YASKAWA MOTOWELD-E500-6N3 Instruction Manual Download Page 12

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HW0482309

CAUTION

Observe the following cautions to prevent a fire accident caused
by deterioration of welder insulation.

•

Perform all welding and grinding away from welder to
protect welder from spattering and metal powder.

Spatter and metal powder inside the welder may cause a deterioration of insulation
resulting in accidental fire.

•

Be sure to perform maintenance and inspection periodically to prevent
deterioration of insulation caused by accumulation of dust and dirt.

•

If spatter or metal powder enters the inside of the welder, remove it by
forced air sprot after turning OFF the welder and switch in the switch
box.

Spatter and metal powder inside the welder may cause a deterioration of insulation
resulting in accidental fire.

Summary of Contents for MOTOWELD-E500-6N3

Page 1: ...1 YASKAWA MOTOWELD E500 6N3 INSTRUCTIONS Upon receipt of the product and prior to initial operation read this instruction thoroughly and retain for future reference MANUAL NO HW0482309 180368 1CD 0...

Page 2: ...ON Some drawings in this manual are shown with the protective covers or shields removed for clarity Be sure all covers and shields are replaced before operating this product The drawings and photos in...

Page 3: ...ries burns both due to high low temperature electric shock fractures poisoning etc which may cause personnel to suffer aftereffects hospitalization or prolonged out patient medical treatment Moderate...

Page 4: ...ecessarily Any person using a pacemaker must not approach the welder or welding site under operation unless permitted by doctor The welder generates a magnetic field around it during current conductio...

Page 5: ...r gases generated at welding may harm your health When welding within such areas as a tank a boiler or a ship s hold be sure to ventilate sufficiently or use an inhaler etc in order to prevent or offs...

Page 6: ...switch box Even if the input power supply is turned OFF the capacitor may still be charged Be sure to confirm that charged voltage is gone before starting operations Do not use any cable of insufficie...

Page 7: ...metals immediately after welding close to inflammables Remove inflammables at the hidden side when welding ceiling floor or wall Failure to observe this caution may result in fire Tighten and insulate...

Page 8: ...Wear protective glasses to protect your eyes from spatters or slags Scattered spatters or slags may damage eyes or burn the skin Use such protectors as leather gloves clothes with long sleeves leg cov...

Page 9: ...as regulator or our recommended one Read carefully the instruction manual of the gas regulator and observe the precautions before using it Hold the gas cylinder in the exclusive use gas cylinder stand...

Page 10: ...t remove the welder case for maintenance and inspection or repair Take preventive measures not to let other personnel approach the welder or welding sites unnecessarily by putting up a guard fence or...

Page 11: ...it may poke you in the eyes face or body When hanging the wire feeder remove the anti fall fastening from the spool shaft and tighten Failure to observe this caution may cause the wire to be removed f...

Page 12: ...may cause a deterioration of insulation resulting in accidental fire Be sure to perform maintenance and inspection periodically to prevent deterioration of insulation caused by accumulation of dust a...

Page 13: ...on Welder Panel 33 4 2 1 Changing Welding Type 33 4 2 2 User Files 35 4 2 3 Changing P Parameters 35 4 2 4 Changing Common C Parmeters 36 4 2 5 Changing D Parmeters 37 4 2 6 Saving welding Conditions...

Page 14: ...gnosis Function 72 12 1 Starting up the Welder in the Diagnosis Mode 72 12 2 Confirmation of the DIP Switch Set Status 74 12 3 Confirmation of the Software Version 75 12 4 Confirmation of Welder Error...

Page 15: ...of Welding Current 98 15 1 Overview of the Welding Current Calibration Function 98 15 2 Procedure of Welding Current Calibration 99 15 3 Parameters for Welding Current Calibration Function 102 16 Weld...

Page 16: ...teel Refer to the Type on the panel for details Welding Voltage Setting Synergic or independent Can be switched by D1 parameter 13 User File The number of files 3 Panel or robot can be switched by D1...

