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YASKAWA YWE-EH500-6N0 Instruction Manual

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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.
YASKAWA
180369-1CD
0
MANUAL NO.
HW0480311
YASKAWA
1/129
2

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Summary of Contents for YASKAWA YWE-EH500-6N0

  • Page 1 YASKAWA 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. 180369-1CD YASKAWA MANUAL NO. HW0480311 1/129...
  • Page 2 If such modification is made, the manual number will also be revised. • If your copy of the manual is damaged or lost, contact a YASKAWA rep- resentative to order a new copy. The representatives are listed on the back cover.
  • Page 3 HW0480311 Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the MOTOWELD-EH500. In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.” Indicates a potentially hazardous situation which, if not WARNING avoided, could result in death or serious injury to personnel.
  • Page 4 HW0480311 WARNING Be sure to observe the following warnings to avoid serious injury to personnel. • Be sure to observe the precautions in this instruction manual although this welder is designed and manufactured with sufficient consideration given to safety. Failure to observe this warning may result in death or serious injury to personnel. •...
  • Page 5 HW0480311 WARNING Be sure to observe the following warnings to avoid an electric shock. • Never touch the charged parts. Touching the charged parts may result in critical electric shock or burns. • Only a qualified person in electric construction should perform ground- ing construction for the welder case and base metals (to be welded) or jigs that are electrically connected to the base metals as specified in the electric facility technical reference.
  • Page 6 HW0480311 WARNING Be sure to observe the following warnings and use protectors to protect yourself or other people from the fumes or gases generated at welding and short of the oxygen. • In order to prevent gas poisoning or suffocation, be sure to ventilate sufficiently or use an inhaler, etc.
  • Page 7 HW0480311 WARNING Observe the following cautions to prevent fire, explosion, or rupture. • Remove inflammables so that they will not get spattered. If they cannot be removed, use the inflammables with nonflammable covers. Spatters or hot base metal immediately after welding may result in fire. •...
  • Page 8 HW0480311 CAUTION Be sure to observe the following cautions and use protectors to protect yourself or other people from arc beams, spatters, slugs or noise generated from weld- ing. • Wear welding mask or shaded glasses appropriate for welding. • Wear protective glasses to protect your eyes from spat- ters or slags.
  • Page 9 HW0480311 CAUTION Be sure to observe the following cautions to prevent a gas cylinder from fall- ing or a gas regulator from rupturing. • Observe the regulations and your own references for the handling of gas cylinders. Since a gas is filled with high pressure gas, improper handling may cause high cylinder pressure gas to blow up, resulting in personal injury.
  • Page 10 HW0480311 CAUTION Observe the following cautions to prevent personal injury by the end tip of the weld- ing wire. • Do not peep through the chip hole to confirm that the wire is being fed. If the wire is projected from the end tip of the welding torch, it may poke you in the eyes or face.
  • Page 11 HW0480311 CAUTION Observe the following cautions to prevent a fire accident caused by deterioration of welder insulation. • Perform all welding and grinding away from welder to pro- tect welder from spattering and metal powder. Spatter and metal powder inside the welder may cause a deterioration of insulation resulting in accidental fire.

  • Page 12: Table Of Contents

    HW0480311 Basic Specifications Installation and Connection 2.1 Installation Site and Welding Source Environment 2.2 Precautions on Grounding ......2 2.3 Power Supply Installed Capacity and Connection Cables .
  • Page 13 HW0480311 Welding Operation 5.1 Checking the Welding Conditions ....5 5.2 Wire Stickout ........5 5.3 Direction of Welding and Torch Angle .
  • Page 14 HW0480311 Robot Interface Signals 10.1 Specifications of Robot Interface Signals ..10 10.2 Meaning and Function of Pr(RC2)-001 Terminal . 10 10.2.1 TB2 Terminal ........10-4 10.2.2 TB3 Terminal .
  • Page 15 HW0480311 Calibration for External Resistance 14.1 Outline of External Resistance Calibration ..14 14.2 Procedure of External Resistance Calibration . . . 14 14.2.1 Connecting the Cable for Resistance Measurement..14-2 14.2.2 Measuring the External Resistance Value .

