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ABLE

ONTENTS

TABLE OF CONTENTS

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Important Information. . . . . . . . . . . . . . . . . . . . . . .ii

Use of the Product  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  ii
Safe Use of the Product  . . . . . . . . . . . . . . . . . . . . . . . . .  ii
Copyright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  ii
When Exporting the Product . . . . . . . . . . . . . . . . . . . . . .  ii
Disposal of the Product . . . . . . . . . . . . . . . . . . . . . . . . . .  ii
Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

CHAPTER 1 SAFETY INFORMATION

1.1 Warning Symbols . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Safety Precaution . . . . . . . . . . . . . . . . . . . . 1-1

1.2.1 Operating precautions . . . . . . . . . . . . . . . . . . . .1-2
1.2.2 Precautions for power supply and electric

shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.2.3 Precautions for air discharge and use of

respiratory protective equipment . . . . . . . . . . . .1-4

1.2.4 Precautions for flammable materials . . . . . . . . .1-5
1.2.5 Precautions for gas cylinder and gas regulator .1-6
1.2.6 Precautions for handling of plastic parts . . . . . .1-6
1.2.7 Precautions for disassembling and modifying

the welding power source . . . . . . . . . . . . . . . . .1-7

1.2.8 Precaution for protective equipment . . . . . . . . .1-7
1.2.9 Precautions for rotating part . . . . . . . . . . . . . . .1-7

1.3 Principal Safety Standards . . . . . . . . . . . . 1-8

CHAPTER 2 PRODUCT SPECIFICATION
AND CONFIGURATION

2.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.2 Applicable welding method  . . . . . . . . . . . . . . . .2-2
2.1.3 External dimensions  . . . . . . . . . . . . . . . . . . . . .2-3
2.1.4 Rated duty cycle  . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.2 Product Configuration . . . . . . . . . . . . . . . . 2-4

2.2.1 Standard composition . . . . . . . . . . . . . . . . . . . .2-5
2.2.2 Accessory (supplied) . . . . . . . . . . . . . . . . . . . . .2-7
2.2.3 Accessory (not supplied) . . . . . . . . . . . . . . . . . .2-8
2.2.4 Optional accessories . . . . . . . . . . . . . . . . . . . . .2-8

2.3 Part Names . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3.1 Front panel. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2.3.2 Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

CHAPTER 3 TRANSPORTATION AND
INSTALLATION

3.1 Required Equipment . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Welding power source equipment . . . . . . . . . . .3-1
3.1.2 Ventilation equipment/partial exhaust facility. . .3-2

3.2 Installation Environment . . . . . . . . . . . . . . 3-3

3.2.1 Installation environment. . . . . . . . . . . . . . . . . . .3-3
3.2.2 Electromagnetic interference . . . . . . . . . . . . . . .3-3

3.3 Transportation Procedure . . . . . . . . . . . . . 3-4

3.3.1 Transportation with lifting lug . . . . . . . . . . . . . . .3-5
3.3.2 Manual transportation with carts . . . . . . . . . . . .3-6

CHAPTER 4 CONNECTION

4.1 Precautions for Connection Procedure

and Grounding . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Connecting the Welding Power Source . . 4-2

4.2.1 Connection of cable at output side . . . . . . . . . . 4-3
4.2.2 Connection of wire feeder . . . . . . . . . . . . . . . . . 4-4
4.2.3 Connection of welding torch . . . . . . . . . . . . . . . 4-5
4.2.4 Connection at TIG welding . . . . . . . . . . . . . . . . 4-6
4.2.5 Connection at DC STICK welding . . . . . . . . . . . 4-7
4.2.6 Connection of shielding gas . . . . . . . . . . . . . . . 4-8

4.3 Grounding and Connection of Input

Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.4 Confirmation of Connection . . . . . . . . . . 4-10

4.5 Connection of External Equipment. . . . . 4-10

4.5.1 Connection of robot. . . . . . . . . . . . . . . . . . . . . 4-10
4.5.2 Connection of automatic machine. . . . . . . . . . 4-12

