YASKAWA MOTOWELD-EH500, Instruction Manual

Page 1: ...NO HW0480311 2 MOTOWELD EH500 INSTRUCTIONS TYPE YWE EH500 6N0 INPUT VOLTAGE 480V Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference 1 129 180369 1CD 0 ...

Page 2: ...ity Be sure all covers and shields are replaced before operating this product The drawings 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 improvements modifications or changes in specifications If such modification is made the manual number will also be...

Page 3: ...y result in a serious accident in some situations At any rate be sure to follow these important items For safe training concerning welding utilize technical institutes held by the welding society or association or related societies or associations technical courses held by the headquarters or their branches or qualifications examinations for welding technicians or engineers Indicates a potentially...

Page 4: ...sarily Any person using a pacemaker must not approach the welder or welding site under operation unless permitted by doctor The welder generates a magnetic field around it during current conduction resulting in bad influence on the pacemaker Clean the cooling water path once a month when using a water cooled torch and the cooling water circulator Failure to observe this warning may result in explo...

Page 5: ...ch box Even if the input power supply is turned OFF the capacitor may still be charged Be sure to confirm that charged voltage is gone before starting operations Do not use any cable of insufficient capacity or damaged or with its con ductor exposed Tighten the cable connecting sections firmly and insulate them Do not use the welder with its case or cover removed Do not use worn damaged or wet glo...

Page 6: ...es generated at welding may harm your health When welding within such areas as a tank a boiler or a ship s hold be sure to ventilate sufficiently or use an inhaler etc in order to prevent or offset any actual or potential oxygen shortage Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom When welding in a small space be sure to ventilate the site sufficiently or use a...

Page 7: ...s immediately after welding close to inflam mables Remove inflammables at the hidden side when welding ceiling floor or wall Failure to observe this caution may result in fire Tighten and insulate the cable connections Imperfect cable connections or imperfect contacting section of the current path at the base metal such as iron framework may result in fire due to heat generation by current conduct...

Page 8: ...r protective glasses to protect your eyes from spat ters or slags Scattered spatters or slags may damage eyes or burn the skin Use such protectors as leather gloves clothes with long sleeves leg covers or leather aprons for welding Install protective curtains around the welding site to protect your eyes from arc beams Arc beams may irritate eyes or burn skins Use noise protector when there is exce...

Page 9: ...ur face close to the discharging opening when opening the valve of the gas cylinder Be sure to attach the protective cap when the gas cylinder is not used Do not hang the welding torch over the gas cylinder or keep the elec trode away from the gas cylinder Observe the following cautions to prevent personal injury due to improper handling Do not use the welder with the case or cover removed Only a ...

Page 10: ...y poke you in the eyes face or body When hanging the wire feeder remove the anti fall fastening from the spool shaft and tighten Failure to observe this caution may cause the wire to be removed from the spool shaft resulting in personal injury Observe the following cautions to prevent burns due to the plasma arc If body parts such as hands and fingers directly touch the plasma arc burns will resul...

Page 11: ...cause a deterioration of insulation resulting in accidental fire Be sure to perform maintenance and inspection periodically to prevent deterioration of insulation caused by accumulation of dust and dirt If spatter or metal powder enters the inside of the welder remove it by forced air spray after turning OFF the welder and switch in the switch box Spatter and metal powder inside the welder may cau...

Page 12: ...nder Environment 2 10 2 8 Ambient Environment 2 12 2 9 Precautions on Transporting 2 13 3 Welding Preparation 4 Operations on Panel 4 1 Explanation of Welding Source Panel 4 1 4 2 Settings on Welding Source Panel 4 4 4 2 1 Changing Welding Type 4 4 4 2 2 User Files 4 6 4 2 3 Changing P Parameters 4 6 4 2 4 Changing Common C Parameters 4 7 4 2 5 Changing D Parameters 4 9 4 2 6 Saving Welding Condit...

Page 13: ...ng Switches 7 1 7 2 Location of Printed Boards 7 2 7 2 1 DIP Switch Settings for Pr MB 021 Board 7 4 7 2 2 Jumper pin Settings of the Pr MB 021 Board 7 4 8 Maintenance and Inspection 8 1 Daily Inspection Items 8 1 8 2 Bimonthly to Semiannual Inspection Items 8 2 8 3 Annual Overhaul and Repair 8 2 8 4 Guideline for Service Lifetime and Replacement of Components Used 8 3 8 5 Replace Fuse 8 4 9 Failu...

Page 14: ...r of Welding Source Errors 12 5 12 5 Clear of Error Record 12 6 12 6 End of Diagnosis Mode 12 6 13 Process Parameters Adjustment of Welding Characteristics 13 1 Adjustable Welding Characteristics 13 1 13 2 Adjustment of Arc Start Characteristics 13 2 13 2 1 Adjustment of Start Pulse 13 2 13 2 2 Adjustment of Hot Characteristics 13 3 13 3 Adjustment of Arc End Characteristics 13 4 13 4 Adjustment o...

Page 15: ...rameter 14 6 14 2 4 Setting the D Parameter for Calibration of External Resistance to Enabled 14 6 15 Calibration Function of Welding Current 15 1 Overview of the Welding Current Calibration Function 15 1 15 2 Procedure of Welding Current Calibration 15 2 15 3 Parameters for Welding Current Calibration Function 15 6 16 Welding Source Condition File of the Robot Controller 17 Setting of Arc Monitor...

Page 16: ...g motors can be selected among 0 Print servomotor default setting 1 Minertia servomotor for servo torch 2 4 roller servomotor YWE WF 340MELC Wire Feeding speed 1 5 to 18 m min Wire Feeding Slow down Speed CO2 short circuit welding Approx 3 m min adjustable range by panel operation 1 5 to 6 m min MAG MIG short circuit welding and pulse welding Approx 2 m min adjustable range by panel operation 1 to...

