OTC Welbee P400 II Owner'S Manual Download | Manualshive

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Chapter 4

Connection

W

IRING

OF

V

OLTAGE

D

ETECTION

C

ABLE

AT

B

ASE

M

ETAL

S

IDE

C

ONNECTION

C

HAPTER

4

4.6.2

Wiring to welding power source

This section explains how to connect the voltage detection cable at the base metal side to the voltage direct detection
terminal at the base metal side of the welding power source.

1.

Check that input power is turned off with the disconnect switch connected to the welding power source.

2.

Connect the voltage detection cable at the base metal side to the voltage direct detection terminal at the base
metal side.

Wiring of voltage detection cable is complete.

4.6.3

Wiring example of voltage detection cable

This section shows the wiring examples of the voltage detection cables at the base metal side to the base metal.

4.6.3.1

Wiring examples for plural welding stages

Connect the base metal side voltage detection cable to the stage farthest from the base metal side power cable which
connects to the base metal terminal of the welding power supply, away from the base metal side cable.

4.6.3.2

Wiring example when power is supplied with a power feeding brush to the positioner

Insulate the power feeding brush from the jig base and connect the voltage detection cable (base metal side) to the jig base.

T I P S

•

Before wiring the voltage detection cable, check that conduction between the jig base and
the base metal is stable.

NOTE

•

If the voltage detection cable is tightened together with the cable terminal on the base metal
side connected to the power supply brush, welding will become unstable.

Welding power source

Terminal for voltage direct detection
at base metal side

Power cable for base
metal side

Voltage detection cable
for base metal side

Stage 1

Stage 2

Stage 3

Keep distance

The wire feeder or the welding
power source is connected

Connect to base
metal terminal side of
welding power supply

Insulation

Base metal

Jig base

Insulation

Feeding brush

Positioner

Voltage detection cable
for base metal side

Power cable for base metal side

Power cable for base
metal side

The wire feeder or the welding
power source is connected

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Summary of Contents for Welbee P400 II

Page 1: ...DAIHEN Corporation June 2021 Manual No P30344 1 Welbee P400 II OWNER S MANUAL DAIHEN Corporation ...

Page 2: ...t See the back cover for contact numbers and mailing addresses When contacting your dealer for service you are required to provide the following information Name address telephone number 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 purchased product ...

Page 3: ...stallation operation maintenance of the welding power source and welding machine is performed by qualified personnel with sufficient knowledge and skills If this manual is lost or damaged immediately contact your dealer Copyright This manual is copyrighted and all rights are reserved by OTC Any part of the manual shall not be copied photocopied or reproduced without the prior consent of OTC When E...

Page 4: ... Connection of welding torch 31 4 2 4 Connection at TIG welding 31 4 2 5 Connection at DC STICK welding 33 4 2 6 Connection of shield gas 33 4 3 Grounding and Connection of Input Power Supply 35 4 4 Confirmation of Connection 36 4 5 Connection of External Equipment 36 4 5 1 Connection of robot 36 4 5 2 Connection of automatic machine 37 4 6 Wiring of Voltage Detection Cable at Base Metal Side 40 4...

Page 5: ...3 5 Backup operation 118 7 3 6 Importing backup data 120 7 4 Initializing Welding Conditions and Internal Functions 121 7 5 Checking the Software Version and Serial Number 122 7 6 Calibration Mode 123 7 6 1 Adjustment of output current 123 7 6 2 Adjustment of output voltage 124 7 7 System Setting 126 CHAPTER 8 MAINTENANCE AND INSPECTION 8 1 Precautions for Maintenance and Inspection 127 8 2 Daily ...

Page 6: ...are as follows Make sure to fully understand 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 Symbols Explanation Gives information regarding possible personal injury or loss of life if the product is used improperly Refers to minor personal injury or possib...

Page 7: ...t no person is allowed unauthorized access near the welding power source or work areas Only authorized personnel or person with full understanding and experience of the welding power source must perform installation maintenance and repair of welding power source Make sure to attach a safety belt when working at high locations For those with pacemaker avoid being close to the machine during operati...

Page 8: ...ves 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 e...

Page 9: ...equipment When it is difficult to provide ventilation equipment or the ventilation 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 equi...

Page 10: ...Y 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 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...

Page 11: ...on gas pipe and closed containers such as tanks or drums Performing arc welding on flammable object such as fuel tank may cause explosion Furthermore welding on closed container such as tanks and pipes may cause burst Watch for fire and keep a fire extinguisher near the welding area Periodically blow the parts of welding power source with dry compressed air to remove dust Powder dust accumulating ...

Page 12: ...INCIPAL SAFETY STANDARDS Keep the cylinder upright and securely chained to a stationary support or a rack Falling or tipping of cylinder may cause serious injury In opening the valve of gas cylinder keep 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 Prot...

Page 13: ...2 from American Welding Society Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society National Electrical Code NFPA Standard 70 from National Fire Protection Association Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Associ...

Page 14: ...ted input current 54 0 49 5 A 1 53 6 48 8 A 1 26 1 A 2 30 0 A 2 Rated output current 400 A 300 A 250 A 200 A 250 A Rated load voltage 34 V 26 V 32 V 26 5 V 24 V 20 V 30 V Maximum no load voltage 3 83 91 V 1 83 91 V 1 80 V 2 80 V 2 Rated duty cycle 60 50 60 80 60 40 60 Number of welding condition 100 Temperature rise 320 F 160 C Operating temperature range 14 to 104 F 10 to 40 C Operating humidity ...

Page 15: ...O2 1 2 STAINLESS STEEL 3 030 035 045 0 8 0 9 1 2 STANDARD HIGH Enable STAINLESS FERRITE 3 030 035 045 0 8 0 9 1 2 STANDARD HIGH Enable MIG 100 Ar 1 3 SOFT ALUMINUM 045 1 16 1 2 1 6 STANDARD HIGH HARD ALUMINUM 045 1 16 1 2 1 6 STANDARD HIGH Brazing CuSi 030 035 045 0 8 0 9 1 2 STANDARD HIGH Brazing CuAl 030 035 045 0 8 0 9 1 2 STANDARD HIGH INCONEL 035 045 0 9 1 2 STANDARD HIGH DC WAVE PULSE MAG 20...

Page 16: ...he duty cycle but also result in degradation or burnout of the welding power source The rated duty cycle of the welding power source is the following Operation cycle at duty cycle of 60 400 A 60 for DC DC TIG three phase 400 A 50 for DC PULSE three phase 300 A 80 for DC STICK three phase 250 A 60 for DC DC TIG DC STICK single phase 200 A 40 for DC PULSE single phase Rated duty cycle of 60 means th...

Page 17: ...e Duty cycle Welding current A 100 50 40 0 100 100 126 200 Usable range Welding current A e l c y c y t u D DC PULSE single phaseࠚ 60 100 50 0 100 194 250 Usable range Welding current A e l c y c y t u D DC DC TIG DC STICK single phaseࠚ 100 50 0 100 200 283 400 Usable range Welding current A e l c y c y t u D DC PULSE three phaseࠚ 60 100 50 0 100 200 310 400 Usable range Welding current A e l c y ...

