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ARTS

IST

EFERENCE

ATERIALS

HAPTER

10-2

R20,21

100-0234

Cement resistor

RD20S 1K

Ω

R22

100-1571

Winding resistor

CS1P 100

Ω

R23

4509-918

Cement resistor

40SH 200

Ω

R24

4509-704

Carbon resistor

RD1/4W 1K

Ω

R25,26

100-1949

Fixed Metal Oxide Film Resistor

MOS1CT52A104J

R27,28

4509-905

Cement resistor

MHR20A513J1

C1 to 4,

13,15

4517-459

Ceramic capacitor

DEHR32E103KA2B

C5,6,9,10

100-1434

Film capacitor

FHC(180)2000V682J

C7,11

100-0227

Film capacitor

0.47

F 50V

100-0177

Electrolysis capacitor

LQA2C222MSMEZ0

C12

100-1712

Film capacitor

FHC(180)2000V103J

C14,16

100-1871

Film capacitor

US20X223JBASA

CON1

100-1435

Receptacle

DPC25-10BP

CON2

4730-010

Receptacle

DPC25-6BP

CON3

4730-192

Receptacle

VLP-03V

TM5

4739-141

Terminal

T-3

（

Black

）

TM6

100-2234

Terminal

DG15HS-1.2-04P-17-100A(H)

DCV1

K5791B00

Power supply

K5791B00

Output DC24V

DCV2

K5791C00

Power supply

K5791C00

Output DC48V

PCB1

P30099P00

Printed circuit board

P30099P00

(*1)

PCB2

P30086R00

Printed circuit board

P30086R00

PCB3

P30086Q00

Printed circuit board

P30086Q00

PCB4

P30087Q00

Printed circuit board

P30087Q00

PCB5

P30086V00

Printed circuit board

P30086V00

PCB6

P30086V00

Printed circuit board

P30086V00

PCB7

P30115M00 Printed circuit board

P30115M00

PCB8

P30086T00

Printed circuit board

P30086T00

PCB9

P30087T00

Printed circuit board

P30087T00

PCB10

P30086S00

Printed circuit board

P30086S00

(1)

P30086G01

Mold cover

P30086G01

Upper side cover

(2)

P30086G02

Mold cover

P30086G02

Under side cover

(3)

P30133W02 Operation panel sheet

P30133W02

(4)

W-W03636

Cap

W-W03636

For P30086G01

(5)

100-1836

Socket

EDZ120b(B)-1

(6)

W-W03784

Output terminal cover

W-W03784

(7)

100-1436

Handle cover

DCP73BH 3POLE H(HANDLE
COVER)

For NF

(8)

4739-476

Cap

W-W02814

For CON1,2

(9)

4735-038

Knob

K-100 22RSB

Parameter
adjustment knob

(10)

4735-039

Cap

K-100 22CSBL

Parameter
adjustment knob

4739-475

Rubber foot

C-30-RK-3220

100-2245

Perfect lock

JPG-29B

*1: When placing an order of a printed circuit board P30099P00, provide us the software version No. shown on the

indication panel (under the input terminal block) at the rear of the welding power source.

Code

Part No.

Product Name

Specifications

Q’ty

Remarks

Содержание WB-M500

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 October 2013 Manual No 1P30135 1 Model WB M500 Welbee Inverter M500 OWNER S MANUAL CO MAG Welding power sour...

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: ...e that installation operation maintenance of the welding power source and welding machine is performed by a qualified personnel with sufficient knowledge and skills If this manual is lost or damaged i...

Страница 5: ...Product model manufacture year serial number and software version number Refer to the diagram below for product information Attachment location and content of nameplate may vary depending on the purc...

Страница 6: ...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 tor...

Страница 7: ...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 3 4 Backup operation 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: ...Electrical Code NFPA Standard 70 from National Fire Protection Association Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Code for Safety in Welding an...