Page 17: ...nt Waveform Control Can be changed by P parameters in the user file Interface for Robot Con troller Refer to 10 Robot Interface Signals Output Setting Analog Input 0 to 14 V The set voltage current and wire feeding speed are displayed on the welding source panel Error Output Outputs the arc failure signal to the robot side Error contents are indi cated on the welding source panel Output for Arc Mo...

Page 18: ...rce so as not to charge its case or lead to unstable operation 2 Connect a grounding cable of 14 mm2 or thicker to the terminal marked GROUND or EARTH 3 Be sure to ground the base metal ground resistance must be 100 Ω or less as well when or any other non conductive material is placed under the base metal The welding source can be moved easily by using the caster After installation use the stopper...

Page 19: ... fluctuations in power supply voltage exceed 10 welding source conditions cannot be guaranteed and problems may occur Diameter of the input cable and the fuse capacity must be in compliance with the table Table 1 Power Supply Installed Capacity and Cables Install a non fuse breaker NFB or a switch with fuse for each welding source The non fuse breaker used should be the same capacity of the fuse i...

Page 20: ... cable with the input terminal of the partition board Connected bolt of the input voltage terminal is M8 2 Ground cable 2 Connection on the Welding Side See Fig 2 Connection Diagram of Welding Source at Front Face for proper connec tions 1 Welding cable The welding cable connects between the welding torch and power output termi 1 The input cable is passed from the hole for wiring in the back of th...

Page 21: ...o the connector CON 3 2 Connect the motor cable of the wire feeder to the connector CON 4 3 Connect the encoder cable of the wire feeder to the connector CON 5 Be sure to connect the welding voltage detecting line If the welding voltage detecting line is not connected the error Err702 Voltage Detection Wire Error may occur and welding cannot be performed Only if the length of the welding cable and...

Page 22: ...2 5 Connection of Electrical System 2 5 HW0480311 HW0480311 Acrobat 文書 Fig 1 Connection Diagram of Welding Source at Rear Face 22 129 ...

Page 23: ...2 5 Connection of Electrical System 2 6 HW0480311 HW0480311 Fig 2 Connection Diagram of Welding source at Front Face 23 129 ...

Page 24: ...f Welding Voltage Detecting Line In the connection of the welding voltage detecting line Be sure to observe the following items If the following items are not observed the amount of the spatter generation might increase 1 Connect the welding voltage detecting line as close to the position where welding is performed as possible 2 The welding voltage detecting line and the welding output cable must ...

Page 25: ...ge Detecting Line when Rotation Axis and two welders is Used Don t connect the welding volt age detection line with the route where the welding current flows Please confirm it has run electrically between the welding workpiece and the screw of the cover by the tester before it wires Fig 3 Connection of Welding Voltage Detecting Line when Rotation Axis and two welders is Used Two voltage detect ing...

Page 26: ...ding current flows Fig 4 Connection of Welding Voltage Detecting Line and Welding outputcable when two or more welders are used Be sure to connect the welding voltage detecting line If the welding voltage detecting line is not connected the error Err702 Voltage Detection Wire Error may occur and welding cannot be performed Only if the length of the welding cable and exclusive use base metal cable ...

Page 27: ...he welding site it must be fixed to post or cylinder stand in an upright position to prevent it from falling Also the gas cylinder must not be heated by a welding arc or the like 2 Type of Gas Cylinder Carbon dioxide gas filled cylinders can be classified into two types one is the general type that is not the siphon type and the other is the siphon type Never use siphon type gas cylinders The prov...

Page 28: ...106 moisture content 0 005 or less or the equivalent Avoid using carbon dioxide gas containing moisture more than 0 005 not only for the adverse effect on welding but also because it may cause clogging in the gas regulator if the water content freezes 4 Gas Regulator with Flow Meter Use gas regulator with flow meter suitable for the gas to be used The following table show the examples of the gas r...

Page 29: ... fan or exhaust duct 3 Shading Measures For shaded glasses of helmets or hand shields use filter numbers 8 to 10 of JIS T8141 for welding of thin plates since it has a weak arc beam and the arc must be seen easily Use numbers 10 to 13 for welding of medium hick plates since the arc is bright For MAG welding for which stronger arc light is required compared to CO2 welding use greater filter numbers...

Page 30: ...e sure to stop the welding source with casters at a step and move it slowly to prevent any shock sudden Do not move the welding source with casters up a slope stairs etc Sling applications and crane or forklift operations must be performed by authorized personnel only Failure to observe this caution may result in injury or damage Avoid excessive vibration or shock while transporting The welding so...

Page 31: ...g a Forklift Observe the following points to use the forklift for transporting 1 Confirm availability of safe operations site and transfer the welding source to the installing site 2 After determining the operation site warnings must be placed on transport path to prevent accidents 3 Put the welding source on the transporting pallet and fix firmly to prevent falling or shifting Employ a stopper on...

Page 32: ...80311 4 Others 1 Do not climb up on the welding source or place anything on it 2 Do not pass a rope directly around the welding source case during transporting Failure to observe this caution may deform the shape of the case or cause mal function 32 129 ...

Page 33: ... 0 Print servomotor default setting 1 Minertia servomotor for servo torch 2 4 roller servomotor YWE WF340MELC Incorrect setting of the feeding motor precludes proper welding because the wire cannot be fed at wire feed ing speed as directed by the set value When the parameter was changed follow the instruc tions as follows 1 Keep on pressing the Record button for more than three seconds to save cha...

Page 34: ...as flow as follows 1 Press the Gas button on the panel of weld ing source The LED indicator lights and the gas flows for 20 seconds The gas automati cally stops after the 20 seconds The gas flow time can be set by the parameter C00 Refer to 4 2 7 Checking the Flow Amount of Shielding Gas 2 Turn the valve of the gas cylinder counter clockwise to open 3 Turn the knob of the gas regulator to adjust t...