4.6 Wiring of Voltage Detection Cable at

Base Metal Side . . . . . . . . . . . . . . . . . . . . 4-15

4.6.1 Wiring to wire feeder . . . . . . . . . . . . . . . . . . . . 4-15
4.6.2 Wiring to welding power source . . . . . . . . . . . 4-16
4.6.3 Wiring example of voltage detection cable . . . 4-17

CHAPTER 5 WELDING OPERATION

5.1 Precaution at Welding Operation . . . . . . . 5-1

5.1.1 Precautions for air discharge and use of

respiratory protective equipment. . . . . . . . . . . . 5-1

5.1.2 Precaution for protective equipment . . . . . . . . . 5-2
5.1.3 Precautions on welding place . . . . . . . . . . . . . . 5-2

5.2 Check before Welding . . . . . . . . . . . . . . . . 5-2

5.3 Power ON and Gas Supply . . . . . . . . . . . . 5-4

5.4 Wire Inching . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5 Check and Setting of Welding Condition . 5-6

5.5.1 Reading welding condition . . . . . . . . . . . . . . . . 5-6
5.5.2 Preventing erroneous operation on operation

panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.6 Performing Welding Operation . . . . . . . . . 5-7

5.6.1 Operation of welding start . . . . . . . . . . . . . . . . . 5-7
5.6.2 Operation during welding . . . . . . . . . . . . . . . . . 5-8
5.6.3 Operation at welding end . . . . . . . . . . . . . . . . 5-10

CHAPTER 6 WELDING CONDITION

6.1 List of Welding Conditions . . . . . . . . . . . . 6-1

6.1.1 Parameter (Welding parameter) . . . . . . . . . . . . 6-1
6.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.3 Internal function . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Function on Operation Panel. . . . . . . . . . . 6-5

6.3 Welding Conditions . . . . . . . . . . . . . . . . . . 6-8

6.3.1 Basic welding conditions . . . . . . . . . . . . . . . . . . 6-8
6.3.2 Useful functions . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.4 Preparing Welding Conditions . . . . . . . . . 6-9

6.5 Memory Function of Welding

Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6.5.1 Memory registration of welding conditions . . . 6-10
6.5.2 Read out of welding conditions . . . . . . . . . . . . 6-11

Содержание OTC Welbee WB-M350

Страница 1: ...t h i s i n s t r u c t i o n m a n u a l thoroughly for safe and proper use of the product November 2015 Manual No 1P30201 1 Model WB M350 Welbee Inverter M350 OWNER S MANUAL DAIHEN Corporation CO MA...

Страница 2: ......

Страница 3: ...nual hereafter referred to as this manual explains the following points for safe use of the product Caution regarding the product Welding operation setting method Daily maintenance cleaning inspection...

Страница 4: ...allation operation maintenance of the welding power source and welding machine is performed by a qualified personnel with sufficient knowledge and skills If this manual is lost or damaged immediately...

Страница 5: ...l 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...

Страница 6: ...s 3 6 CHAPTER 4 CONNECTION 4 1 Precautions for Connection Procedure and Grounding 4 1 4 2 Connecting the Welding Power Source 4 2 4 2 1 Connection of cable at output side 4 3 4 2 2 Connection of wire...

Страница 7: ...welding control items 7 5 7 3 Data Backup Utilization of data 7 9 7 3 1 Setting of welding conditions internal functions 7 10 7 3 2 Simplified data log function 7 12 7 3 3 Failure log function 7 13 7...

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

Страница 9: ...stand the content before beginning operation The below symbols are categorized by the degree of possible hazard and damage The below symbols are categorized according to the content to be followed 1 2...

Страница 10: ...chine or work areas Only authorized personnel or person with full understanding and experience of the welding machine must perform installation maintenance and repair of welding machine Make sure to a...

Страница 11: ...ource and wait three minutes or more The capacitors may be still charged even after the input power is cut Make sure that there is no charged voltage before starting the work Wear dry insulating glove...

