Daihen OTC WB-P400, Owner'S Manual

Page 1: ...ad this instruction manual thoroughly for safe and proper use of the product March 2017 Manual No P30194 2 Model WB P400 Welbee Inverter P400 OWNER S MANUAL Pulsed MAG MIG Welding power source DAIHEN...

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Page 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...

Page 4: ...tallation operation maintenanceoftheweldingpowersourceandweldingmachineis performed by a qualified personnel with sufficient knowledge and skills If this manual is lost or damaged immediately contact...

Page 5: ...model manufacture year serial number and software version number Referto thediagram below forproductinformation Attachment location andcontentofnameplatemay vary depending on the purchased product Exa...

Page 6: ...ting lug 3 5 3 3 2 Manual transportation with carts 3 6 CHAPTER 4 CONNECTION 4 1 Precautions for Connection Procedure and Grounding 4 1 4 2 Connecting the Welding Power Source 4 2 4 2 1 Connection of...

Page 7: ...result control function 7 4 7 2 2 Details of welding control items 7 5 7 3 Data Backup Utilization of data 7 9 7 3 1 Setting of welding conditions internal functions 7 10 7 3 2 Simplified data log fu...

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

Page 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...

Page 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...

Page 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...

Page 12: ...entive 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 inspect the v...

Page 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...

Page 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...

Page 15: ...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 face...

Page 16: ...an Welding Society RecommendedSafePracticesforthePreparationforWeldingandCuttingofContainersThatHaveHeld HazardousSubstances AmericanWeldingSocietyStandardAWSF4 1 fromAmericanWeldingSociety National E...

Page 17: ...208 230 V 10 460 V 10 Rated input DC 17 8 kVA 16 4 kW Pulse 19 7 kVA 18 1 kW DC 21 4 kVA 16 8 kW Pulse 20 8 kVA 18 3 kW Rated input current DC 49 4 A Pulse 54 0 A DC 26 9 A Pulse 26 1 A Rated output c...

Page 18: ...DC 250 A Pulse 200 A Rated load voltage DC 30 V Pulse 24 V Rated output current range DC 30 to 250 A Pulse 30 to 200 A Rated output voltage range DC 12 to 30 V Pulse 12 to 24 V Maximum no load voltag...

Page 19: ...8 0 9 1 0 1 2 1 4 2 3 Enable MIG 2 O2 1 2 STAINLESS STEEL 030 035 0 45 0 8 0 9 1 2 2 3 Enable STAINLESS FERRITE 030 035 045 0 8 0 9 1 2 2 3 Enable MIG 100 Ar 1 3 SOFT ALUMINUM 045 1 16 1 2 1 6 2 3 HA...

Page 20: ...CT SPECIFICATION AND CONFIGURATION CHAPTER 2 2 4 2 1 3 External dimensions This section explains the external dimensions of the welding power source 31 9 810 mm 15 6 395 mm 28 0 710 mm 12 6 320 mm 18...

Page 21: ...elding power source is the following Operation cycle at duty cycle of 60 400 A 60 for DC three phase 400 A 50 for DC pulse three phase 250 A 60 for DC single phase 200 A 40 for DC pulse single phase R...

Page 22: ...ation with the specified wire feeder Connecting to any equipment other than specified may cause failure of the welding power source No Name Required component Optional accessories Remarks 1 Gas regula...

Page 23: ...ories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Welding torch 3 Gas hose 118 1 3 m 1 Included in feeder 4 Power cable for base metal side 1 5 Shield gas To...

Page 24: ...r the warranty instruction manual this publication and the quantity of parts when opening the package No Name Required component Optional accessories Remarks 1 Welding electrode holder To be prepared...

Page 25: ...explains the optional accessories used with the welding power source 2 2 4 1 Remote control voltage detection cable and other optional items Following items are optionally available including remote...

Page 26: ...e may cause an unstable arc Use extension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 196 9 5 m 393 7 10 m 590 6 15 m 787 4 20 m 1 Ga...

Page 27: ...of the welding power source 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 Outp...

Page 28: ...on 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 circuit board Terminal bloc...

Page 29: ...plate or on steel structure install a leakage breaker Otherwise electric shock due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker for motor to the inpu...

Page 30: ...icitythatmaycauseproductdamageontheweldingpowersource 3 1 2 Ventilation equipment partial exhaust facility This section explains the ventilation equipment and partial exhaust facility in welding work...