  • Page 16: Wire

    HW0480311 1 Basic Specifications Item Specifications Model MOTOWELD-EH500 Type YWE-EH500-6N0 ± Number of Phases, Three-phase, 480 V 10 % Rated Input Voltage Rated Frequency 50/60 Hz common Rated Input 27.5kVA 24.3 kW Welding Current Adjust- 30 to 500 A (depends on the wire diameter)
  • Page 17 HW0480311 Item Specifications ± Voltage for Starting Point Peak value: 220 V 20 % (full-wave rectification) Detecting Function (Optional) External Dimensions 371 x 810 x 641 (width x depth x height) [mm] (excluding the projections such as screws or eyebolts) Mass Approx.

  • Page 18: Installation Site And Welding Source

    HW0480311 2.1 Installation Site and Welding Source Environment 2 Installation and Connection Installation Site and Welding Source Environment CAUTION • The welding source can be moved easily by using the caster. After installation, use the stopper to fix the welding source before starting operations.

  • Page 19: Cables

    HW0480311 2.3 Power Supply Installed Capacity and Connection Cables 4. If there is a pool or pond between the grounding of the power supply switchboard and the welding source, the leak current is concentrated in the pool or pond. In such a case, connect the grounding with a cable to escape the leak current through the cable.

  • Page 20: Combination With Earth Leakage

    HW0480311 2.4 Combination with Earth Leakage Breaker The input cable is passed from the hole for wiring in the back of the power supply. NOTE When the outside diameter of the cable exceeds φ30.0mm, match the plate to the size of the input cable, process the hole, and use it. Be sure to use cables for welding.
  • Page 21 HW0480311 2.5 Connection of Electrical System nal (+). 2) Exclusive-use base metal cable The exclusive-use base metal cable connects between the base metal and power output terminal (-). 3) Welding Voltage Detecting Line The welding voltage detecting line connects between the base metal and con- nector "CON 7"...
  • Page 22 HW0480311 2.5 Connection of Electrical System Acrobat 文書 Fig. 1 Connection Diagram of Welding Source at Rear Face HW0480311 22/129...
  • Page 23 HW0480311 2.5 Connection of Electrical System Fig 2 Connection Diagram of Welding source at Front Face HW0480311 23/129...

  • Page 24: Connection Of Welding Voltage Detecting

    HW0480311 2.6 Connection of Welding Voltage Detecting Line 4. Grounding Ground terminal is provided at the input voltage terminal in the partition board of the welding source for safe operation. Connect the grounding cable of 14 mm or more to Ω...
  • Page 25 HW0480311 2.6 Connection of Welding Voltage Detecting Line When a rotation axis is used, connect the welding voltage detecting line with the screw of the cover that exists in the base of MOTOPOS. Don’t connect output cable and the welding volt- age detection line with the same part as indicated in "...
  • Page 26 HW0480311 2.6 Connection of Welding Voltage Detecting Line When you use two or more welders, Connect the each welding output cable of the welder as close to the position where welding is performed as possible. Separate the welding output cable A from the welding voltage detecting line B,and separate the welding output cable B from the welding voltage detecting line A as far as possible.(Dis- tance between Cable A and cable B is required 100mm or more.) Don't connect the welding voltage detection line with the route where the welding current flows...

  • Page 27: For Mixed Gas Or Carbon Dioxide Gas Welding

    HW0480311 2.7 Connection of Shielding Gas System Connection of Shielding Gas System 2.7.1 For Mixed Gas or Carbon Dioxide Gas Welding The 100 VAC power supply is required for a heater of carbon dioxide gas regulator. Connect the gas cylinder as follows: 1.
  • Page 28 HW0480311 2.7 Connection of Shielding Gas System 3. Quality of Gas for Welding Moisture or impurity in the carbon dioxide gas or argon gas used to shield welding arcs adversely influenced welding. High purity and low moisture gas must be used. Use MAG gas containing 80 % argon and 20 % carbon dioxide gas for mixed gas.

