Daihen OTC Welbee P402L, Owner'S Manual

Page 1: ...Welbee P402L P502L OWNER S MANUAL October 2021 Manual No P30334 2 DAIHEN Corporation...

Page 2: ...ck 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 manufacture...

Page 3: ...ure 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 i...

Page 4: ...ion of welding torch 34 4 2 4 Connection of voltage detection cable Voltage detection cable is used 34 4 2 5 Connection at TIG welding 36 4 2 6 Connection at MMA welding 38 4 2 7 Connection of shield...

Page 5: ...ackup operation 126 7 3 6 Importing backup data 128 7 4 Initializing Welding JOB and Internal Functions 129 7 5 Checking the Software Version and Serial Number 130 7 6 Calibration Mode 131 7 6 1 Adjus...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 13: ...iety National Electrical Code NFPA Standard 70 from National Fire Protection Association Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Code for Safety...

Page 14: ...20 1kVA 18 1kW 25 4 kVA 23 1 kW Rated input current 29 A 36 6 A Rated output current 400 A 300 A 500 A 400 A 400 A 490 A Rated load voltage 34 V 26 V 32 V 39 V 34 V 26 V 39 6 V Maximum no load voltag...

Page 15: ...1 6 Manual 2 Cu Si 0 8 1 0 1 2 0 8 1 0 1 2 Manual 2 Cu Al 0 8 1 0 1 2 0 8 1 0 1 2 Manual 2 DC LOW SPATTER 3 CO2 Fe 0 8 1 0 1 2 0 8 1 0 1 2 Manual Auto MAG 18 CO2 1 1 Fe 0 8 1 0 1 2 0 8 1 0 1 2 Manual...

Page 16: ...ing gas other than those with the following mixing ratios is used 1 1 MAG gas Argon Ar 82 Carbon dioxide CO2 18 1 2 MAG gas Argon Ar 90 Carbon dioxide CO2 10 1 3 MAG gas stainless steel Argon Ar 98 Ox...

Page 17: ...D CONFIGURATION CHAPTER 2 15 Chapter 2 Product Specification and Configuration 2 1 3 External dimensions This section explains the external dimensions of the welding power source WB P402L WB P502L 592...

Page 18: ...ult in degradation or burnout 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 a...

Page 19: ...current A Duty cycle DC DC TIG 100 50 0 100 200 283 400 Usable range Welding current A Duty cycle DC PULSE Welding current A Duty cycle 100 80 50 0 100 200 250 300 Usable range MMA 100 60 50 0 100 200...

Page 20: ...ied may cause failure of the welding power source No Name Supplied unit 1 Optional accessories Remarks 1 Gas regulator To be prepared by the customer 2 2 3 Accessory not supplied 2 Wire feeder 3 Weldi...

Page 21: ...6 Power cable for torch side 2 m 2 7 Power cable for base metal side 2 m 2 8 Shield gas To be prepared by the customer 2 2 3 Accessory not supplied 9 Digital remote control optional E 2454 2 2 4 Opti...

Page 22: ...r To be prepared by the customer 2 2 3 Accessory not supplied 2 Welding torch 3 Gas hose 3 m 2 3 4 Power cable for base metal side 2 m 2 5 Shield gas To be prepared by the customer 2 2 3 Accessory not...

Page 23: ...ed unit 1 Optional accessories Remarks 1 Welding electrode holder To be prepared by the customer 2 2 3 Accessory not supplied 2 Power cable for welding electrode holder 38mm2 or more 3 Power cable for...

Page 24: ...r optional items Following items are optionally available including remote control and voltage detection cable Name Remarks CO2 gas Carbon dioxide CO2 100 MAG gas Argon Ar 82 Carbon dioxide CO2 18 Arg...

Page 25: ...nsion cable may cause an unstable arc Use extension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 5 m 10 m 15 m 20 m 1 Gas hose BKGG 06...

Page 26: ...or analog remote control Output terminal Torch side Output terminal Base metal side Power switch Main power lamp Operation panel 6 2 Function on Operation Panel Terminal for directly detecting voltage...

Page 27: ...Blind bush for drawing externally connecting wire Cover for external connections Connector for connecting CAN Print circuit board Terminal block for external connections 4 5 2 Connection of automatic...