Страница 17: ...ase Three phase Rated frequency 50 60 Hz Rated input voltage 400 V Input voltage range 400 V 15 Rated input 23 6 kVA 21 2 kW Rated input current 34A Rated output current 500 A Rated load voltage 39 V...

Страница 18: ...1 2 1 6 2 3 Enable STAINLESS FERRITE 1 2 2 3 Enable MIG 2 5 CO2 1 4 STAINLESS STEEL 0 8 1 0 1 2 1 6 2 3 Enable MIG 100 Ar 1 5 Al PURE 1 2 1 6 2 3 Al Mg 1 0 1 2 1 6 2 3 Brazing CuSi 0 8 1 0 1 2 2 3 Br...

Страница 19: ...t Specification and Configuration SPECIFICATION PRODUCT SPECIFICATION AND CONFIGURATION CHAPTER 2 2 1 3 External dimensions This section explains the external dimensions of the welding power source 76...

Страница 20: ...rt accumulate on the radiation fin it may not only reduce the duty cycle but also result in degradation or burnout of the welding power source Rated duty cycle of this welding power source is 100 at t...

Страница 21: ...ce No Name Suppliedunit 1 Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Wire feeder 3 Welding torch 4 Gas hose 3 m 2 5 Control cable for wi...

Страница 22: ...m 2 4 Power cable for base metal side 2 m 2 5 Shielding gas To be prepared by the customer 2 2 3 Accessory not supplied 6 Digital remote control optional 2 7 Analog remote control 3 m optional 2 1 St...

Страница 23: ...section explains the accessories to be prepared by the customer before operating the welding power source Prepare the following No Name Suppliedunit 1 Optional accessories Remarks 1 Welding electrode...

Страница 24: ...ontrol and voltage detection cable Name Remarks CO2 gas Carbon dioxide CO2 100 MAG gas Argon Ar 80 Carbon dioxide CO2 20 Argon Ar 90 Carbon dioxide CO2 10 MIG gas Argon Ar 97 5 Carbon oxygen CO2 2 5 M...

Страница 25: ...roll them out 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 5 m 10 m 15...

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: ...eration Setting to an extremely high output voltage may result in damage to the welding power source When the welding power source is used in a humid environment such as construction site or location...

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: ...20 C Location with an altitude of less than 1000 m Location with an incline of 10 or less Location with no metallic foreign body such as spatter entering the welding power source Installation distance...

Страница 32: ...lding power source Welding cables Do not use an unnecessarily long cable Place a base metal cable and a torch side cable as closely as possible Equipotential bonding Bonding of all metallic objects in...

Страница 33: ...nd floor Do not apply strong shock to the welding power source when placing it on the floor It may cause damage to the welding power source Since large current abruptly flows inside the welding power...

Страница 34: ...ents be sure to observe the following For operation of a crane or hoisting make sure that a qualified personnel operate them with attention to the surrounding area for safety Use the lifting tool such...

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: ...tal side with the fixing screws 3 Connect the power cable for torch side to the output terminal torch side Connect the connectors as same as above 4 Restore the output terminal cover Connection for ca...

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

Страница 39: ...using the water cooled welding 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 dis...

Страница 40: ...nect the connectors as same as above 4 Restore the output terminal cover In using the welding power source for TIG welding prepare a welding torch by the customer Contrary to the normal connection the...

Страница 41: ...ide with the fixing screws 3 Connect the cable for welding electrode holder side to the output terminal torch side Connect the connectors as same as above 4 Restore the output terminal cover In using...

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: ...k due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker for motor to the input side of each welding power source Otherwise electric shock and fire due to o...

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

Страница 45: ...ol cable for wire feeder BKCPJ 1010 10 m For details on cables see 2 2 4 2 Details on extension cables and hoses 7 Cable at torch side BKPDT 6012 10 m 8 Cable at base metal side BKPDT 6012 10 m 9 Gas...