Page 35: ...ons during welding does not change any operation other than user file selection Be sure to stop welding before starting the panel operations NOTE Power Warning Search V Type Wire m min A PRM Select Common PRM Select PRM Set Record Gas Weld Type File No 1 File No 2 File No 3 User File Select Auto Adjustment Individual Auto Adj 1 2 3 4 5 6 7 12 16 11 R L 13 15 10 14 8 9 35 129 ...

Page 36: ...g Displays the weld ing voltage value V that is fed back Displays the weld ing current value A that is fed back Displays the feed ing amount m min of the motor that is fed back or the motor current Can be switched by the parameter D1 5 Displays the weld ing type Type During setting param eter Displays the parameter num ber Normally displays When the arc touch start is selected displays in the para...

Page 37: ... and the 7 segment LED indicator f blinks The welding type setting is confirmed with pressing of this button again and the 7 segment LED indicator f stops blinking Right to Left or Up and Down Move Button Used to change the settings Press L or R to move the digit Press or to increase or decrease the value Saving Conditions Used to save the setting The LED indicator lamp blinks when the setting is ...

Page 38: ...hts Press the button Record for 3 seconds or more to save the changed value Do not turn OFF the welding source while pressing this button The saving of condi tions is completed when the 7 segment LED indicators are lit again The welding types available for software version 3 20 000 6 CPU are listed on the nameplate attached to the front panel of the welding source Welding types other than listed o...

Page 39: ...φ1 0 5 31 φ1 2 5 33 MIG Ar 98 O2 2 Stainless steel SUS Pulse φ 0 9 5 46 φ 1 0 5 42 φ 1 2 5 44 MAG Ar 80 CO2 20 Stainless steel SUS Pulse φ 0 9 5 28 φ 1 0 5 30 φ 1 2 5 32 MIG Ar 98 O2 2 SUS Pulse φ 1 2 4 43 Ar Aluminum 5000 Pulse φ 1 2 2 12 Servo torch Recommended Low pulse φ 1 2 2 14 Servo torch Necessary MIG Ar 92 O2 8 Mild steel Fe Zinc Pulse φ 1 2 3 59 For galvanized sheet iron Welding types ot...

Page 40: ...ification ratio The change of the P parameters is allowed only when the user file file No 1 No 2 or No 3 is selected For details on the P parameter refer to 4 3 List of Process Parameters Follow the instructions to change P parameter value as follows 1 Press the button j PRM Select during standby status The 7 segment LED indi cator c voltmeter V displays P 00 blinking and the 7 segment LED indicat...

Page 41: ...saving of conditions is completed 4 2 4 Changing Common C Parameters For the details on the common parameter refer to 4 4 List of Common Parameters The C parameter is the common parameters for the welding source Follow the instructions to change C parameter value as follows 1 Press the button k Common PRM Select during standby status The 7 segment LED indicator c voltmeter V displays C 00 blinking...

Page 42: ...press the button PRM Set again The blinking digits move as shown below with each pressing of the button PRM Set 6 After changing the value press the button k Common PRM Select or leave it without doing anything for 10 seconds to return to the standby display Press the button Record for three seconds or more to save the changed values conditions Do not turn OFF the welding source during saving cond...

Page 43: ...icator d ammeter A displays the soft ware switch number blinking and the 7 segment LED indicator e Wire m min WF displays ON or OFF lighting 2 Use the button or to switch d 1 and d 2 3 The blinking digits move as shown below with each pressing of the button PRM Set Use the button L R or to change the parameter number and the set contents When the 7 segment LED indicator d ammeter A is blinking the...

Page 44: ...e file number where the data are to be saved 2 Press the button Record for 3 seconds or more and the 7 segment LED indica tors display dashes 3 When the saving is completed the 7 segment LED indicators returns to the status where the conditions were saved If the power supply is turned OFF while saving the welding conditions the data can not be successfully saved Confirm that the 7 segment LED indi...

Page 45: ...ue of C parameter C09 C09 0 Print servo Default setting C09 1 Servo torch C09 2 4 roller servo YWE WF340MELC Press the button Record button for 3 seconds or more to save the changed value To validate the change in setting turn OFF the welding source and ON again after saving the conditions Do not turn OFF the breaker until the 7 segment LED indicators are lit again when the Record button was press...

Page 46: ...e error level Motor current warning Outputs a warning signal when the motor current exceeds the warning level which has been set by C parameter C25 Wire feeding and welding will be continued although the motor current exceeds the warning level The warning signal will be output through the terminals 524 and 525 on the Pr RC2 001 board Motor current error Outputs Err502 motor overcurrent and ends wi...

Page 47: ... e Wire m min blinks Change the setting value of parameter C23 to 2004 When the setting value is four digits or more use the button L to move the cursor to the 7 segment LED indicator d ammeter A The indicator d amme ter A displays the number s above the forth digit The system reset will be exe cuted at C23 2004 Wait until sys rst starts blinking 4 Turn OFF the welding source when sys rst is displ...

Page 48: ...tion R button is pushed continuousness three times while pushing L button After the condition is stored HOLd is displayed If HOLd is displayed lock of panel operation is set In the state of lock of panel operation only the gas check button can be operated HOLd is displayed when buttons other than the gas check button are pushed and the button operation is not accepted Wire m min Type Power Warning...

Page 49: ...he panel operation locked After the condition is memorized and 7 Segment LED lights again lock of panel operation has been released All the button operations of a front panel become possible Wire m min Type Power Warning Search Record Gas Common PRM Select PRM Select PRM Set Weld Type File No 1 File No 2 File No 3 User File Select L R Auto Adjustment Individual Auto Adj V A 49 129 ...

