltage detection cable for base metal si...

Page 42: ...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 43: ...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 44: ...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 Secu...

Page 45: ...ck 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...

Page 46: ...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 47: ...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 hose BKGG 0610 10 m 10 Gas regulator To be prepared by the cust...

Page 48: ...tage detection cable for torch side K5416P00 optional accessory Connect the other end of the voltage detection cable for torch side K5416P00 to the tip of the torch Use the voltage detection cable for...

Page 49: ...nput Disconnecting 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...

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 compl...

Page 51: ...a knife and 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...

Page 52: ...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 w...

Page 53: ...etection 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 conn...

Page 54: ...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 detec...

Page 55: ...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 56: ...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 57: ...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 58: ...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 cylin...

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...

Page 60: ...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 61: ...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 62: ...just 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 ope...

Page 63: ...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 64: ...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 65: ...he end of welding Voltage INDIVIDUAL 10 0 to 50 0 V 23 5 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...

Page 66: ...0 s Sets the display time for the current voltage after completion of welding F9 Analog remote control scale 200 350 500 500 A Configures the settings of scale plate of the analog remote control F10 M...

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...

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 clickin...

Page 69: ...s the adjustment value of pulse peak time at the LOW side in pulse welding F65 L base current fine adjustment 60 to 60 0 A Sets the adjustment value of base current at the LOW side in pulse welding F6...

Page 70: ...uence 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...

Page 71: ...he 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 cra...

Page 72: ...lding 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 mode...

Page 73: ...onditions The welding power source is equipped with the function to register the welding conditions and reads them out for use The number of welding conditions that are able to be registered are 100 a...

Page 74: ...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 75: ...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 76: ...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 77: ...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 del...

Page 78: ...2 1 2 MILD STEEL 0 8 1 0 1 2 STANDARD MIG 2 O2 1 3 STAINLESS STEEL 0 8 1 0 1 2 STANDARD STAINLESS FERRITE 0 8 1 0 1 2 STANDARD MIG 2 5 CO2 1 4 STAINLESS STEEL 0 8 1 0 1 2 STANDARD STAINLESS FERRITE 0...

Page 79: ...um material Wire diameter mm Welding method Range of stable welding power source A HARD ALUMINUM A5183 A5336 etc 1 0 DC 60 to 150 DC pulse DC wave pulse 50 to 150 1 2 DC 75 to 250 DC pulse DC wave pul...

Page 80: ...er gas discharge time welding current voltage The welding parameters are set according to the welding sequence 6 6 2 1 Welding sequence The basic welding sequence is the process of PRE FLOW MAIN CONDI...

Page 81: ...ed speed In this case refer to 6 7 2 19 F24 Wire feeding speed setting Turn the parameter adjustment knob to set the welding current The set parameter is displayed on the left digital meter TIPS In th...

Page 82: ...h pulse Arc Spot The pattern of the following combinations and can not be selected Mode Initial condition Description CRATER FILL OFF In the welding process only available process is the main welding...

Page 83: ...me 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 10 no pulse DC P...

Page 84: ...rch switch should remain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON no pulse Regardless of the setting by the WELDING METHOD key the machine automatically t...

Page 85: ...itch should remain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON no pulse Regardless of the setting by the WELDING METHOD key the machine automatically turns t...

Page 86: ...s 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 c...

Page 87: ...dition 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...

Page 88: ...feeding speed becomes stable and only the unit pulse condition changes Image of welding bead form in the wave frequency TIPS This function is available when DC WAVE PULSE is selected by the WELDING M...

Page 89: ...complete Press the DISPLAY CHANGE key and select either INITIAL CONDITION MAIN CONDITION or CRATER FILL CONDITION The LED for the selected welding sequence lights up The LED for the WAVE FRQ key light...

Page 90: ...ns 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 i...

Page 91: ...able mode Set to ON for the length of extension 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...

Page 92: ...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 T...

Page 93: ...pe time 0 0 to 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 wir...

Page 94: ...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 welding conditi...

Page 95: ...Sets the operation time of water cooled pump after welding ends When the water cooled welding torch is used the water cooled pump operates to cool the welding torch as the welding ends The operation...

Page 96: ...wire tip can be arranged to obtain a stable start of the next welding The time and voltage for anti stick process are automatically set to appropriate conditions depending on the welding method wire...

Page 97: ...tes in a control mode power saving operation due to the temperature detection inside the welding power source This mode is effective in saving power consumption and preventing suction of extra powder...

Page 98: ...the maximum command voltage is 22 m min Depending on the welding mode the wire feed speed does not always reach 22 m min The minimum wire feed speed is approximately 0 6 to 2 0 m min This depends on t...

Page 99: ...rt circuit between terminals allows DC welding mode Open circuit between terminals allows DC pulse welding mode Selecting optional DC Wave Pulse beforehand allows DC wave pulse welding mode 6 7 7 WAVE...

Page 100: ...l of external input terminal to which this function is allocated to has any change again 6 Even after reading out the welding method by this function welding method can be changed either via the front...

Page 101: ...isplays the inhabitation 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...

Page 102: ...ity 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 sens...

Page 103: ...wire extension 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 t...

Page 104: ...t 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...

Page 105: ...he center of 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...

Page 106: ...e 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 a...

Page 107: ...le clicking or 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...

Page 108: ...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...

Page 109: ...rt or 5 Loading 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...

Page 110: ...er in the pulse condition of the wave pulse welding at HIGH side fine adjustment is available to the standard pulse peak current at HIGH side by setting the adjustment value Example of current wavefor...

