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ABLE

ONTENTS

TABLE OF CONTENTS

Forward

Service and Support

Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Use of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safe Use of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
When Exporting the Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Disposal of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 1 SAFETY INFORMATION

1.1 Warning Symbols . . . . . . . . . . . . . . . . . . . . . .4
1.2 Safety Precaution . . . . . . . . . . . . . . . . . . . . . .5

1.2.1

Operating precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2.2

Precautions for power supply and electric shock. . . . . . 6

1.2.3

Precautions for handling of plastic parts . . . . . . . . . . . . 7

1.2.4

Precautions for disassembling and modifying the
welding power source . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2.5

Precautions for air discharge and use of respiratory
protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2.6

Precaution for protective equipment . . . . . . . . . . . . . . . 8

1.2.7

Precautions for flammable materials . . . . . . . . . . . . . . . 9

1.2.8

Precautions for gas cylinder and gas regulator . . . . . . 10

1.2.9

Precautions for rotating part . . . . . . . . . . . . . . . . . . . . 10

1.3 Principal Safety Standards . . . . . . . . . . . . .11

CHAPTER 2 PRODUCT SPECIFICATION
AND CONFIGURATION

2.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . .12

2.1.1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.2

Applicable welding method . . . . . . . . . . . . . . . . . . . . . 13

2.1.3

External dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.4

Rated duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Product Configuration . . . . . . . . . . . . . . . . .18

2.2.1

Standard composition . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2.2

Accessory (supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.2.3

Accessory (not supplied) . . . . . . . . . . . . . . . . . . . . . . . 22

2.2.4

Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3 Part Names . . . . . . . . . . . . . . . . . . . . . . . . . .24

2.3.1

Front panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.3.2

Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

CHAPTER 3 TRANSPORTATION AND
INSTALLATION

3.1 Required Equipment. . . . . . . . . . . . . . . . . . .25

3.1.1

Welding power source equipment . . . . . . . . . . . . . . . . 25

3.1.2

Ventilation equipment/partial exhaust facility. . . . . . . . 26

3.2 Installation Environment . . . . . . . . . . . . . . .27

3.2.1

Installation environment. . . . . . . . . . . . . . . . . . . . . . . . 27

3.2.2

Electromagnetic interference . . . . . . . . . . . . . . . . . . . . 27

3.3 Transportation Procedure . . . . . . . . . . . . . .28

3.3.1

Transportation with lifting lug . . . . . . . . . . . . . . . . . . . . 29

3.3.2

Manual transportation with carts . . . . . . . . . . . . . . . . . 30

CHAPTER 4 CONNECTION

4.1 Precautions for Connection Procedure

and Grounding . . . . . . . . . . . . . . . . . . . . . . .31

4.2 Connecting the Welding Power Source . . .31

4.2.1

Connection of cable at output side . . . . . . . . . . . . . . . 32

4.2.2

Connection of wire feeder . . . . . . . . . . . . . . . . . . . . . . 34

4.2.3

Connection of welding torch . . . . . . . . . . . . . . . . . . . . . 35

4.2.4

Connection of voltage detection cable
(Voltage detection cable is used) . . . . . . . . . . . . . . . . . 35

4.2.5

Connection at TIG welding . . . . . . . . . . . . . . . . . . . . . . 37

4.2.6

Connection at DC STICK welding . . . . . . . . . . . . . . . . 39

4.2.7

Connection of shield gas . . . . . . . . . . . . . . . . . . . . . . . 41

4.2.8

Connection of cooling water circulation device and
water hose (In using water-cooled welding torch) . . . . 42

4.3 Grounding and Connection of Input

Power Supply . . . . . . . . . . . . . . . . . . . . . . . .43

4.4 Confirmation of Connection . . . . . . . . . . . .44
4.5 Connection of External Equipment. . . . . . .44

4.5.1

Connection of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.5.2

Connection of automatic machine . . . . . . . . . . . . . . . . 46

4.6 Wiring of Voltage Detection Cable at Base

Metal Side . . . . . . . . . . . . . . . . . . . . . . . . . . .48

4.6.1

Wiring to wire feeder . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.6.2

Wiring to welding power source . . . . . . . . . . . . . . . . . . 49

4.6.3

Wiring example of voltage detection cable. . . . . . . . . . 50

CHAPTER 5 WELDING OPERATION

5.1 Precaution at Welding Operation . . . . . . . .51

5.1.1

Precautions for air discharge and use of respiratory
protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.1.2

Precaution for protective equipment. . . . . . . . . . . . . . . 52

5.1.3

Precautions on welding place. . . . . . . . . . . . . . . . . . . . 52

5.2 Check before Welding  . . . . . . . . . . . . . . . . .52
5.3 Power ON and Gas Supply  . . . . . . . . . . . . .54
5.4 Wire Inching  . . . . . . . . . . . . . . . . . . . . . . . . .55
5.5 Check and Setting of Welding Condition . .56