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

Page 32: ...strong shock to the welding power source when placing it on the floor It may cause damage to the welding power source Since large current abruptly flows inside the welding power source during welding...

Page 33: ...e and resulting accidents be sure to observe the following For operation of a crane or hoisting make sure that a qualified personnel operate them with attention to the surrounding area for safety Use...

Page 34: ...h as carriers secure the welding power source and carrier with a rope before transporting When lifting the welding power source make sure to hold the bottom of the welding power source by more than on...

Page 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...

Page 36: ...e 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 Conn...

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

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

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

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

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

Page 42: ...o observe the following points to prevent from suffocation due to gas leakage or explosion Be sure to turn off the shield gas at the main tap when the welding power source is not in use Securely conne...

Page 43: ...input side of each welding power source Otherwise electric shock and fire due to overcurrent or damage to the welding power source may occur If the welding power source which is not grounded is used v...

Page 44: ...t only the cable of the welding power source to the breaker Capacityoftheswitchandtheratingoffuseandcircuitbreakerareappropriate 3 1 1 Weldingpower source equipment Perform grounding for the case of t...

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

Page 46: ...ining switches use a push lock turn reset switch for preventing accidental reset 5 9 IN EXT1 External input 1 Reserve inputs for expanding terminal functions Setting the internal functions Function al...

Page 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...

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

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

Page 50: ...able at the base metal side to the voltage direct detection terminal at the base metal side of the welding power source 1 Check that input power is turned off with the disconnect switch connected to t...

Page 51: ...h 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 voltage dete...

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

Page 53: ...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 welding o...

Page 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...

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

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

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

Page 58: ...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 change...

Page 59: ...ht 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 the bas...

Page 60: ...values 2 Adjust 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 cont...

Page 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...

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

Page 63: ...ondition set the current and voltage value at the end of welding Voltage INDIVIDUAL 10 0 to 45 0 V 10 0 to 30 0 V 23 5 V Voltage SYNERGY 100 to 100 0 Post flow time 0 to 10 sec 0 4 sec Set the gas dis...

Page 64: ...ime 0 0 to 10 0 0 0 s Sets the slope time from the welding condition to the crater condition F8 Welding result display time 0 to 60 20 s Sets the display time for the current voltage after completion...

Page 65: ...0 4 0 Sets the functions of output terminal of the programmable I O F26 External output 2 setting F27 External output 3 setting F28 External output 4 setting F29 External input 1 setting 0 to 9 0 Set...

Page 66: ...e and decrease by double clicking 50 to 50 0 A Sets current increase decrease volume by double clicking of the torch switch available when ON is selected in F48 F51 Special crater repeat OFF ON OFF Wi...

Page 67: ...welding F67 Setting change of current value initial condition crater condition OFF ON OFF When CRATER ON is selected sets the current value of the initial condition and crater condition in the percen...

Page 68: ...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 source 6 7 Setting Internal Functio...

Page 69: ...e 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 lights up For details of the crat...

Page 70: ...elding 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 mod...

Page 71: ...tions The welding power source is equipped with the function to register the welding conditions and reads them out for use The number of welding conditions that are able to be registered are 100 at ma...

Page 72: ...ng conditions 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 B...

Page 73: ...ite The 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 ca...

Page 74: ...and the 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 re...

Page 75: ...the registration at the same time turn theparameteradjustmentknobcounterclockwise to display ALL on the right digital meter When ALL is selected the current welding condition set on the operation pane...

Page 76: ...ITE 030 035 045 0 8 0 9 1 2 2 3 Enable MIG 100 Ar 1 3 SOFT ALUMINUM 045 1 16 1 2 1 6 2 3 HARD ALUMINUM 045 1 16 1 2 1 6 2 3 Brazing CuSi 030 035 045 0 8 0 9 1 2 2 3 Brazing CuAl 030 035 045 0 8 0 9 1...

Page 77: ...0 to 150 045 1 2 DC 75 to 250 DC pulse DC wave pulse 50 to 250 1 16 1 6 DC 100 to 350 DC pulse DC wave pulse 75 to 350 SOFT ALUMINUM A4043 etc 045 1 2 DC 90 to 250 DC pulse DC wave pulse 60 to 300 1 1...

Page 78: ...ess the DISPLAY CHANGE key and select the LED of PRE FLOW or POST FLOW Turn the parameter adjustment knob to set the gas discharge time The set parameter is displayed on the left digital meter Process...

Page 79: ...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 voltage adjustm...

