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Welding Conditions

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13.1

Selection of Welding Method

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13.2

Electrode and Gas Flow Rate for Various Welding Current

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13.3

Welding Conditions of Stainless Steel (SUS 304) and Middle Pulse

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13.4

Conditions of Low-pulse Welding

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13.5

Welding Conditions of Aluminum

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Connection Diagrams

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14.1

Connection System Diagram

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14.2

External Signal System Diagram

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Lists of Service Components

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Содержание MOTOWELD-T300D

Страница 1: ...r MOTOMAN MOTOWELD T300D INSTRUCTIONS YWE T30D 0 Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MANUAL NO HW0481095 YASKA...

Страница 2: ...awings and photos in this manual are representative examples and differences may exist between them and the delivered product YASKAWA may modify this model without notice when necessary due to product...

Страница 3: ...c shock fractures poisoninig etc which may cause personnel to suffer aftereffects hospitalization or prolonged out patient medical treatment Moderate injury indicates injuries burns or electric shock...

Страница 4: ...r to secure safe operations only a person that has understood this instruction manual and has knowledge and techniques to handle the welder safely must operate the welder Do not use the welder for any...

Страница 5: ...th its conductor exposed Tighten the cable connecting sections firmly and insulate them Connect the cable at the base metal as close to the welding part as possible Do not use the welder with its case...

Страница 6: ...al as close to the welding part as possible Do not weld a gas tube having gas inside or an enclosed tank or pipe Welding an enclosed tank or pipe may result in rupture Be sure to observe the following...

Страница 7: ...d close to eyes face or body to perform inching or pulling the torch switch If the wire is projected from the end tip of the weld wire guide it may poke you in the eyes face or body When hanging the w...

Страница 8: ...djuster and Flow Meter 22 6 Shading Measures 23 7 Precautions on Welding and Preparation Procedure 24 7 1 Precautions on Welding 24 7 2 Welding Preparation Procedure 27 8 Basic Specifications 30 8 1 S...

Страница 9: ...us Welding Current 50 13 3 Welding Conditions of Stainless Steel SUS 304 and Middle Pulse 51 13 4 Conditions of Low pulse Welding 53 13 5 Welding Conditions of Aluminum 55 14 Connection Diagrams 56 14...

Страница 10: ...Argon gas 1 2 3 1 Do not connect any other cable other than the torch power cable to the negative side output terminal of the welder output terminal of the torch side power cable Failure to observe th...

Страница 11: ...time Moving the welder with casters quickly may result in an accident due to inertia and you cannot control the direction of movement Be sure to stop the welder with casters at a step and move it slow...

Страница 12: ...e After determinig the operation site warnings must be placed on transport path to prevent accidents Put the welder on the transporting pallet and fix firmly to prevent falling or shifting Employ a st...

Страница 13: ...ding using shielding gas is approx 1 5 m s or less If the wind speed is higher than this limit stop operation or take some countermeasures such as putting up a screen At operations indoor or in a cont...

Страница 14: ...14 Fix the gas regulator to prevent it from falling Gas regulator Gas regulator stand...

Страница 15: ...tion Follow the local regulations for ground line size Connect the ground wire of 14 mm2 or more to the terminal which is specified as ground terminal Refer to Fig 4 1 Connection at the Rear Face If t...

Страница 16: ...uctuated within 10 from rated power supply voltage However use as stable a power supply as possible for proper welding If voltage varies more than 10 from rated power supply voltage proper welding con...

Страница 17: ...law In such a case connect a leakage breaker of current sensitivity 30 mA for each welder The welder may malfunction because of the inverter operations depending on the model or current sensitivity o...

Страница 18: ...se metal confirms the proper application of high DC voltage approx 10 mm under the argon shielding gas environment Welder Cooling water circulator Use the circulator for high DC voltage Insulate from...

Страница 19: ...cable of 8 mm 2 or more for each phase Remove the input terminal cover and connect the three cables After connection be sure to reattach the input terminal cover Input cable argon gas pressure adjuste...