5.5.1

Reading welding condition . . . . . . . . . . . . . . . . . . . . . . 56

5.5.2

Preventing erroneous operation on operation panel . . 56

5.6 Performing Welding Operation . . . . . . . . . .57

5.6.1

Operation of welding start . . . . . . . . . . . . . . . . . . . . . . 57

5.6.2

Operation during welding . . . . . . . . . . . . . . . . . . . . . . . 58

5.6.3

Operation at welding end . . . . . . . . . . . . . . . . . . . . . . . 60

CHAPTER 6 WELDING CONDITION

6.1 List of Welding Conditions . . . . . . . . . . . . .61

6.1.1

Parameter (Welding parameter). . . . . . . . . . . . . . . . . . 61

6.1.2

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.1.3

Internal function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6.2 Function on Operation Panel. . . . . . . . . . . .66

6.2.1

Operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.2.2

Setting screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.3 Welding Conditions . . . . . . . . . . . . . . . . . . .70

6.3.1

Basic welding conditions . . . . . . . . . . . . . . . . . . . . . . . 70

6.3.2

Useful functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.4 Preparing Welding Conditions . . . . . . . . . .70
6.5 Memory Function of Welding Conditions. .71

6.5.1

Memory registration of welding conditions . . . . . . . . . . 71

6.5.2

Read out of welding conditions . . . . . . . . . . . . . . . . . . 72

6.5.3

Deletion of memory registration . . . . . . . . . . . . . . . . . . 73

6.6 Setting Welding Conditions. . . . . . . . . . . . .75

6.6.1

Welding mode setting. . . . . . . . . . . . . . . . . . . . . . . . . . 75

6.6.2

Setting welding conditions . . . . . . . . . . . . . . . . . . . . . . 77

6.6.3

Setting welding parameter . . . . . . . . . . . . . . . . . . . . . . 77

6.6.4

Crater setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

6.6.5

Arc spot time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Содержание Welbee P400L II

Страница 1: ...Welbee P400L II P500L II OWNER S MANUAL July 2021 Manual No P30345 1 DAIHEN Corporation...

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

Страница 3: ...e that installation operation maintenance of the welding power source and welding machine is performed by qualified personnel with sufficient knowledge and skills If this manual is lost or damaged imm...

Страница 4: ...lding torch 35 4 2 4 Connection of voltage detection cable Voltage detection cable is used 35 4 2 5 Connection at TIG welding 37 4 2 6 Connection at DC STICK welding 39 4 2 7 Connection of shield gas...

Страница 5: ...n 127 7 3 4 Welding Result Control Function 128 7 3 5 Backup operation 128 7 3 6 Importing backup data 130 7 4 Initializing Welding Conditions and Internal Functions 131 7 5 Checking the Software Vers...

Страница 6: ...re as follows Make sure to fully understand the content before beginning operation The below symbols are categorized by the degree of possible hazard and damage The below symbols are categorized accor...

Страница 7: ...no person is allowed unauthorized access near the welding power source or work areas Only authorized personnel or person with full understanding and experience of the welding power source must perfor...

Страница 8: ...e minutes or more The capacitors may be still charged even after the input power is cut Make sure that there is no charged voltage before starting the work Wear dry insulating gloves for protection Do...

Страница 9: ...hemical agent Doing so may cause crack breaking and degrade the strength If there is any abnormality in the plastic parts such as front panel rear panel and fan immediately stop the use and contact yo...

Страница 10: ...ve equipment Welding or cutting the coating steel plate or galvanized steel sheet will cause toxic gas or fume Do not perform welding operation in the vicinity of degreasing cleansing or spraying oper...

Страница 11: ...n gas pipe and closed containers such as tanks or drums Performing arc welding on flammable object such as fuel tank may cause explosion Furthermore welding on closed container such as tanks and pipes...

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

Страница 13: ...from American Welding Society Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from...

Страница 14: ...50 1 A 31 7 A 26 3 A 2 Rated output current 400 A 300 A 250 A 200 A 250 A 500 A 400 A Rated load voltage 34 V 26 V 32 V 26 5 V 24 V 20 V 30 V 39 V 34 V 26 V 36 V Maximum no load voltage 3 73 79 V 1 73...

Страница 15: ...4 CO2 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD HIGH MAG 20 CO2 1 1 MILD STEEL 030 035 040 045 0 8 0 9 1 0 1 2 030 035 040 045 0 8 0 9 1 0 1 2 STANDARD HIGH M...

Страница 16: ...ode the standard mode or extended cable mode extended mode of power cable is available 6 7 2 1 F1 Standard Extended cable mode 3 Two types of welding performances can be selected 6 7 2 19 F22 SUS EX p...

Страница 17: ...of the welding power source The rated duty cycle of the welding power source is the following Rated duty cycle of 60 means the power source must be rested for 4 minutes after 6 minutes of continuous...