Page 80: ...ard time setting crater standard time setting Pattern No Crater setting WELDING METHOD TRAVEL SPEED GAS WIRE MATERIALS 1 with pulse DC 2 no pulse DC PULSE DC WAVE PULSE INCONEL 3 no pulse DC PULSE DC...

Page 81: ...Select CRATER OFF by the CRATER FILL key 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 Mai...

Page 82: ...f hold The torch switch should remain depressed and held during the CRATER phrases When selecting CRATER FILL ON no pulse RegardlessofthesettingbytheWELDINGMETHODkey themachineautomaticallyturnstothew...

Page 83: ...orch switch should remain depressed and held during the INITIAL and CRATER phrases When selecting CRATER FILL ON no pulse RegardlessofthesettingbytheWELDINGMETHODkey themachineautomaticallyturnstothew...

Page 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...

Page 85: ...lue 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 extended cable for the base material...

Page 86: ...speedbecomesstableandonlytheunitpulsecondition changes Image of welding bead form in the wave frequency TIPS This function is available when DC WAVE PULSE is selected by the WELDING METHOD key Wave pa...

Page 87: ...equency is complete Press the DISPLAY CHANGE key and select either INITIAL CONDITION MAIN CONDITION or CRATER FILL CONDITION TheLEDfortheselectedweldingsequencelightsup The LED for the WAVE FRQ key li...

Page 88: ...S 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 in the...

Page 89: ...s can cause extraordinary volume of spatter When this happens turning this function ON extended cable mode can improve the status ON Extended cable mode Set to ON for the length of extension cable lon...

Page 90: ...the cause of error the power is restored After removing the cause of error the power is restored Or open short circuit the deactivated terminal pins 3 4 of the external connection terminal block TM3 4...

Page 91: ...6A Part No 4730 009 6 If you want to use Automatic machine 3 conditions will change for the following functions F5 Maximum external command voltage Fixed to 10 0V F24 Wire feeding speed setting Fixed...

Page 92: ...splay time 0 to 60 sec 6 7 2 7 F9 Analog remote control scale Change the setting of the scale plate of analog remote control when using the optional analog remote control Scale plate is available sepa...

Page 93: ...urrent or voltage turn the knob clockwise In the following cases this function cannot be used Welding conditions are not registered to the memory Analog remote control optional is not connected to the...

Page 94: ...PM 0 4 m min Based on 0 adjusting it to the negative direction lowers the speed and adjusting it to the positive direction accelerates the speed Whenthestartingperformanceispoor decreasetheslow downsp...

Page 95: ...oltage detection level on the primary side When the input voltage is lower than the set value an error code is displayed Set the value in the range of 140 to 460 V TIPS The factory default setting is...

Page 96: ...ching to the welding current display can check the welding current value automatically set Inusingtheweldingpowersourceintheautomaticmachinemode refertothefollowingdiagramfor the relationship of comma...

Page 97: ...7 2 20 F25 to F28 External output terminal setting Set the function of external output terminals when using robot or automatic machines Through F25 you can set the functions of OUT EXT1 3 4 on the te...

Page 98: ...ve Pulse has been selected short circuit between terminals allows DC wave pulse welding mode Open circuit between terminals allows DC pulse welding mode 6 7 8 JOB shift Causing short circuit between t...

Page 99: ...s allocated to has any change again 6 Even after reading out the welding method by this function welding method can be changed either via the front panel or by the Loading welding condition of the ext...

Page 100: ...the setting of 5 Secondary condition current ON OFF 1 Primary condition current 5 2 1 OPEN CLOSE OPEN OPEN CLOSE OPEN EXT3 F31 5 EXT1 F29 5 JOB No Primary condition Secondary condition Third condition...

Page 101: ...play adjustment Gain offset Settheadjustmentvalue gain offset whenthecurrentdisplayvalueontheleftdigitalmeterisdifferent from the actual current value The currentvaluedisplayedonthedigitalmeterisobtai...

Page 102: ...oltagesettingknob Toincreasethewelding 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 di...

Page 103: ...IPS When the internal function F45 is set to ON automatically the setting of No crater is selected disabling other welding modes The CRATER FILL key does not work Welding method at crater treatment is...

Page 104: ...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 as that of...

Page 105: ...7 2 31 F51 Special crater repeat In the sequence of main welding of the CRATER FILL ON REPEATED during start input holding the torch switch operation can switch the welding and crater treatment repea...