Page 50: ...isplay No 1 Items Description P00 C Wire slow down speed P01 C Wire speed at start P02 C Starting pulse peak current P03 Reserved for system Do not change P04 C Starting pulse peak time P05 C Average value of hot current P06 C Average value of hot voltage P07 C Hot time P08 P Pulse current P09 P Base current P10 P Pulse time P11 C Average current at ending VALID when the parameter D1 4 ON P12 C Av...

Page 51: ...hort circuit current increasing speed 1 P38 S Short circuit current decreasing speed 2 P39 Reserved for system Do not change P40 Reserved for system Do not change P41 Reserved for system Do not change P42 Reserved for system Do not change P43 C Hot slope time P44 C Ending slope time P45 Reserved for system Do not change P46 Reserved for system Do not change P47 Reserved for system Do not change P4...

Page 52: ... feeding speed ratio for welding type 2 14 aluminum Changes the amplitude based on C parameter C04 E g When C04 10 and P55 200 C04 200 20 P57 to P59 Reserved for system Do not change P60 C Synergic voltage adjustment automatic adjustment Compensates the voltage by 1V with 10 P61 P Arc length control gain P62 C Current output characteristic 1 Wire feeding speed compensation ratio 1 unit P63 C Curre...

Page 53: ...type 2 14 alu minum 100 Current at low pulse deceleration C07 Digital meter displayed speed 1000 ms Time for average moving for dis play of current voltage digital meter C08 External resistance set value 505 1 10 5 Ω Electric resistance value of weld ing current path such as power cable jig stand connected to weld ing source C09 Motor setting 2 Motor selection 0 Print type servomotor default setti...

Page 54: ...em 48 Do not change C27 Reserved for system 600 Do not change C28 Error outside the range of out put current 0 0 If the output current is outside the range the error Err790 Err791 is issued after welding 1 If the output current is outside the range the error Err790 Err791 is issued during welding and the welding stops 2 If the output current is outside the range the error is not issued C29 Setting...

Page 55: ...change D 1 Display No Contents ON OFF Default Setting 1 Reserved for system Do not change OFF 2 Reserved for system Do not change ON 3 Wire slow down Enabled Disabled ON 4 End event End condition process ing enabled End condition process ing disabled ON 5 Display of feeding speed motor current Displays feeding speed Displays motor current ON 6 Reserved for system Do not change OFF 7 Reserved for s...

Page 56: ...between 50 and 150 5V The percent age that is set at robot synergic voltage is displayed on the welding source in the unit of V For the welding type CO2 short circuit arc welding do not use the touch start but select the normal start When aluminum welding is selected the touch start arc becomes enabled default set D 2 Display No Contents ON OFF Default Setting 1 External resistance cali bration 1 ...

Page 57: ...4 5 List of D Parameters 4 23 HW0480311 HW0480311 ting with the parameters D2 2 D2 3 and D2 4 set to OFF 57 129 ...

Page 58: ...shows the length of wire stickout as standard 5 3 Direction of Welding and Torch Angle There are two welding types backhand welding same as manual welding in which the torch is tilted by 0 to 10 in the direction of welding and forward welding in which welding is carried out in the same state but in the opposite direction The forward welding is more popular in robot welding because it results in be...

Page 59: ...xtension cables are used for both ways the voltage drop becomes twice as much as the value indicated in this graph This graph indicates the relationship between voltage drop and welding current when an extension cable of 80 mm2 is used If extension cables are used for both ways the voltage drop is twice as much as the value indicated in this graph If an extension cable is used for pulse welding th...

Page 60: ...econds Check the input voltage Err102 Excessive temperature The temperature in the primary or secondary control circuit exceeds the specified value of the welding source Check the ambient temperature 40 C or less and operational ratio 100 Check if there are dust dirt and clogging on the dust protective filter Clean or replace the dust protective filter if necessary Err107 Input output overcurrent ...

Page 61: ...g amount command value There is a certain difference between the feeding amount command value and the feed back from the encoder Check the following Check that the encoder cable is not damaged Check if the screws of the con nector terminal block are securely fastened If the encoder cable is disconnected or the screws are loosened the wire feeding speed becomes excessively fast and an error occurs ...

Page 62: ...d Check if the voltage detection wire is connected Check if the voltage detection line or the short circuit cap is connected to the connector CON7 Check that the contact tip does not contact the workpiece to be welded Set the contact tip so as not to contact the workpiece Temporary power failure may have occurred Err790 Outside of output cur rent setting Over the upper limit The actual welding cur...

Page 63: ... during the starting point detection optional function since the voltage of approx 300 V is applied to the wire 2 If a conduit cable is extremely bent the welding wire cannot be smoothly fed and thus the set welding conditions may be altered To prevent this place conduit as straight as possible 3 If welding is performed at a current exceeding the rated output current internal parts of the welding ...

Page 64: ...fan restarts rotating when welding starts and it stops approx 15 minutes after the welding ends One of three fans operates at all times in sync with the power supply switch 6 Stretch a protective curtain around the welding operation space for workers and others to protect from arc light spatter and slag 7 Installation Environment Do not weld on a wet earth floor or metallic floor to avoid electric...

Page 65: ... the switches are prepared for adjuste ment and maintenace performed by manufacturers Table 7 DIP Switch Setting for Pr CR 008 Board DIP Switch DSW Default Setting Remarks 1 8 OFF 1 7 OFF 1 6 OFF 1 5 OFF 1 4 OFF 1 3 OFF 1 2 OFF 1 1 OFF 2 8 OFF 2 7 OFF 2 6 OFF 2 5 OFF 2 4 OFF 2 3 OFF 2 2 OFF 2 1 OFF 3 8 OFF 3 7 OFF 3 6 ON 3 5 OFF 3 4 OFF 3 3 ON 3 2 ON 3 1 OFF 4 8 OFF 4 7 OFF 4 6 OFF 4 5 OFF 4 4 OFF...

