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Daihen Welbee WB-A350P, Owner'S Manual

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S

AFETY

 P

RECAUTION

S

AFETY

 I

NFORMATION

C

HAPTER

1

1-2

1.2.2

Precautions for power supply and electric shock

To prevent electric shock or burn injury, ensure to follow the instructions below:

 • For those with pacemaker, avoid being close to the machine during operation or work 

area until obtaining physician's approval. Machine at operation will generate magnetic 
field nearby that may cause influence upon the working of pacemaker.

 • Do not use the welding power source for purpose other than welding such as thawing a 

frozen pipe.

 • Do not use the welding power source when the case and the cover are removed.

 • Removing the cases for maintenance, inspection and repair should be performed by 

qualified persons or persons familiar with the welding machine. Also put up a barrier 
around the welding machine or take other necessary measure to prevent other people 
from getting in the nearby area.

 • Do not touch the input and output terminals and the internal live electrical 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.

 • Before starting maintenance and inspection, make sure to cut the input power with the 

disconnect switch in the box connected with the welding power 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 before use.

 • Turn off POWER switch of all the related equipment when not in use.

 • Periodically blow the parts of welding power source with dry compressed air to remove 

dust.
Powder dust accumulating inside may cause insulation deterioration, resulting in 
electric shock or fire.

 • Do not use a cable with insufficient capacity, serious damage or cable without 

grounding.

 • When the power switch is tripped, never turn it on again and contact your dealer.

Summary of Contents for Welbee WB-A350P

Page 1: ...to read this instruction manual thoroughly for safe and proper use of the product October 2018 Manual No P30249 2 Model WB A350P Welbee Inverter A350P OWNER S MANUAL TIG Welding power source DAIHEN Corporation ...

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: ...esurethatinstallation operation maintenanceoftheweldingpowersourceandweldingmachineis 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 Wh...

Page 5: ... manufacture year serial number and software version number Referto thediagram below forproductinformation Attachment location andcontentof nameplatemay vary depending on the purchased product Example Attachment location of the nameplate No Serial No 1 Serial number 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...

Page 6: ...PTER 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 base metal side 4 3 4 2 2 Connection of TIG welding torch 4 4 4 2 3 Connection of DC STICK welding torch 4 7 4 2 4 Connection of shield gas 4 8 4 2 5 Connection of water hose with cooling water circulation device 4 9 4 3 Grounding and Connection of Inpu...

Page 7: ... 7 1 7 1 1 Setting Changing password 7 1 7 1 2 Disabling erroneous operation prevention 7 3 7 2 Welding Result 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 functions 7 9 7 3 2 Simplified data log function 7 11 7 3 3 Failure log function 7 12 7 3 ...

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

Page 9: ...ssible personal injury or loss of life if the product is used improperly Refers to minor personal injury or possible equipment damage if the product is used improperly Symbols Explanation Instruction indicates Instruction matters to be followed Prohibited indicates Prohibited matters Be sure to read and understand the information in the manual before operating the product Have only trained and exp...

Page 10: ... 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 Before starting maintenance and inspection make sure to cut the input power with the disconnect switch in the box connected with the welding power source and wait three minutes or more The capacitors may be still cha...

Page 11: ...uipment 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 ...

Page 12: ...nd 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 inside may ca...

Page 13: ...ep your face away 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...

Page 14: ... 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 protective leather glo...

Page 15: ...as close to the floor or the ground as possible The cable for base metal side and the cable for electrode side should be aligned with each other Do not share the earth connections of the base metal and the welding power source with those of other machines Close all the doors and covers of the welding power source and securely fix them not to come loose for use If electromagnetic interference has o...

Page 16: ...can Welding Society RecommendedSafePracticesforthePreparationforWeldingandCuttingofContainersThatHaveHeld HazardousSubstances AmericanWeldingSocietyStandardAWSF4 1 fromAmericanWeldingSociety 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 Safety in Welding an...

Page 17: ...voltage range 460 V 10 Rated input 12 9 kVA 11 9 kW 12 5 kVA 11 0 kW 16 5 kVA 15 1 kW 16 0 kVA 14 5 kW Rated input current 16 2 A 16 3 A 21 2 A 21 4 A Rated output current 350 A 350 A 350 A 350 A Rated output voltage 24 V 24 V 34 V 34 V Rated output current range 5 to 350 A 2 to 350 A 10 to 350 A Maximum no load voltage 85 V Rated duty cycle 40 30 Number of welding condition 100 Operating temperat...

Page 18: ...sed air to clean dust and dirt accumulated on the transistor and radiation fin of the diode If dust and dirt accumulate on the radiation fin it may not only reduce the duty cycle but also result in degradation or burnout of the welding power source The rated duty cycle of the welding power source is as follows At TIG welding 350 A 24 V 40 At STICK welding 250 A 30 V 40 Rated duty cycle of 40 means...

Page 19: ...o the instruction manual of the robot controller Use the welding power source within its usable range by observing the duty cycle for the welding current Use the welding power source within the lowest rated duty cycle of combined accessories such as welding torches Relationship between welding current and duty cycle AC TIG welding DC TIG welding AC STICK welding DC STICK welding 100 40 50 0 100 20...

Page 20: ...118 1 3 m 3 5 Water hose water feed condensed water set 4 6 Power cable for base metal side 3 7 Shield gas To be prepared by the customer 2 2 3 Accessory not supplied 8 Cooling water circulation device 4 9 Digital remote control optional 2 2 4 Optional accessories 10 Analog remote control 118 1 3 m optional 3 1 Standard component with welding power source Supplied when placing order for the weldin...

Page 21: ...able and a welding electrode 2 2 4 Optional accessories This section explains the optional accessories used with the welding power source 2 2 4 1 Remote controls Following items are optionally available including remote controls Product name Part No Model Remarks Analog remote control K5023L00 Includes 118 1 3 m cable Digital remote control E 2452 CAN communication cable and BKCAN conversion conne...