Page 18: ...n specified may cause failure of the welding power source No Name Required component Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Wire feeder 㾎 3 Welding torch 㾎 4 Gas hose 10 ft 3 m 㾎 1 Included in feeder 5 Control cable for wire feeder 5 ft 1 5 m 㾎 1 Included in feeder 6 Power cable for torch side 㾎 1 7 Power cable for base metal side...

Page 19: ...ories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Welding torch 3 Gas hose 10 ft 3 m 㾎 1 Included in feeder 2 4 Power cable for base metal side 㾎 1 Included in feeder 5 Shield gas To be prepared by the customer 2 2 3 Accessory not supplied 6 Digital remote control optional 㾎 E 2454 1 7 Analog remote control 10 ft 3 m optional 㾎 K5804S00 1 8 TIG valve kit o...

Page 20: ...ction manual this publication and the quantity of parts when opening the package No Name Required component Optional accessories Remarks 1 Welding electrode holder To be prepared by the customer 2 2 3 Accessory not supplied 2 Power cable for welding electrode holder AWG2 38mm2 or more 㾎 3 Power cable for base metal side 㾎 1 4 Digital remote control optional 㾎 E 2454 1 5 Analog remote control 10 ft...

Page 21: ...rol voltage detection cable and other optional items Following items are optionally available including remote control and voltage detection cable Name Remarks CO2 gas Carbon dioxide CO2 100 MAG gas Argon Ar 80 Carbon dioxide CO2 20 MIG gas stainless Argon Ar 98 Oxygen O2 2 MIG gas aluminum aluminum bronze Silicon bronze Argon Ar 100 Product name Part No Model Remarks Analog remote control K5804S0...

Page 22: ...ension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 16 ft 5 m 33 ft 10 m 50 ft 15 m 66 ft 20 m 1 Gas hose BKGG 0605 BKGG 0610 BKGG 0615 BKGG 0620 2 Control cable for wire feeder BKCPJ 1005 BKCPJ 1010 BKCPJ 1015 BKCPJ 1020 3 Power cable torch side BKPDT 6007 BKPDT 6012 BKPDT 8017 BKPDT 8022 4 Power cable base metal side 5 Control cab...

Page 23: ...ains the rear section of the welding power source Socket for wire feeder Output terminal Torch side Power switch Operation panel 6 2 Function on Operation Panel Terminal for directly detecting voltage on the base metal side Socket for analog remote control Output terminal Base metal side Main power lamp Blind bush for drawing externally connecting wire Input cable Grounding cable Connector for con...

Page 24: ... the commercial power source If the engine generator does not have sufficient capacity sudden current change such as arc start will occur and this may result in an abnormal decrease in output current or arc loss When the welding power source is used in a humid environment such as construction site or location with highly conducting material such as steel plate or on steel structure install a leaka...

Page 25: ...tilation ensure to provide ventilation equipment Condition of ventilation equipment Oxygen concentration of 18 or more must be maintained in the welding work area 3 1 2 2 Partial exhaust facility To prevent any health damage due to poisonous gas or particle substances fume emitted in the welding operation provide partial exhaust facility Gas of larger gravity than that of oxygen such as carbon dio...

Page 26: ... temperature of 68 F 20 C Location with an incline of 10 or less For the welding power source with wheels use chock to prevent from sliding Location with no metallic foreign body such as spatter entering the welding power source Installation distance of 11 8 30 cm or more between the welding power source and the wall or other welding power source Ensure not to block the ventilation hole Location w...

Page 27: ...rce and 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 source during welding other machine near the welding power source may be failed due to electromagnetic noise Follow the instructions below Do not ground the welding power source commonly with oth...

Page 28: ...idents 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 of the eyebolts Do no...

Page 29: ...When using a tool such as carriers secure the welding power source and carrier with a rope before transporting When lifting the welding power source make sure to hold the bottom of the welding power source by more than one person If attempting to lift by holding the front plastic part top cover side plates it may cause back pain deformation or damage to the welding power source When using a tool s...

Page 30: ...lation 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 with specified thickness Do not use damaged cable or cable with stripped conductor Ensure to tighten and insulate the connection of cables Securely attach the case and cover of the welding power...

Page 31: ...direction 2 Connect the power cable for torch side to the output terminal torch side Connect the connectors as same as above Connection for cable at output side is complete Procedure is followed by 4 2 2 Connection of wire feeder Use a grounding cable for the case of welding power source and perform grounding Otherwise voltage may increase in the case or base metal which could cause electric shock...

Page 32: ... 10 cores to the socket for the wire feeder Fit the concave part of the connector and convex part of the socket for secure connection and tighten the knurled screws in the clockwise direction When using an analog remote control optional accessory remove the cap of socket for analog remote control and insert the control cable 6 cores 4 Restore the right side panel of the wire feeder Connection for ...

Page 33: ...rrow mark direction shown in the figure Connection for welding torch is complete Procedure is followed by 4 2 6 Connection of shield gas 4 2 4 Connection at TIG welding CAUTION In using the welding power source for TIG welding prepare a welding torch by the customer Contrary to the normal connection the TIG welding requires connection of the welding torch to the output terminal base metal side Als...

Page 34: ...torch side and base metal Connect the connectors as same as above Connecting TIG valve kit TIPS For the procedure for installing the TIG valve kit optional accessory to the welding power source refer to the instruction manual of the TIG valve kit Connect the kit to the torch as shown in the following figure Ground a base metal if required by local law Power cable for base metal side Base metal Pow...

Page 35: ...nto the connector terminal and fix the sleeve using a screw Tighten the screw at 12 N m using a hexagonal wrench 5 Fit the grip onto the connector terminal 6 Connect the power cable for welding electrode holder side to the output terminal torch side Connect the connectors as same as above 4 2 6 Connection of shield gas This section explains the procedure for connecting the shield gas Refer also to...

Page 36: ...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 compressed gas cylinder that conforms to the specific application o...

Page 37: ...tric shock due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker 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 power source which is not grounded is used voltage will be generated in the case through the capacitor between the welding powe...

Page 38: ...cted to the breaker s ground terminal No tools or equipments are left placed on the surface of the welding power source Do not place any material on the surface of the welding power source 4 5 Connection of External Equipment This section explains the method for connecting the welding power source with automatic machines 4 5 1 Connection of robot This section explains the configuration example of ...

Page 39: ...4 is also required Terminal No Signal name Function TM1 1 2 Ａ Output for ammeter Output terminal to connect a separately sold Ammeter 600 A 60 mV Part No 4403 054 TM2 1 2 V Output for voltmeter Output terminal to connect a separately sold Voltmeter 100V F S Part No 4401 019 TM3 1 2 READY Power ready output When the welding power source side is ready to start welding the contact between the termina...