Page 66: ...rds Fig 14 Top View without the Top Cover from the Welding Source Be sure not to switch the selecting switch which is designated as switch disabled by mistake Failure to observe this caution may result in a trouble 8 7 6 5 4 3 2 1 DSW1 8 7 6 5 4 3 2 1 DSW2 8 7 6 5 4 3 2 1 DSW3 ON OFF Pr CR 008 8 7 6 5 4 3 2 1 DSW4 CAUTION 66 129 ...

Page 67: ...f Printed Boards 7 3 HW0480311 HW0480311 Fig 15 Location of Printed Board Pr MB 021 and Pr CR 008 To Replace Printed Board Pr MB 021 and Pr CR 008 Remove two screws at a control panel and open a control panel 67 129 ...

Page 68: ...ard are for manintenance Do not change these settings 7 2 2 Jumper pin Settings of the Pr MB 021 Board The settings of the Pr MB 021 board are for maintenance Do not change these settings Table 8 Settings of DIP Switches SW1 Setting 1 ON 2 OFF 3 ON 4 OFF Table 9 Settings of Jumper Pins no mark Open Circle Side SW5 H SW6 H SW7 5 SW8 R 68 129 ...

Page 69: ...the connection cable such as a cable on the input side or on the base metal side resulting in imperfect insulation 8 Each connecting section is tightened securely Before maintenance or inspection or wiring be sure to turn OFF the switch in the switchgear on the input side and put up a warning sign ex DO NOT TURN THE POWER ON Failure to observe this warning may result in electric shock or injury Fo...

Page 70: ...es not deteriorate the contacts in the connecting sections with the external wiring such as input output ter minals or with the internal wiring Retighten the bolts if necessary or use a file to remove rust if any so that the metallic faces contact with each other 3 Inspection of ground line Confirm that the case is grounded properly 8 3 Annual Overhaul and Repair Carry out the integrated repair su...

Page 71: ...inspection and take proper corrective action These components cannot be used continuously for ever Even under normal operation status they are apt to have variation of the characteristics or malfunction after the life elapses Therefore it is recommended that the components be replaced periodically so that the welder can operate at optimum performance Normally refer to the following guideline of th...

Page 72: ...askawa representative Table 10 Fuse To Replace Fuse 5A Remove two screws at a control panel and open a control panel Item Fault Fuse 10A blown purple color Although the start signal is ON or the wire inching signal is ON Motor does not operate Cooling fan does not rotate Fuse 5A blown Although power switch is ON the Digital Meter does not dis play 72 129 ...

Page 73: ...tion Before maintenance inspection or wiring be sure to turn OFF the switch in the primary side switch gear and put up a warning sign ex DO NOT TURN THE POWER ON Failure to observe this warning may result in electric shock or injury To connect a nylon connector insert the connector after matching the connector number and confirm that it is locked Do not apply excessive force to the printed board w...

Page 74: ... Check if the voltage detection wire is correctly connected P Parame ters cannot be changed P parameters are effective only when the user file is selected Select the user file File 1 File 2 File 3 when using P parameters User files cannot be selected D parameter D1 11 is used to specify whether the user file is selected from the panel or the robot D1 11 OFF from panel ON from robot Record of condi...

Page 75: ... flow Check for gas leakage Also check that the gas regulator has been correctly adjusted and the gas cylinder is not empty Gas shielding in the welding section does not properly work due to wind etc When the wind blows hard stop the operation or use a screen etc to help block the wind Spatters adhere to the nozzle and the gas does not flow out smoothly Often remove the spatters from the nozzle an...

Page 76: ...performed only with carbon dioxide gas Use gas mixed with carbon dioxide gas and argon gas to improve the arc behavior The connecting section is loose Check each terminal connection and the connec tions with the base metal Securely re tighten if necessary Voltage drop is excessive with the extension cable Shorten the extension cable s length Use a thicker cable Use the extension cable with out ben...

Page 77: ...e status of the base metal is poor Check that dirt or insulating material does not adhere to the base metal or slugs do not remain on it The welding torch operations are not correct The wire stickout of the welding wire is too long Shorten it a little Change the welding torch angle Or slow down the welding speed The power cable is wired with the cable being winded Wire the power cable as straight ...

Page 78: ...ntact Check contacting sec tions Replace the power supply indicator lamp 3 The welding source does not start although the start signal is turned ON The start signal is not sent to the welding source Check for the welding command cable Check for insertion of the connector CR4 on the printed board CR 008 3 Although the start signal is ON only the motor does not operate Voltage is applied to the moto...

Page 79: ... or stopped Failure of the gas solenoid valve Investigate the gas sys tem Fuse 10 A on the board Pr SD 006 blown Upon investigating the error cause replace the fuse 10 A on the printed board Pr SD 006 Failure of the printed board SD 006 Check or replace the printed board SD 006 The printed board SD 004 is installed by mistake The printed board SD 004 cannot be used Replace the board with the print...

Page 80: ...nt the arc volt age is sent directly R W Analog voltage input of 0V to 14V 2 C D 0V side Welding cur rent instruc tion Gives the set value of the output current wire feeding amount for the welding source R W Analog voltage input of 0V to 14V 3 F G Wire inching instruction Performs the wire inching R W Contact input Valid at closed 4 H J Wire retract instruction Withdraws the wire R W Contact input...

Page 81: ...r the arc occurrence is detected within 1 5 seconds the signal is output when the arc occurrence is not detected for 0 6 seconds or more con tinuously 3 After the arc failure is detected the states described in 1 and 2 are self maintained until the start command of welding source is released 4 The signal is output also when an error occurs in the welder W R Contact output Valid at closed 9 S E COM...

Page 82: ... user file selection by connecting each signal to common Z Note Connected to the pin terminals OP1 and OP2 of the standard welding instruction cable To externally switch the user file set D parameter D1 11 to ON R W 24V 10 current capacity of 50mA or more 15 Y Z User file selection OP2 16 a Z Gas check GAS Turns ON OFF the gas solenoid valve by connecting to common Z Note Connected to GAS pin term...