Page 17: ...fer to Robot Interface Signals Voltage for Starting Point Detecting Function optional Peak value 280V 10 full wave rectification Dimensions W D H 360mm W x 670mm D x 601mm H excluding the protrusion s...

Page 18: ...re starting operations 2 2 Precautions for Grounding 1 Be sure to carry out secure grounding work on the welder for safety If the unit is not properly grounded its case may be charged and operation of...

Page 19: ...se requirements If breaker capacity is insufficient or primary voltage is too high the breaker will be tripped at power on Table 2 1 Power Supply Capacity and Power Cables Power Supply Capacity 30 kVA...

Page 20: ...er to Fig 2 1 Fig 2 2 for proper connections 2 Connection on the Welding Side Refer Fig 2 3 for proper connections For carbon dioxide gas or MAG gas arc welding connect the base metal to the minus cab...

Page 21: ...HW0482309 21 Fig 2 2 Connections at the Rear Face of Welder Exhaust air Exhaust air The cooling fan is the Air suction type...

Page 22: ...HW0482309 22 Fig 2 3 Connections on the Welding side...

Page 23: ...cylinder 2 Insert one end of the supplied rubber gas hose into the outlet of the gas regulator and the other end into the gas terminal inlet of the wire feeder Clamp both ends securely with hose band...

Page 24: ...mixing ratio of MAG gas is content which contributes to constant welding quality Especially for pulse welding improper pulse welding will be resulted if the argon gas ratio is less than 80 Use carbon...

Page 25: ...uct 3 Shading Measures For shaded glasses of helmets or hand shields use filter numbers 8 to 10 of JIS T8141 for welding of thin plates since it has a weak arc beam and the arc must be seen easily On...

Page 26: ...he direction of movement Moreover be sure to stop the welder with casters at a step and move it slowly to prevent any shock sudden Do not move the welder with casters up a slope stairs etc 2 Using a C...

Page 27: ...to prevent falling or shifting Employ a stopper on the casters to fix the welder Over tightening the cover may cause it to deform Do not raise the lift excessively Avoid excessive shock or vibration w...

Page 28: ...r the default setting is print servo When the parameter was changed follow the instructions as follows 1 Keep on pressing the Record button for more than three seconds to save changes 2 The LED indica...

Page 29: ...seconds The gas flow time can be set by the parameter C00 Refer to 4 2 8 2 Turn the valve of the gas cylinder counterclockwise to open 3 Turn the knob of the gas regulator to adjust the flow accordin...

Page 30: ...change any operation other than user file selection Be sure to stop welding before starting the panel operations Fig 4 1 Welder Panel Type Wire m min A V L R 11 12 13 14 15 16 P R M Select Common PRM...

Page 31: ...power supply is turned ON Warning Lamp Lights or blinks when an error occurs The error number is displayed on the digital meter Search Lamp Lights while the starting point detecting function is used H...

Page 32: ...for the selection of saving destination The indicators on the panel are extinguished while the data is being saved If the power supply is turned OFF during this time the data cannot be correctly saved...

Page 33: ...value press the button No 12 Weld Type or leave it without doing anything for 10 seconds and the indicator No 4 Type lights Press the button No 14 Record for 3 seconds or more to save the changed valu...

Page 34: ...O2 2 SUS short circuit 1 2 5 33 0 9 5 46 1 0 5 42 MIG Ar98 CO2 2 SUS Pulse 1 2 5 44 0 9 5 28 1 0 5 30 MAG Ar80 CO2 20 SUS Pulse 1 2 5 32 MIG Ar95 CO2 5 Flux SUS Pulse 1 2 4 43 Pulse 1 2 2 12 Servo tor...

Page 35: ...Record button was pressed When the welding type which is set in the user file is changed the P parameter is initialized and everything becomes the value at 100 4 2 3 Changing P Parameters For details...

Page 36: ...ire m min WF displays the parameter value lighting 2 Press the button No 13 L or R to change the number of blinking digits to one Press the button No 13 L to move the blinking to the left and press th...