Page 40: ...n terminal block Use switches and relays with contact capacity of 24 V 10 mA or more for connecting with the input terminal Output signal of the external connection terminal block Output signal is open collector output Ensure to keep the maximum rated power of the transistor Maximum rated power of transistor READY DC50 V 100 mA OUT EXT1 to 4 DC50 V 100 mA WCR output signal WCR signal is the output...

Page 41: ...lectrical 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 wait three minutes or more In addition do not turn on the primary power until the work is complete Do not use damaged cable or cable without grounding Securely attach the case and cover of the welding power source after connectin...

Page 42: ...ltage detection cable set the internal function F38 to 1 6 7 1 Setting procedure Details on the internal function F38 6 7 2 23 F38 Arc voltage direct detection switching 4 6 1 Wiring to wire feeder This section explains how to connect the voltage detection cable at the base metal side to the wire feeder 1 Check that input power is turned off with the disconnect switch connected to the welding powe...

Page 43: ...the base metal terminal of the welding power supply away from the base metal side cable 4 6 3 2 Wiring example when power is supplied with a power feeding brush to the positioner Insulate the power feeding brush from the jig base and connect the voltage detection cable base metal side to the jig base TIPS Before wiring the voltage detection cable check that conduction between the jig base and the ...

Page 44: ...ent 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 concentr...

Page 45: ...of others in the work area from arc ray Wear an ear protector when noise level is high Ignoring the above may cause hearing disorder CAUTION When the welding is performed outside with wind or when wind is caused by the indoor ventilation facility including fan provide a partition to avoid the arc generating part being exposed to wind Check parameter Countermeasures Check 1 There should be no loose...

Page 46: ... size is smaller than the above set the anti stick voltage to a higher value whereas if the particle size is larger than the above set the anti stick voltage to a lower value 14 At start point of welding the tip of welding wire and the welding workpiece should not be contacted When using a robot operate several times with welding OFF and confirm that the welding wire and the welding workpiece do n...

Page 47: ...uge open the main tap by checking the pressure gauge until the appropriate pressure is obtained 5 Turn the flow rate adjustment knob to OPEN and adjust the flow rate of shield gas 6 Press the GAS CHECK key B The LED of the GAS CHECK key lights off to stop gas check Handle the gas cylinder according to the related laws or regulations as well as the internal standard of the customer Note that the ga...

Page 48: ...ve wire cut the wire using a plier B Turning the parameter adjusting knob during the wire feeding can adjust the feed speed TIPS Wire feeding is also enabled by a remote control optional Turning the welding current adjustment knob can adjust the feed speed 6 8 Operation of Analog Remote Control Optional Do not look into the tip of the welding torch during the inching operation Do not bring the tip...

Page 49: ...ching gas check or reading saving of the welding condition In using the analog remote control however the adjustment of current voltage by the analog remote control is available The erroneous operation prevention function does not need any password to release the lock To allow only selected personnel to change the welding conditions use the protection function of the welding conditions which requi...

Page 50: ...s of welding operation is completed by the torch switch operation 6 6 3 Crater setting B 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 result display on the digital meter in a flashing mode except for the output at crater filler B At the end of welding the Welding time Total welding time Total wire con...

Page 51: ...e start and completion of the welding operation can be controlled by the torch switch operation 6 7 2 55 F81 TIG Mode torch switch setting 5 6 2 Operation during welding This section explains the operation requiring adjustment of welding current voltage during the welding The welding current voltage can be adjusted during each sequence such as welding under initial condition welding condition or c...

Page 52: ...s operation is not necessary Turn the parameter adjustment knob for the remote control the welding voltage adjustment knob to adjust the welding voltage 4 Press the DISPLAY CHANGE key B The displays on the left right digital meters return to the display of current voltage in welding B The LED for the welding sequence returns to the flashing mode TIPS When no operation is performed for approximatel...

Page 53: ...gas piping is discharged 3 After the shield gas is discharged press the GAS CHECK key B 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 B The power LED switch lights off 6 Shut off the input power Operate the disconnect switch to shut off the input pow...

Page 54: ... 10 0 to 30 0 V 23 5 V 21 5 V initial crater Voltage SYNERGY 1 100 to 100 3 0 to 3 0 MS MIG 0 Post flow time 0 to 10 sec 0 4 sec Set the gas discharge time after the welding ends Arc spot time 0 1 to 10 sec 3 sec Set the welding time at arc spot Arc characteristics 10 to 10 0 Set the arc to the condition from soft to hard Welding condition memory No 1 to 100 1 Register the welding conditions stora...

Page 55: ... condition 㾎 F8 Welding result display time 0 to 60 20 s Sets the display time for the current voltage after completion of welding F9 Analog remote control scale 200 350 350 A Configures the settings of scale plate of the analog remote control F10 Motor over current detection level 20 to 150 70 Sets the over current warning level for the rated current of the wire feed motor F11 Fine adjustment of ...

Page 56: ...justment 10 to 10 0 A Adjusts the voltage output value Is used when calibration of welding current or voltage is needed F40 Fine adjustment of Output current gain 0 99 to 0 99 0 00 A F41 Output voltage gain adjustment 1 0 to 1 0 0 0 V Adjusts the current output value Is used when calibration of welding current or voltage is needed F42 Fine adjustment of output voltage gain 0 09 to 0 09 0 00 V F43 ...

Page 57: ...th automatic machine made by other manufacturer F56 Arc start error detection time F57 WCR output ON delay time F58 WCR output OFF delay time F59 Analog setting switch F60 Pulse peak current fine adjustment 150 to 150 0 A Sets the adjustment value of pulse peak current in pulse welding 㾎 F61 Pulse peak time fine adjustment 1 5 to 1 5 0 0 ms Sets the adjustment value of pulse peak time in pulse wel...

Page 58: ...ached to wire feeder and intelli torch 2 Push Pull torch 3 Inline Assist feeder F80 Switching of CAN communication speed 0 1 2 3 0 Sets the connection speed of the CAN connection 0 500kbps 1 1Mbps 2 125kbps 3 250kbps F81 TIG Mode switch setting OFF ON OFF During TIG MODE operating the torch switch can control the welding start and end F82 Extended correction for DC Pulse welding 0 to 30 0 If DC pu...

Page 59: ... will be 10 times larger 4 UNIT CHANGE key Switches between welding current wire feeder speed when the left digital meter is selected When the right digital meter is selected and when the SYNERGIC mode is selected as the welding voltage adjustment method pressing this key switches the value displayed on the right digital meter between fine adjustment value and actual voltage value In the SYNERGIC ...

Page 60: ...cted by the WELDING METHOD menu 6 6 9 Adjustment of wave frequency Pressing this key makes the LED lit enabling to adjust the wave frequency by the parameter adjustment knob The set wave frequency is displayed on the left digital meter 13 EN ratio key Not used on this model 14 WIRE INCH key Feeds the wire 5 4 Wire Inching The LED lights during when the key is pressing allowing the wire to be fed T...