Page 83: ...526 Voltmeter terminal Directly outputs the output voltage W R 4 527 5 Reserved 6 1 R indicates the robot side while W indicates the welding source side The external meters connected to the TB2 terminal are analog meters of ammeter 600A 60mV and voltmeter 75V Values of the ten s volts for wire stick or ground detection at the robot controller side may be displayed in the analog voltmeter which is ...

Page 84: ... the warning level W OP At normal time Open At warning Closed 2 525 3 539 Reserved for system Contact input 4 538 Reserved OP W Contact input valid at closed 5 537 Reserved OP W Contact input valid at closed 6 531 Common OP W 1 W indicates the welding source side while OP indi cates the option The external detection signals connected to TB3 terminal are output from each external device To use thes...

Page 85: ...Terminal Block Cable No Signal Meaning Function Direc tion 1 Signal Form 1 520 Power supply for starting point detec tion I F Power supply for starting point detecting instruction and sending receiving of the starting point detection signal R W 24V 10 current capac ity of 30mA or more 2 521 Starting point detection sig nal The signal is output when the output torch side of welding source drops to ...

Page 86: ...ce side 5 V Monitoring output for out put voltage Monitoring signal for output volt age 5V 50V For arc sensor W R Analog voltage 6 A Monitoring output for out put current Monitoring signal for output cur rent 5V 500A For arc sensor W R Analog voltage 7 COM Common Common of the monitoring sig nal W R No Connection Terminal Block Cable No Signal Meaning Function Direc tion 1 Signal Form 86 129 ...

Page 87: ...11 1 HW0480311 HW0480311 11 Connection System Diagram 87 129 ...

Page 88: ...tion is displayed in the 7 segment LED indicators on the welding source front panel once the Diagnosis mode is launched The set status of DIP switch is displayed in the 7 segment LED indicators when the Diagnosis mode is launched Fig 15 Panel at Launch of MOTOEWELD EH500 Diagnosis Mode Wire m min Type ON OFF Power Warning Search Record Gas Common PRM Select PRM Select PRM Set Weld Type File No 1 F...

Page 89: ...gment LED indicator can be changed with using the buttons or on the MOTOWELD EH500 front panel Fig 16 Diagnosis Mode Operation L R At start up of welding source in the Diagnosis mode d C Err DIP switch set status Software version The number of error occurrence The displayed contents are changed with the buttons or 89 129 ...

Page 90: ...e welding source Fig 19 DIP Switch of MOTOWELD EH500 For displaying the DIP switch status ON OFF state of each switch is displayed with 0 1 bit data Fig 20 Display of DIP Switch Set Status The figure Fig 20 Display of DIP Switch Set Status shows that the switches No 2 3 and 6 of DSW3 are ON If the display of Diagnosis mode is different from the actual DIP switch setting there may be failure on the...

Page 91: ... displayed as shown below Fig 19 Display of Software Version The figure Fig 19 Display of Software Version shows that the software version of the main CPU is 3 20 000 6 For main circuit board Pr MB 021 which is installed in MOTOWELD EH500 make sure that 6 is displayed in the model NO of the software version display If welding is performed with the main circuit board Pr MB whose model No is other t...

Page 92: ...he number of welding source errors The number of welding source errors is counted from when the welding source is delivered to when the weld ing source is started up in the Diagnosis mode Once an error has occurred the 7 segment LED indicator displays 1 for the error From then onward every time the error occurs one is added to the number of errors In case of the figure Fig 20 Display of the Number...

Page 93: ...splayed to clear the error record To cancel the operation for clearing the error record press L button again 12 6 End of Diagnosis Mode To end the diagnosis mode turn OFF the MOTOWELD EH500 main power once then start up the welding source as normal without pressing any buttons Welding cannot be performed in the Diagnosis mode After diagnosing be sure to start up the welding source in the usual mod...

Page 94: ...ion All the values are set to 100 Operating as specified by the characteristics in the database before shipping 13 1 Adjustable Welding Characteristics The welding characteristics that can be adjusted by P parameters are as follows User file File 1 File 2 File 3 needs to be selected to change P parameters Arc start characteristics Characteristics from when ARCON signal is out put until the main we...

Page 95: ...ue When arc does not start Increase the value P01 Wire speed from when the wire con tacts the base metal until arc starts For excessive repelling at arc start Decrease the value For arc burning at arc start Increase the value P02 Peak value of pulsed current that flows for arc start For arc burning at arc start Decrease the value For excessive repelling at arc start Increase the value P04 Peak tim...

Page 96: ...cessive repelling Increase the value For excessive arc burning Decrease the value P07 Output time of hot character istics to stabilize the molten pool When taking time to stabilize arc Increase the value For burn through at start point Decrease the value P43 Transition time from hot char acteristics to main welding characteristics When taking time to stabilize arc Increase the value For burn throu...

Page 97: ...the value When wire sticks to the contact tip Decrease the value P15 Average voltage to adjust the burning after welding P16 Arc time to adjust the burning after welding P17 Peak current to adjust the spherical diameter of wire end after welding When arc does not start at next ARCON signal Increase the value When the wire is repelled at next ARCON signal Decrease the value P18 Peak time to adjust ...

Page 98: ...Average burning voltage Average voltage under main conditions Instructed from the robot side Average voltage under main conditions Instructed from the robot side Average current under main conditions Instructed from the robot side End slope time Voltage only Wire stick prevention Wire stop Adjustment of sphere at end tip Burning conditions Droplet pulse End conditions Main conditions P44 P15 P12 P...