Page 22: ...le 50 50 100 Applied electrode diameter 0 5 mmƕ to 2 4 mmƕ 3 32 ƕ 0 5 mmƕ to 4 0 mmƕ 5 32 ƕ 0 5 mmƕ to 4 0 mmƕ 5 32 ƕ Cable length 13 1 ft or 26 2 ft 4 m or 8 m 13 1 ft or 26 2 ft 4 m or 8 m 13 1 ft or 26 2 ft 4 m or 8 m Torch type Torch adapter type Adapter to be connected AW 4 5 9 BBAWD 1701 P1600N02 AW 17 BBAWD 1701 Unnecessary AW 26 BBAWD 2601 Unnecessary AW 18 BBAWD 1801 Unnecessary When usin...

Page 23: ...m Torch switch control cable 2 core K527K00 1 36 1 ft 11 m Connection cover H558M01 1 BAWE 2016 Part for extending the cable length 13 1 ft 4 m of AWD 26 or AW 26 torch to 787 4 20 m Extension torch cable H959B00 1 52 5 ft 16 m Torch switch control cable 2 core K527L00 1 52 5 ft 16 m Connection cover H558M01 1 BAWE 3004 Part for extending the cable length 13 1 ft 4 m of AW 18 torch to 26 2 ft 8 m ...

Page 24: ... For air cooled torch 2 2 4 4 TIG filler Control unit Wire guide CM 7471 wire feeder CM 7472 wire feeder A CAN communication module and CAN communication cables are necessary separately Type HC 71D Input voltage number of phases 200 220 V 10 single phase Rated frequency 50 60 Hz common Type Applicable welding torch BHCD 7117 AW D 17 BHCD 7118 AW D 18 BHCD 7126 AW D 26 K1588 AWP 9 AWP 17 Extension ...

Page 25: ...0 5 32 4 0 5 91 150 mm 500 360 0870 048 3 16 4 8 5 91 150 mm 670 450 0870 064 1 4 6 4 5 91 150 mm 950 550 0870 316 1 16 1 6 2 95 75 mm 150 130 0870 324 3 32 2 4 2 95 75 mm 250 220 0870 332 1 8 3 2 2 95 75 mm 400 290 Part No Electrode dimension in mm Maximum allowable current A Diameter Length DC positive polarity AC 0850 005 0 5 5 91 150 mm 20 50 0850 010 0 040 1 0 5 91 150 mm 80 80 0850 016 1 16 ...

Page 26: ... Dedicated connector base metal side Use thisconnectorto connectthecable basemetalside andthecable STICK weldingholderside with the welding power source Type Part No Applicable cable diameter Rated current DIXSKK50 70 4734 025 50 to 70 mm2 400 A DIXSKK70 95 4734 026 70 to 95 mm2 500 A ...

Page 27: ...switch Socket for analog remote control Output terminal Torch side Gas supply inlet Connect the torch Output terminal Base metal side Main power lamp Water feed connection Connect the torch Operation panel ࠉࠉ6 2 Function on Operation Panel Power switch Cover for external connections Connector for connecting CAN Print circuit board Terminal block for external connections 4 6 1 Connection with exter...

Page 28: ...PART NAMES PRODUCT SPECIFICATION AND CONFIGURATION CHAPTER 2 2 12 ...

Page 29: ... 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 source Otherwise electric shock and fire due to overcurrent or d...

Page 30: ...become unstable with a likely result of arc loss Use the auxiliary power of engine welder with an improved voltage waveform Someengineweldershavepoorelectricitythatmaycauseproductdamageontheweldingpowersource 3 1 2 Ventilation equipment partial exhaust facility This section explains the ventilation equipment and partial exhaust facility in welding work area 3 1 2 1 Ventilation equipment When weldi...

Page 31: ...ith the eyebolt on upside to prevent from falling Location with an ambient temperature of 14 to 104 F 10 to 40 C No condensation at location with an ambient humidity 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 Location with no metallic foreign body such...

Page 32: ... terminals and the internal live electrical parts of the welding power source It may cause electric shock Before starting the work make sure to cut the input power with the disconnect switch in the box 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 If work is performed while the input power is on electric...

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: ...lding power source after securing the eyebolts of the welding power source and the carrier with a rope 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 c...

Page 35: ...l 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 to the welding power source Do not turn on the input power before confirming the completion of connection Use a cable wit...

Page 36: ... 2 4 Connection of shield gas Grounding work 4 3 Grounding and Connection of Input Power Supply Connection of water hose and cooling water irculation device When using water cooled welding torch 4 2 5 Connection of water hose with cooling water circulation device Connection of input power connectors 4 3 Grounding and Connection of Input Power Supply Confirmation of connection 4 4 Confirmation of C...

Page 37: ... 3 Fit the sleeve to the connector terminal and secure with the screws Tighten the screws by 15 N m with the hexagon wrench 4 Connect the base metal side cable to the output terminal base metal side and the base metal For theconnection on the welding power source side fit the convex portion of the connector with the concave portion of theoutput terminal and firmly insert the connector and then tig...

Page 38: ...ion and tighten the knurled screws in the clockwise direction When using an analog remote control optional accessory remove the cap of socket for the analog remote control and insert the control cable 4 core 5 Drain the condensate hose Whenusingtapwater drainthecondensatehose Thisoperationisnotrequiredforair cooledtorch When using thecooling water circulation device connect the condensate hose wit...

Page 39: ...e following points Bundle both the base metal cable and the torch cable and apply tape on them Straighten the cables as much as possible If you cannot straighten the cables as explained run the torch cable on the base material When using the welding power source with surplus cables wound wind them referring to the following good example Bad example Good example Do not wind all surplus cables in th...

Page 40: ...d them in the same manner times of winding and diameter 2 Pile the bundle A on the bundle B Pile them so that their winding directions are opposite 3 Connect the bundles A and B with a wire or the like so that they do not get loose Top view Side view Top view Side view Top view Side view A B A B A B A B ...

Page 41: ...od plus Welding rod Base metal connection the cable STICK welding holder side is connected to the output terminal base metal side and the cable base metal side is connected to the output terminal torch side When used in the DC welding rod minus condition the output terminals to be connected should be interchanged 1 Install a dedicated connector at the end of the cable DC STICK welding holder side ...