Page 28: ...th highly conducting material such as steel 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...

Page 29: ...y cause product damage 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 are...

Page 30: ...power source Installation distance of 30 cm or more between the welding power source and the wall or other welding power source Ensure not to block the ventilation hole Location with no wind on the a...

Page 31: ...s of the welding power source It may cause electric shock Shut off the input power with the disconnect switch all turned off even the distance of transportation is short If work is performed while the...

Page 32: ...dents be sure to observe the following For operation of a crane or hoisting make sure that a qualified personnel operate them with attention to the surrounding area for safety Use the lifting tool suc...

Page 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...

Page 34: ...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 Connect...

Page 35: ...he 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 using an analog r...

Page 36: ...ng 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 end and press the collar part to the arrow mark directio...

Page 37: ...terminal for base metal of the welding power source When using the welding power source by lifting with hoisting equipment connect the voltage detection cable for base metal side to the direct voltage...

Page 38: ...roper connection of the voltage detection cable on the base metal side 4 2 5 Connection at TIG welding CAUTION In using the welding power source for TIG welding prepare a welding torch by the customer...

Page 39: ...terminal torch side and base metal Connect the connectors as same as above Connecting TIG valve kit TIPS For the procedure for installing the TIG valve kit optional accessory to the welding power sou...

Page 40: ...ach 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 grip onto t...

Page 41: ...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...

Page 42: ...th highly conducting material such as steel 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...

Page 43: ...ing 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 of the welding...

Page 44: ...terface 3 Wire feeder Wiring for wire feeder needs to be changed 4 6 1 Wiring to wire feeder 4 Welding torch K2331 type curved torch 5 Uni cord power cable K5369 1 1 m K5370 1 2 m 6 Control cable for...

Page 45: ...minals closes When an error is detected the contact opens 3 4 STOP Operation stop input Disconnecting the terminals stops output of the welding power source When combining switches use a push lock tur...

Page 46: ...ximum rated power of the contact Maximum rated power of relay contact WCR 125 VAC 0 5 A 30 VDC 1 A at resistance load As a rough indication use at 80 of the ratings To prevent electric shock ensure to...

Page 47: ...oltage detection cable needs to be wired so that the correct feedback of the arc voltage can be obtained Connect the voltage detection cable as near as possible to the base metal to avoid detection of...

Page 48: ...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 detection termina...

Page 49: ...the welding power supply away from the base 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 ba...

Page 50: ...ent 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 operatio...

Page 51: ...s of others in the 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 w...

Page 52: ...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...

Page 53: ...uge open the main 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 CHEC...

Page 54: ...e wire cut the wire using a plier 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 Turning the weld...

Page 55: ...gas check 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 pre...

Page 56: ...ding the LED for the welding sequence being carried out flashes 2 A series of welding operation is completed by the torch switch operation 6 6 3 Crater setting At the end of welding the average value...

Page 57: ...completion of the welding operation can be controlled by the torch switch operation 6 7 2 63 F81 Torch switch setting with TIG mode 5 6 2 Operation during welding This section explains the operation r...

Page 58: ...peration 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 The displays on the...

Page 59: ...he gas piping is discharged 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...

Page 60: ...welding Voltage INDIVIDUAL 1 WB P402L 10 0 to 45 0 V 23 5V 21 5V initial crater 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 4 sec Set the gas...

Page 61: ...ndition 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 Con...

Page 62: ...the correction value of low spatter function OFF ON OFF Sets whether to save the automatic correction value of the low spatter function at completion of welding OFF Not to save ON To save until the n...

Page 63: ...ng voltage Sequence information 7 Welding current Feeding command Sequence information 8 Welding voltage Feeding command Sequence information F53 Sampling speed of data log function 1 2 3 2 Sets sampl...

Page 64: ...function F73 Interval function Arc OFF time 0 20 to 9 99 1 00 s Sets the Arc OFF time in the Interval function F74 to F76 No function OFF fixed OFF No functions are provided F77 Welding power source i...

Page 65: ...l meter F89 Voltage 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...

Page 66: ...ings 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 automatic...

Page 67: ...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...

Page 68: ...lding mode setting 2T 4T Select 2T 4T trigger with the crater treatment method or arc spot at the end of welding For details of 2T 4T 6 6 4 Crater setting For details of arc spot 6 6 5 Arc spot time S...