Page 61: ...rs ὶ㺨㺽㺷㺛 1 0 7 2 1 6 7 17 5 KHQ ZHOGLQJ LV XQVWDEOH ZLWK WKH ORQJ H WHQGHG SRZHU FDEOH RYHU P OHQJWK WHQGHG FDEOH PRGH PD LPSURYH ZHOGLQJ VWDELOLW 2 67 1 5 PRGH 21 WHQGHG SRZHU PRGH ࠉ 6WDQGDUG WHQGHG FDEOH PRGH 0 18 6 7 17 5 81 7 216 0 18 20 6 7 17 5 0 18 6 7 17 5 HOME screen MENU screen Setting screen Screen of function setting Displays current setting welding conditions Cursor The screen switche...

Page 62: ...ng CRATER FILL Select the crater treatment method or arc spot at the end of welding For details of the crater treatment 6 6 4 Crater setting For details of arc spot 6 6 5 Arc spot time SPOT TIME Sets the arc spot time This item is displayed when ARC SPOT is selected by the CRATER FILL menu 6 6 5 Arc spot time INITIAL CONDITION When CRATER FILL ON is selected by the CRATER FILL menu the sequence of...

Page 63: ...ding current voltage shield gas type and wire type wire diameter currently set and reads them out for use Synergic adjustment of voltage 6 2 Function on Operation Panel Using the VOLT ADJUST menu enables to automatically set the welding voltage according to the welding current Fine adjustment of the welding voltage automatically set is also available Penetration control 6 6 8 Penetration control a...

Page 64: ...le for the welding condition 10 3 Materials for Setting Welding Conditions Setting wire material shield gas and travel speed 6 6 1 Welding mode setting Setting wire diameter 6 6 1 Welding mode setting Setting crater treatment 6 6 4 Crater setting Setting pre flow Setting gas discharge time 6 6 3 Setting welding parameter Setting initial condition Setting welding current voltage 6 6 3 Setting weldi...

Page 65: ...e registered welding condition can be read out for use Turn the screen operation knob and point the cursor to SAVE JOB Press the screen operation knob B The JOB No registration No is displayed on the right digital meter in a flashing mode and the LED of JOB lights up B 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 reg...

Page 66: ...LED of JOB lights up B 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 B If the welding condition corresponding to the selected JOB No is not registered no data is displayed on the LCD panel and will flash on the left digital meter B When there is no registration data on...

Page 67: ...MENU is displayed on the LCD panel Release the keys after USER MENU is displayed Turn the screen operation knob and point the cursor to Delete JOB Press the screen operation knob B dEL is displayed when the system transits to the DELETE mode B The JOB No registration No is displayed on the right digital meter in a flashing mode and the LED of JOB lights up To delete all the registration at the sam...

Page 68: ...arts flashing To cancel the deletion turn off the power switch B The welding condition of the selected JOB No is deleted and End is displayed on the left right digital meters WELDING METHOD GAS 1 WIRE MATERIALS WIRE DIA in mm TRAVEL SPEED Penetration adjustment DC CO2 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD 2 HIGH Enable MAG 20 CO2 1 1 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 STANDAR...

Page 69: ...1 16 1 2 1 6 STANDARD HIGH MS MIG MIG 100 Ar 1 3 HARD ALUMINUM 1 16 1 6 STANDARD HIGH DC TIG DC STICK 1 Note that the collective voltage adjustment may not meet the appropriate condition if a mixing gas other than those with the following mixing ratios is used 1 1 MAG gas Argon Ar 80 Carbon dioxide CO2 20 1 2 MIG gas Argon Ar 98 Oxygen O2 2 1 3 MIG gas Argon Ar 100 2 For STANDARD mode the standard...

Page 70: ...t penetration Turn the screen operation knob and point the cursor to the WELDING METHOD Eg DC PULSE Press the screen operation knob B The setting screen of welding conditions of WELDING METHOD will be displayed Turn the screen operation knob and point the cursor to the changing item Press the screen operation knob B Change of the welding method is confirmed and the screen returns to the HOME scree...

Page 71: ... set the welding parameters gas discharge time welding current voltage according to the welding sequence 1 Set the gas discharge time Press the DISPLAY CHANGE key and select the LED of PRE FLOW or POST FLOW Turn the parameter adjustment knob to set the gas discharge time The set parameter is displayed on the left digital meter Process Description PRE FLOW It is the sequence to discharge gas before...

Page 72: ...regardless of the welding current B The set value is displayed on the right digital meter TIPS Switch the mode by the VOLT ADJUST menu 6 6 6 Welding voltage adjustment The mode set by the VOLT ADJUST menu is applied all of the conditions INITIAL CONDITION MAIN CONDITION CRATER FILL CONDITION 4 Register to the memory as necessary 6 5 Memory Function of Welding Conditions 6 6 4 Crater setting This s...

Page 73: ...rater condition after the main welding 6 7 2 28 F45 F46 F47 Special crater sequence effective initial standard time setting crater standard time setting 6 6 4 1 Crater OFF Select CRATER OFF by the CRATER FILL menu In synchronous to the ON OFF operation of the torch switch the welding starts stops Torch switch Gas flow Output voltage Wire feeding speed Welding current Main welding Anti stick time O...

Page 74: ...tch should remain depressed and held during the CRATER phrases When selecting CRATER FILL ON no pulse Regardless of the setting by the WELDING METHOD menu the machine automatically turns to the welding with no pulse when the crater fill process starts When selecting CRATER FILL ON with pulse When DC PULSE or DC WAVE PULSE is selected by the WELDING METHOD menu the machine automatically turns to th...

Page 75: ...emain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON no pulse Regardless of the setting by the WELDING METHOD menu the machine automatically turns to the welding with no pulse when the crater fill process starts When selecting CRATER FILL ON with pulse When DC PULSE or DC WAVE PULSE is selected by the WELDING METHOD menu the machine automatically turns to th...

Page 76: ...he nozzle for arc spot see the instruction manual of the torch 6 6 6 Welding voltage adjustment This section explains how to adjust the welding voltage The adjustment of welding voltage can be carried out either by the SYNERGIC mode or INDIVIDUAL mode TIPS Some conditions such as synergic condition does not meet the appropriate level if a mixing gas ratio of shield gas is not the specified value 6...

Page 77: ...in low current region and soft in high current region When using an extended cable for the base material side torch side or using an extended torch cable it is likely that good welding can be performed by adjusting it to hard 6 6 8 Penetration control adjustment This section explains how to adjust the penetration control Using the constant penetration function enables to automatically adjust the w...

Page 78: ...re 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 METHOD menu Wave pattern of the welding bead may not appear clearly depending on the temperature heat input during welding When using hard aluminum or soft aluminum bead surface may blacken somewhat ...

Page 79: ...he weld joint that needs to be changed Adjust the value between 0 5 to 32 Hz Turn the screen operation knob and point the cursor to WELDING GUIDE then press the screen operation knob B WELDING GUIDE screen is displayed B The color of the selected parameter will be inverted on the display Turn the screen operation knob to place the cursor on the parameter that needs to be set and press the knob B C...