Page 42: ...se with cooling water circulation device Be sure to observe the following points to prevent from suffocation due to gas leakage or explosion Be sure to turn off the shield 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 compres...

Page 43: ...er source 4 3 Grounding and Connection of Input Power Supply 2 Connect the water feed hose to the welding power source and the cooling water circulation system 3 Connect the condensate hose with the cooling water circulation system Connections of the cooling water circulation device and the water hose is complete Procedure is followed by 4 3 Grounding and Connection of Input Power Supply Before co...

Page 44: ...n 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 source Otherwise electric shock and fire due to overcurrent or damage to the welding power source may occur If the welding p...

Page 45: ...rtowhichinputcableoftheweldingpowersource is connected Connect only the cable of the welding power source to the breaker Capacity of the disconnect 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 c...

Page 46: ... it with a hexagonal bolt M8 x 20 a washer a spring washer and a hexagonal nut 2 Install the voltage reducing device to the right side plate of the welding power source Mate the bracket to the eye bolt or hexagonal bolt of the top plate of the welding power source and tighten the bolt Installationofthevoltagereducingdeviceisnowcomplete Next proceedto 4 5 2Connectionofoutput cable Side plate of wel...

Page 47: ... an insulation tape or the like 3 Connect the output cable 5 to the output terminal of the welding power source and securely tighten it 4 Insulate the connection between the output cable 5 and the output terminal securely with an insulation tape or the like 5 Connect the output cable 3 to the terminal of the cable welding rod holder side and securely tighten it 6 Insulate the connection between th...

Page 48: ...e method for connecting the welding power source with robots and automatic machines 4 6 1 Connection with external equipment Thissectionexplainstheprocedureforconnectionofautomaticmachinewiththeweldingpowersource When voltage reducing device and the welding power source are used in a humid environment such as construction site or location with highly conducting material such as steel plate or on s...

Page 49: ...ns the welding power source can output the signal to the external equipment 6 10 Setting Internal Functions 6 9 IN EXT2 External input 2 7 9 IN EXT3 External input 3 8 9 IN EXT4 External input 4 TM4 1 2 24 V 0 2 A 24 V power source Outputs power supply of 24 V Current capacity 0 2 A Maximum 3 4 OUT EXT1 External output 1 Reserve outputs for expanding terminal functions By setting the internal func...

Page 50: ...ard To prevent electric shock ensure to follow the instructions below Wiring should be performed by qualified persons or persons familiar with the welding machine Do not touch the input and output terminals and the internal live electrical parts of the welding power source Before starting the work make sure to cut the input power with the disconnect switch connected to the welding power source and...

Page 51: ...ssing 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 The control cable drawn out from the terminal for external connection should be kept away from the welding power cable or the torch cable as much as possible Otherwise failure may occur due to noise during use Do not pull out the cables other t...

Page 52: ...CONNECTION OF EXTERNAL EQUIPMENT CONNECTION CHAPTER 4 4 18 ...

Page 53: ...n 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 the dust ...

Page 54: ... ray 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 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...

Page 55: ... those of other machines Close all the doors and covers of the welding power source and securely fix them not to come loose for use If electromagnetic interference has occurred follow the steps above as well as the safety measures described in 3 2 2 Electromagnetic interference Check parameter Countermeasures Check 1 There should be no loose connections of the cables Use a proper tool to ensure co...

Page 56: ...ain tap of shield gas Whenthegasregulatorisequippedwithapressuregauge openthemaintapbycheckingthepressure gauge until the appropriate pressure is obtained 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 in serious physical i...

Page 57: ...4 2 Preventing erroneous operation on operation panel Erroneous operation prevention function This section explains how to prevent erroneous operation on the operation panel To prevent accidental change of the welding condition the erroneous operation prevention function is furnished to disable operations other than gas check and loading saving of the welding condition In using the analog remote c...

Page 58: ...ut per approximately one second 2 A series of welding operation is completed by the torch switch operation 6 6 3 Crater setting At the end of welding the average value of the welding current and the welding voltage at the last second of the welding sequence is displayed on each digital meter in a flashing mode except for the output at crater filler High frequency voltage is impressed for five seco...

Page 59: ...ʉ key to light up its LED When adjustment is made on the remote control this operation is not necessary Turn the parameter adjustment knob to adjust welding current 3 Press the ɽ key or ɻ key The displays on the left right digital meters return to the display of current voltage in welding TIPS When no operation is performed for approximately five seconds the display will return to the one showing ...

Page 60: ...discharged 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 SHUT GAS Input ...

Page 61: ...rent value soon after welding starts Crater current 1 0 to 380 A 150 A Sets the current value soon after welding ends Post flow time 0 to 99 sec 7 0 sec Set the gas discharge time after the welding ends Displays the value in the unit of 0 1 sec in case of less than 10 sec Displays the value in the unit of 1 sec in case of 10 sec to 99 sec Arc spot time 0 1 to 10 sec 3 0 sec Set the welding time at...

Page 62: ...atic machine 2 3 Almega OTC s robots specification 4 Almega OTC s robots specification for high speed communication F5 Maximum external command voltage 10 0 12 0 14 0 15 0 15 0 V Sets the maximum value of voltage supplied when current voltage command is externally input F6 Hazard reducing function ON OFF ON Sets ON OFF of the hazard reducing function in the DC STICK welding mode ON Hazard reducing...

Page 63: ...tion level 260 to 380 320 V Adjusts the low primary input voltage detection level F21 Maximum cooling fan operation OFF ON OFF Sets the operation mode of cooling fan OFF Economical operation ON Rotates the fan at maximum speed at all time F22 Operation sound switching OFF ON ON Sets the operation sound when any key is pressed on the operation panel OFF Turns off the sound ON Turns on the sound F23...

Page 64: ...OFF Not applied ON Applied Time set by F46 and F47 is applied F46 Special crater sequence initial time 0 0 to 10 0 0 0 s Sets initial time in the special crater sequence available when ON is selected in F45 F47 Special crater sequence crater time 0 0 to 10 0 0 0 s Sets crater time in the special crater sequence available when F45 is enabled F48 Setting change of current value initial current crate...