Страница 18: ...urrent A Duty cycle 80 60 DC DC TIG three phase 100 50 0 100 200 310 400 Usable range Welding current A Duty cycle DC PULSE three phase 100 50 0 100 200 283 400 Usable range Welding current A Duty cyc...

Страница 19: ...PTER 2 Relationship between welding current and duty cycle WB P 02L 100 50 0 100 200 300 400 DC TIG DC STICK Usable range Welding current A Duty cycle 100 80 50 0 100 200 300 350 400 DC PULSE Usable r...

Страница 20: ...her than specified may cause failure of the welding power source No Name Required component Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 W...

Страница 21: ...le for wire feeder 5 ft 1 5 m Included in feeder 1 6 Power cable for torch side 1 7 Power cable for base metal side 1 8 Shield gas To be prepared by the customer 2 2 3 Accessory not supplied 9 Digital...

Страница 22: ...mponent Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Welding torch 3 Gas hose 10 ft 3 m 1 Included in feeder 2 4 Power cable for base meta...

Страница 23: ...on and the quantity of parts when opening the package No Name Required component Optional accessories Remarks 1 Welding electrode holder To be prepared by the customer 2 2 3 Accessory not supplied 2 P...

Страница 24: ...source 2 2 4 1 Remote control voltage detection cable and other optional items Following items are optionally available including remote control and voltage detection cable Name Remarks CO2 gas Carbo...

Страница 25: ...able may cause an unstable arc No Product name Model 16 ft 5 m 33 ft 10 m 50 ft 15 m 66 ft 20 m 1 Gas hose BKGG 0605 BKGG 0610 BKGG 0615 BKGG 0620 2 Control cable for wire feeder BKCPJ 1005 BKCPJ 1010...

Страница 26: ...wer source Socket for wire feeder Socket for analog remote control Output terminal Base metal side Power switch Main power lamp Terminal for directly detecting voltage on the base metal side Output te...

Страница 27: ...shock due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker to the input side of each welding power source Otherwise electric shock and fire due to overcu...

Страница 28: ...e on the welding power source 3 1 2 Ventilation equipment partial exhaust facility This section explains the ventilation equipment and partial exhaust facility in welding work area 3 1 2 1 Ventilation...

Страница 29: ...90 or lower ambient temperature of 68 F 20 C Location with an incline of 10 or less For the welding power source with wheels use chock to prevent from sliding Location with no metallic foreign body s...

Страница 30: ...pply 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 wel...

Страница 31: ...ce and resulting accidents be sure to observe the following For operation of a crane or hoisting make sure that a qualified personnel operate them with attention to the surrounding area for safety Use...

Страница 32: ...as carriers secure the welding power source and carrier with a rope before transporting When lifting the welding power source make sure to hold the bottom of the welding power source by more than one...

Страница 33: ...ocal regulation Make sure to cut the input power with the disconnect switch in the box connected to the welding power source Do not turn on the input power before confirming the completion of connecti...

Страница 34: ...on 2 Connect the power cable for torch side to the output terminal torch side Connect the connectors as same as above Connection for cable at output side is complete Procedure is followed by 4 2 2 Con...

Страница 35: ...for base metal 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 Conne...

Страница 36: ...10 cores to the socket for the wire feeder Fit the concave part of the connector and convex part of the socket for secure connection and tighten the knurled screws in the clockwise direction When usin...

Страница 37: ...gas 4 2 4 Connection of voltage detection cable Voltage detection cable is used This section explains the procedure for connecting the voltage detection cable TIPS When the voltage detection cable is...

Страница 38: ...l side can also be connected to the direct voltage detection terminal for base metal of the welding power source When using the welding power source by lifting with hoisting equipment connect the volt...

Страница 39: ...a welding torch by the customer Contrary to the normal connection the TIG welding requires connection of the welding torch to the output terminal base metal side Also connect the power cable for base...

Страница 40: ...IG valve kit TIPS For the procedure for installing the TIG valve kit optional accessory to the welding power source refer to the instruction manual of the TIG valve kit Connect the kit to the torch as...

Страница 41: ...sleeve 3 Attach the sleeve to the conductor of the cable 4 Insert the sleeve into the connector terminal and fix the sleeve using a screw Tighten the screw at 12 N m using a hexagonal wrench 5 Fit the...

Страница 42: ...d terminals of the power cable for base metal side with the fixing screws 3 Connect the power cable for welding electrode holder side to the output terminal torch side Connect the connectors as same a...

Страница 43: ...described in 4 3 Grounding and Connection of Input Power Supply Be sure to observe the following points to prevent from suffocation due to gas leakage or explosion Be sure to turn off the shield gas...

Страница 44: ...he cooling water circulation device 4 Connect the condensing hose to the cooling water circulation device and the wire feeder Connection of cooling water circulation device and water hose is complete...

Страница 45: ...ck due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker to the input side of each welding power source Otherwise electric shock and fire due to overcurren...

Страница 46: ...ble of the welding power source is connected to the breaker s ground terminal No tools or equipments are left placed on the surface of the welding power source Do not place any material on the surface...