Page 37: ...tems are available Follow the instructions to change D parameter as follows 1 Keep pressing the button No 9 Common P R M Select and press the button No 8 P R M Select during standby status The indicat...

Page 38: ...were saved While the data is being saved the panel LED indicators are extinguished If the power supply is turned OFF while the LED indicators are extinguished the data cannot be correctly saved Confir...

Page 39: ...hange in the numerical value of C parameter C00 while the default setting is 20 seconds unit second Press the button No 14 Record for 3 seconds or more to save the changed value Do not turn OFF the br...

Page 40: ...ata in the welder Reset the system only when the software is updated or initialization or when Memory Error Error 14 occurs Be sure that executing System Reset initializes all the internal data If som...

Page 41: ...umber s above the forth digit When the parameter C23 becomes 2004 System reset will be executed The panel LED indicators are extinguished In a few seconds Err 0 starts blinking Now the initialization...

Page 42: ...parameter set values the welding characteristics start main conditions end that are specified by database in the welder can be adjusted according to your environmental conditions All the values are se...

Page 43: ...t P40 Reserved for system Do not change P10 P Pulse time P41 Reserved for system Do not change P11 C Average current at ending VALID when D 1parameter 4 ON P42 Reserved for system Do not change P12 C...

Page 44: ...time 20 s C01 Gas pre flow time 56 ms Gas flowing time before welding output starts minimum 56 ms C02 Gas after flow time 500 ms Gas flowing time after welding output completes C03 Low pulse frequency...

Page 45: ...nt 2 for the user file No 3 C19 Reserved for system 0 Do not change C20 Reserved for system 0 Do not change C21 Reserved for system 41 Do not change C22 Reserved for system 0 Do not change C23 System...

Page 46: ...Enabled Disabled ON 3 Wire slow down Enabled Disabled ON 4 End event End condition processing enabled Disabled ON 5 Display of feeding speed motor current Displays feeding speed Displays motor curren...

Page 47: ...Set Timer instruction about 2 seconds after ARCOF instruction since crater time is about 2 seconds For synergic voltage the voltage that Yaskawa deems adequate is specified as 100 Changing it by 10 vo...

Page 48: ...er of 1 2 mm 10 to 15 mm for wire diameter of 0 9 mm 20 mm for wire diameter of 1 4 mm 5 3 Direction of Welding and Torch Angle There are two types of welding available backhand welding same as manual...

Page 49: ...delayed which may prevent the spatter less pulse welding Use a cable as short as possible for high quality welding Extension cable length one way Extension cable Length one way Voltage drop V Voltage...

Page 50: ...usly for 2 seconds Check the input voltage Err4 Excessive temperature The temperature in the primary or secondary control circuit exceeds the specified value of the welder Check the ambient temperatur...

Page 51: ...e following precautions when before starting welding 1 The welding current flows to the wire while welding Be careful that the welding voltage still remains for two seconds after the welding ends due...

Page 52: ...ses without arc start However the fan restarts rotating when welding starts and it stops approx 15 minutes after the welding ends 6 Stretch a protective curtain for workers and others to protect from...

Page 53: ...o the welding wire and the wire will be fed regardless of the manipulator motion Using Method Follow these procedures to use Arc Start terminal to check the welding voltage output or the motor rotatio...

Page 54: ...FF 1 2 5 Reserved OFF 1 2 4 Reserved OFF 1 2 3 Reserved OFF 1 2 2 Reserved OFF 1 2 1 Reserved OFF 1 3 8 Reserved OFF 1 3 7 Reserved OFF 1 3 6 Reserved ON 1 3 5 Reserved OFF 1 3 4 Reserved OFF 1 3 3 Re...

Page 55: ...he Welder 7 3 1 DIP Switch Settings of the Pr MB 011Board The settings of the Pr MB 011 board are for maintenance Do not change these settings Table 7 2 Settings of DIP Switches SW1 Setting 1 ON 2 OFF...

Page 56: ...Reserved Reserved DJ10 Reserved Reserved 7 4 How to Use the Selecting Switch The selecting switch is installed on the assembly of the printed board as shown in the following figure Change the short c...