Page 80: ...the combination of welding conditions The WELDING GUIDE function cannot be used when an analog remote control optional accessory is connected B and will be displayed above and below the plate thickness value and the value becomes adjustable B Welding current will be set automatically according to the WELD JOINT and plate thickness B The welding current is displayed on the left digital meter B and ...

Page 81: ...ed at the point when the setting value is changed To change the set values of internal functions ensure that there is no mistake in the function No as well as in the function setting 1 Display FUNCTIONS in the MENU screen 2 Turn the screen operation knob to display the function No to set 3 Press the screen operation knob B The display on the right digital meter changes to a flashing mode Turn the ...

Page 82: ...splayed at the welding method menu in HOME screen OFF Standard mode TIPS In using the welding power source in the HIGH mode the setting of this function is set to OFF and cannot be changed When the status is not improved even by setting of this function to ON combined use of the voltage detection cable is recommended When using the voltage detection cable set the internal function F38 Arc voltage ...

Page 83: ... power source Retract function 3 Disabled Enabled Error reset 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 4 1 In the Auto mode voltage to release welding is output for approx 0 2 seconds after the anti stick process This voltage i...

Page 84: ... adjust the time period changing from the welding current to the crater current downslope time longer Setting range of downslope time 0 0 to 10 0 sec 6 7 2 7 F8 Welding result display time Set the time period for the output current and voltage to be displayed on the left right digital meters in a flashing mode after the completion of welding Set the display time in the flashing mode The value of d...

Page 85: ...emi auto mode is set to 0 OFF disables the function 1 to 30 enables the function Turning the welding current adjustment knob on the analog remote control enables to fine adjust the current and turning the voltage knob enables to fine adjust the voltage Setting range 1 to 30 Turning both of the current and voltage knobs to the center of scales sets the welding conditions to those stored on the weld...

Page 86: ... F14 Start control time adjustment Set the current in the range from 100 to 100 A through F15 Start control current adjustment TIPS When DC pulse or DC Wave Pulse is selected as welding method the time set in internal function F14 is deactivate 6 7 2 13 F16 Slowdown speed adjustment Slow down speed is the speed to slowly feed the wire from the time of the machine start to the time of arc start The...

Page 87: ...urce can be stopped Yet for some alarm codes it is possible to continue welding even if the alarm level is detected which may sometimes cause the alarm display to be ignored Using the alarm setting switch function ensures to stop the output from the welding power source ON any alarm detection stops the output of welding power source OFF alarm detection does not stop the output of welding power sou...

Page 88: ...Each pressing the UNIT CHANGE key the wire feed speed display and the welding current display switches alternatively Switch to the wire feed speed display and set the feed speed in the unit of 3 9 IPM 0 1 m min Switching to the welding current display can check the welding current value automatically set In using the welding power source in the automatic machine mode refer to the following diagram...

Page 89: ...External output terminal setting Through F25 you can set the functions of OUT EXT1 3 4 on the terminal block for external connection Through F26 you can set the functions of OUT EXT2 5 6 on the terminal block for external connection Through F27 you can set the functions of OUT EXT3 7 8 on the terminal block for external connection Through F28 you can set the functions of OUT EXT4 9 10 on the termi...

Page 90: ...OFF open OFF open OFF open 2 ON close OFF open OFF open OFF open 3 OFF open ON close OFF open OFF open 4 ON close ON close OFF open OFF open 5 OFF open OFF open ON close OFF open 6 ON close OFF open ON close OFF open 7 OFF open ON close ON close OFF open 8 ON close ON close ON close OFF open 9 OFF open OFF open OFF open ON close 10 ON close OFF open OFF open ON close 11 OFF open ON close OFF open ...

Page 91: ...t terminal signals welding method is optimized The relationship between the welding method and the signal is as follows Welding method External input terminal DC PULSE switch WAVE PULSE PULSE switch DC pulse OFF open OFF open DC ON close OFF open ON close DC Wave Pulse OFF open ON close Secondary condition current ON OFF 1 Primary condition current 5 2 1 㻌㻌㻌 OPEN CLOSE OPEN OPEN CLOSE OPEN 㻌䠥䠪 ...

Page 92: ...et to 1 When using a reverse polarity wire set this function to 2 6 7 2 24 F39 F40 Output current gain adjustment If there is difference between the current value indicated on the digital meter and the actual output current value the difference can be calibrated through adjustment of F39 F40 The output current value that can be changed by F39 is 1 which is equivalent to 1A The value that can be ch...

Page 93: ...ise and to reduce the welding voltage turn the knob counterclockwise The fine adjustment range for welding voltage is up to 20 OFF disables the function In the following cases this function cannot be used Welding conditions are not registered to the memory Analog remote control optional is not connected to the welding power source Internal function F11 Fine adjustment of welding conditions memory ...

Page 94: ... function F45 is set to ON automatically the setting of special crater is selected disabling other welding modes The CRATER FILL menu does not work Welding method at crater treatment is the same as that of main welding In the following cases this function cannot be used Internal function F11 Fine adjustment of welding conditions memory is set to 1 to 30 enabled Internal function F44 Reading weldin...

Page 95: ... double clicking Single 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 as that of main welding Example In the setting examples of Crater setting ON Initial condition OFF Welding current 100 A Crater current 60 A F48 ON F49 10 and F50 20 the followin...

Page 96: ...sequence start input holding It is available to return to the main welding as many times as needed even after transit to the crater treatment by single clicking of the torch switch When this function is enabled special crater repeat is displayed in the HOME screen OFF disables the function TIPS When this function is set to ON automatically the setting of CRATER FILL ON Repeat is selected disabling...

Page 97: ...on enables to start the wire feeding speed with the normal feeding speed without slow down after the welding completion which enables the tack welding of less transition time ON Pressing the torch switch within 0 5 seconds after the welding completion can start it with the normal feeding speed The wire feeding speed at this time is not exceeding 197 IPM 5 m min OFF disables the function 6 7 2 36 F...

Page 98: ...lse condition first adjust the pulse peak time When large droplet and unstable arc droplet transfer occurs adjust to a longer pulse peak time Adjust to a shorter pulse peak time when tip of wire becomes sharp and extremely strong arc occurs For more improvement adjust the pulse peak current following the same steps as pulse peak time adjustment TIPS Maximum pulse peak current which can be output v...

Page 99: ...lse welding by setting the adjustment value finely adjusted pulse base current at LOW side can be obtained Set the adjustment value in the range of 60 to 60 A Fine adjustment of unit pulse condition 6 7 2 37 F60 Fine adjustment of pulse peak current Fine adjustment of unit pulse condition Example of current waveform of wave pulse welding 6 7 2 43 F66 Adjustment of feed amplitude ratio This functio...

Page 100: ...it is difficult to perform fine current adjustment with the knob of the analog remote control when welding in the low current region fine current adjustment will be easier if this function is used to lower the upper limit Setting range of the value 20 to 400 A TIPS When using in DC STICK welding the upper current setting limit will be 300 A 6 7 2 48 F71 Interval welding function This function repe...