Страница 12: ...or preventive measure from falling due to anoxia apply lifelines such as a safety belt For the welding operation in a narrow space perform the operation with the trained supervisor Periodically inspec...

Страница 13: ...on gas pipe and closed containers such as tanks or drums Performing arc welding on flammable object such as fuel tank may cause explosion Furthermore welding on closed container such as tanks and pipe...

Страница 14: ...ay from the gas discharge port Keep protective cap in place over valve except when gas cylinder is in use or connected for use Do not place the gas cylinder under high temperature Protect compressed g...

Страница 15: ...g by customer is out of the warranty scope When welding or watching a welder work wear face shield with a proper shade of filter See ANSI Z 49 1 listed in PRINCIPAL SAFETY STANDARDS to protect the fac...

Страница 16: ...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 Weldi...

Страница 17: ...230 V 10 460 V 10 208 230 V 10 460 V 10 Rated input 15 3 kVA 13 1 kW 15 0 kVA 13 3 kW 11 3 kVA 8 4 kW 10 9 kVA 8 3 kW Rated input current 37 4 A 18 8 A 48 8 A 23 7 A Rated output current 350 A 250 A...

Страница 18: ...RED 045 1 2 STANDARD 3 Enable MIG 2 O2 1 2 STAINLESS STEEL 030 035 040 045 0 8 0 9 1 0 1 2 2 3 Enable MIG 100 Ar 1 3 SOFT ALUMINUM 045 1 16 1 2 1 6 2 3 HARD ALUMINUM 045 1 16 1 2 1 6 2 3 1 Note that t...

Страница 19: ...iguration SPECIFICATION PRODUCT SPECIFICATION AND CONFIGURATION CHAPTER 2 2 1 3 External dimensions This section explains the external dimensions of the welding power source 31 9 810 mm 15 6 395 mm 28...

Страница 20: ...ay not only reduce the duty cycle but also result in degradation or burnout of the welding power source The rated duty cycle of the welding power source is the following Operation cycle at duty cycle...

Страница 21: ...ding power source No Name Required component Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Wire feeder 3 Welding torch 4 Gas hose 118 1 3 m...

Страница 22: ...2 Welding torch 3 Gas hose 118 1 3 m 1 Included in feeder 4 Power cable for base metal side 1 5 Shielding gas To be prepared by the customer 2 2 3 Accessory not supplied 6 Digital remote control opti...

Страница 23: ...welding power source Check for the warranty instruction manual this publication and the quantity of parts when opening the package No Name Required component Optional accessories Remarks 1 Welding ele...

Страница 24: ...e optional accessories used with the welding power source 2 2 4 1 Remote control voltage detection cable and other optional items Following items are optionally available including remote control and...

Страница 25: ...ut Winded extension cable may cause an unstable arc Use extension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 196 9 5 m 393 7 10 m 59...

Страница 26: ...ce 2 3 1 Front panel The section explains the front section of the welding power source Socket for wire feeder Socket for analog remote control Output terminal Torch side Output terminal Base metal si...

Страница 27: ...3 2 Rear panel The section explains the rear section of the welding power source Blind bush for drawing externally connecting wire Cover for external connections Connector for connecting CAN Print ci...

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

Страница 29: ...high output voltage may result in damage to the welding power source When the welding power source is used in a humid environment such as construction site or location with highly conducting material...

Страница 30: ...ent and partial exhaust facility in welding work area 3 1 2 1 Ventilation equipment When welding is required in tank boiler reaction tower or hold of a ship closed space or any other places of poor ve...

Страница 31: ...f 50 or lower ambient temperature of 104 F 40 C and 90 or lower ambient temperature of 68 F 20 C Location with an altitude of less than 3280 ft 1000 m Location with an incline of 10 or less For the we...

Страница 32: ...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...

Страница 33: ...e 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...

Страница 34: ...h 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 on...

Страница 35: ...parts of the welding power source Have a qualified electrical engineer ground the case of the welding power source and base metal or jig electrically connected in accordance with local regulation Make...