Страница 20: ...ch applies DC voltage between the electrode and the base metal If insulation is not made between the electrode and the base metal the welder is hard to start Confirm that the welding torch the cables...

Страница 21: ...or Do the wiring after turning OFF the switch in the switch gear Be sure to attach the cover after connecting the torch or base metal cable Output trminal Output terminal cover Base metal terminal Coo...

Страница 22: ...hod argon gas is mainly used as shielding gas Water or any impurities in the gas adversely affects welding Use the gas of high purity with little water content 5 2 Gas Pressure Adjuster and Flow Meter...

Страница 23: ...generation may damage eyes or burn the skin of those without proper protection For shaded glasses of helments or hand shields use filter numbers 8 to 10 of JIS T8141 for welding of thin plates since...

Страница 24: ...and the welder can be used again Flashes Lights Lights continuously Checking Point and Corrective Action Input Voltage Exceeded Check that input voltage is not increased excessively Input voltage must...

Страница 25: ...lecric Systems To improve current conduction for welding do not fail to tighten all the connections of the cables and the other devices Imperfect contact or tightening of the connections may cause the...

Страница 26: ...e whitened part for better start performance Electrode diameter and material Good start performance can be obtained with tungsten electrode diameter 1 0 mm and 1 6 mm when welding current is approx 5...

Страница 27: ...r burn caused by clogging of the cooling water 3 Turn ON the switch in the switch gear When turning ON the switch at the welder main power supply indicator lamp lights 4 Turn ON the power supply switc...

Страница 28: ...age 9 Set the after flow time Use the knob to set the after flow time after completion of welding according to the used electrode 1 Never use cistern water or industrial use water for cooling water si...

Страница 29: ...ch Pulse frequency adjustment knob Pulse width adjustment knob Base current adjustment knob Welding current pulse current adjustment knob Wire feeder connector Gas outlet terminal Cooling water outlet...

Страница 30: ...5 to 15 Hz Middle pulse Frequency 15 to 500 Hz Crater Control None Start Method High DC voltage Pre flow Time 0 2 second internal adjustment 0 1 to 10 seconds After flow Time 3 to 25 seconds Pulse Wid...

Страница 31: ...nal and be sure to connect the ground of the base metal Insulate the base metal ground line so that it does not contact with other devices 6 The electrical lifetime of the circuit magnetic contactor a...

Страница 32: ...0D 0 External Dimensions For wire feeder Front cover Output terminals Output terminal cover Eyebolts M8 2 Places diagonally Cooling fans 200 220 V selector switch Input terminal cover Input terminal G...

Страница 33: ...20 29S made by Japan Aviation Electronics Industry Ltd Manipulator side MS3106B20 29P made by Japan Aviation Electronics Industry Ltd 9 2 Connector CON3 for Manipulator 11 Pins No Pin No Corresponding...

Страница 34: ...ade by Nanaboshi Electric Mfg Co Ltd Wire feeder side NCS 304PM made by Nanaboshi Electric Mfg Co Ltd 9 4 Analog Signals Relation between Analog Voltage and Output Current Analog Voltage V 0 1 2 3 4 5...

Страница 35: ...ding Speed m min 0 13 0 44 0 9 1 28 1 86 2 29 2 87 3 29 3 76 4 22 4 71 5 14 5 54 6 07 6 53 Weld wire feeder type YWE WFT40 12 0 1 0 4 0 9 1 3 1 9 2 3 2 9 3 3 3 8 4 2 4 7 5 1 5 5 6 1 6 5 0 0 0 5 1 0 1...

Страница 36: ...eedback Voltage Output Voltage V 10 15 20 Feedback Voltage V 1 8 2 38 3 No load voltage 75V No load feedvack voltage 5 9V No load DC high voltage 6 9kV 1 8 2 38 3 1 5 1 7 1 9 2 1 2 3 2 5 2 7 2 9 3 1 1...