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

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: ...d pass the cable through Process any given blind bush among the several available types 4 Connect the cable to the terminal for external connection Strip the cable cover by 10 to 11 mm from the end wh...

Страница 49: ...rce 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 23 F38 Arc voltage direct detection switching 4 6 1 Wi...

Страница 50: ...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...

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: ...re the adequate shield gas flow rate as follows CO2 MAG gas MIG gas 10 to 25L min 15 to 25L min 11 When the shield gas is mixed each gas pressure should be the same Set pressures of the respective gas...

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

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

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

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: ...ischarged 3 After the shield gas is discharged press the GAS CHECK key The LED of the GAS CHECK key lights off to stop gas check 4 Set the flow adjustment knob to SHUT to adjust the shield gas flow ra...

Страница 63: ...set the current and voltage value at the end of welding Voltage INDIVIDUAL 10 0 to 50 0 V 19 0 V Voltage SYNERGY 100 to 100 0 Post flow time 0 to 10 sec 0 4 sec Set the gas discharge time after the we...

Страница 64: ...isplay time for the current voltage after completion of welding F9 Analog remote control scale 200 350 500 500 A Configures the settings of scale plate of the analog remote control F10 Motor over curr...

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: ...he setting of Crater 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...

Страница 67: ...condition in the percentage based on the current value of the welding condition OFF invalid ON settable with percentage F68 Setting of current value initial condition 10 to 300 100 Sets the current va...

Страница 68: ...es the welding sequence as the set target During the welding the display can be switched to display the value set as the welding condition 7 F function key Sets the internal function of welding power...

Страница 69: ...hich cannot be used is selected the LED flashes 6 6 1 Welding mode setting 15 CRATER FILL key Select the crater treatment method or arc spot at the end of welding The LED of the parameter in selection...

Страница 70: ...he welding voltage is automatically set according to the set welding current To fine tune welding voltage adjust the synergic fine adjustment knob When the LED of the VOLT ADJUST key is off INDIVIDUAL...

Страница 71: ...use The number of welding conditions that are able to be registered are 100 at maximum Single welding condition can contain the following information at registration Welding mode selected by the keys...

Страница 72: ...ns electronic data stored by this function are susceptible to occurrence of static electricity impact repair etc and there is a possibility that the stored contents may be changed or lost BE SURE TO M...

Страница 73: ...setting values are displayed on the left right digital meters in a flashing mode To change the JOB No to register press the SAVE key The display returns to the status described in step 1 To cancel th...

Страница 74: ...he SAVE key depressed together turn ON the power switch The LED of ENTER key flashes Pressing the DISPLAY CHANGE key enables to check the set values of welding conditions welding parameters to read ou...

Страница 75: ...et on the operation panel is also deleted and the welding parameters including the internal functions return to the initial values The display dEL on the left digital meter starts flashing Pressing th...

Страница 76: ...MAG 10 CO2 1 2 MILD STEEL 0 8 1 0 1 2 2 3 Enable MIG 2 O2 1 3 STAINLESS STEEL 0 8 1 0 1 2 1 6 2 3 Enable STAINLESS FERRITE 1 2 2 3 Enable MIG 2 5 CO2 1 4 STAINLESS STEEL 0 8 1 0 1 2 1 6 2 3 Enable MIG...

Страница 77: ...o set the welding 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 m min V r A V r Al PURE OP3 Al Mg...

Страница 78: ...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 INITI...

Страница 79: ...elding 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 Welding v...

Страница 80: ...condition before the main welding and the welding process in the Crater condition after the main welding 6 7 2 28 F45 F46 F47 Special crater sequence effective initial standard time setting crater sta...

Страница 81: ...er 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 during the INITIAL and CRATER phrases When selecting C...

Страница 82: ...h is switched off during welding the signal will be self hold The torch switch should remain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON Regardless of the se...

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: ...e 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 using an exte...

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

Страница 87: ...cables 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 cabl...