Страница 47: ...emarks 1 Welding power source 2 Interface IFR 101WB Connection robot controller cable optional is also available Refer to instruction manual of Interface 3 Wire feeder Wiring for wire feeder needs to...

Страница 48: ...serve inputs for expanding terminal functions Setting the internal functions Function allows you to externally open and close the gas valve and perform inching operation 6 7 Setting Internal Functions...

Страница 49: ...persons or persons familiar with the welding machine Do not touch the input and output terminals and the internal live electrical parts of the welding power source Before starting the work make sure...

Страница 50: ...n length in total use of the voltage detection cable at the base metal side is recommended The voltage detection cable needs to be wired so that the correct feedback of the arc voltage can be obtained...

Страница 51: ...Wiring of voltage detection cable is complete 4 6 2 Wiring to welding power source This section explains how to connect the voltage detection cable at the base metal side to the voltage direct detect...

Страница 52: ...e metal side cable 4 6 3 2 Wiring example when power is supplied with a power feeding brush to the positioner Insulate the power feeding brush from the jig base and connect the voltage detection cable...

Страница 53: ...lation 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 wel...

Страница 54: ...he work area from arc ray Wear an ear protector when noise level is high Ignoring the above may cause hearing disorder CAUTION When the welding is performed outside with wind or when wind is caused by...

Страница 55: ...f the particle size is smaller than the above set the anti stick voltage to a higher value whereas if the particle size is larger than the above set the anti stick voltage to a lower value 14 At start...

Страница 56: ...in tap by checking the pressure gauge until the appropriate pressure is obtained 5 Turn the flow rate adjustment knob to OPEN and adjust the flow rate of shield gas 6 Press the GAS CHECK key B The LED...

Страница 57: ...g For excessive wire cut the wire using a plier B Turning the parameter adjusting knob during the wire feeding can adjust the feed speed TIPS Wire feeding is also enabled by a remote control optional...

Страница 58: ...k or reading saving of the welding condition In using the analog remote control however the adjustment of current voltage by the analog remote control is available The erroneous operation prevention f...

Страница 59: ...hes 2 A series of welding operation is completed by the torch switch operation 6 6 3 Crater setting B At the end of welding the average value of the welding current and the welding voltage at the last...

Страница 60: ...pletion of the welding operation can be controlled by the torch switch operation 6 7 2 60 F81 TIG Mode torch switch setting 5 6 2 Operation during welding This section explains the operation requiring...

Страница 61: ...mote control this operation is not necessary Turn the parameter adjustment knob for the remote control the welding voltage adjustment knob to adjust the welding voltage 4 Press the DISPLAY CHANGE key...

Страница 62: ...ischarged 3 After the shield gas is discharged press the GAS CHECK key B The LED of the GAS CHECK key lights off to stop gas check 4 Set the flow adjustment knob to SHUT to adjust the shield gas flow...

Страница 63: ...UAL 1 WB P402L Three phase 10 0 to 45 0 V 23 5 V 21 5 V initial crater Single phase 12 0 to 34 0 V WB P502L 10 0 to 50 0 V Voltage SYNERGY 1 100 to 100 3 0 to 3 0 MS MIG 0 Post flow time 0 to 10 sec 0...

Страница 64: ...ition to 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 1 350 A Confi...

Страница 65: ...splay for s ueeze detection When F33 is selected the S ueeze detection inhibition ratio is displayed on the right digital meter This function is not configurable F34 Automatic correction of s ueeze de...

Страница 66: ...d 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 function 0 to 8 0 Sets sample data on the data log 0 No sam...

Страница 67: ...Sets the Arc ON time in the Interval welding function F73 Setting Arc OFF time Interval function 0 20 to 9 99 1 00 s Sets the Arc OFF time in the Interval welding F74 to F76 No function OFF fixed OFF...

Страница 68: ...ltage display adjustment OFFSET 2 0 to 2 0 0 0 V 1 WB P402L 2 WB P502L No Name Function 1 Left digital meter Displays various information The welding current is displayed in welding and the LED of A l...

Страница 69: ...of the setting screens displayed on the LCD panel 10 CONSTANT PENETRATION key Activates the penetration control 6 6 9 Penetration control adjustment Press this key makes the LED lit and automatically...

Страница 70: ...1 6 7 17 5 6WDQGDUG WHQGHG FDEOH PRGH 0 18 6 7 17 5 81 7 216 0 18 20 6 7 17 5 0 18 6 7 17 5 KHQ ZHOGLQJ LV XQVWDEOH ZLWK WKH ORQJ H WHQGHG SRZHU FDEOH RYHU P OHQJWK WHQGHG FDEOH PRGH PD LPSURYH ZHOGLQ...

Страница 71: ...ng mode setting CRATER FILL Select the crater treatment method or arc spot at the end of welding For details of the crater treatment 6 6 4 Crater setting For details of arc spot 6 6 5 Arc spot time SP...