Страница 36: ...ource until confirming the completion of connection work Otherwise electric shock may occur Connection of cable at output side 4 2 1 Connection of cable at output side Connection of wire feeder 4 2 2...

Страница 37: ...ighten them in the clockwise direction 2 Connect the power cable for torch side to the output terminal torch side Connect the connectors as same as above Connection for cable at output side is complet...

Страница 38: ...der and insert the control cable 10 cores to the socket for the wire feeder Fit the concave part of the connector and convex part of the socket for secure connection and tighten the knurled screws in...

Страница 39: ...lding torch connect the water feeding hose and condensing hose of the welding torch to the wire feeder Fully insert the hose end to the connection port of wire feeder For disconnection hold the hose e...

Страница 40: ...tal Connect the connectors as same as above In using the welding power source for TIG welding prepare a welding torch by the customer Contrary to the normal connection the TIG welding requires connect...

Страница 41: ...n them in the clockwise direction 2 Connect the cable for welding electrode holder side to the output terminal torch side Connect the connectors as same as above In using the welding power source for...

Страница 42: ...sure to observe the following points to prevent from suffocation due to gas leakage or explosion Be sure to turn off the shielding gas at the main tap when the welding power source is not in use Secur...

Страница 43: ...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 v...

Страница 44: ...y the cable of the welding power source to the breaker Capacity of the switch and the rating of fuse and circuit breaker are appropriate 3 1 1 Welding power source equipment Perform grounding for the...

Страница 45: ...e for wire feeder BKCPJ 1010 393 7 10 m For details on cables see 2 2 4 2 Details on extension cables and hoses 7 Cable at torch side BKPDT 6012 393 7 10 m 8 Cable at base metal side BKPDT 6012 393 7...

Страница 46: ...s stops output of the welding power source When combining switches use a push lock turn reset switch for preventing accidental reset 5 9 IN EXT1 External input 1 Reserve inputs for expanding terminal...

Страница 47: ...ing 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 wor...

Страница 48: ...e through Process any given blind bush among the several available types 4 Connect the cable to the terminal for external connection Strip the cable cover by 25 64 to 7 16 10 to 11 mm from the end whi...

Страница 49: ...source When using the voltage detection cable set the internal function F38 to ON 6 7 1 Setting procedure Details on the internal function F38 6 7 2 22 F38 Arc voltage direct detection switching 4 6 1...

Страница 50: ...able 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 t...

Страница 51: ...pplied 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 vo...

Страница 52: ...WIRING OF VOLTAGE DETECTION CABLE AT BASE METAL SIDE CONNECTION CHAPTER 4 4 18...

Страница 53: ...ilation equipment does not give sufficient performance ensure to use respiratory protective equipment For preventive measure from falling due to anoxia apply lifelines such as a safety belt For the we...

Страница 54: ...rom spatter and spattering dross Wear protective equipment such as protective leather gloves long sleeve clothes leg covers and leather apron Ignoring the above may cause electrical shock and burn Ins...

Страница 55: ...MAG gas MIG gas 21 to 53 CFH 10 to 25 L min 32 to 53 CFH 15 to 25 L min 11 When the shield gas is mixed each gas pressure should be the same Set pressures of the respective gas to the same level 12 O...

Страница 56: ...er take care for the followings If the liner is too long feeding resistance increases resulting in shorter life of wire feeder If the liner is too short feeding failure occurs Handle the gas cylinder...

Страница 57: ...6 Press the GAS CHECK key The LED of the GAS CHECK key lights off to stop gas check 5 4 Wire Inching This section explains the inching operation feeding operation of the wire 1 Straighten the torch c...

Страница 58: ...that the welding conditions are correct 5 5 2 Preventing erroneous operation on operation panel This section explains how to prevent erroneous operation on the operation panel To prevent accidental ch...

Страница 59: ...e right digital meter both in a real time basis This indication is the average value of the output per approximately one second In TIG welding arc start requires contact of the torch electrode with th...