Page 57: ...ssively heated 6 There is no part where the connection cable such as a cable on the input side or on the base metal side is damaged resulting in imperfect insulation 7 Each connecting section is tight...

Page 58: ...ts cannot be used continuously for ever Even under normal operation status they are apt to have variation of the characteristics or malfunction after the life elapses Therefore it is recommended that...

Page 59: ...per corrective action with the following sections 9 1 Confirming Setting Conditions If any fault occurs check the following items in Table 9 1 Check Items Afterwards take proper corrective actions fol...

Page 60: ...el 1 from robot Record of changing data After selecting the welding type or changing the parameter save the conditions before turning OFF the welder power supply The changed data will be lost if any o...

Page 61: ...s been correctly adjusted and that the gas cylinder is not empty Gas shielding in the welding section does not properly work because of influence of wind etc When the wind blows hard stop the operatio...

Page 62: ...upply from that of other machines that cause the imbalance Or increase the power supply transformer capacity The welding conditions are not correct Use the test arc to increase or decrease the setting...

Page 63: ...as flow amount is not sufficient let the gas flow 10 to 25 litters per minute and mix argon gas if necessary Or use a gas of better quality Bead form is bad and the appearance is poor The welding cond...

Page 64: ...tip of the chip The welding wire almost buckles Pull the welding wire from the inside of the conduit and pass the welding wire again through the conduit 9 3 Cause and Remedy of Electrical Circuit Sec...

Page 65: ...g command is not sent from the robot side Check the command output at the robot side 5 Welding voltage cannot be changed from the robot side The analog command is not sent from the robot side Check th...

Page 66: ...wire R W Contact input Valid at closed 5 K L ARCON ARCOF instruction Instructions in starting stopping of the welding R W Contact input Valid at closed 6 M N Wire stick detection Sends the output term...

Page 67: ...t current 3 0V 60V 66V for 66V or more Note When using the arc monitoring function refer to 17 Setting of Arc Monitoring Function W R Analog voltage 14 b Z User file selection OP1 15 Y Z User file sel...

Page 68: ...r 600A 60mV and voltmeter 75V Values of the ten s volts for wire stick or ground detection at the robot controller s side may be displayed in the analog voltmeter which is not a failure of the device...

Page 69: ...age of welding wire remaining amount OP W Contact input Valid at closed 5 537 Gas pressure reduced Indicates the shortage of shielding gas pressure OP W Contact input Valid at closed 6 531 Common OP W...

Page 70: ...side drops to approximately 0V while the starting point detecting instruction is ON W R Transistor output ON when 0V sink current of 50 mA or less 3 522 Common Power line on 0V side of the power suppl...

Page 71: ...HW0482309 71 11 Connection System Diagram The figure below shows the connection system diagram of the MOTOWELD E500III...

Page 72: ...TOWELD E500III once and turn ON the main power again while pressing the Record button The diagnosis information is displayed in the LED indicators on the front panel once the Diagnosis mode is launche...

Page 73: ...0III front panel At power ON buttons switch the display Fig 12 1 3 Diagnosis Mode Operation d DIP switch set status C Software version E Error occurrence status Err The number of error occurrence V A...

Page 74: ...LD E500III DIP Switch For displaying the DIP switch status ON OFF status of each switch is displayed with 0 1 bit information Fig 12 2 2 Display of DIP Switch Set Status The above display shows that t...

Page 75: ...y of Software Version The above display shows that the main CPU software version is 3 00 000 6 CAUTION Confirm that the type number of software version display is 6 for the main circuit board Pr MB 01...

Page 76: ...ring the period since the welder main power is turned ON before the operation However the errors before the previous main power OFF are not saved During the Record operation do not turn OFF the welder...

Page 77: ...d of welder main power ON until the conditions saved the bit corresponding to the error is displayed with 1 For instance if the Err10 Feeding Error occurs the error occurrence status is displayed as f...

Page 78: ...of Welder Error Occurrence The number of error occurrence is displayed by the number of errors Err 0 to Err 15 which occur during the period from when the welder is delivered until the Diagnosis mode...