Page 65: ...TIG mode OFF No electrode formation function 1 6 to 6 4 ƕ Sets the electrode diameter to be rounded F61 Fine adjustment of electrode formation time 99 to 99 0 Fine adjust the shape of the electrode tip when the electrode formation function is set to 1 6 to 6 4 F62 Extended cable mode OFF ON OFF Sets the welding control for an extension cable when the welding power source is used in AC TIG mode or ...

Page 66: ...e discharged After discharging the gas for approximately 2 minutes automatically stops the discharge Pressing this key again lights off the LED stopping the shield gas discharge 7 TORCH key Selects whether to use the air cooled welding torch or the water cooled welding torch Press the key to switch over each mode LED ON Water cooled welding torch mode LED OFF Air cooled welding torch mode 8 WELDIN...

Page 67: ... and Down slope are added Pressing this key makes the LED lit adding Up slope and Down slope 18 TORCH CURRENT ADJUSTMENT key Adds the current adjustment function by the torch switch operation Pressing this key long makes the LED lit switching the mode to the CREATER FILL ON repeat mode and adding the current adjustment function by the torch switch operation 6 8 Adjusting current with torch switch ...

Page 68: ...ing conditions the welding current and other parameters currently set can be registered and loaded to use for operation Current adjustment function by the torch switch operation 6 8 Adjusting current with torch switch This function can increase and decrease the welding current set by the torch switch operation Available only for the main welding in the CRATER FILL ON mode Welding Setting Guide 6 9...

Page 69: ...tions Start setting 6 6 2 Start setting Touch High frequency Up slope setting 6 6 4 Slope setting Setting crater treatment 6 6 3 Crater setting Setting pre flow Setting gas discharge time 6 6 1 Setting welding parameter Initial current setting Welding current setting 6 6 1 Setting welding parameter Main welding setting Welding current pulse setting 6 6 1 Setting welding parameter Down slope settin...

Page 70: ...inaflashingmode andthe LED of JOB No lights up On the left digital meter the setting value of the welding current registered to the JOB No if any is displayed if there is no registration is displayed and the A LED lights up 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...

Page 71: ...lashingmode andthe LED of JOB No lights up On the left digital meter the setting value of the welding current registered to the JOB No if any is displayed if there is no registration is displayed and the A LED lights up 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...

Page 72: ...e left digital meter Release the keys after dEL is displayed dEL is displayed when the system transits to the DELETE mode Theconditionnumber registrationNo isdisplayed ontherightdigitalmeterinaflashingmode andthe LED of JOB No lights up To delete all the registration at the same time turn theparameteradjustmentknobcounterclockwise to display ALL on the right digital meter When ALL is selected the ...

Page 73: ... depending on the crater setting The welding parameters such as gas discharge time welding current and voltage should be set to this sequence Each sequence process has the following description The welding condition of the selected JOB No is deleted and End is displayed on the right left digital meters Process Description PRE FLOW It is the sequence to discharge gas before the welding starts INITI...

Page 74: ...LED A unit of welding current is lit Turn the parameter adjustment knob to set the welding current The set parameter is displayed on the left digital meter 3 Register to the memory as necessary 6 5 Memory Function of Welding Conditions 6 6 2 Start setting Touch High frequency Switch the starting method with the LIFT START key The Lift Start mode is on when the LED at the upper left of the key is l...

Page 75: ...the startup no electromagnetic disturbance occurs since high frequency voltage is not generated 1 Press the torch switch while the electrode is off the base metal 2 Contact the electrode with the base metal Press the torch switch while the electrode is off the base metal 3 Pull the electrode off the base metal Arc is generated No load voltage will not be impressed even when the torch switch is pre...

Page 76: ...ding process only available process is the main welding 6 6 3 1 Crater OFF CRATER FILL ON Unavailable After the main welding you can weld by a crater current 6 6 3 2 Crater ON no initial current Available In addition to the above you can weld by the initial current before the main welding 6 6 3 3 Crater ON with initial current CRATER FILL ON repeat Unavailable After the main welding you can weld b...

Page 77: ...the LED of the INITIAL CURRENT SELECT key Carry out twice the ON OFF operation of the torch switch and carry out the welding operation The operation from the first ON to OFF enables the welding by the initial current and 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 rema...

Page 78: ...ombining functions The following types of welding operation are available by combining the crater filler and pulse slope functions 6 6 4 Slope setting The selection of Slope ON OFF is done with the SLOPE SELECT key in the CRATER FILL ON CRATER ON repeat or ARC SPOT mode The Slope ON mode is on when the LED at the upper left of thekeyislitwhiletheSlopeOFFmodeisonwhentheLEDisnotlit IntheSlopeONmode ...

Page 79: ...n the left digital meter when pressing the SPOT TIME key and is adjustable by the parameter adjustment knob Arc can be broken even in the Arc Spot period when the torch switch is turned off in the Arc Spot mode 6 10 2 2 F2 Chenge in sequence at arc spot Output current Slope ON Adjustable parameters Arc spot time Down slope time Welding current Crater current Output current Slope OFF Adjustable par...

Page 80: ...n the base current will be the welding current The standard pulse width is 50 The pulse width can be changed by the internal function For details refer to 6 10 2 Detailed information on internal functions NOTE When the base current value in the pulse welding is set below 10 A arc loss is likely to occur in some cases Increase the base current value in such a case 6 7 Settings for AC TIG Welding an...

Page 81: ...alue of AC frequency for each AC waveform is as follows Standard Soft 70 Hz Hard 100 Hz AC TIG welding This is a TIG welding method that takes full advantage of the bipolar characteristics of the electrode which obtains cleaning action and the electrode with less electrode wear By making the polarity of the welding rod inverted from plus to minus from minus to plus in a short period this method ta...

Page 82: ... to the period during which the base material is the positive electrode and the torch is the negative electrode EP means the period during which the base material is the negative electrode and the torch is the positive electrode If you adjust the cleaning width the EP ratio changes by 1 against the operation amount 1 The standardvalueoftheEPratio thevalueatthecenterposition 0 differsforeachACwavef...