Страница 37: ...open contact Contact capacity is as follows 24 VDC 0 2 A or less 24 VDC 0 2 A or less Circuit is closed only during pulse period Effective only in pulse mode Photocoupler capacity is as follows 30 VD...

Страница 38: ...it Manufacturer s settings Cannot be selected JS5 3 Manufacturer s settings Cannot be selected JS6 EN Shortcircuit Manufacturer s settings Cannot be selected JS8 M Can change the strength of arc start...

Страница 39: ...icator Lamp Indicator lamps LED on each board indicate the control circuit operations Board Name LED Operation Pr MB2 V15 15 V power supply Pr MB2 V Output signal Pr IF LED1 24 V for gas magnetic valv...

Страница 40: ...r switch The following diagrams show the selector switches on the printed board Replace the shortcircuit cap as described below Note To operate the adjusting volumes or selector switches on the printe...

Страница 41: ...oard MD5 and output plus terminal R40 2W10k before performing the withstand voltage test If they are not removed and voltage is applied the parts are destroyed After completion of the test reconnect t...

Страница 42: ...f Components Used The welder is composed of many components Unless all these components operate normally the welder cannot utilize its essential functions Therefore it is absolutely necessary to find...

Страница 43: ...odify the connections Failure to observe this caution may result in device troubles Check the following items in Table 12 1 Check Items and confirm that the connecting parts of all the connectors and...

Страница 44: ...s adjusting position Starting relay 1Y operates Gas circuit failure Check the printed boards MB2 and 1F Connector improper contact Check the connector Staring relay 1Y improper contact Check the start...

Страница 45: ...he printed board MX Diode REC1 breakage Check the diode Replace it if necessary 8 Power supply switch trips and cannot be turned ON Secondary side transistor UP UN VP VN breakage Check the transistors...

Страница 46: ...inals for automatic machine Nos 171 and 173 Replace Pr IF or Pr MB2 Gas circuit or Pr MX failure Pr IF or Pr MB2 failure Output current system failure All current high voltage and gas do not operate e...

Страница 47: ...or switch set to water cooing Does fault monitor flash Check whether water or air cooled torch is selected Does fault monitor flash Does starting relay 1Y operate Is voltage applied to magnetic valves...

Страница 48: ...d Use 500 V megger to measure insulation resistance between electrode and base metal Does resistance exceed 20 M at electrode negative side Is voltage of approx 60 VAC applied between connectors HVI N...

Страница 49: ...r less Mild steel 2 3 mmt or more 2 3 mmt or less Stainless steel 2 3 mmt or more Aluminum Aluminum casting Titanium Copper Aluminum bronze 2 3 mmt or less Brass 2 3 mmt or more Optimum Suitable Combi...

Страница 50: ...to 150 120 to 200 10 to 25 7 to 10 3 2 140 to 210 200 to 320 20 to 30 10 to 15 4 0 180 to 280 320 to 400 30 to 45 12 to 20 4 8 230 to 330 400 to 640 45 to 65 15 to 25 6 4 300 to 450 640 to 880 65 to...

Страница 51: ...30 4 to 5 1 a or b 1 0 1 0 to 1 6 0 to 1 0 25 to 30 4 to 7 1 a or b 1 5 1 0 to 1 6 0 to 1 6 50 to 70 6 to 9 1 b 2 5 1 6 to 2 4 1 6 to 2 4 65 to 95 6 to 9 1 b 3 0 1 6 to 2 4 1 6 to 2 4 90 to 120 7 to...

Страница 52: ...A Pulse Frequency Hz Pulse Width Remarks 10 50 5 250 to 500 10 Excellent arc concentricity can be obtained at 250 to 500 Hz Stainless Steel 10 15 5 250 50 80 100 60 250 50 SUS 304 150 180 120 250 to 5...