Page 99: ...1 When arc occurs for a long time without sphere drip dropping Decrease P49 increase P50 and P51 When arc is not stable Increase P49 decrease P50 and P51 To make beads flat for stainless steel or the like Increase P49 P50 and P51 When short circuit occurs for a long time Decrease P parameter P49 increase P parameter P50 and P51 When burn through occurs Decrease P parameter P49 P50 and P51 When wel...

Page 100: ...Pulse peak current for droplet transition For excessive spatters Increase the value For excessive burning Decrease the value P09 Base current to keep arc P10 Pulse peak time for droplet transition P31 Pulse current increasing speed For arc repelling Increase the value For arc burning Decrease the value P33 Pulse current decreasing speed For arc burning Increase the value For arc repelling Decrease...

Page 101: ...peak current for droplet transition For excessive spatters Increase the value For excessive burning Decrease the value P09 Base current to keep arc P10 Pulse peak time for droplet transition P35 Pulsed current increasing rate For arc repelling Increase the value For arc burning Decrease the value P36 Pulsed current decreasing rate Base current Pulse time Pulse current decreasing rate Pulse current...

Page 102: ...ntrol for arc length at pulse welding For improper arc length follow up Increase the value For arc length oscillation Decrease the value P61 NG NG OK Welding advancing direction Arc length constant control gain Arc length c Arc length oscillation large Arc length constant control gain is too large Arc length response slowly Arc length constant control gain is too small Transient state Static state...

Page 103: ...al welding current value is higher than the welding current com mand Decrease the value When real welding current value is lower than the welding current command Increase the value P63 Welding current output characteristic 2 250 A or more default setting Changes the wire feeding amount so that the real welding current value corre sponds to the welding current com mand When real welding current val...

Page 104: ...D EH500 can automatically compensate for the voltage drop due to external resistance by measureing the electric resistance of the connected power cable or jig stand to set the resistance value By calibrating the external resistance the same actual welding voltage can be obtained with the same synergic voltage command even in a station having different power cable length or jig stand with different...

Page 105: ...rameter for calibration of the external resistance to enabled Refer to 14 2 4 Setting the D Parameter for Calibration of External Resistance to Enabled 14 2 1 Connecting the Cable for Resistance Measurement Use a machine tool etc to securely tighten the connecting section of the cable for resistance measurement Since approx 300 A current flows at measurement of the external resistance excessive he...

Page 106: ...ck and short as possible and securely connect the tip body at the torch end and the jig stand using a bolt or vice Fig 23 Connection of Cable for Resistance Measurement Connect in this order negative side power cable welder Remove the nozzle and chip from the torch and pull back the wire Cable for resistance measurement 38 mm2 0 5 m Jig stand Use a bolt or vice to connect the other end of the cabl...

Page 107: ...obtained by out putting the constant current of approx 300 A and measuring the voltage required at that time Fig 24 Start up of the Resistance Measurement Mode V A Wire m min Type ON OFF Record Gas Common PRM Select PRM Select PRM Set Weld Type File No 1 File No 2 File No 3 User File Select Power Warning Search L R V A Wire m min Type Record Gas Common PRM Select PRM Select PRM Set Weld Type File ...

Page 108: ...Press the Record button again to stop the current output during conduction however the resistance is not measured When cable for resistance measurement or the power cable etc is not connected the ammeter 7 segment LED indicator for current displays 0 A Confirm the connection path when the contact of the cable for the resistance measurement and the joint of the power cable is insufficient wrong res...

Page 109: ...isplay the parameter that sets calibration for external resistance as follows 1 With the Common PRM Select button pressed press the PRM Select button The setting of D parameter appears 2 Pressing of the button once displays the parameter d 2 1 that sets the external resistance calibration to Enabled or Disabled Fig 27 Display of D Parameter V A Wire m min Type Record Gas Common PRM Select PRM Sele...

Page 110: ... on the set parameter are saved If the set parameters are not saved the set data will be deleted with the main power supply OFF Fig 29 Saving the Setting V A Wire m min Type Record 20 Gas Common PRM Select PRM Select PRM Set Weld Type File No 1 File No 2 File No 3 User File Select Power Warning Search L R Press the PRM Set button twice so that the OFF display blinks Then press button to change the...

Page 111: ... at 2 points Fig 30 Compensation of Wire Feeding Speed Command by Welding Current Calibration Function When the calibration function of welding current is set to enabled The set values of P62 and P63 are other than 100 be sure to record the parameter values of C parameter C13 to C18 and P parameter of each user file P62 and P63 If parameters were initialized input the recorded parameter contents d...

Page 112: ...ect button to start up the welding source in the Welding Current Calibration mode If the 7 segment LED indicators of V and A on the panel blink the mode is being set to the Welding Current Calibration mode 2 Welding by the current calibration 1 1 If the 7 segment LED indicators of V and A on the panel blink the current cali bration 1 is in standby state The welding current calibration cannot be pe...

Page 113: ...the current calibration 1 and current cali bration 2 Set the welding current command value so that the command value of the current calibra tion 1 is lower than that of the current calibration 2 If the welding time is less than six seconds the LED indicator lamp above the Record button does not flash after welding Perform welding for a longer time and welding current calibration again NOTE NOTE V ...

Page 114: ...e welding current command value so that the command value of the current calibra tion 2 is higher than that of the current calibration 1 If the welding time is less than six seconds the LED indicator lamp above the Record button does not flash after welding Perform welding for a longer time and welding current calibration again V A Wire m min Type NOTE NOTE V A Wire m min Type The display of 7 seg...

Page 115: ...c onds or more to save the result 7 Returning to the usual welding mode Perform either of the following procedures to return to the usual welding mode Press PRM Select button or Turn OFF the welding source once and turn it ON again The welding after the welding current calibration is performed by the wire feeding speed command which is calculated from the result of welding current calibration 115 ...