Page 83: ...atically ThestandardACratiois70 ACratioistheratioofACperiodinonecycleofAC DCperiod expressed by a percentage and is defined by the following formula Also the AC ratio can be changed by the internal function 6 10 2 14 F14 AC ratio When frequency is low AC DC switchover frequency setting When frequency is high When insertion interval is long Filler wire insertion interval Insertion interval is short...

Page 84: ... CRATER FILL key does not work For each single clicking and double clicking respective value can be set for the current increase and decrease Single clicking or double clicking operation should be done within 0 3 seconds In order to transit to the crater process press the torch switch for 0 3 seconds or more Example TheoperationflowwillbeasfollowswhenCraterON InitialcurrentOFF Weldingcurrent100A C...

Page 85: ...one second or more 2 Using the parameter adjustment knob and the PARAMETER SELECT key select an intended setting item No 3 Change the set value by using the parameter adjustment knob and the PARAMETER SELECT key The LED of the WELDING SETTING GUIDE key turn on in green The setting item No is displayed on the left digital meter The set value set to the setting item No is displayed on the right digi...

Page 86: ... Guide This section explains details of the welding control items 6 9 2 1 S1 Electrode diameter The electrode diameter can be set by setting the left digital meter to S1 Select one of 063 Ʒ1 6 094 Ʒ2 4 126 Ʒ3 2 157 Ʒ4 0 189 Ʒ4 8 220 Ʒ5 6 and 252 Ʒ6 4 6 9 2 2 S2 Base metal material The base metal material can be set by setting the left digital meter to S2 Material is set by number as shown on the t...

Page 87: ...g Setting Guide Tap the WELDING SETTING GUIDE key The LED of the WELDING SETTING GUIDE key turn on in green Exiting the Welding Setting Guide Press and hold the WELDING SETTING GUIDE key for one second or more The LED of the WELDING SETTING GUIDE key turn off Base metal material Mild steel Stainless steel Aluminum Welded joint Plate thickness lower limit in mm Plate thickness upper limit in mm Pla...

Page 88: ...nged 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 OFF ON SPOT REPEAT AC DC FREQ SYNERG A C FREQ AC TIG AC DC TIG DC TIG AC STICK DC STICK 3sec A C WAVE A sec Hz mm JOB No DC NO LOAD VOLTAGE V Φ CRATER FILL CURR INITIAL CURR PULSE CURR PULSE FREQ UPSLOPE DOWN SLOPE GAS WATER TORCH SPOT TIME STANDARD SOFT HARD ON...

Page 89: ...e 5 Depress the F Function key for one second or more The setting of internal function completes and the display returns to a normal state The function No is displayed on the left digital meter in a flashing mode The setting value of each function No is displayed on the right digital meter The set value is activated as it is changed Pressing the F Function key enables to return the display to the ...

Page 90: ...ne adjustment value or the Absolute value is displayed on the right digital meter Every pressing the ʉ or ʇ key switches over the display with each other You can check which value is displayed by the LED of the unit When the LED is ON Fine adjustment value is displayed When V Ʒ LED is ON Absolute value a value with the adjustment value increased to decreased from the standard value is displayed Fi...

Page 91: ...repeat In the CRATER FILL ON repeat mode welding current and crater current can be switched over with each other by tapping the start switch Press the start switch for a long time to stop welding ON This function is enabled OFF This function is disabled Example The welding flow will be as follows when the Initial welding current is set to 80 A the Main welding current to 100 A and the Crater curre...

Page 92: ...After removing 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 2 1 If an external command voltage is input it should be input to the terminal pins 2 3 2 4 of the remote control receptacle as shown in the below figure Relationship between input and o...

Page 93: ...w 6 10 2 6 F6 Hazard reducing function The voltage reducing function is used for AC STICK welding and DC STICK welding This is a safety function to reduce the risk of an electric shock to workers by limiting the no load voltage of the welding power source to a low voltage when welding is not performed Therefore iftheweldingpowersourceisusedinanelevatedornarrowworkplace useitwiththehazard reducing ...

Page 94: ...nt region set the scale plate to 100A 6 10 2 10 F10 Analog remote control upper limit settings Thisfunctionsetstheupperlimitvalue thevaluewhentheknobisturnedfullyclockwise ofthesetting range of the welding current and the pulse current that can be adjusted by the analog remote control When welding is going to be performed in the low current range it will be easier to fine adjust the current if the...

Page 95: ... shipment AC ratio setting range 10 to 90 6 10 2 15 F15 Switchover of cleaning width display When setting the cleaning width you can select either EP ratio or Strength of cleaning action as the value to display on the rightdigital meter When EP ratio is selected the LED of the unit LEDs is illuminated Also the standard value is displayed on the left digital meter ON Shows the EP ratio EP ratio set...

Page 96: ...ource Means to reset alarms is the same as those for errors including restoration of the power 9 1 Action in Case of Error 6 10 2 19 F20 Low input voltage detection level Set the low input voltage detection level on the primary side When the input voltage is lower than the set value an error code is displayed Set the value in the range of 260 to 380 V TIPS The factory default setting is 320 V Howe...

Page 97: ...1 9 10 on the external connection terminal block TM4 Details of external connection terminal blocks 4 6 1 Connection with external equipment The functions set to F25 to F28 are as shown on the table below In the sleep mode the dot at the first digit on the left right digital meters flashes All the other displays on the operation panel are turned OFF Any operation during the sleep mode restores the...

Page 98: ...he base current is selected when they are opened 5 5 JOB shift Causing short circuit between terminals shifts to the following JOB No 6 8 6 JOB shift Causing short circuit between terminals shifts to the previous JOB No 7 8 1 When the gas valve is opened by the signal from the external input terminal the gas valve will not close when welding completes or according to the timer 2 minutes In order t...

Page 99: ...nal of external input terminal to which this function is allocated to has any change again 5 The pulse output does not issue even when the pulse synchronization input terminals are shorted in the initial current and crater current periods The selection changes only when the level of the input signal is held at least for 2 ms 6 The JOB No shifts to the following number and read out the condition by...