Page 111: ...lue Example of current waveform of wave pulse welding 6 7 2 45 F65 Fine adjustment of L base current Set the adjustment value in the range of 1 5 to 1 5 ms Fine adjustment of unit pulse condition 6 7...

Page 112: ...e of current waveform of wave pulse welding 6 7 2 46 F66 Adjustment of feed amplitude ratio This function sets the feed amplitude ratio of wire amplitude change of wire feed speed in the wave pulse we...

Page 113: ...ndition and the crater condition becomes settable in percentage based on the current value of crater condition OFF disables the function 6 7 2 48 F68 Setting of current value initial condition The cur...

Page 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...pre_iset Initial current 1 A wld_feed Welding feed speed 0 1 m min pre_vset Initial voltage 0 1 V cre_feed Crater feed speed 0 1 m min pre_uni_vset Initial voltage synergic 1 ant_tim_adj Anti stick t...

Page 125: ...ata pls_pki_adj Pulse peak current fine adjustment 1 A CreIsetPer reserved pls_pkt_adj Pulse peak time fine adjustment 0 1 ms TsCrickIset Torch switch current adjustment 0 1 OFF ON pls_bsi_adj Base cu...

Page 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...nsumable 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 venti...

Page 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 140: ...rrect 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...

Page 141: ...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 142: ...TROUBLESHOOTING TROUBLESHOOTING CHAPTER 9 9 6...

Page 143: ...DR14 100 0188 Diode module DIN60 1 TR1 to 4 100 1750 IGBT module CM300DU 12NFH 4 TR5 to 7 100 2033 IGBT module FZ600R12KP4 3 CT1 4810 030 Current transformer W W03029A ROHS 1 CT2 100 0956 Hall current...

Page 144: ...Output DC48V PCB1 P30099P00 Printed circuit board P30099P00 1 CHASSIS 1 PCB2 P30086R00 Printed circuit board P30086R00 1 FRONT PANEL PCB3 P30086Q00 Printed circuit board P30086Q00 1 CHASSIS PCB4 P300...

Page 145: ...Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 2 Reference Drawing This section contains the schematic diagram and the parts layout drawing of the welding power so...

Page 146: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 4 10 2 1 Schematic diagram P30086Q00 P30086V00 PCB6 Driver P30086V00 P30115M00...

Page 147: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 P30099P00 CN1 2 13 16 18 26 33 34 36 39 43 45 48 49 51 52 54 56 60 62 Not connected P30088V00 CN2 to 4 8 Not connected P30086T00 CN7 Not connected P300...

Page 148: ...Lower P30086Q00 P30115M00 P30087Q00 P30099P00 PS1 P30086S00 P30086V00 DR1 P30086V00 P30088V00 P30087T00 P30086T00 SH DR12 13 CT2 CT1 PL1 FM1 FM2 FM3 TM5 NF 6 CON1 7 CON2 7 R19a b L10 FM4 TR6 TR5 TR7...

Page 149: ...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...

Page 150: ...5 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 10 0 to 12 0 1 2...

Page 151: ...0 to 25 Back 16 0 4 to 6 1 2 300 to 350 32 to 35 30 to 35 20 to 25 Front 2 300 to 350 32 to 35 30 to 35 20 to 25 Back 1 6 380 to 420 36 to 39 35 to 40 20 to 25 Front 380 to 420 36 to 39 35 to 40 20 to...

Page 152: ...0 29 50 1 4 330 30 90 1 6 370 33 90 6 1 2 270 29 45 1 4 330 31 80 1 6 380 34 80 7 1 2 280 30 40 1 4 350 32 50 1 6 380 34 65 8 1 2 300 31 30 1 4 350 33 45 1 6 380 34 52 9 1 2 320 32 30 1 4 350 34 40 1...

Page 153: ...150 26 to 27 60 4 5 5 1 170 26 to 27 40 6 0 6 1 200 27 to 28 40 8 0 8 1 250 29 to 30 35 12 0 10 1 180 to 200 25 to 27 45 2 180 to 200 25 to 28 45 3 180 to 200 25 to 28 45 16 0 12 1 220 to 230 25 to 2...

Page 154: ...min 6 0 1 170 25 to 26 30 2 180 26 to 27 30 9 0 1 270 29 to 30 30 2 290 30 to 31 30 12 0 1 280 30 to 31 40 2 330 33 to 34 40 19 0 1 300 31 to 32 45 2 300 31 to 32 45 1 340 32 to 33 45 2 280 30 to 31 4...

Page 155: ...mm Number of oscillation 120 times min Bevel shape Number of layers Current A Voltage V Remarks 1 100 20 to 21 Slight oscillation 2 280 26 to 27 Slight oscillation 3 280 26 to 27 Slight oscillation 4...

Page 156: ...V Travel speed cm min Wire feeding length mm Gas flow rate L min 1 5 1 2 60 to 80 16 to 18 60 to 80 12 to 15 20 2 0 1 2 70 to 80 17 to 18 40 to 50 15 20 3 0 1 2 80 to 100 17 to 20 40 to 50 15 20 4 0 1...

Page 157: ...urrent A Voltage V Travel speed cm min Wire feeding length mm Gas flow rate L min 3 0 1 2 120 to 140 20 to 22 60 to 80 15 20 4 0 1 2 150 to 170 22 to 24 60 to 80 15 to 18 20 6 0 1 6 180 to 210 23 to 2...

Page 158: ...MATERIALS FOR SETTING WELDING CONDITIONS REFERENCE MATERIALS CHAPTER 10 10 16...

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