Страница 88: ...circuit the deactivated terminal pins 3 4 of the external connection terminal block TM3 4 1 In the Auto mode voltage to release welding is output for approx 0 2 seconds after the anti stick process T...

Страница 89: ...pe time 0 0 to 10 0 sec 6 7 2 5 F7 Downslope time When the difference between the welding current and crater current is large the wire may plunge into weld pool at the change of the conditions the wir...

Страница 90: ...not stopped According to the use environment such as wires and torches and the customer s judgment criteria adjust the detection level at your discretion 6 7 2 9 F11 Fine adjustment of welding conditi...

Страница 91: ...ool the welding torch as the welding ends The operation time of water cooled pump at this time can be set Setting range of water cooled pump operation time 20 to 60 min ON Water cooled pump is always...

Страница 92: ...voltage adjustment Set the anti stick time voltage which is the anti stick processing time and voltage Optimum setting of the anti stick time voltage enables to obtain the following effects At the wel...

Страница 93: ...alue an error code is displayed Set the value in the range of 260 to 400 V TIPS The factory default setting is 320 V However the specification of input voltage as welding power source is the range of...

Страница 94: ...in the unit of 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 fol...

Страница 95: ...xternal connection terminal block TM3 For the details of external connection terminal block 4 5 2 Connection of automatic machine The functions allocable to F29 to F32 are as follows Setting Function...

Страница 96: ...ng the signal of external input terminal IN EXT2 to ON enable to read out the JOB No 3 For F29 F31 and F32 other functions can be set Example 2 In reading out the welding condition of the JOB No 3 Set...

Страница 97: ...he torch switch 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 E...

Страница 98: ...offset when the current display value on the left digital meter is different from the actual current value The current value displayed on the digital meter is obtained by software processing of the a...

Страница 99: ...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 to 20 OFF disa...

Страница 100: ...e internal function F45 is set to ON automatically the setting of No crater is selected disabling other welding modes The CRATER FILL key does not work Welding method at crater treatment is the same a...

Страница 101: ...le clicking or double clicking operation should be within 0 3 seconds At the time of transition to crater press the torch switch for at least 0 3 seconds Welding method at crater treatment is the same...

Страница 102: ...F51 Special crater repeat In the sequence of main welding of the CRATER FILL ON REPEATED during start input holding the torch switch operation can switch the welding and crater treatment repeatedly as...

Страница 103: ...rt or 5 Loading welding condition 6 7 2 33 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...

Страница 104: ...tic machines of other manufacturers 6 7 2 37 F67 Setting change of current value initial condition crater condition When CRATER ON is selected the current value of the initial condition and the crater...

Страница 105: ...ccording to the 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 wi...

Страница 106: ...OPERATION OF ANALOG REMOTE CONTROL OPTIONAL WELDING CONDITION CHAPTER 6 6 44...

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: ...ord will be requested Hold the two keys pressed down until Loc is displayed on the left digital meter PAS Loc will be displayed in order Release the keys after Loc is displayed If a password has alrea...

Страница 109: ...ied as password 3 Select the tens place digit and ones place digit in the same manner as the step 2 4 Press the ENTER key Loc flashes on the left digital meter PAS Loc will be displayed in order The h...

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

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

Страница 112: ...d P21 Target wire consumption Select the target value of wire consumption in the range from 0 to 999 kg When the P20 count value reaches the wire consumption specified here an alarm appears indicating...

Страница 113: ...ing is monitored When it exceeds the range specified here an alarm displays and the output stops P40 Max fluctuation value of average range monitor If the average current voltage per second becomes ou...

Страница 114: ...continue After the welding is finished next welding cannot start until any key of the operation panel is pressed Continuous operation is not possible 2 Welding stops immediately Next welding cannot st...

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 We...

Страница 117: ...oth or either 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...

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

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 USB...

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

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

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

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: ...not grounded electric shock failure malfunction may occur Status of cables Primary power cable for facility side cables for base metal side torch side torch cable voltage detection cable etc Check th...