Page 100: ...to control heat input in AC TIG mode AC DC TIG mode and DC TIG mode ON This function is enabled OFF This function is disabled TIPS Since arc turns ON OFF repeatedly high frequency voltage is applied frequently Lift start cannot be used when this function is enabled 6 10 2 26 F34 Arc ON time of TIG interval Set the arc ON time in the TIG interval function Set the arc on time within the range of 0 0...

Page 101: ...will remain on the work as arc is not generated when the welding rod is pulled off 6 10 2 29 F37 Switchover of characteristics AC STICK welding Switches the static characteristics to constant current characteristics or drooping characteristics in AC STICK welding mode By setting to drooping characteristics the output current increases as the arc length becomes short and it decreases as the arc len...

Page 102: ... dealer NOTE Do not carelessly change the setting of this function 6 10 2 32 F41 F42 Voltage display adjustment Gain offset Set the adjustment value gain offset when the voltage display value on the right digital meter is different from the actual voltage value Thevoltagevaluedisplayedonthedigitalmeterisobtainedbysoftwareprocessingoftheaveragevalue ofoutputs therefore it may not be consistent with...

Page 103: ...onthecenterof weldingvoltagesettingknob Toincreasethewelding 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...

Page 104: ...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 F44 Reading welding condition with remote control is set to ON enabled TORCH CURRENT ADJUSTMENT key is set to ON enabled EitheroftheinternalfunctionF29toF32 Externalinputter...

Page 105: ...of data log function Selects the data sampling interval in using data log function The relationship between the setting value and the data sampling is as follows For data log function 7 3 Data Backup Utilization of data 6 10 2 41 F55 to F59 Reserved Used in connection with the automatic machines of other manufacturers 6 10 2 42 F60 Electrode formation function In the AC TIG mode and AC DC TIG mode...

Page 106: ...extension cableexceeds30m round trip When setto ON the AC WAVEFORM LED flashes OFF Standard mode This is the standard AC TIG mode and AC DC TIG mode NOTE When the extended cable mode is set to ON the AC frequency setting range is limited within 30 to 100 Hz Depending on the condition of the output cable current may not be output as specified in comparison with the standard mode If the output cable...

Page 107: ...g remote control and turning ON the power switch No Name Function 1 Welding current adjustment knob Set the welding current The set value is displayed on the left digital meter at the welding power source side 2 Pulse current adjustment knob Sets the pulse current The set value is displayed on the left digital meter when the pulse current is selected with the PARAMETER SELECT key 3 Scale plate 1 T...

Page 108: ...OPERATION OF ANALOG REMOTE CONTROL OPTIONAL WELDING CONDITION CHAPTER 6 6 48 ...

Page 109: ...erations above will become possible 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 ...

Page 110: ...assword 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 e...

Page 111: ...fied 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 Displaythenumberspecifiedasthepassword and press the ʉ or ʇ key Then the tens place will flash on the right digital meter When thenumbermatchesthesetp...

Page 112: ... the time when the target total welding time is achieved Welding monitor P30 0 Max fluctuation value of average range monitor A or V P31 100 0 to 100 Current tolerance P32 100 0 to 100 Current tolerance P33 100 1 to 100 Welding voltage upper limit value setting V 1 P34 0 0 to 99 Welding voltage lower limit value setting V 1 P35 0 0 to 100 WARNING judgment time second P36 0 0 to 2 Operation at the ...

Page 113: ...count value will be cleared according to the P12 setting Ifcontinuousoperationisenabled thevaluewillbeclearedwhenexceeding999andreturn 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 4 Alarm indicatio...

Page 114: ...heexternaloutputterminalifthesettingrangeisexceeded 6 10 SettingInternalFunctions P30 Max fluctuation value of average value monitor If the average current voltage average per second becomes outside the allowable tolerance range specified in P30 to P34 an alarm is displayed indicating the following contents 7 2 2 5 Alarm indication at the time of WARNING detection Welding Monitor P35 P36 P31 Curre...

Page 115: ...ayed and normal display is restored When the torch switch is set to ON while an alarm is displayed to start welding only when P36 is set to 0 When operation is stopped by releasing 3 4 operation stop terminal on the external connection terminal block TM3 during alarm indication and then the operation stop is canceled by short circuiting these terminals only when F4 setting is 1 or 2 7 2 2 4 Alarm ...

Page 116: ...ween 0 and 999 hours The time between 0 and 99 9 hoursare displayed in the unit of 0 1 hour and the time exceeding 100 hours is displayed in the unit of 1 hour Refer to P42 Clear the control data value about how to clear P41 P42 Clear of the control data value After setting the set value of P42 to cLr finishthe welding control setting with the WELD MONITOR key held pressed for one second or more T...

Page 117: ...ad it from our home page URL http www daihen co jp products welder software en html 7 3 1 Setting of welding conditions internal functions The following contents can be stored in the DAIHEN_OTC_WELDING_PRAMETER CSV file All the welding condition data recorded in memory The internal function values at the time of data backup Thecurrentweldingconditionssetwiththeoperationpanelwillnotbesaved Ifnecess...

Page 118: ...n_pls_frq Welding setting guide Pulse frequency 1 Hz 5 H cre_iset Crater current 1 A 4 AF syn_pls_wid Welding setting guide Pulse width 1 I aff_tim Post flow time 0 1 s AG syn_spot_tim Welding setting guide Arc spot time 0 1 s J pls_iset Pulse current 1 A 4 AH syn_cleaning Welding setting guide Cleaning width K pls_freq Pulse frequency 1 Hz 5 AI syn_ac_frq Welding setting guide AC frequency 1 Hz L...

Page 119: ...ta can be sampled S syn_s1_dia Welding setting guide S1 Electrode diameter 1 ƕ AQ TsCrickIset TS click current adjustment 0 1 OFF ON T syn_s2_mtrl Welding setting guide S2 Material AR CriIsetStep1 Current increase decrease value by single clicking 0 1 A 4 U syn_s3_seam Welding setting guide S3 Joint AS CriIsetStep2 Current increase decrease value by double clicking 0 1 A 4 V syn_s4_thick Welding s...