Page 69: ...automatically adjust the wire feed speed so that the constant welding current is always kept even with the wire feeding length changes Available only for steel or stainless steel type wire in the WIRE...

Page 70: ...d out from the memory by the analog remote control optional 6 7 Setting Internal Functions 6 5 1 Memory registration of welding JOB This section explains how to register the current welding condition...

Page 71: ...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...

Page 72: ...er 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 any registration da...

Page 73: ...splayed when 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...

Page 74: ...0 1 2 1 0 1 2 Manual 2 Al Mg 1 0 1 2 1 6 1 0 1 2 1 6 Manual 2 Cu Si 0 8 1 0 1 2 0 8 1 0 1 2 Manual 2 Cu Al 0 8 1 0 1 2 0 8 1 0 1 2 Manual 2 DC LOW SPATTER 3 CO2 Fe 0 8 1 0 1 2 0 8 1 0 1 2 Manual Auto...

Page 75: ...CO2 10 1 3 MAG gas stainless steel Argon Ar 98 Oxygen O2 2 1 4 MAG gas Argon Ar 97 5 Carbon oxygen CO2 2 5 1 5 MIG gas Aluminum Aluminum bronze Silicon bronze Argon Ar 100 2 For Manual mode the Manua...

Page 76: ...nce is the process of PRE FLOW MAIN CONDITION and POST FLOW To this sequence start condition and crater fill condition can be added depending on the crater setting The welding parameters such as gas d...

Page 77: ...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 case refer to 6 7 2 20...

Page 78: ...B 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 select availab...

Page 79: ...OFF Select 2T by the 2T 4T 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...

Page 80: ...uld remain depressed and held during the CRATER phrases When selecting 4T Crater DC Regardless of the setting by the WELDING PROCESS menu the machine automatically turns to the welding with no pulse w...

Page 81: ...in depressed and held during the START and CRATER phrases When selecting 4T Crater DC Regardless of the setting by the WELDING PROCESS menu the machine automatically turns to the welding with no pulse...

Page 82: ...ft 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 stick treatment from...

Page 83: ...e value automatically set can be finely adjusted by the parameter adjustment knob Welding voltage on the positive side high negative side low INDIVIDUAL mode Select the Synergic menu When OFF is selec...

Page 84: ...n 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 molten pool and the welded part becomes more r...

Page 85: ...T and 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 sett...

Page 86: ...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 of the weld joint...

Page 87: ...vated 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 function setting 1 Display FUNC...

Page 88: ...ll be displayed at the welding process menu in HOME screen OFF Standard cable mode TIPS In using the welding power source in the Auto mode the setting of this function is set to OFF and cannot be chan...

Page 89: ...power source Retract 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 d...

Page 90: ...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 change of the cond...

Page 91: ...t setting is 70 of 2 8 A 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 us...

Page 92: ...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 function OFF disables...

Page 93: ...sed on 0 adjusting it to the negative direction shortens the time and adjusting it to the positive extends the time Adjust the anti stick process voltage in the range of 9 9 V through the internal fun...

Page 94: ...matically set In using the welding power source in the automatic machine mode refer to the following diagram for the relationship of command voltage and the wire feed speed when the internal function...

Page 95: ...No function is allocated in this machine 4 Alarm Signal of Welding Monitor A welding condition error is detected during welding and the signal is output to the external terminal If either of the curr...

Page 96: ...No 3 Setting F29 to F32 to 5 and turning the signal of external input terminal IN EXT2 to OFF enable to read out the JOB No 3 Example 3 In reading out the welding condition of the JOB No 7 Setting F30...

Page 97: ...e torch switch OFF start signal OFF to 100 ms after it do not change the setting of 5 Secondary condition current ON OFF 1 Primary condition current 5 2 1 OPEN CLOSE OPEN OPEN CLOSE OPEN EXT3 F31 5 EX...

Page 98: ...enon 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 force and enable...

Page 99: ...N TIPS If wire extension and welding JOB greatly vary by welding section it is recommended to use the machine with this function set to OFF 6 7 2 26 F36 F37 Spatter adjustment P1P P2P Use this functio...