Страница 72: ...e wire feed speed so that the constant welding current is always kept even with the wire feeding length changes Available only for MILD STEEL SOLID MILD STEEL CORED STAINLESS STEEL SOLID or STAINLESS...

Страница 73: ...rent voltage values read out from the memory by the analog remote control optional 6 7 Setting Internal Functions 6 5 1 Memory registration of welding conditions This section explains how to register...

Страница 74: ...ted JOB No no data is displayed on the LCD panel and is displayed on the left digital meter When there is a registration data on the selected JOB No the set welding current value is displayed on the l...

Страница 75: ...s depressed together turn ON the power switch When there is no registration data on the selected JOB No no data is displayed on the LCD panel and is displayed on the left digital meter When there is a...

Страница 76: ...n the system transits to the DELETE mode The JOB No registration No is displayed on the right digital meter in a flashing mode and the LED of JOB lights up To delete all the registration at the same t...

Страница 77: ...1 3 SOFT ALUMINUM 045 1 16 1 2 1 6 045 1 16 1 2 1 6 STANDARD 2 HIGH HARD ALUMINUM 045 1 16 1 2 1 6 045 1 16 1 2 1 6 STANDARD 2 HIGH Brazing CuSi 030 035 045 0 8 0 9 1 2 030 035 045 0 8 0 9 1 2 STANDA...

Страница 78: ...MIG gas Argon Ar 100 2 For STANDARD mode the standard mode or extended cable mode extended mode of power cable is available 6 7 2 1 F1 Standard Extended cable mode 3 Two types of welding performances...

Страница 79: ...asic welding sequence is the process of PRE FLOW MAIN CONDITION and POST FLOW To this sequence initial condition and crater fill condition can be added depending on the crater setting The welding para...

Страница 80: ...n the LED above the 7 segment display for current adjustment is off press the parameter adjustment knob to light up the LED The welding current can also be set based on the wire feed speed In this cas...

Страница 81: ...ding Conditions 6 6 4 Crater setting This section explains the details of crater treatment and torch switch operation There are modes listed below for the crater setting For initialization conditions...

Страница 82: ...FF by the CRATER FILL menu In synchronous to the ON OFF operation of the torch switch the welding starts stops Torch switch Gas flow Output voltage Wire feeding speed Welding current Main welding Anti...

Страница 83: ...The torch switch should remain depressed and held during the CRATER phrases When selecting CRATER FILL ON no pulse Regardless of the setting by the WELDING METHOD menu the machine automatically turns...

Страница 84: ...and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON no pulse Regardless of the setting by the WELDING METHOD menu the machine automatically turns to the welding with no pulse...

Страница 85: ...s displayed on the left digital meter when pressing the SPOT TIME menu and is adjustable by the parameter adjustment knob Turning OFF the torch switch before reaching the arc spot time starts the anti...

Страница 86: ...omatically set can be finely adjusted by the parameter adjustment knob Welding voltage on the positive side high negative side low INDIVIDUAL mode Press the VOLT ADJUST menu When the INDIVIDUAL is sel...

Страница 87: ...luminum welding makes a ripple bead using an overlap method It can also make welding easier even if there is a gap between weld parts because it performs a crystal miniaturization by vibrating the mol...

Страница 88: ...PLATE THICKNESS the welding current will be set automatically according to each parameter 1 Select WELDING GUIDE on the HOME screen The LED for the WAVE FRQ key lights up The wave frequency setting v...

Страница 89: ...sory is connected The color of the selected parameter will be inverted on the display Turn the screen operation knob to place the cursor on the parameter that needs to be set and press the knob Change...

Страница 90: ...oint when the setting value is changed To change the set values of internal functions ensure that there is no mistake in the function No as well as in the function setting 1 Display FUNCTIONS in the M...

Страница 91: ...ll be displayed at the welding method menu in HOME screen OFF Standard mode TIPS In using the welding power source in the HIGH mode the setting of this function is set to OFF and cannot be changed Whe...

Страница 92: ...etract function 3 Disabled Enabled Error reset After removing the cause of error the power is restored After removing the cause of error the power is restored Or open short circuit the deactivated ter...

Страница 93: ...me longer Setting range of upslope time 0 0 to 10 0 sec 6 7 2 6 F7 Downslope time When the difference between the welding current and crater current is large the wire may plunge into weld pool at the...

Страница 94: ...continuous If the current flows to the motor exceed the set value the alarm display of E 820 is displayed output of the welding power source is not stopped According to the use environment such as wi...

Страница 95: ...0 min ON Water cooled pump is always ON 6 7 2 12 F13 Turbo start The welding power source has the turbo start function using capacitor discharge in order to obtain smooth welding start ON enables the...

Страница 96: ...just the anti stick process time in the range of 50 unit 0 01 seconds through the internal function F17 Based on 0 adjusting it to the negative direction shortens the time and adjusting it to the posi...

Страница 97: ...reduced 6 7 2 21 F24 Wire feeding speed setting The welding current can be automatically set based on the wire feed speed ON enables the function The welding power source is automatically set based o...