Page 79: ...agnosis mode press the L button and Record button simultaneously to set the status ready for error clear Err CLr on is displayed 2 Confirm that the Err CLr on is displayed and press the Record button...

Page 80: ...peration conditions or some other reasons change the characteristic values referring to the following description All the values are set to 100 Operating as specified with the characteristics in the d...

Page 81: ...crease the value P01 Wire speed from when the wire contacts the base metal until arc starts For excessive repelling at arc start Decrease the value For arc burning at arc start Increase the value P02...

Page 82: ...For excessive arc burning Decrease the value P07 Output time of hot conditions to stabilize the molten pool For burn through at start section Decrease the value When taking time to stabilize arc Incre...

Page 83: ...urning after welding P15 Average voltage to adjust the burning after welding P16 Arc time to adjust the burning after welding When wire sticks to the chip Decrease the value When wire sticks to the ba...

Page 84: ...nder main conditions Commanded from the robot side P16 Sphere drip pulse Wire stick prevention End time P13 Wire stop Adjustment of Sphere at end tip Voltage only P15 Wire stick prevention time P20 P4...

Page 85: ...2 P51 Arc control 3 When arc occurs for a long time without sphere drip dropping Decrease P49 increase P50 and P51 When arc is not stable Increase P49 decrease P50 and P51 To make beads flat for stai...

Page 86: ...P09 Base current to keep arc P10 Pulse peak time for droplet transition For excessive spatters Increase the value For excessive burning Decrease the value P31 Pulse current increasing speed For arc b...

Page 87: ...arc P10 Pulse peak time for droplet transition For excessive spatters Increase the value For excessive burning Decrease the value P35 Pulse current increasing rate For arc burning Decrease the value F...

Page 88: ...gth at pulse welding For arc length oscillation Decrease the value For improper arc length follow up Increase the value P61 Welding advancing direction Arc length c OK NG NG Arc length oscillation lar...

Page 89: ...real welding current value is higher than the welding current command Decrease the value Refer to example in the figure below When real welding current value is lower than the welding current command...

Page 90: ...everal volts compared with the voltage output from the welder The MOTOWELD E500III can automatically compensate for this voltage drop using the external resistance by measuring the electric resistance...

Page 91: ...abled Refer to 14 2 4 14 2 1 Connecting the Cable for Resistance Measurement CAUTION Use a machine tool etc to securely tighten the connecting section of the cable for resistance measurement Since app...

Page 92: ...connect the chip body at the torch end tip and the jig stand using a bolt or vice Fig 14 2 1 Connection of Cable for Resistance Measurement Jig stand Connect in this order torch cable wire feeder pos...

Page 93: ...ent of approx 300A and measuring the voltage required at that time Fig 14 2 2 1 Entering the Resistance Measurement Mode P R M Select P R M Set Weld Type Common PRM select Record Gas User File Select...

Page 94: ...istance is measured and its result is stored in the C 08 parameter Fig 14 2 2 2 Current Output for Measurement of Resistance Press the Record button again to stop the output during conduction however...

Page 95: ...e setting of common parameters Pressing the button increases the displayed parameter number by one 2 Press the button 8 times to display the measured data of C 08 parameter Confirm the value Fig 14 2...

Page 96: ...o change the display from OFF to on When it is on the calibration for the external resistance becomes the valid 3 Press the P R M Select button to return to the standby status Fig 14 2 4 2 Setting of...

Page 97: ...ton is extinguished the set parameter has been saved Fig 14 2 4 3 Saving the Setting P R M Select P R M Set Weld Type Common PRM select Record Gas User File Select File No 1 V V Set AW S L R File No 3...

Page 98: ...rameter values of C parameter C13 to C18 and P parameter of each user file P62 and P63 If parameters were initialized input the recorded parameter contents directly Set the parameters P62 and P63 to 1...

Page 99: ...ng current calibration cannot be performed without selecting the user file Be sure to select either of user file No 1 No 2 or No 3 beforehand save the conditions and turn ON the welder with the status...