Page 100: ...ading out of welding JOB in F2 F29 to 32 F44 can be read only for the welding JOB whose welding process is DC The welding process cannot be changed to other than DC with this function to 2 Be sure to...

Page 101: ...g power source Internal function F11 Fine adjustment of welding JOB memory is set to 1 to 30 enabled Internal function F45 Special 2T is set to ON enabled Internal function F48 Adjusting current with...

Page 102: ...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 enabling the internal fu...

Page 103: ...rease volume by single clicking in the range of 100 to 100 A 6 7 2 35 F50 Current increase and decrease by double clicking To increase decrease the welding current by the torch switch operation set th...

Page 104: ...justing 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 Loading welding condition 6 7 2 37 F...

Page 105: ...the range of 0 01 to 9 99 seconds 6 7 2 41 F56 Arc start failure detection time The detection time to output the arc start failure signal to the external output terminal is set Set the value in the ra...

Page 106: ...absolute values The LED of DISPLAY CHANGE key gives information which value is currently displayed When LED is OFF Fine adjustment value is displayed Adjusted value is displayed on the left digital m...

Page 107: ...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 45 F60 Pulse peak current fine adju...

Page 108: ...ndition Setting range of current value start condition 10 to 300 6 7 2 54 F69 Setting of current value crater condition The current value of the crater condition can be set in percentage based on the...

Page 109: ...e in the Interval function Set the arc OFF time in the range of 0 20 to 9 99 seconds 6 7 2 59 F77 Welding power source identification numbers Sets the identification numbers of welding power source wh...

Page 110: ...OFF disables the function 6 7 2 64 F82 Arc stabilization 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 plung...

Page 111: ...mount of pulse 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 T...

Page 112: ...hange For more information on the adjustment procedure contact dealer NOTE Do not carelessly change the setting of this function 6 7 2 69 F88 F89 Voltage display adjustment GAIN OFFSET Set the adjustm...

Page 113: ...rrent 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 sta...

Page 114: ...on 1 Crater setting 6 6 4 Crater setting 2T 4T Crater DC Pulse 4T Crater DC 2 Gas check 5 3 Power ON and Gas Supply OFF OFF ON 3 Constant penetration 6 6 8 Penetration control adjustment OFF OFF ON 4...

Page 115: ...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 operation prevent...

Page 116: ...o 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 I...

Page 117: ...vention 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 Dis...

Page 118: ...assword changing or deleting operation the screen will shift to the Password Setting screen 7 1 1 Setting Changing password The number is confirmed and the display will change from color inversion dis...

Page 119: ...re consumption P20 0 00 Cumulative wire consumption used in welding kg P21 0 0 to 9999 Target wire consumption kg P22 0 0 to 5 Operation at the time when the target wire consumption is achieved Total...

Page 120: ...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 Opera...

Page 121: ...time when the target wire consumption is achieved Select the operation from 0 to 5 for the time when the target specified for P21 is achieved The set values and operations when the target is achieved...

Page 122: ...on from 0 to 2 The set values and operations at the time of WARNING detection are as below Alarm signal output function to external output terminal If the average current voltage average per second du...

Page 123: ...erence between the average value and the specified value will flash P50 Cumulative total operation time P51 Cumulative total welding time In the right example the control No P20 flashes on the left di...

Page 124: ...e formatted as FAT32 Compatibility of the following USB flash drives has been confirmed Model No SFU22048E3BP2TO I MS 121 STD swissbit Part No 100 1820 There is software allowing you to easily display...

Page 125: ...vset Welding voltage 0 1 V cre_tim Crater time 0 1 s wld_uni_vset Welding voltage synergic 1 KubireAutoAdj Automatic correction of squeeze 0 1 OFF ON cre_iset Crater current 1 A KubireAutoSave Saving...

Page 126: ...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 simplified dat...

Page 127: ...It will be deleted when the power switch is turned off The simplified data log can be exported even if an error code is displayed error code is output on the left right digital meters In that case bac...

Page 128: ...ack up the data such as welding JOB 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 it to F...

Page 129: ...o display the data to back up on the right digital meter The display changes in order of ALL 1 2 3 4 ALL means that all the data 1 to 4 available for backup are selected Details of the numbers display...

Page 130: ...een operation knob to place the cursor on RESTORE and press the knob ALL or JOB No registration No is displayed on the right digital meter in a flashing mode and the LED of JOB lights up USb is displa...