Page 101: ...pre flow to avoid an unexpected torch switch operation ON If welding is not performed for five seconds after the pre flow Error code E 011 is displayed on the left and right digital meters and the output of the welding power source stops OFF disables the function 9 1 Action in Case of Error 6 7 2 53 F79 Switching of CAN communication connection device Set the connection device to be used for the C...

Page 102: ...plunges into base metal Adjustment of this parameter may stabilize the welding Setting range of the value 0 to 30 Increase the adjustment value if the length of the extended cable is long or when the cable is turned several times The following is a rough indication of the adjustment value according to the number of turns of the cable when the length of the extended cable is 99 ft 30 m 6 7 2 57 F83...

Page 103: ... state The retained adjustment amount can be checked in internal function F85 Adjustment amount of pulse automatic adjustment 2 Pulse mode for automatic adjustment Fixing of adjustment value Sets the adjustment amount of pulse automatic adjustment at a fixed value currently retained value so that the adjustment amount will not be updated even if welding is carried out The adjustment amount of puls...

Page 104: ...ue displayed on the digital meter is obtained by software processing of the average value of outputs therefore it may not be consistent with the value indicated on a needle meter etc When this happens using this function enables to finely adjust the current display value For F86 set gain and for F87 set offset Changing the set value only corrects the display the output welding current does not cha...

Page 105: ...t is automatically set and fine adjustment is available for the set welding voltage Align the welding voltage adjustment knob to the center mark and adjust the voltage with the position as the standard INDIVIDUAL adjustment The welding voltage can be individually adjusted without being influenced by the welding current 3 Inching button Feeds the wire 5 4 Wire Inching During when the button is pres...

Page 106: ... 6 4 Crater setting CRATER FILL OFF CRATER FILL ON with pulse CRATER FILL ON No pulse 2 Gas check 5 3 Power ON and Gas Supply OFF OFF ON 3 Constant penetration 6 6 8 Penetration control adjustment OFF OFF ON 4 Tack Start 6 7 2 35 F54 Tack start process OFF OFF ON 5 Read out of welding conditions 6 7 2 27 F44 Reading welding conditions with remote control OFF OFF ON 6 Welding method 6 6 2 Setting w...

Page 107: ...evention function is disabled NOTE Write down the password on a piece of paper and store it safely The current password will be requested also when you change it If a password is set and the erroneous operation prevention function is enabled the erroneous operation prevention function will not be disabled even if the power is turned off and on or if the welding conditions and internal functions ar...

Page 108: ... To change the password delete the password with the operation from the step 3 of 7 1 2 Disabling erroneous operation prevention and go to the next step If a password has not been set yet the Password Setting screen will be displayed on the LCD panel Check that the Password Setting screen is displayed and go to the next step B The color of the selected digit will be inverted on the display B The n...

Page 109: ... prevention function the password will be requested 7 1 2 Disabling erroneous operation prevention This section explains how to disable the password protected erroneous operation prevention function 1 Display KEY LOCK in the MENU screen 2 Turn the screen operation knob to select the digit that needs to be entered and press the knob To cancel setting of the password turn off the power switch Turn t...

Page 110: ...e password changing or deleting operation the screen will shift to the Password Setting screen 7 1 1 Setting Changing password B The number is confirmed and the display will change from color inversion display to digit selection display To cancel deleting the password press the CANCEL key B When the number matches the set password Password OK is displayed on the LCD panel and the lock will be rele...

Page 111: ...on P20 0 00 Cumulative wire consumption used in welding lbs kg P21 0 0 to 9999 0 to 4535 Target wire consumption lbs kg P22 0 0 to 5 Operation at the time when the target wire consumption is achieved Total welding time P30 0 Cumulative total welding time minute P31 0 0 to 9999 Target total welding time minute P32 0 0 to 5 Operation at the time when the target total welding time is achieved Welding...

Page 112: ... to 9999 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 6 Alarm indication when target is achieved P12 Operation at the time when the target value of welding points is achieved Select the operation from 0 to 5 for the time when the target specified for P11 is achieved The set values and operations when the ...

Page 113: ... achieved 7 2 2 6 Alarm indication when target is achieved P22 Operation at the time when the target wire consumption is achieved Select the operation from 0 to 5 for the time when the target specified for P21 is achieved The set values and operations when the target is achieved are the same as those of the P12 function P12 Operation at the time when the target number of welding points is achieved...

Page 114: ...oltage average per second during welding is out of the allowable tolerance range When the out of range state becomes longer than the time specified here an alarm displays 7 2 2 7 Alarm indication at the time of WARNING detection Welding Monitor P45 P46 If 0 is set WARNING detection will not be performed P46 Operation at the time of WARNING detection Select the operation at the time of WARNING dete...

Page 115: ...P51 P52 Clear of the control data value Clear the various control data After setting the setting value of P52 to cLr return to the MENU screen Then the control data shown below will be cleared 7 2 2 6 Alarm indication when target is achieved When any of the number of welding points wire consumption and total welding time reaches the target specified its corresponding control No will flash 7 2 2 7 ...

Page 116: ...ol No P40 flashes on the left digital meter and the difference between the average value and specified value 1 5 on the right digital meter with the A LED lighting In case of voltage error the difference between the average voltage and specified voltage is displayed in one decimal place The display returns to the normal state when any key of the operation panel is pressed If continuous operation i...

Page 117: ...ime 0 1 s pre_uni_vset Initial voltage synergic 1 dwn_slp_tim Down slope time 0 1 s wld_iset Welding current 1 A pre_tim Initial time 0 1 s wld_vset Welding voltage 0 1 V cre_tim Crater time 0 1 s wld_uni_vset Welding voltage synergic 1 KubireAutoAdj Automatic correction of squeeze 0 1 OFF ON cre_iset Crater current 1 A KubireAutoSave Saving squeeze cre_vset Crater voltage 0 1 V KubireP1P Spatter ...

Page 118: ...er A csv file will be created per welding pls_bsi_adj Base current fine adjustment 1 A pre_uni_fset Initial arc length adjustment value when MS MIG is selected 0 1 lpls_pki_adj L pulse peak current fine adjustment 1 A cre_uni_fset Crater arc length adjustment value when MS MIG is selected 0 1 lpls_pkt_adj L pulse peak time fine adjustment 0 1 ms Interval Interval welding 0 1 OFF ON lpls_bsi_adj L ...

Page 119: ...apacity 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 error code is displayed error code is output on the left right digital meters In that case back up...

Page 120: ...ack 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 Insert the USB flash drive to the USB connector of the operation panel 3 Display BACKUP in the MENU screen Turn the screen operation knob to place the cursor o...

Page 121: ...play the data to back up on the right digital meter B The display changes in order of ALL 1 2 3 4 B ALL means that all the data 1 to 4 available for backup are selected B Details of the numbers displayed B Flashing of the left right digital meter displays will stop and the display changes to the light up mode B Data backup starts During backup the display of right digital meter changes B When back...