Страница 60: ...djust the welding current When the LED of the CURRENT SETTING DISPLAY SWITCH key is off press the CURRENT SETTING DISPLAY SWITCH key to light up the LED In the adjustment by the remote control this op...

Страница 61: ...ly 5 seconds the display will return to the one showing current voltage in welding Using the internal function F48 enables to increase decrease the welding current by the torch switch operation It is...

Страница 62: ...harged 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...

Страница 63: ...nd voltage value during the welding Crater condition set the current and voltage value at the end of welding Voltage INDIVIDUAL 12 0 to 38 0 V 12 0 to 34 0 V 19 0 V Voltage SYNERGY 100 to 100 0 Post f...

Страница 64: ...the crater condition F8 Welding result display time 0 to 60 20 s Sets the display time for the current voltage after completion of welding F9 Analog remote control scale 200 350 350 A Configures the s...

Страница 65: ...g 0 to 9 0 Sets the functions of input terminal of the programmable I O F30 External input 2 setting 0 F31 External input 3 setting 0 F32 External input 4 setting 0 F33 No function OFF fixed OFF No fu...

Страница 66: ...rater sets whether to switch the welding condition and crater condition by the click operation of the torch switch OFF not to use torch switch ON uses the torch switch F52 Data type of data log functi...

Страница 67: ...h setting corresponding setting values are displayed and the LED lit position automatically switches 2 Right digital meter Displays various information The welding voltage is displayed in welding In e...

Страница 68: ...b When the analog remote control optional is connected the speed can be adjusted by the welding current setting knob 10 TRAVEL SPEED key Select the TRAVEL SPEED to apply 1 The LED of the parameter in...

Страница 69: ...cooled welding torch mode 1 When the LED is OFF air cooled welding torch mode 21 VOLT ADJUST key Sets welding voltage Switching the mode is enabled by pressing the key When the LED of the VOLT ADJUST...

Страница 70: ...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 key enables to...

Страница 71: ...ing mode setting Setting crater treatment 6 6 3 Crater setting Setting pre flow Setting gas discharge time 6 6 2 Setting welding parameter Setting initial condition Setting welding current voltage 6 6...

Страница 72: ...dition by the analog remote control optional 6 7 Setting Internal Functions Use of the internal function F11 enables to finely adjust the current voltage values read out from the memory by the analog...

Страница 73: ...o the setting value of the welding current is displayed on the left digital meter At this time the LEDs for the keys of crater or wire material also light up The LED of ENTER key flashes Pressing the...

Страница 74: ...heck the welding JOB No to delete When there is no registration data on the selected JOB No is displayed on the left digital meter When there is any registration data on the selected JOB No the settin...

Страница 75: ...the registration at the same time turn the parameter adjustment knob counterclockwise to display ALL on the right digital meter When ALL is selected the current welding condition set on the operation...

Страница 76: ...9 1 0 1 2 2 3 Enable MILD STEEL CORED 045 052 1 2 1 4 STANDARD 3 Enable STAINLESS CORED 045 1 2 STANDARD 3 Enable MIG 2 O2 1 2 STAINLESS STEEL 030 035 040 045 0 8 0 9 1 0 1 2 2 3 Enable MIG 100 Ar 1...

Страница 77: ...parameter gas discharge time welding current voltage The welding parameters are set according to the welding sequence 0 8 OP 0 9 1 0 1 2 1 6 1 4 F A IPM V r A V r OP5 OP1 OP2 OP4 OP3 DC STICK DC TIG W...

Страница 78: ...er adjustment knob to set the gas discharge time The set parameter is displayed on the left digital meter Process Description PRE FLOW It is the sequence to discharge gas before the welding starts INI...

Страница 79: ...on the welding voltage automatically set according to the welding current At INDIVIDUAL mode voltage setting is made in regardless of the welding current Switch the mode by the VOLT ADJUST key 6 6 5...

Страница 80: ...condition before the main welding and the welding process in the Crater condition after the main welding 6 7 2 27 F45 F46 F47 Special crater sequence effective initial standard time setting crater sta...