Page 106: ...condition 6 7 2 32 F52 Data type of data log function This function enables to select data to save when using the data log function The patterns of data which can be saved are as shown in the below t...

Page 107: ...btained Moreover in the pulse condition of the wave pulse welding at HIGH side fine adjustment is available to the standard pulse peak current at HIGH side by setting the adjustment value Exampleofcur...

Page 108: ...he adjustment value Example ofcurrentwaveformofwavepulsewelding 6 7 2 41 F65 FineadjustmentofLbasecurrent Set the adjustment value in the range of 1 5 to 1 5 ms Fine adjustment of unit pulse condition...

Page 109: ...of current waveform of wave pulse welding 6 7 2 42 F66 Adjustment of feed amplitude ratio This function sets the feed amplitude ratio of wire amplitude change of wire feed speed in the wave pulse weld...

Page 110: ...ontrol function identification numbers Sets the identification numbers of welding power source when using welding result control function The identificationnumberset inthisfunctionbecomes the partoffi...

Page 111: ...g 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 with the...

Page 112: ...OPERATION OF ANALOG REMOTE CONTROL OPTIONAL WELDING CONDITION CHAPTER 6 6 50...

Page 113: ...ome possible 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...

Page 114: ...password 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...

Page 115: ...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...

Page 116: ...s achieved Wire consumption P20 0 00 Cumulative wire consumption used in welding lbs kg P21 0 0 to 999 0 to 453 Target wire consumption lbs kg P22 0 0 to 5 Operation at the time when the target wire c...

Page 117: ...and 999 The count value will be cleared according to the P12 setting Ifcontinuousoperationisenabled thevaluewillbeclearedwhenexceeding999andreturn to 0 P11 Target value of welding points Select the t...

Page 118: ...lue of wire consumption in the range from 0 to 999 lbs 0 to 453 kg Whenthe P20 countvaluereachesthewireconsumptionspecifiedhere analarmappearsindicatingthat the target is achieved 7 2 2 5 Alarm indica...

Page 119: ...chieved 7 2 2 1 Number of welding point 7 2 2 4 Welding monitor Average current voltage during welding is monitored When it exceeds the range specified here an alarm displays and the output stops P40...

Page 120: ...e and the specified value will flash Set value Operation Alarm indication only Welding can continue Continuous operation is possible 1 The ongoing welding can continue After the welding is finished ne...

Page 121: ...ntrol 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 diff...

Page 122: ...Initial feed speed 3 9 IPM 0 1 m min pre_iset Initial current 1 A wld_feed Welding feed speed 3 9 IPM 0 1 m min pre_vset Initial voltage 0 1 V cre_feed Crater feed speed 3 9 IPM 0 1 m min pre_uni_vset...

Page 123: ...erved PerIset reserved pre_sens_cnst PreIsetPer reserved pls_pki_adj Pulse peak current fine adjustment 1 A CreIsetPer reserved pls_pkt_adj Pulse peak time fine adjustment 0 1 ms TsCrickIset Torch swi...

Page 124: ...set to 1 detected values of welding current welding voltage and feeding speed and F53 to 2 100 ms TIPS The length of time that can be used for recording depends on the sampling speed If the sampling...

Page 125: ...DAIHEN_WELDING_MONITOR_DATA_MACHINE_ CSV Welding machine identification Number Cumulative values of Welding result control function The values of internal function F77 Welding result control function...

Page 126: ...hts up Turn the parameter adjusting knob further counterclockwise to display the data to backup on the right digital meter The display changes in order of ALL 1 2 3 4 ALL meansthatallthedata 1 to 4 av...

Page 127: ...t digital meter 5 Select the data to import 6 Press the SAVE key 7 Press the ENTER key The LED of SAVE key lights up Turn the parameter adjusting knob further counterclockwise to display the data to i...

Page 128: ...will return to the default initial setting 1 Turn off the power switch 2 Press and hold the F function key and GAS CHECK key simultaneously and turn on the power switch 3 Check that End is displayed...

Page 129: ...e 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 manufacturer s management It is not necessary for the user to check...

Page 130: ...CHECKING SOFTWARE VERSION ADMINISTRATOR FUNCTIONS CHAPTER 7 7 18...

Page 131: ...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...

Page 132: ...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...

Page 133: ...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...

Page 134: ...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...

Page 135: ...stand Voltage Test If insulationresistance measurement and withstand voltagetest isnecessary pleasecontact your dealer When measuring insulation resistance and testing withstand voltage follow the ste...