Page 122: ...operation knob to place the cursor on RESTORE and press the knob B ALL or JOB No registration No is displayed on the right digital meter in a flashing mode and the LED of JOB lights up B USb is displayed on the left digital meter Turn the parameter adjusting knob further counterclockwise to display the data to import on the right digital meter B The display changes in order of ALL 1 2 ALL means th...

Page 123: ...ions registered in memory NOTE F39 to 42 will not be initialized 1 Turn OFF the power switch 2 Press and hold the WIRE INCH key and left DISPLAY CHANGE key simultaneously and turn ON the power switch 3 Check that End is displayed on the left right digital meters and turn OFF the power switch B The power LED switch lights off The status returns to normal when the power switch is turned on B Importi...

Page 124: ...o normal when the power switch is turned on B The product information will be displayed on the LCD panel When the screen operation knob is turned information on the peripheral equipment will be displayed Not connected if not connected To return to the MENU screen after checking press the CANCEL key B The Product No is displayed on the left and right digital meters B The display changes every time ...

Page 125: ...section of 38 mm2 or more The following methods can be carried out to form a short circuit 1 Connect a cable having cable connectors at both ends specification DIX SK 50 part No 4734 016 to the welding power source 2 Directly tighten the torch side cable for connecting to wire feeder and base metal side cable using a bolt and nut 2 Connect an external ammeter or a measuring device that can measure...

Page 126: ... 1 Connect a resistance load 0 1 Ƙ 12 6 kW or more to the output terminal If no resistance load is applied open the circuit between the output terminals 2 Connect an external voltmeter and a voltage detection line to both ends of the resistance load if no load is applied connect to the output terminal 3 While both DISPLAY CHANGE keys are pressed at the same time turn ON the power switch 4 Turn the...

Page 127: ...voltage increase the value to side If the output current needs to be adjusted finely change the value of F42 When the value of F42 is 0 01 it is equivalent to the output current of 0 01 V 8 When you have adjusted the output voltage turn ON the torch switch to confirm the adjusted result Make sure that the difference between the measured value and the value indicated on the operation panel is withi...

Page 128: ...l be displayed Font Size LCD Background Turn the screen operation knob to select the Font Size from Standard and Large and press the knob Turn the screen operation knob to select the background color White Black The background color will switch every time the knob is pressed Language Turn the screen operation knob to select the language and press the knob RQW 6L H㸸 6WDQGDUG DFNJURXQG㸸 DQJXDJH㸸 QJO...

Page 129: ...ee 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 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 inver...

Page 130: ...utral detergent wring it well and wipe off the dirt Do not use organic detergent or chemical agent Doing so may cause crack breaking and degrade the strength If there is any abnormality in the plastic parts such as front panel rear panel and fan immediately stop the use and contact your dealer Daily inspection item Content Status of the grounding cable Check that the grounding terminal on the back...

Page 131: ...of the bearing Periodical inspection item Inspection work Grounding wire Refer to the description for the same item in 8 2 Daily Inspection Each cable Primary power cable for facility side cables for base metal side torch side torch cable voltage detection cable etc Welding torch Check that there is no deterioration damage or other abnormality in consumable parts of the welding torch Abnormality i...

Page 132: ...accumulating on the fin or winding of heat sink can cause insufficient heat radiation Remove the left side panel and fan frame and check the dirt inside If there is heavy dirt blow the fin and coils of heat sink directly with compressed air to remove dust inside Periodical inspection item Inspection work Heat sink Fan Fan Connector Connector Fan frame Fan frame ...

Page 133: ... source and damage of the high voltage electrolysis capacitor or other parts It is recommended to replace the printed circuit board PCB7 every five years For replacement of the printed circuit board PCB7 contact your dealer Others Fan relay and rated power supply has a certain lifetime they are recommended to be replaced once in approximately five years When replacement of fan relay and rated powe...

Page 134: ...gative output side Short circuit between TR1 C1 and E1C2 TR1 E1C2 and E2 TR3 C2 and E2 TR5 C and E TR6 C and E 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 measurement should be conducted by qualifie...

Page 135: ...appropriate action according to the table below If the welding power source is combined with robots manufactured by OTC see the instruction manual of the robot controller Before inspecting the welding power source make sure to read 8 1 Precautions for Maintenance and Inspection CAUTION If an error code not listed in the table is displayed write it down on paper turn off the power switch and contac...

Page 136: ... Primary Side HCI Communication Error NAK Resending Over E 054 Communication Error in Control Board Primary Side HCI Communication Error Application Parameter E 055 Communication Error in Control Board Secondary Side HCI Communication Error Timeout E 056 Communication Error in Control Board Secondary Side HCI Communication Error Watchdog E 057 Communication Error in Control Board Secondary Side HC...

Page 137: ...side the welding power source 8 3 Periodical Inspection The error code will disappear when the power switch is turned off After recovery be careful not to exceed the rated duty cycle E 310 to 313 Rotation problem of the cooling fan 2 Clean dusts inside the welding power source 8 3 Periodical Inspection Cooling fan may not work normally due to powder dust or foreign matter If the problem persists t...

Page 138: ...Printed Circuit Board Inline Assist Feeder Driver Error E 820 The current in the wire feeder motor exceeded the warning level 2 Check that the wires are not stuck or there are no other abnormalities in the welding torch or wire feeder The error code will disappear when the power switch is turned off The E 820 indication will disappear when any key of the operation panel is pressed E 821 Push Pull ...

Page 139: ...nd Inspection No Problem Possible cause Corrective action 1 The power switch has tripped Leak has occurred in the welding power source DO NOT turn on the power switch Contact your dealer 2 The power LED switch does not light even when the power switch is turned on The primary power source is not supplied Supply the primary power source 208 230 460V 10 3 Nothing is displayed on the left right digit...

Page 140: ...lfunction of the operation panel is enabled Erroneous operation prevention function Release the KEY LOCK to disable the erroneous operation prevention function the operation panel 5 5 2 Preventing erroneous operation on operation panel 11 Arc is unstable The setting of welding mode is not correct Check the settings of wire diameter wire materials and shield gas The wire is defective or there is a ...

Page 141: ...41B00 Inverter transformer P30141B00 1 T2 W W03830 Transformer W W03830 1 L1 P30086L00 Input reactor P30086L00 1 L2 P30124C00 DC reactor P30124C00 1 L3 100 1950 Ferrite core TW70W R402715 2 L4 to 5 100 2321 Ferrite core TW70W R311019 2 L6 100 0620 Ferrite core SN 20 OR23 5 9 5 12 6 2 L7 P30194C00 Reactor P30194C00 1 THP2 100 2216 Thermostat US 602SXTTAS 284 F 140 1 THP3 4258 040 Thermostat 67L085 ...

Page 142: ... P30086G02 Mold cover P30086G02 2 Under side cover 3 P30344W02 Operation panel sheet P30344W02 1 4 W W03636 Cap W W03636 1 For P30086G01 5 4734 007 Socket DIX BE 50 70 2 6 100 1436 Handle cover DCP73BH 3POLE H HANDLE COVER 1 For NF 7 4739 476 Cap W W02814 2 For CON1 2 8 4735 038 Knob K 100 22RSB 2 Parameter adjusting knob 9 4735 039 Cap K 100 22CSBL 2 10 100 0201 Fixed type caster 420SR RD50 4 11 ...