Страница 81: ...he welding operation In the second ON operation the welding sequence is carried out by the crater current Even if the torch switch is switched off during welding the signal will be self hold The torch...

Страница 82: ...the second ON operation enables the welding by the crater current Even if the torch switch is switched off during welding the signal will be self hold The torch switch should remain depressed and held...

Страница 83: ...on again within 2 seconds the machine starts on the Crater condition and continues operation Repeating this allows crater process to be carried out as many times as needed ON ON OFF ON OFF OFF ON OFF...

Страница 84: ...s on the nozzle for arc spot see the instruction manual of the torch 6 6 5 Welding voltage adjustment This section explains how to adjust the welding voltage The adjustment of welding voltage can be c...

Страница 85: ...tive value soft arc condition negative value hard arc condition TIPS It is likely that good weld can be obtained by adjusting it to hard in low current region and soft in high current region When usin...

Страница 86: ...ions TIPS The internal function is activated at the point when the setting value is changed To change the set values of internal functions ensure that there is no mistake in the function No as well as...

Страница 87: ...s can cause extraordinary volume of spatter When this happens turning this function ON extended cable mode can improve the status ON Extended cable mode Set to ON for the length of extension cable lon...

Страница 88: ...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...

Страница 89: ...If you want to use Automatic machine 3 conditions will change for the following functions F5 Maximum external command voltage Fixed to 10 0V F24 Wire feeding speed setting Fixed to ON E 800 and 801 en...

Страница 90: ...ay time 0 to 60 sec 6 7 2 7 F9 Analog remote control scale Change the setting of the scale plate of analog remote control when using the optional analog remote control Scale plate is available separat...

Страница 91: ...ent or voltage turn the knob clockwise In the following cases this function cannot be used Welding conditions are not registered to the memory Analog remote control optional is not connected to the we...

Страница 92: ...justment 6 7 2 12 F16 Slowdown speed adjustment Slow down speed is the speed to slowly feed the wire from the time of the machine start to the time of arc start The slowdown speed is automatically set...

Страница 93: ...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 sw...

Страница 94: ...time When the welding power source is not operated for a fixed period of time it can be turned into the sleep mode 0 disables the function 1 to 10 enables the function Set the transition time to the s...

Страница 95: ...um command voltage is 866 IPM 22 m min Depending on the welding mode the wire feed speed does not always reach 866 IPM 22 m min The minimum wire feed speed is approximately 24 to 79 IPM 0 6 to 2 0 m m...

Страница 96: ...emory can be read out by combination of signals 4 6 No function is allocated 7 No function is allocated 8 JOB shift Causing short circuit between terminals shifts to the following JOB No 5 7 9 JOB shi...

Страница 97: ...out the welding condition of the JOB No 7 Setting F30 and F31 to 5 and turning the two signals of the external input terminal IN EXT2 IN EXT3 to ON enable to read out the JOB No 7 For F29 and F32 othe...

Страница 98: ...h OFF start signal OFF to 100 ms after it do not change the setting of 5 Secondary condition current ON OFF 1 Primary condition current 5 2 1 OPEN CLOSE OPEN OPEN CLOSE OPEN EXT3 F31 5 EXT1 F29 5 JOB...

Страница 99: ...tment Gain offset Set the adjustment value gain offset when the current display value on the left digital meter is different from the actual current value The current value displayed on the digital me...

Страница 100: ...elding voltage setting knob To increase the welding voltage turn the knob clockwise and to reduce the welding voltage turn the knob counterclockwise The fine adjustment range for welding voltage is up...

Страница 101: ...s TIPS When the internal function F45 is set to ON automatically the setting of No crater is selected disabling other welding modes The CRATER FILL key does not work Welding method at crater treatment...

Страница 102: ...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 ma...

Страница 103: ...50 A 6 7 2 31 F51 Special crater repeat In the sequence of main welding of the CRATER FILL ON REPEATED during start input holding the torch switch operation can switch the welding and crater treatment...

Страница 104: ...g welding condition 6 7 2 32 F52 Data type of data log function This function enables to select data to save when using the data log function The patterns of data which can be saved are as shown in th...