Page 120: ...eed 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 during welding only and not recorded when there is no output The simplified data log cannot be backed up It will be deleted when the power switch is turned off The simplified data log can be exported even if an e...

Page 121: ...ters into in the end of filename 6 10 2 45 F77 Welding result control function identification numbers 7 3 5 Backup operation This section explains how to back up the data such as welding conditions The data can be backed up in a USB 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 Inse...

Page 122: ... 2 Insert the USB flash drive to the USB connector of the operation panel Turn the parameter adjusting knob further counterclockwise to display the data to backup on the right digital meter The display changes in order of ALL 1 2 3 4 ALL meansthatallthedata 1 to 4 availablefor backup are selected Details of the numbers displayed 7 3 Data Backup Utilization of data The LED of ENTER key lights up Da...

Page 123: ...heir default initial settings at shipment However welding conditions registered in the memory are not affected The LED of SAVE key lights up 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 meansthatallthedata 1 to 2 availablefor importing are selected Details of the numbers displayed 7 3...

Page 124: ...urn 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 on H...

Page 125: ...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 126: ...tion 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 powder dust accumulating on the welding power source do not vacuum bet...

Page 127: ... 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 128: ...deterioration damage or other abnormality in consumable parts of the welding torch 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 transistor Also accumulation of ...

Page 129: ...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 Even if the part is replaced...

Page 130: ...y Short circuit between TR1 C1 and E1C2 TR1 E1C2 and E2 TR3 C1 and E1C2 and TR4 E2 and E1C2 Short circuit between TR5 C1 and E1C2 and TR6 E1C2 and E2 Apply NF After finishing insulation resistance measurement return the above to the original state The customer MUST NOT perform the withstand voltage test If withstand voltage test is necessary ensure to contact your dealer Insulation resistance meas...

Page 131: ...perature WARNING LED light flash An error code flashes 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 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 outp...

Page 132: ...de will disappear when the power switch is turned off E 300 The temperature of the output terminal has exceeded the allowable range 1 Turn off the power switch Confirm that the connection part is not loose after the temperature of the output terminal has lowered The error code will disappear when the power switch is turned off after the output terminal cools down E 301 to 303 The temperature insid...

Page 133: ...e primary power source is not supplied Supply the primary power source within 414 to 506 V 3 Nothing is displayed on the right left digital meters even when the power switch is turned on 4 Temperature WARNING LED lights and an error code is displayed when the power switch is turned on The protection circuit has been activated due to temperature error Leave it untouched with the power on and operat...

Page 134: ...annot be set with the operation panel The welding mode does not change even when switched with the operation panel The erroneous prevention function to prevent malfunction of the operation panel is enabled Erroneous operation prevention function Press and hold the ENTER key three seconds or more to disable the erroneous operation prevention function the operation panel 11 The password is lost Cont...

Page 135: ...00DUS 12F 4 TR5 6 100 3129 IGBT module 2MBI300XBE 065 50 2 TR7 100 2381 IGBT GT50JR21 1 CT1 4810 030 Current transformer W W03029 1 CT2 100 0956 Hall current detector CS 40GEH 1 T1 P30160B00 Inverter transformer P30160B00 1 T2 W W04046 Auxiliary transformer W W04046 1 C C P30160C00 Coupling coil P30160C00 1 L1 P30086L00 Input reactor P30086L00 1 L2 P30160H00 Reactor P30160H00 1 L3 100 1950 Ferrite...

Page 136: ... 1 Output DC24V F1 100 3393 Fuse 0213005 MXP 1 PCB1 P30160P00 Printed circuit board P30160P00 1 1 4341 206 Relay G6A 274P DC24V 1 1 With PCB1 PCB2 P30086R00 Printed circuit board P30086R00 1 100 1421 Encoder EVEGA1F2524B 1 1 With PCB2 PCB3 P30086Q00 Printed circuit board P30086Q00 1 PCB4 P10536X00 Printed circuit board P10536X00 1 PCB5 6 P30086V00 Printed circuit board P30086V00 2 PCB7 P30099M00 P...

Page 137: ...ing This section contains the schematic diagram and the parts layout drawing of the welding power source Code Part No Product Name Specifications Qʼty R29 30 4501 039 Variable resistor RV24YN20SB 5KƘ 2 R31 100 0487 Carbon resistor RD20S 12ƘJ 1 4730 005 Metal connector plug DPC25 4A 1 4735 007 Knob K 2195 Large 2 3361 655 Cosmetic screw N 3 M5 L 10 Black 1 ...

Page 138: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 4 10 2 1 Schematic diagram ...

Page 139: ...10 5 Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 ...

Page 140: ...1 to 14 NF 6 CON1 7 CON2 7 P30086S00 P30160P00 P30086V00 P30160V00 P30086V00 P30099M00 FM4 DR1 FM1 FM2 C C L2 T1 4 3 8 9 P30086R00 Back of operation panel Upper DCV1 Lower P30086Q00 P30205S00 TR1 to 4 R18 Back of P30099M00 Top When the cover is opened Back Right side Front When the fan frame is removed Left side DR1 T2 PS 10 10 TM6 DR8 Back of T2 F1 Back of T2 ...

Page 141: ...djust them according to the shape of actual weld zone and position of welding Problem Symptom The wire feeding length is too long The arc length becomes long The bead width becomes wide Shielding becomes 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 142: ...14 4 1 a 5 32 4 0 3 32 1 8 2 4 3 2 3 32 to 1 8 2 4 to 3 2 130 to 180 0 18 5 1 c d 3 16 4 8 3 32 1 8 5 32 2 4 3 2 4 3 32 to 5 32 2 4 to 4 0 150 to 220 0 18 5 1 c d 1 4 6 4 1 8 5 32 3 16 3 2 4 4 8 1 8 to 3 16 3 2 to 4 8 180 to 250 0 18 5 1 to 2 c d Killed steel DC 24ga 0 6 0 040 1 16 1 1 6 to 1 16 to 1 6 50 to 70 0 11 to 0 14 3 to 4 1 a 20ga 1 0 1 16 1 6 to 1 16 to 1 6 60 to 90 0 11 to 0 14 3 to 4 1...