Страница 98: ...machine 1 mode 6 7 2 22 F25 to F28 External output terminal setting Through F25 you can set the functions of OUT EXT1 3 4 on the terminal block for external connection Through F26 you can set the func...

Страница 99: ...hen disconnect the external input terminals 3 The starting terminal of the feeder receptacle on the front of welding power source becomes deactivated 4 Combination of the external input terminals enab...

Страница 100: ...condition of the external input terminal In this case the welding condition is newly read out when the signal of external input terminal to which this function is allocated to has any change again 7 T...

Страница 101: ...tion a phenomenon called Squeeze shown in the below figure occurs on the wire Detecting this Squeeze and rapidly decreasing current at the exact moment prevent molten metal being blown off by arc forc...

Страница 102: ...and welding conditions greatly vary by welding section it is recommended to use the machine with this function set to OFF 6 7 2 27 F36 F37 Spatter adjustment P1P P2P Use this function to manually set...

Страница 103: ...his function set to 1 When using a reverse polarity wire set this function to 2 6 7 2 29 F39 F40 Output current gain adjustment If there is difference between the current value indicated on the digita...

Страница 104: ...F11 Fine adjustment of welding conditions memory is set to 1 to 30 enabled Internal function F45 Special crater sequence is set to ON enabled Internal function F48 Adjusting current with torch switch...

Страница 105: ...ingle clicking or double clicking the torch switch in the period of welding condition during start input holding If this function is enabled ADJUST CURRENT by TS is displayed in the HOME screen enabli...

Страница 106: ...volume by single clicking in the range of 100 to 100 A 6 7 2 36 F50 Current increase and decrease by double clicking To increase decrease the welding current by the torch switch operation set the cur...

Страница 107: ...nabled Internal function F48 Adjusting current with torch switch is set to ON enabled or Either of the internal functions F29 to F32 External input terminal setting is set to either 4 Start or 5 Loadi...

Страница 108: ...ne adjustment of unit pulse condition The unit pulse conditions such as pulse peak current pulse peak time and base current at pulse welding are properly set according to welding method or wire diamet...

Страница 109: ...e finely adjusted pulse peak current at LOW side can be obtained Set the adjustment value in the range of 150 to 150 A Fine adjustment of unit pulse condition 6 7 2 42 F60 Fine adjustment of pulse pea...

Страница 110: ...current value of the welding condition Setting range of current value initial condition 10 to 300 6 7 2 51 F69 Setting of current value crater condition The current value of the crater condition can b...

Страница 111: ...erval function Sets the arc OFF time in the Interval welding function Set the arc OFF time in the range of 0 20 to 9 99 seconds 6 7 2 56 F77 Welding result control function identification numbers Sets...

Страница 112: ...ion 6 7 2 61 F82 Extended correction for DC Pulse welding If welding is done with the output cable extended or bent welding may become unstable e g arc becomes unstable wire plunges into base metal Ad...

Страница 113: ...lse automatic adjustment is set by carrying out the welding after setting at 1 or by manually changing the setting of internal function F85 Adjustment amount of pulse automatic adjustment TIPS When se...

Страница 114: ...hange For more information on the adjustment procedure contact dealer NOTE Do not carelessly change the setting of this function 6 7 2 66 F88 F89 Voltage display adjustment GAIN OFFSET Set the adjustm...

Страница 115: ...ent is automatically set and fine adjustment is available for the set welding voltage Align the welding voltage adjustment knob to the center mark and adjust the voltage with the position as the stand...

Страница 116: ...Crater setting CRATER FILL OFF CRATER FILL ON with pulse CRATER FILL ON No pulse 2 Gas check 5 3 Power ON and Gas Supply OFF OFF ON 3 Constant penetration 6 6 8 Penetration control adjustment OFF OFF...

Страница 117: ...vention function is disabled NOTE Write down the password on a piece of paper and store it safely The current password will be requested also when you change it If a password is set and the erroneous...

Страница 118: ...To change the password delete the password with the operation from the step 3 of 7 1 2 Disabling erroneous operation prevention and go to the next step If a password has already been set the Password...

Страница 119: ...prevention function the password will be requested 7 1 2 Disabling erroneous operation prevention This section explains how to disable the password protected erroneous operation prevention function 1...

Страница 120: ...password changing or deleting operation the screen will shift to the Password Setting screen 7 1 1 Setting Changing password B The number is confirmed and the display will change from color inversion...

Страница 121: ...ion P20 0 00 Cumulative wire consumption used in welding lbs kg P21 0 0 to 9999 0 to 4535 Target wire consumption lbs kg P22 0 0 to 5 Operation at the time when the target wire consumption is achieved...

Страница 122: ...to 9999 When the P10 count value reaches the number of welding points specified here an alarm appears indicating that the target is achieved 7 2 2 6 Alarm indication when target is achieved P12 Operat...