Page 116: ...nce current 2 File No 1 250 Reference current 2 for the user file No 1 Unit A Display No Item Initial Value Content P62 Current output characteristic 1 100 Compensation ratio 1 for wire feed ing speed Unit P63 Current output characteristic 2 100 Compensation ratio 2 for wire feed ing speed Unit C15 Current calibration Reference current 1 File No 2 150 Reference current 1 for the user file No 2 Uni...

Page 117: ...e 0 6 seconds Command Voltage V Welding Current A Command Voltage V Welding Voltage 0 00 30 0 00 50 1 35 77 7 20 99 2 70 124 7 50 100 10 80 406 7 80 101 12 15 453 14 00 150 13 50 500 0 00 0 0 00 0 0 00 0 0 00 0 0 00 0 Command Voltage V Welding Current A Command Voltage V Welding Voltage V 0 00 30 0 00 12 0 1 35 77 2 25 17 5 2 70 124 4 50 23 0 10 80 406 6 75 28 5 12 15 453 9 00 34 0 13 50 500 11 25...

Page 118: ...tion Magnification of current conversion 200 For welder 2 S2C360 Arc monitoring function Current offset 0 For welder 2 S2C361 Arc monitoring function Magnification of voltage conversion 200 For welder 2 S2C362 Arc monitoring function Voltage offset 0 For welder 2 S2C363 Arc monitoring function Magnification of current conversion 200 For welder 3 S2C364 Arc monitoring function Current offset 0 For ...

Page 119: ...00 For welder 2 S2C288 Arc monitoring function Current offset 0 For welder 2 S2C289 Arc monitoring function Magnification of voltage conversion 200 For welder 2 S2C290 Arc monitoring function Voltage offset 0 For welder 2 S2C291 Arc monitoring function Magnification of current conversion 200 For welder 3 S2C292 Arc monitoring function Current offset 0 For welder 3 S2C293 Arc monitoring function Ma...

Page 120: ...m adjacent to the connector on the robot controller side of welding command cable 18 1 Gas Check Connect contacts to the pin terminals GAS and COM which emerge from adjacent to the connector of the welding command cable Contact ON closed The shielding gas flows with the gas magnet valve ON Contact OFF open The shielding gas stops with the gas magnet valve OFF Welding command cable Pin terminal for...

Page 121: ... welding command cable The user files can be selected by combinations of contacts ON OFF as follows Selection of User File Contact OP1 Contact OP2 No user files OFF OFF User file No 1 ON OFF User file No 2 OFF ON User file No 3 ON ON The user files cannot be selected externally when the D parameter D1 11 is set to OFF Additionally the switch of user files is only enabled either by the external com...

Page 122: ...nt Face Item No Parts Code No Parts Name Q ty per Welding Source 505 DTB30505 Eyebolt M8 2 510 2ECEL3510 Front panel 1 511 2ECEL3511 Control panel 1 513 6N2A30513 Cover top 1 514 DTCP50514 Side cover right 1 515 DTCP50515 Side cover left 1 521 GP430521 Terminal Cover 1 590 2ECEL3590 Sheet panel 1 775 6N0EH5775 Nameplate 1 122 129 ...

Page 123: ...de No Parts Name Q ty per Welding Source 001 6N0EH5001 Control transformer for motor 1 002 6N3E50002 Transformer 1 1 003 6N3E50003 Transformer 2 1 004 AJ3E50004 DC reactor 1 500 6N3EH5500 Base 1 533 AJ2S35533 Terminal Seat bottom 1 534 DTR35534 Terminal 2 535 DTR35535 Terminal Seat upper 1 662 AJ3E50662 Ground terminal seat 1 123 129 ...

Page 124: ...rvice Parts Right Face Item No Parts Code No Parts Name Q ty per Welding Source 008 DTE50008 Shunt 600A 60mV 1 536 6N3EH5536 Current limiting reactor 1 541 AJ3E50541 Diode 3 582 91197 Plate 1 739 DTVT50739 Thermal guard 85 C 1 772 DTJ15982 Line filter 6 901 6N0EH5901 Mounting Base 2 124 129 ...

Page 125: ...e Q ty per Welding Source 012 6N3E50012 Fuse free breaker 1 021 6N3E50021 PC board set DR 006 1 710 910816 Aluminium electro capacitor 4 717 6N3E50717 Diode bridge 3 730 6N3E50730 IGBT 4 740 ADVT50739 Thermal guard 90 1 741 6N3E50741 Sunbber mold 4 750 6N0EH5750 FFB Holder 1 862 DTR50862 Filter transformer 1 925 DTYA30925 Shunt 60A 1 125 129 ...

Page 126: ...e 18 List of YWE EH500 6N0 Service Parts Partition Board Item No Parts Code No Parts Name Q ty per Welding Source 022 6N0EH5022 PC board set PS 008 1 024 AJ0EL3024 PC board set MB 021 1 026 AJ0EL3026 PC board set SD 006 1 027 AJ0EL3027 PC board set RC2 001 1 028 AJ0EL3028 PC board set CR 008 1 032 902159 Circuit board spacer 16 055 AJ0E35033 Power supply 1 553 6N0EH5553 Partition 1 650 AJ0EL3650 R...

Page 127: ...r Face Item No Parts Code No Parts Name Q ty per Welding Source 102 AJ0E35102 Connector 4 pins 1 114 AJ0E35114 Connector 6 pins 1 512 6N0EH5905 Rear cover plate 1 825 AJ2S35825 Connector 26 pins 1 905 6N0EH5905 Cable clamp 1 952 DTPT35952 4 pin receptacle 1 953 DTPT35953 4 pin short circuit cap 1 127 129 ...

Page 128: ...WE EH500 6N0 Filter Unit Table 20 List of YWE EH500 6N0 Service Parts Filter Unit Item No Parts Code No Parts Name Q ty per Welding Source 516 6N0EH5516 Filter cover set 1 919 6N0EH5919 Cooling fan 3 986 6N0EH5986 Filter case 1 128 129 ...

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