Page 143: ... 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 source ...

Page 144: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 142 10 2 1 Schematic diagram P30086V00 P30086Q00 P30194X00 P30086V00 P30133M00 1 QRW FRQQHFWHG 1 QRW FRQQHFWHG ...

Page 145: ...3 Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 P30099P00 P30087T00 P30087Q00 P30086S00 P30086T00 P30304R00 1 WR WR ȼ WR WR QRW FRQQHFWHG 1 QRW FRQQHFWHG 1 QRW FRQQHFWHG ...

Page 146: ...oved C11 C12 T1 P30304R00 Rear side of operation panel PL1 TM5 NF 6 CON1 7 CON2 7 5 2 1 4 3 8 9 Front P30087Q00 P30099P00 FM4 Top R19a b P30087V00 CT1 P30086V00 P30087T00 P30086T00 SH TM6 Right side T2 10 10 P30194X00 R12 R11 DR2 to 5 8 9 CT2 P30124M00 TR1 to 4 R18 Back of P30124M00 DR1 R16 DR7 SCR1 R17 C7 DR6 C8 C8 CT3 TR5 R28 R29 11 Back P30086S00 When the cover is opened ...

Page 147: ...o low The wire contacts the base metal and spatter is generated The bead width becomes narrow The welding current is too high The bead width becomes wide Penetration and bead become large The travel speed is too high The bead width becomes narrow Penetration and bead become small Plate thickness t in mm Leg length L in mm Wire diameter in mm ƕ Current A Voltage V Travel speed IPM cm min CO2 gas fl...

Page 148: ...32 16 to 20 40 to 50 32 to 42 15 to 20 23 64 9 0 15 64 to 5 16 6 0 to 8 0 045 1 2 300 to 350 32 to 34 16 to 18 40 to 45 32 to 42 15 to 20 15 32 12 0 25 64 to 15 32 10 0 to 12 0 045 1 2 320 to 350 33 to 36 10 to 14 25 to 35 42 to 53 20 to 25 Plate thickness t in mm Root opening g in mm Wire diameter in mm ƕ Current A Voltage V Travel speed IPM cm min CO2 gas flow rate CFH L min Number of layers 18 ...

Page 149: ...0 32 to 35 12 to 14 30 to 35 42 to 53 20 to 25 Back 1 16 1 6 380 to 420 36 to 39 14 to 16 35 to 40 42 to 53 20 to 25 Front 380 to 420 36 to 39 14 to 16 35 to 40 42 to 53 20 to 25 Back 3 4 19 0 13 64 to 9 32 5 to 7 1 16 1 6 400 to 450 36 to 42 10 to 12 25 to 30 42 to 53 20 to 25 Front 2 400 to 450 36 to 42 10 to 12 25 to 30 42 to 53 20 to 25 Back 1 16 1 6 400 to 420 36 to 39 18 to 20 45 to 50 42 to...

Page 150: ... 2 280 30 16 40 052 1 4 350 32 20 50 1 16 1 6 380 34 26 65 5 16 8 045 1 2 300 31 12 30 052 1 4 350 33 18 45 1 16 1 6 380 34 20 52 23 64 9 045 1 2 320 32 12 30 052 1 4 350 34 16 40 1 16 1 6 380 34 16 40 Joint shape Plate thickness t in mm Wire diameter in mm ƕ Gap in mm Current A Voltage V Travel speed IPM cm min Butt joint 19 5 ga 1 0 030 to 040 0 8 to 1 0 0 50 to 55 13 to 15 16 to 22 40 to 55 18 ...

Page 151: ...4 6 0 0 2 6 1 200 27 to 28 16 40 5 16 8 0 0 3 8 1 250 29 to 30 14 35 15 32 12 0 0 4 10 1 180 to 200 25 to 27 18 45 2 180 to 200 25 to 28 18 45 3 180 to 200 25 to 28 18 45 5 8 16 0 0 5 12 1 220 to 230 25 to 28 18 45 2 220 to 230 25 to 28 18 45 3 210 to 220 25 to 28 18 45 Plate thickness t in mm Shape of joint weld Current A Voltage V Travel speed IPM cm min Remarks 12 ga 2 3 Butt 100 22 to 23 28 70...

Page 152: ...Voltage V Travel speed IPM cm min 15 64 6 0 1 170 25 to 26 12 30 2 180 26 to 27 12 30 23 64 9 0 1 270 29 to 30 12 30 2 290 30 to 31 12 30 15 32 12 0 1 280 30 to 31 16 40 2 330 33 to 34 16 40 3 4 19 0 1 300 31 to 32 18 45 2 300 31 to 32 18 45 1 340 32 to 33 18 45 2 280 30 to 31 18 45 63 64 25 0 1 300 31 to 32 18 45 2 320 32 to 33 18 45 3 320 32 to 33 18 45 1 340 32 to 33 18 45 2 320 32 to 33 18 45 ...

Page 153: ...50 15 64 6 0 1 130 23 to 24 10 25 2 150 25 to 26 10 25 15 32 12 0 1 180 24 to 25 10 25 2 290 30 to 32 10 25 15 32 12 0 1 180 to 190 24 to 25 10 25 2 200 25 to 26 10 25 3 200 26 to 27 10 25 3 4 19 0 1 180 24 to 25 10 25 2 300 29 to 30 10 25 3 300 29 to 30 10 25 Root path oscillation width 0 1 in 2 mm Number of oscillation 120 times min Bevel shape Number of layers Current A Voltage V Remarks 1 100 ...

Page 154: ...mm Gas flow rate CFH L min 16 5 ga 1 5 045 1 2 60 to 80 16 to 18 24 to 31 60 to 80 0 5 to 0 6 12 to 15 42 20 14 ga 2 0 045 1 2 70 to 80 17 to 18 16 to 20 40 to 50 0 6 15 42 20 1 8 3 0 045 1 2 80 to 100 17 to 20 16 to 20 40 to 50 0 6 15 42 20 5 32 4 0 045 1 2 90 to 120 18 to 21 16 to 20 40 to 50 0 6 15 42 20 15 64 6 0 045 1 16 1 2 1 6 150 to 180 20 to 23 16 to 20 40 to 50 0 6 to 0 7 15 to 18 42 20 ...

Page 155: ... 24 to 31 60 to 80 0 6 15 42 20 5 32 4 0 045 1 2 150 to 170 22 to 24 24 to 31 60 to 80 0 6 to 0 7 15 to 18 42 20 15 64 6 0 1 16 1 6 180 to 210 23 to 25 16 to 24 40 to 60 0 7 to 0 8 17 to 20 42 to 53 20 to 25 Plate thickness t in mm Wire diameter in mm ƕ Current A Voltage V Travel speed IPM cm min Wire feeding length in mm Gas flow rate CFH L min 1 8 3 0 045 1 2 140 to 160 21 to 22 24 to 28 60 to 7...

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