Page 136: ...ive output side and the AC side and negative output side respectively Short circuit between TR1 C1 E1 TR2 C2 E2 TR4 C2 E2 TR5 C1 E1 TR5 C2 E2 TR6 C1 E1 Apply NF After finishing insulation resistance m...

Page 137: ...e The meanings of 1 and 2 in the table below are as follows 1 When the error occurs the welding power source stops the output 2 Even when the error occurs the welding power source does not stop the ou...

Page 138: ...ear 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 side is the range of 208 230 460 V 10 Check t...

Page 139: ...801 The rotation rate of the motor of wire feeder was not detected 1 Check that there is no disconnection short circuit or other abnormalities in the cables connecting the wire feeder Check that ther...

Page 140: ...not correct Check that the setting of internal functions F29 to F32 is correct 6 7 2 21 F29 to F32 External input terminal setting The external input cables are disconnected short circuited Check that...

Page 141: ...ltage 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 f...

Page 142: ...TROUBLESHOOTING TROUBLESHOOTING CHAPTER 9 9 6...

Page 143: ...FH 4 TR5 100 2219 IGBT module 1MBI300HH 120L 50 1 SCR1 4530 412 Thyristor SG25AA20 1 CT1 4810 030 Current transformer W W03029 1 CT2 100 0956 Hall current detector CS 40GEH 1 CT3 K5791N00 Current tran...

Page 144: ...board P30086R00 1 100 1421 Encoder EVEGA1F2524B 1 With PCB2 PCB3 P30086Q00 Printed circuit board P30086Q00 1 PCB4 P30087Q00 Printed circuit board P30087Q00 1 PCB5 P30086V00 Printed circuit board P3008...

Page 145: ...10 3 Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 2 1 Schematic diagram P30141X00 P30087V00 P30086V00 P30124M00 CN1 Not connected CN1 3 Not connected...

Page 146: ...DRAWING REFERENCE MATERIALS CHAPTER 10 10 4 P30099P00 CN1 13 16 26 31 36 39 43 45 47 49 51 52 54 57 59 62 Not connected P30086T00 P30086R00 P30086S00 P30087T00 P30087Q00 CN7 Not connected CN5 7 9 Not...

Page 147: ...nel Upper DCV1 Lower P30086Q00 P30124M00 P30087Q00 P30099P00 P30086S00 P30087V00 CT1 P30086V00 P30087T00 P30086T00 SH TM6 PL1 FM1 FM2 FM3 TM5 NF 6 CON1 7 CON2 7 FM4 DCV2 5 2 L7 L1 1 4 3 8 9 Top Back W...

Page 148: ...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...

Page 149: ...rate CFH L min 18 ga 1 2 3 32 to 1 8 2 5 to 3 0 035 040 0 9 1 0 70 to 100 18 to 19 20 to 24 50 to 60 21 to 32 10 to 15 16 ga 1 6 3 32 to 1 8 2 5 to 3 0 035 to 045 0 9 to 1 2 90 to 120 18 to 20 20 to 2...

Page 150: ...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...

Page 151: ...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...

Page 152: ...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 4...

Page 153: ...0 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 25 to 28 18 45 2...

Page 154: ...30 23 64 9 0 1 270 29 to 30 12 30 2 290 30 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...

Page 155: ...width 0 1 in 2 mm Number of oscillation 120 times min Bevel shape Number of layers Current A Voltage V Remarks 1 100 20 to 21 Slight oscillation 2 280 26 to 27 Slight oscillation 3 280 26 to 27 Sligh...

Page 156: ...o 80 0 5 to 0 6 12 to 15 42 20 14 ga 2 0 045 1 2 70 to 80 17 to 18 16 to 20 40 to 50 0 6 15 42 20 1 8 3 0 045 1 2 80 to 100 17 to 20 16 to 20 40 to 50 0 6 15 42 20 5 32 4 0 045 1 2 90 to 120 18 to 21...

Page 157: ...to 140 20 to 22 24 to 31 60 to 80 0 6 15 42 20 5 32 4 0 045 1 2 150 to 170 22 to 24 24 to 31 60 to 80 0 6 to 0 7 15 to 18 42 20 15 64 6 0 1 16 1 6 180 to 210 23 to 25 16 to 24 40 to 60 0 7 to 0 8 17 t...

Page 158: ...MATERIALS FOR SETTING WELDING CONDITIONS REFERENCE MATERIALS CHAPTER 10 10 16...