Page 131: ...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 Check that En...

Page 132: ...g the UNIT CHANGE key can also return to normal state without turning off the power switch The product information will be displayed on the LCD panel When the screen operation knob is turned informati...

Page 133: ...W 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 app...

Page 134: ...t is equivalent to the output current of 0 01 A 8 When you have adjusted the output current turn ON the torch switch to confirm the adjusted result to the set value Make sure that the value of the out...

Page 135: ...etween the output voltage displayed on the voltmeter and the voltage displayed on the operation panel 7 Correct the difference by using the values of internal functions F41 and F42 so that the differe...

Page 136: ...the cursor on SYSTEM SETTING and press the knob The menu of SYSTEM SETTING will be displayed LCD Background Language Turn the screen operation knob to select the background color White Black The backg...

Page 137: ...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 During maintenance and inspection take an ap...

Page 138: ...arts soak a soft cloth in water alcohol or neutral detergent wring it well and wipe off the dirt Do not use organic detergent or chemical agent Doing so may cause crack breaking and degrade the streng...

Page 139: ...riodical inspection item Inspection work Grounding wire Refer to the description for the same item in 8 2 Daily Inspection Each cable Primary power cable for facility side cables for base metal side t...

Page 140: ...fin or winding of heat sink can cause insufficient heat radiation Remove the left side panel and fan frame and check the dirt inside If there is heavy dirt blow the fin and coils of heat sink directly...

Page 141: ...source and damage 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 PC...

Page 142: ...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...

Page 143: ...ing power source may stop or may not stop output depending on the type of error code The meanings of 1 and 2 in the table below are as follows 1 When the error occurs the welding power source stops th...

Page 144: ...0 The input voltage for primary side exceeded the allowable range 1 Check that the input voltage for primary side is between 340 to 460 V The error code will disappear when the power switch is turned...

Page 145: ...WARNING detection level 1 E 951 There is a duplicate ID on a single bus 1 Turn off the power switches of all other CAN connected welding power sources then turn on the power switches and check the se...

Page 146: ...f the operation panel is enabled Erroneous operation prevention function Release the KEY LOCK to disable the erroneous operation prevention function the operation panel 5 5 2 Preventing erroneous oper...

Page 147: ...o 5 8 4531 308 Diode module DBA200UA60 5 DR2 to 5 8 11 4531 119 DSEI 2X101 06A 8 DR6 100 0179 Diode module DSEI 2X101 12A 1 DR7 4531 505 Diode module S2L60 1 DR9 4531 710 Diode D1N60 1 DR12 13 100 017...

Page 148: ...r FHN50 471J RO 2 2 R20 21 100 0234 Carbon resistor RD20S 1 K J 2 2 R22 100 1571 Winding resistor CS1P 100 J 1 1 R23 4509 918 Cement resistor 40SH 200 J 1 1 R24 100 0234 Carbon resistor RD20S 1 K J 1...

Page 149: ...ap W W03636 1 1 For P30086G01 5 100 2218 Receptacle CX0059 2 2 6 K5804Q00 Resin panel K5804Q00 1 1 7 4739 476 Cap W W02814 2 2 For CON1 2 8 4735 038 Knob K 100 22RSB 2 2 Parameter adjustment knob 9 47...

Page 150: ...ons Q ty Remarks WB P402L WB P502L PCB2 P30304R00 Printed circuit board P30304R00 1 1 100 2518 Encoder RE1201XE1 H01 2 2 With PCB2 8 4735 038 Knob K 100 22RSB 2 2 Parameter adjustment knob 9 4735 039...

Page 151: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 149 Chapter 10 Reference Materials 10 2 1 Schematic diagram WB P402L P30133Q00 P30133M00 P30086V00 P30088V00 P30086V00...

Page 152: ...DRAWING REFERENCE MATERIALS CHAPTER 10 150 P30099P00 P30304R00 CN2 3 5 to 8 Not connected P30086T00 CN7 Not connected P30087Q00 P30087T00 P30086S00 CN1 6 13 16 26 31 36 39 43 45 47 49 54 57 59 62 Not...

Page 153: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 151 Chapter 10 Reference Materials WB P502L P30133Q00 P30115M00 P30086V00 P30086V00...