Страница 53: ...eding Speed mm min 0 200 50 2 5 50 600 600 1 2 150 20 1 5 40 300 600 Mild Steel spcc 1 6 130 20 1 50 150 400 0 150 50 2 5 50 800 1 2 150 20 1 40 200 400 1 6 130 20 0 8 30 100 400 Stainless Steel SUS 3...

Страница 54: ...m Pulse Current A Base Current A Pulse Frequency Hz Pulse Width Welding Speed mm min Stainless 150 50 1 2 60 300 130 60 1 5 55 200 Stainless 150 60 1 4 50 250 Butt Copper stainless 210 10 1 7 50 Horiz...

Страница 55: ...to 1 6 40 to 60 6 to 7 1 a or b 1 6 1 6 to 2 4 0 to 1 6 50 to 90 7 to 10 1 a or b 2 0 1 6 to 2 4 1 6 to 2 0 80 to 110 7 to 12 1 b 3 0 2 4 to 3 2 2 0 to 2 4 100 to 140 10 to 13 1 b 4 0 2 4 to 3 2 2 4...

Страница 56: ...56 14 Connection Diagrams 14 1 Connection System Diagram...

Страница 57: ...synchronous output signal Self adjustment Manipulator Pulse None Middle Low Gas always Gas adjustment Water Air cooling Welding voltage output signal Motor reverse run Motor forward run Motor speed r...

Страница 58: ...detection output signal Contact rated capacity 24 VDC 50 mA or less Pulse synchronous output signal Photocoupler rated capacity 30 VDC 20 mA or less Pay attention to the polarity Welding voltage outpu...

Страница 59: ...59 15 Lists of Service Components...

Страница 60: ...60 Fig 15 1 YWE T30D Front Face Fig 15 2 YWE T30D Rear Face...

Страница 61: ...14 Side cover right 68W3029889XA 3 1 515 GF30515 Side cover left 68W3029889XA 4 1 521 GP430521 Terminal cover 68W3030197 A 1 1 664 911946 Variable resistor 5K 0J2610018 3 665 895649 Variable resistor...

Страница 62: ...DTR35537 Input terminal cover 68W2009476 1 1 630 DTR35630 Ground terminal J816R1405 1 631 GP430631 Ground nameplate NW43235 1 632 C GB 22 Rubber bush C GB 22 1 711 GP430711 Warning nameplate NW6563 1...

Страница 63: ...63 Fig 15 3 YWE T30A D 0 Right Side Face Fig 15 3 YWE T30D Right Side Fade...

Страница 64: ...set SR 68W9019294 A B 658 895657 Printed board set SH1 68W9019295 A B 659 895658 Printed board set SH2 68W9019296 A B 660 895659 Printed board set SC 68W9019200 B D 724 ADH50724 Cement resistor MSS 10...

Страница 65: ...65 Fig 15 4 YWE T30D Left Side Face...

Страница 66: ...68W3025296 2 1 640 GF30640 HF cover 68W4044278 1 1 710 911965 Aluminum electrolytic capacitor 400LGSN1000M 0J1470018 2 711 GP430711 Warning nameplate NW6563 1 717 895538 Input diode module RM30TB H 0...

Страница 67: ...67 Fig 15 5 YWE T30D Base Section...

Страница 68: ...DE20528 Wire clamp 14 L56800014 2 530 ADH30530 Hose joint water KW713130 1 533 DTR35533 Terminal seat bottom 68W3023958 1 1 534 DTR35534 Terminal 68W4045521 1 2 535 DTR35535 Terminal seat top 68W30239...

Страница 69: ...69 Fig 15 6 YWE T30D Compartment Barrier Section...

Страница 70: ...inted board set MD5 68W9018712 to 714 A B 1 032 911640 Cicuit board spacer 1 PCB 10L 20 033 895535 Relay 1 G2R 2 S DC24V 0K1100034 2 036 895536 Relay 2 G5V 2 DC24V 0K1110031 1 518 GP430518 Adjustable...

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