Страница 123: ...rget is achieved 7 2 2 6 Alarm indication when target is achieved P22 Operation at the time when the target wire consumption is achieved Select the operation from 0 to 5 for the time when the target s...

Страница 124: ...ltage average per second during welding is out of the allowable tolerance range When the out of range state becomes longer than the time specified here an alarm displays 7 2 2 7 Alarm indication at th...

Страница 125: ...51 P52 Clear of the control data value Clear the various control data After setting the setting value of P52 to cLr return to the MENU screen Then the control data shown below will be cleared 7 2 2 6...

Страница 126: ...l No P40 flashes on the left digital meter and the difference between the average value and specified value 1 5 on the right digital meter with the A LED lighting In case of voltage error the differen...

Страница 127: ...tim Down slope time 0 1 s wld iset Welding current 1 A pre tim Initial time 0 1 s wld vset Welding voltage 0 1 V cre tim Crater time 0 1 s wld uni vset Welding voltage synergic 1 KubireAutoAdj Automat...

Страница 128: ...AIHEN_OTC_Welbee DAT DAT00001 folder is already existing DAT00002 folder will be created below the DAIHEN_OTC_Welbee DAT folder and folder for the consecutive number will per created for each simplifi...

Страница 129: ...and not recorded when there is no output The simplified data log cannot be backed up It will be deleted when the power switch is turned off The simplified data log can be exported even if an error co...

Страница 130: ...ack up the data such as welding conditions The data can be backed up in a USB flash drive TIPS The USB flash drive to be used should be formatted as FAT32 If it is formatted as FAT16 or NTFS reformat...

Страница 131: ...lay the data to back up on the right digital meter B The display changes in order of ALL 1 2 3 4 B ALL means that all the data 1 to 4 available for backup are selected B Details of the numbers display...

Страница 132: ...operation knob to place the cursor on RESTORE and press the knob B ALL or JOB No registration No is displayed on the right digital meter in a flashing mode and the LED of JOB lights up B USb is displa...

Страница 133: ...ons registered in memory NOTE F39 to 42 will not be initialized 1 Turn OFF the power switch 2 Press and hold the WIRE INCH key and left DISPLAY CHANGE key simultaneously and turn ON the power switch 3...

Страница 134: ...eturns to normal when the power switch is turned on B The product information will be displayed on the LCD panel When the screen operation knob is turned information on the peripheral equipment will b...

Страница 135: ...or more If no resistance load is applied short circuit between the output terminals by using a cable with a cross section of 38 mm2 or more WB P502L 0 09 22 5 kW or more If no resistance load is appl...

Страница 136: ...output current turn ON the torch switch to confirm the adjusted result to the set value Make sure that the value of the output current is within the following limits WB P402L 400 1 A WB P502L 500 1 A...

Страница 137: ...ed on the operation panel 7 Correct the difference by using the values of internal functions F41 and F42 so that the difference is within the range of 0 1 V hen the value of F41 is 0 1 it is equivalen...

Страница 138: ...SETTING will be displayed Font Size LCD Background Turn the screen operation knob to select the Font Size from Standard and Large and press the knob Turn the screen operation knob to select the backg...

Страница 139: ...fter 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 Spec...

Страница 140: ...as printed 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 compre...

Страница 141: ...e metal side torch side torch cable voltage detection cable etc Check that there is no abnormal heat generation in cable connections Check that cable connections are not loose Check that there is no p...

Страница 142: ...nt slit ventilation hole to the back side to remove dust inside the welding power source Dust accumulating on the heat sink of transistor and rectifier may prevent heat radiation adversely affecting t...

Страница 143: ...of the high voltage electrolysis capacitor or other parts It is recommended to replace the printed circuit board PCB7 every five years For replacement of the printed circuit board PCB7 contact your de...

Страница 144: ...e and the cathode For DR4 short circuit between the anode and the cathode Short circuit between TR1 C1 and E1C2 TR1 E1C2 and E2 TR3 C2 and E2 TR5 C and E TR6 C and E Apply NF After finishing insulatio...

Страница 145: ...ppropriate action according to the table below If the welding power source is combined with robots manufactured by OTC see the instruction manual of the robot controller Before inspecting the welding...

Страница 146: ...ion Error Application Parameter E 055 Communication Error in Control Board Secondary Side HCI Communication Error Timeout E 056 Communication Error in Control Board Secondary Side HCI Communication Er...

Страница 147: ...witch is turned off After recovery be careful not to exceed the rated duty cycle E 310 to 313 Rotation problem of the cooling fan 2 Clean dusts inside the welding power source 8 3 Periodical Inspectio...

Страница 148: ...ror E 820 The current in the wire feeder motor exceeded the warning level 2 Check that the wires are not stuck or there are no other abnormalities in the welding torch or wire feeder The error code wi...

Страница 149: ...on The primary power source is not supplied Supply the primary power source in the following range WB P402L 208 230 460 V 10 WB P502L 460 V 10 3 Nothing is displayed on the left right digital meters...