Page 154: ...AWING REFERENCE MATERIALS CHAPTER 10 152 P30088V00 P30099P00 P30304R00 CN2 3 5 to 8 Not connected P30086T00 CN7 Not connected P30087Q00 P30087T00 P30086S00 CN1 13 26 36 39 43 44 46 49 52 54 57 59 62 N...

Page 155: ...30304R00 DCV1 P30133Q00 P30133M00 P30087Q00 P30099P00 P30086S00 P30086V00 P30086V00 P30087T00 P30086T00 C8 SCR1 R17 C7 R16 DR7 PL1 FM1 FM2 TM5 NF CON1 7 CON2 7 DR1 FM4 R12 DCV2 5 2 1 4 3 8 9 Upper Low...

Page 156: ...5M00 P30087Q00 P30099P00 P30086S00 P30086V00 DR1 P30086V00 P30088V00 Fan inside plate P30087T00 P30086T00 SH DR12 13 CT2 CT1 PL1 FM1 FM2 FM3 TM5 NF CON1 7 CON2 7 R19a b FM4 TR6 TR5 TR7 DCV2 5 R15a b 2...

Page 157: ...hort 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 bead become small The welding voltage is...

Page 158: ...3 0 1 0 3 1 to 3 7 1 2 4 5 to 5 3 2 3 3 0 to 3 5 0 9 120 to 140 19 to 21 50 to 60 15 to 20 2 5 to 3 0 1 0 3 1 to 3 7 1 2 4 5 to 5 3 3 2 3 0 to 4 0 0 9 130 to 170 20 to 22 45 to 55 15 to 20 2 3 to 2 8...

Page 159: ...6 3 380 to 420 36 to 39 45 to 50 20 to 25 Back 7 1 to 7 9 16 0 to 0 5 4 to 6 1 2 300 to 350 32 to 35 25 to 30 20 to 25 Front 2 2 2 to 2 7 300 to 350 32 to 35 30 to 35 20 to 25 Back 2 7 to 3 1 1 6 380...

Page 160: ...to 130 18 to 20 45 to 55 A or B 15 to 20 2 8 to 3 4 1 2 4 0 to 4 9 2 3 1 0 120 to 140 19 to 21 45 to 50 B 15 to 20 2 8 to 3 1 1 2 4 0 to 4 5 3 2 1 0 130 to 160 19 to 22 45 to 50 B 15 to 20 2 8 to 3 1...

Page 161: ...16 to 17 40 to 60 10 to 15 1 6 to 2 3 0 9 2 0 to 3 0 1 0 2 5 to 3 7 2 3 0 9 0 to 1 0 110 to 120 17 to 18 30 to 40 10 to 15 1 5 to 2 0 1 0 1 9 to 2 5 1 2 2 7 to 3 6 3 2 0 9 1 0 to 1 5 120 to 140 17 to...

Page 162: ...joint weld Current A Voltage V Manual Auto cm min Gas flow rate L min Remarks 12 1 2 100 to 110 20 to 21 30 15 to 20 Weaving Leg length 10 mm Plate thickness t mm Wire diameter mm Bevel shape Number o...

Page 163: ...1 180 to 190 24 to 25 15 to 20 25 2 2 2 200 25 to 26 25 2 2 3 200 26 to 27 25 2 2 19 0 1 2 1 180 24 to 25 15 to 20 25 2 2 2 300 29 to 30 25 2 2 3 300 29 to 30 25 2 2 Root path oscillation width 2 mm...

Page 164: ...30 15 to 20 2 2 to 2 7 No oscillation Plate thickness t mm Wire diameter mm Current A Voltage V Manual Auto cm min Wire extension mm Gas flow rate L min Wire consumption g min 1 5 1 2 60 to 80 16 to 1...

Page 165: ...rate L min Wire consumption g min 3 0 1 2 120 to 140 20 to 22 60 to 80 15 20 1 8 to 2 4 4 0 1 2 150 to 170 22 to 24 60 to 80 15 to 18 20 1 8 to 2 4 6 0 1 6 180 to 210 23 to 25 40 to 60 17 to 20 20 to...

Page 166: ...MATERIALS FOR SETTING WELDING JOB REFERENCE MATERIALS CHAPTER 10 164...