Страница 105: ...sed in connection with the automatic machines of other manufacturers 6 7 2 36 F67 Setting change of current value initial condition crater condition When CRATER ON is selected the current value of the...

Страница 106: ...e welding current is automatically set and fine adjustment is available for the set welding voltage Align the welding voltage adjustment knob to the center mark and adjust the voltage with the positio...

Страница 107: ...ble if the erroneous operation prevention function is disabled NOTE Write down the password on a piece of paper and store it safely The current password will be requested also when you change it If a...

Страница 108: ...ssword 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 al...

Страница 109: ...cified 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 Th...

Страница 110: ...oints is achieved Wire consumption P20 0 00 Cumulative wire consumption used in welding lbs kg P21 0 0 to 999 0 to 453 Target wire consumption lbs kg P22 0 0 to 5 Operation at the time when the target...

Страница 111: ...value will be cleared according to the P12 setting If continuous operation is enabled the value will be cleared when exceeding 999 and return to 0 P11 Target value of welding points Select the target...

Страница 112: ...nsumption in the range from 0 to 999 lbs 0 to 453 kg When the P20 count value reaches the wire consumption specified here an alarm appears indicating that the target is achieved 7 2 2 5 Alarm indicati...

Страница 113: ...ints is achieved 7 2 2 1 Number of welding point 7 2 2 4 Welding monitor Average current voltage during welding is monitored When it exceeds the range specified here an alarm displays and the output s...

Страница 114: ...ration Alarm indication only Welding can continue Continuous operation is possible 1 The ongoing welding can continue After the welding is finished next welding cannot start until any key of the opera...

Страница 115: ...right example shows a voltage error The control No P40 flashes on the left digital meter and the difference between the average value and specified value 1 5 on the right digital meter with the A LED...

Страница 116: ...Reserved pre_iset Initial current 1 A reserve Reserved pre_vset Initial voltage 0 1 V reserve Reserved pre_uni_vset Initial voltage synergic 1 ant_tim_adj Anti stick time adjustment 0 01 s wld_iset W...

Страница 117: ...ither of the data above can be imported at one time ALL Welding condition data recorded in memory Internal function setting data 1 Welding condition data recorded in memory 2 Internal function setting...

Страница 118: ...52 is set to 1 detected values of welding current welding voltage and feeding speed and F53 to 2 100 ms TIPS The length of time that can be used for recording depends on the sampling speed If the samp...

Страница 119: ...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 US...

Страница 120: ...ten by the backup data Make sure of it before overwriting 1 Turn on the power switch 2 Insert the USB flash drive to the USB connector of the operation panel 3 Press the SAVE key The LED of ENTER key...

Страница 121: ...ons in memory and internal function values will return to the default initial setting Turn the parameter adjusting knob further counterclockwise to display the data to import on the right digital mete...

Страница 122: ...and turn on the power switch The Product No is displayed on the left and right digital meters The display changes every time the F function key is pressed The display order of 5 or later is for manufa...

Страница 123: ...en after the input power is cut Make sure that there is no charged voltage before starting the work During maintenance and inspection take an appropriate measure to prevent turning on the input power...

Страница 124: ...rinted document Please note that OTC will not be liable for any alteration or loss of electronic information When cleaning the welding power source do not expose the cooling fan directly to compressed...

Страница 125: ...k 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 hea...

Страница 126: ...nsumable parts of the welding torch Abnormality in consumable parts can prevent smooth wire introduction Cleaning inside the welding power source Blow with dry compressed air from the front slit venti...

Страница 127: ...dealer When measuring insulation resistance and testing withstand voltage follow the steps below Refer to the schematic diagram parts layout and parts list for maintenance Disconnect the input power c...

Страница 128: ...circuit between TR1 C1 E1 TR2 C2 E2 TR4 C2 E2 TR5 C1 E1 TR5 C2 E2 Apply NF After finishing insulation resistance measurement return the above to the original state After finishing insulation resistanc...

Страница 129: ...re 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 i...