Страница 150: ...roneous operation on operation panel 11 Arc is unstable The setting of welding mode is not correct Check the settings of wire diameter wire materials and shield gas The wire is defective or there is a...

Страница 151: ...12A 1 DR7 4531 505 Diode S2L60 1 DR12 13 100 0179 Diode module DSEI 2X101 12A 2 TR1 to 4 100 2215 IGBT module CM200DU 12NFH 4 100 1750 CM300DU 12NFH 4 TR5 100 2219 IGBT module 1MBI300HH 120L 50 1 TR6...

Страница 152: ...27 Film capacitor 0 47 uF 50 V 1 C12 100 1572 Film capacitor FHC 180 2000 V 103J 1 C13 4514 206 Film capacitor US20X472JAASA 1 C14 100 2227 Film capacitor US20X682JAASA 1 CON1 100 1435 Receptacle DPC2...

Страница 153: ...3674 Side cover right P30099G17 1 1 15 100 3675 Top cover P30086G18 1 1 16 W W03784 Socket cover W W03784 1 17 K5804Q00 Resin panel K5804Q00 1 1 1 When placing an order of a printed circuit board P30...

Страница 154: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 152 10 2 1 Schematic diagram WB P402L P30194X00 P30133M00 P30086V00 P30088V00 P30086V00...

Страница 155: ...Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 P30099P00 P30304R00 CN2 3 5 to 8 Not connected P30086T00 CN7 Not connected P30087Q00 P30087T00 P30086S00 CN1 16 31 36 39 43 45 47 49 51 52 5...

Страница 156: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 154 WB P502L P30115M00 P30086Q00 P30086V00 P30086V00...

Страница 157: ...erials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 P30088V00 P30099P00 P30304R00 CN2 3 5 to 8 Not connected P30086T00 CN7 Not connected P30087Q00 P30087T00 P30086S00 CN1 13 26 36 39 43 45 47 49 5...

Страница 158: ...TM5 NF 6 CON1 7 CON2 7 5 2 1 4 3 Front P30304R00 Rear side of operation panel 8 9 13 12 17 P30087Q00 P30099P00 FM4 Top R19a b TR6 7 P30087V00 CT1 P30086V00 P30087T00 P30086T00 SH TM6 Right side T2 PS1...

Страница 159: ...00 P30086T00 SH CT1 PL1 FM1 FM2 FM3 TM5 NF 6 CON1 7 CON2 7 R19a b DCV2 5 R15a b 2 1 4 3 8 9 Top Back When the cover is opened Front Right side When the fan frame is removed Left side TR6 DR1 T3 L2 T2...

Страница 160: ...me small The welding voltage is too low The wire contacts the base metal and spatter is generated The bead width becomes narrow The welding current is too high The bead width becomes wide Penetration...

Страница 161: ...21 to 32 10 to 15 14 ga 2 0 1 8 to 9 64 3 0 to 3 5 035 to 045 0 9 to 1 2 100 to 130 19 to 20 20 to 24 50 to 60 32 to 42 15 to 20 12 ga 2 3 1 8 to 9 64 3 0 to 3 5 035 to 045 0 9 to 1 2 120 to 140 19 t...

Страница 162: ...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 163: ...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 164: ...2 280 30 16 40 052 1 4 350 32 20 50 1 16 1 6 380 34 26 65 5 16 8 045 1 2 300 31 12 30 052 1 4 350 33 18 45 1 16 1 6 380 34 20 52 23 64 9 045 1 2 320 32 12 30 052 1 4 350 34 16 40 1 16 1 6 380 34 16 40...

Страница 165: ...6 0 0 2 6 1 200 27 to 28 16 40 5 16 8 0 0 3 8 1 250 29 to 30 14 35 15 32 12 0 0 4 10 1 180 to 200 25 to 27 18 45 2 180 to 200 25 to 28 18 45 3 180 to 200 25 to 28 18 45 5 8 16 0 0 5 12 1 220 to 230 2...

Страница 166: ...to 31 12 30 15 32 12 0 1 280 30 to 31 16 40 2 330 33 to 34 16 40 3 4 19 0 1 300 31 to 32 18 45 2 300 31 to 32 18 45 1 340 32 to 33 18 45 2 280 30 to 31 18 45 63 64 25 0 1 300 31 to 32 18 45 2 320 32...

Страница 167: ...ltage V Remarks 1 100 20 to 21 Slight oscillation 2 280 26 to 27 Slight oscillation 3 280 26 to 27 Slight oscillation 4 280 26 to 27 Slight oscillation 5 280 26 to 27 Slight oscillation 6 280 26 to 27...

Страница 168: ...in mm Wire diameter in mm Current A Voltage V Travel speed IPM cm min Wire feeding length in mm Gas flow rate CFH L min 16 5 ga 1 5 045 1 2 60 to 80 16 to 18 24 60 0 6 15 32 to 42 15 to 20 1 8 3 0 04...

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