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: ...and Voltage Test If insulation resistance measurement and withstand voltage test is necessary please contact your dealer When measuring insulation resistance and testing withstand voltage follow the s...

Страница 128: ...AC side and positive output side and the AC side and negative output side respectively Short circuit between TR1 C1 and E1C2 TR1 E1C2 and E2 TR3 C2 and E2 Apply NF After finishing insulation resistanc...

Страница 129: ...s on the left right digital meters The welding power source may stop or may not stop output depending on the type of error code The meanings of 1 and 2 in the table below are as follows 1 When the err...

Страница 130: ...een 340 to 460 V The error code will disappear when the power switch is turned off E 160 The input voltage for primary side fell below the allowable range 2 Check that the input voltage for primary si...

Страница 131: ...cables connecting the wire feeder Check that there is no problem in the wire feeder The error code will disappear when the power switch is turned off E 810 The temperature of the governor circuit exc...

Страница 132: ...rrect Check that the setting of internal functions F29 to F32 is correct 6 7 2 22 F29 to F32 External input terminal setting The external input cables are disconnected short circuited Check that there...

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: ...module D1N60 1 TR1 to 4 100 1750 IGBT module CM300DU 12NFH 4 SCR1 4530 412 Thyristor SG25AA20 1 CT1 4810 030 Current transformer W W03029 1 CT2 100 0956 Hall current detector CS 40GEH 1 T1 T2 P30089B...

Страница 136: ...board P30086R00 1 PCB3 P30086Q00 Printed circuit board P30086Q00 1 PCB4 P30087Q00 Printed circuit board P30087Q00 1 PCB5 P30086V00 Printed circuit board P30086V00 1 PCB6 P30086V00 Printed circuit boa...

Страница 137: ...Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 2 Reference Drawing This section contains the schematic diagram and the parts layout drawing of the welding power so...

Страница 138: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 4 10 2 1 Schematic diagram PCB6 Driver P30086V00 P30115M00 P30086Q00 P30086V00...

Страница 139: ...ials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 P30099P00 CN1 2 13 16 18 26 31 32 36 39 43 45 48 49 51 52 54 56 60 62 Not connected CN2 to 4 8 Not connected P30086T00 CN7 Not connected P30086R00...

Страница 140: ...ration panel Upper DCV1 Lower P30086Q00 P30115M00 P30087Q00 P30099P00 P30086S00 P30086V00 DR1 P30086V00 P30087T00 P30086T00 SH CT2 CT1 PL1 FM1 FM2 FM3 TM5 NF 7 CON1 8 CON2 8 L10 FM4 DCV2 5 2 T2 T1 L1...

Страница 141: ...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 142: ...5 to 20 4 5 4 0 to 4 5 1 2 200 to 250 23 to 26 45 to 55 15 to 20 6 0 5 0 to 6 0 1 2 280 to 300 29 to 32 40 to 50 15 to 20 9 0 6 0 to 8 0 1 2 300 to 350 32 to 34 40 to 45 15 to 20 12 0 10 0 to 12 0 1 2...

Страница 143: ...to 25 Front 380 to 420 36 to 39 35 to 40 20 to 25 Back 19 0 5 to 7 1 6 400 to 450 36 to 42 25 to 30 20 to 25 Front 2 400 to 450 36 to 42 25 to 30 20 to 25 Back 1 6 400 to 420 36 to 39 45 to 50 20 to 2...

Страница 144: ...MATERIALS FOR SETTING WELDING CONDITIONS REFERENCE MATERIALS CHAPTER 10 10 10...

Страница 145: ...ong Da Dao Shanghai The People s Republic of China Post Code 200120 Phone 86 21 5882 8633 Fax 86 21 5882 8846 OTC Taiwan Co Ltd 2F No 153 Huanbei Rd Chung Li City Taoyuan Hsien Taiwan R O C Phone 886...

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