Страница 130: ...tage for primary side is the range of 208 230 460 V 10 The error code will disappear when the power switch is turned off E 155 The input voltage for primary side was out of allowable range from 265 to...

Страница 131: ...E 800 801 The rotation rate of the motor of wire feeder was not detected 1 Check that there is no disconnection short circuit or other abnormalities in the cables connecting the wire feeder Check that...

Страница 132: ...puts is not correct Check that the setting of internal functions F29 to F32 is correct 6 7 2 21 F29 to F32 External input terminal setting The external input cables are disconnected short circuited Ch...

Страница 133: ...tage detection cable is correct There is noise in the voltage detection cable Adjust the arc characteristics to the plus side 12 Wire is not fed no error code is displayed The pressure roll of wire fe...

Страница 134: ...TROUBLESHOOTING TROUBLESHOOTING CHAPTER 9 9 6...

Страница 135: ...6 IGBT module CM100DUS 12F 4 TR5 100 2219 IGBT module 1MBI300HH 120L 50 1 SCR1 4530 412 Thyristor SG25AA20 1 CT1 4810 030 Current transformer W W03029 1 CT2 100 0956 Hall current detector CS 40GEH 1 C...

Страница 136: ...CHASSIS 1 4341 206 Relay G6A 274P DC24V 1 With PCB1 PCB2 P30086R00 Printed circuit board P30086R00 1 100 1421 Encoder EVEGA1F2524B 1 With PCB2 PCB3 P30086Q00 Printed circuit board P30086Q00 1 PCB4 P30...

Страница 137: ...10 3 Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 2 1 Schematic diagram P30139H00 P30087V00 P30086V00 P30138M00 CN1 Not connected P30086Q00 CN1 3 Not connected...

Страница 138: ...5 6 7 8 9 CN15 R19a b 48 126 127 128 129 130 131 132 133 134 135 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 163 164 165 166 167 168 156 157 158 159 160 161 301 302 303 304 305 306...

Страница 139: ...r DCV1 Lower P30086Q00 P30138M00 P30087Q00 P30099P00 P30086S00 P30087V00 CT1 P30086V00 P30087T00 P30086T00 SH TM6 PL1 FM1 FM2 FM3 TM5 NF 6 CON1 7 CON2 7 FM4 DCV2 5 2 L1 1 4 3 8 9 Top Back When the cov...

Страница 140: ...omes poor The wire feeding length is too short The arc length becomes short Spatter is generated The welding voltage is too high The arc length becomes long The bead width becomes wide Penetration and...

Страница 141: ...rate CFH L min 18 ga 1 2 3 32 to 1 8 2 5 to 3 0 035 040 0 9 1 0 70 to 100 18 to 19 20 to 24 50 to 60 21 to 32 10 to 15 16 ga 1 6 3 32 to 1 8 2 5 to 3 0 035 to 045 0 9 to 1 2 90 to 120 18 to 20 20 to 2...

Страница 142: ...21 to 23 16 to 20 40 to 50 21 to 32 10 to 15 1 15 64 6 0 3 64 to 1 16 1 2 to 1 5 045 1 2 220 to 260 24 to 26 16 to 20 40 to 50 32 to 42 15 to 20 Front 1 2 Back 1 23 64 9 0 3 64 to 1 16 1 2 to 1 5 045...

Страница 143: ...16 1 6 400 to 420 36 to 39 16 to 18 40 to 45 42 to 53 20 to 25 1 Front Back 4 420 to 450 39 to 42 12 to 14 30 to 35 42 to 53 20 to 25 2 Plate thickness t in mm Wire diameter in mm Current A Voltage V...

Страница 144: ...3 2 035 to 045 0 9 to 1 2 0 to 0 1 1 0 to 1 5 120 to 140 17 to 19 10 to 12 25 to 30 5 32 4 0 035 to 045 0 9 to 1 2 0 1 to 0 1 1 5 to 2 0 150 to 170 18 to 21 10 to 16 25 to 40 Plate thickness t in mm...

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