Page 100: ...Displays the execution of calibration 1 The display of A Displays the welding current command value at the execution of calibration 1 The value is registered in C parameter The display of Wire Display...

Page 101: ...he welding current command value at the execution of calibration 2 The value is registered in C parameter The display of Wire Displays the measurement result of calibration 2 The result is registered...

Page 102: ...Items Initial Value Contents P62 Current output characteristic 1 100 Compensation ratio 1 for wire feeding speed Unit P63 Current output characteristic 2 100 Compensation ratio 2 for wire feeding spee...

Page 103: ...A Command Voltage V Welding Voltage 0 00 30 0 00 50 1 35 77 7 20 99 2 70 124 7 50 100 10 80 406 7 80 101 12 15 453 14 00 150 13 50 500 0 00 0 0 00 0 0 00 0 0 00 0 0 00 0 16 2 Common for All Welding Ty...

Page 104: ...tion of current conversion 200 For welder 2 S2C360 Arc monitoring function Current offset 0 For welder 2 S2C361 Arc monitoring function Magnification of voltage conversion 200 For welder 2 S2C362 Arc...

Page 105: ...C287 Arc monitoring function Magnification of current conversion 200 For welder 2 S2C288 Arc monitoring function Current offset 0 For welder 2 S2C289 Arc monitoring function Magnification of voltage c...

Page 106: ...to the connector on the robot controller side of welding command cable 18 1 Gas Check Connect the contacts to the pin terminals GAS and COM which come from adjacent to the connector of the welding com...

Page 107: ...The user files can be selected by combinations of contacts ON OFF as follows Selection of User Files Contact OP1 Contact OP2 No User File OFF OFF User File No 1 ON OFF User File No 2 OFF ON User File...

Page 108: ...ce Parts Front Face Item No Parts Code No Parts Name Qty per Welder 505 DTB30505 Eyebolt M8 2 510 6N3E50510 Front panel 1 513 GF30513 Cover top 1 514 GF30514 Side cover right 1 515 GF30515 Side cover...

Page 109: ...s Code No Parts Name Qty per Welder 002 N3E50002 Transformer 1 1 003 N3E50003 Transformer 2 1 004 AJ3E50004 DC reactor 1 500 AJ3E50500 Base 1 533 AJ2S35533 Terminal seat bottom 1 534 DTR35534 Terminal...

Page 110: ...Parts Name Qty per Welder 008 DTE50008 Shunt 600A 60mV 1 536 AJ3E50536 Current limiting reactor 1 541 AJ3E50541 Diode 3 582 91197 Plate 1 739 DTVT50739 Thermal guard 85 C 1 772 DTJ15982 Line filter 6...

Page 111: ...HW0482309 111 Left Side Face...

Page 112: ...Fuse free breaker 1 021 AJ3E50021 PC board set DR 006 1 710 910816 Aluminum electro capacitor 4 717 6N3E50717 Diode bridge 3 730 6N3E50730 IGBT 4 740 ADVT50739 Thermal guard 90 C 1 741 6N3E50741 Snubb...

Page 113: ...3E50022 PC board set PS 004 1 024 AJ3E50024 PC board set MB 011 1 026 AJ3E50026 PC board set SD 004 1 027 AJ0E35027 PC board set RC2 1 028 AJ0E35028 PC board set CR 002 1 032 911640 Circuit board spac...

Page 114: ...Face Item No Parts Code No Parts Name Qty per Welder 102 AJ0E35102 Connector 4 pins 1 114 AJ0E35114 Connector 6 pins 1 512 6N3E50512 Rear cover plate 1 630 DTR35630 Ground terminal 1 825 AJ2S35825 Co...

Page 115: ...OREA CORPORATION 1F Samyang Bldg 89 1 Shinchun dong Donk Ku Daegu Korea Phone 82 53 745 7844 Fax 82 2 784 8495 YASKAWA ELECTRIC SINGAPORE PTE LTD 151 Lorong Chuan 04 01 New Tech Park Singapore 556741...

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