Page 143: ...0 1 to 2 0 14 to 0 21 4 to 6 0 5 0 040 1 0 0 2 to 3 0 14 to 0 21 4 to 6 Wire diameter Material Joint shape Gap G in mm Pulse condition Travel speed IPM cm min Filler wire feed speed IPM cm min Pulse current A Base current A Frequency Hz Pulse width Mild steel spcc 0 200 50 2 5 50 23 6 60 23 6 60 0 047 1 2 150 20 1 5 46 11 8 30 23 6 60 0 063 1 6 130 20 1 50 5 9 15 15 7 40 Stainless steel SUS304 0 1...

Page 144: ...A Frequency Hz Pulse width Copper Mild steel 1 250 50 0 8 20 3 9 10 23 6 60 Cu Stainless steel Mild steel 1 170 60 2 5 50 19 7 50 23 6 60 SUS Mild steel 1 120 50 2 50 7 9 20 11 8 30 Stainless steel 4 160 50 1 5 46 3 3 8 5 23 6 60 Shield gas Argon 0 35 CFH 10 L min Electrode Tungsten electrode with cerium 3 32 2 4 mm ƕ Filler wire 0 045 1 2 mm ƕ Arc length 0 08 to 0 12 2 to 3 mm spcc C1100P 1 2 spc...

Page 145: ...Φ Feed speed IPM cm min Aluminum 20ga 1 0 70 25 1 50 1 16 1 6 29 5 75 1 5 80 40 1 50 1 16 1 6 37 4 95 1 5 90 25 1 50 1 16 1 6 29 5 75 1 5 85 25 1 50 0 045 1 2 37 4 95 1 8 3 2 170 25 1 50 0 045 1 2 114 1 290 3 0 170 25 1 50 1 16 1 6 66 9 170 6 0 220 25 1 50 1 16 1 6 98 4 250 6 0 180 25 1 50 1 16 1 6 98 4 250 1 8 3 2 170 25 1 50 0 045 1 2 114 1 290 6 0 220 25 1 50 1 16 1 6 106 2 270 3 0 120 25 1 50 ...

Page 146: ...2 3 32 2 4 185 3 32 2 4 0 25 to 0 32 7 to 9 6 0 1 8 3 2 260 5 32 4 0 0 32 to 0 39 9 to 11 6 0 1 8 3 2 1 8 3 2 200 3 32 2 4 0 32 to 0 39 9 to 11 4 5 1 8 3 2 270 5 32 4 0 0 32 to 0 39 9 to 11 Plate thickness 1 in mm Plate thickness 2 in mm Plate thickness 2 in mm Welding current A Welding current in mm Argon flow rate CFH L min 0 030 0 8 20ga 1 0 16ga 1 6 25 0 0 18 to 0 25 5 to 7 0 045 1 2 16ga 1 6 ...

Page 147: ...2 2 4 50 1 16 1 6 0 21 to 0 28 6 to 8 0 045 1 2 3 32 2 4 60 1 16 1 6 0 21 to 0 28 6 to 8 2 3 3 32 2 4 85 1 16 1 6 0 21 to 0 28 6 to 8 1 8 3 2 3 32 2 4 105 3 32 2 4 0 21 to 0 28 6 to 8 4 5 3 32 2 4 115 3 32 2 4 0 21 to 0 28 6 to 8 6 0 3 32 2 4 130 3 32 2 4 0 21 to 0 28 6 to 8 2 3 20ga 1 0 3 32 2 4 55 1 16 1 6 0 21 to 0 28 6 to 8 0 045 1 2 3 32 2 4 65 1 16 1 6 0 21 to 0 28 6 to 8 16ga 1 6 3 32 2 4 8...

Page 148: ...5 32 4 0 0 39 to 0 46 11 to 13 6 0 3 0 3 32 2 4 190 3 32 2 4 0 32 to 0 39 9 to 11 5 32 4 0 1 8 3 2 230 5 32 4 0 0 39 to 0 46 11 to 13 Plate thickness 1 in mm Plate thickness 2 in mm Plate thickness 2 in mm Welding current A Filler wire dia in mm ƕ Argon flow rate CFH L min 0 030 0 8 20ga 1 0 16ga 1 6 25 0 0 18 to 0 25 5 to 7 0 045 1 2 16ga 1 6 30 0 0 18 to 0 25 5 to 7 1 5 16ga 1 6 40 0 0 18 to 0 2...

Page 149: ...6 to 8 6 0 3 32 2 4 110 1 16 1 6 0 25 to 0 32 7 to 9 1 5 20ga 1 0 16ga 1 6 45 0 0 21 to 0 28 6 to 8 0 045 1 2 3 32 2 4 50 1 16 1 6 0 21 to 0 28 6 to 8 2 0 3 32 2 4 70 1 16 1 6 0 21 to 0 28 6 to 8 3 0 3 32 2 4 90 1 16 1 6 0 21 to 0 28 6 to 8 5 32 4 0 3 32 2 4 100 3 32 2 4 0 25 to 0 32 7 to 9 6 0 3 32 2 4 120 3 32 2 4 0 25 to 0 32 7 to 9 2 0 0 045 1 2 3 32 2 4 55 0 0 21 to 0 28 6 to 8 1 5 3 32 2 4 6...

Page 150: ... 0 25 5 to 7 1 5 16ga 1 6 45 0 0 21 to 0 28 6 to 8 2 0 3 32 2 4 50 0 0 21 to 0 28 6 to 8 3 0 3 32 2 4 60 0 0 21 to 0 28 6 to 8 5 32 4 0 3 32 2 4 65 0 0 21 to 0 28 6 to 8 0 045 1 2 1 5 3 32 2 4 50 0 0 21 to 0 28 6 to 8 2 0 3 32 2 4 60 0 0 21 to 0 28 6 to 8 3 0 3 32 2 4 65 0 0 21 to 0 28 6 to 8 5 32 4 0 3 32 2 4 70 0 0 21 to 0 28 6 to 8 6 0 3 32 2 4 80 1 16 1 6 0 21 to 0 28 6 to 8 1 5 2 0 3 32 2 4 6...

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