  • Page 29: Ambient

    HW0480311 2.8 Ambient Environment Ambient Environment 1. Wind Prevention Normally, the allowable wind limit for welding using shielding gas is approx. 1.5 m/s or less. If the wind speed is higher than this limit, stop operation or take some counter- measures such as putting up a screen.
  • Page 30 HW0480311 2.9 Precautions on Transporting Helmet Handshield Jacket must be long-sleeved. Welding gloves Foot covers Safety boots Fig. 8 Protection Example Precautions on Transporting CAUTION • 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.
  • Page 31 HW0480311 2.9 Precautions on Transporting 2. Transporting with Using a Crane When using the crane, be sure to confirm the following points before transporting. 1) Confirme the mass of the welding source by referring to " 1 Basic Specifications ". Select the wire rope suitable for the mass and angle. 2) Use eyebolts for transporting and confirm that the eyebolts are tightened firmly before transporting.
  • Page 32 HW0480311 2.9 Precautions on Transporting 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.
  • Page 33 HW0480311 3 Welding Preparation The following table describes the preparation procedure to start actual welding. Table. 3 Welding Preparation Procedure Step Item Details Setting welding wire Set a wire suitable to the welding method. Make sure that the diameter of the roller of wire feeder matches the wire diameter.
  • Page 34 HW0480311 Table. 3 Welding Preparation Procedure Step Item Details Selecting welding type Before Setting; Select the welding type according to the type of shielding gas and wire, or short-circuit/ pulse. Selectable types are written on the nameplate on the front face of the panel. Set the welding type number to the Type on the welding source panel.

  • Page 35: Explanation Of Welding Source

    HW0480311 4.1 Explanation of Welding Source Panel 4 Operations on Panel Explanation of Welding Source Panel Pressing the panel buttons during welding does not change any operation other than user NOTE file selection. Be sure to stop welding before starting the panel operations. Wire m/min Type Power...
  • Page 36 HW0480311 4.1 Explanation of Welding Source Panel The following table explains the display of the meters , and The content of the display differs according to the status as follows: Type Wire m/min Status Welding Volt- Welding Cur- Wire Feeding Welding Type age Indicator rent Indicator...
  • Page 37 HW0480311 4.1 Explanation of Welding Source Panel Setting Buttons Item Content Explanation Parameter Select When the "PRM Select" button is pressed during standby status, (P parameter) the display changes to the P parameter setting display. The 7-seg- ment LED indicator displays "P.00", and the 7-segment LED indi- cator displays the parameter set value.

  • Page 38: Changing Welding Type

    HW0480311 4.2 Settings on Welding Source Panel Settings on Welding Source Panel 4.2.1 Changing Welding Type The following describes how to change the welding type. (1) Press the button "Weld. Type", and the 7-segment LED indicator "Type" blinks. Type Wire m/min (2) Use the button "+"...
  • Page 39 HW0480311 4.2 Settings on Welding Source Panel Table. 4 List of Weld Types Pulse or Wire Weld Shielding Gas Wire Remarks Short-circuit Diameter Type No. φ 0.9 3.21 φ 1.0 3.24 Soft steel (Ar 80%, CO Short-circuit φ 1.2 3.27 20%) φ...

  • Page 40: User Files

    HW0480311 4.2 Settings on Welding Source Panel 4.2.2 User Files The conditions changed by the P parameter concerning any welding type are saved in the user files: File No. 1, File No. 2, and File No. 3. Also, the user file can be called up from the manipulator controller to perform welding. The P parameters cannot be changed or saved unless the user file is selected (No File sta- tus).

  • Page 41: Changing Common (C) Parameters

    HW0480311 4.2 Settings on Welding Source Panel (5) Press the button “PRM Set”, and the parameter value on the 7-segment LED indi- cator “Wire m/min” blinks. The set value of parameter is ready to be changed. Change the set value in the range between 10 and 200 %. For changing the parameter number, press the button “PRM Set”...
  • Page 42 HW0480311 4.2 Settings on Welding Source Panel indicator "Wire m/min" blinks. The set value of parameter is ready to be changed. If the set value is four digits or more, use the button "L" to move the cursor to the indicator ammeter (A).

  • Page 43: Changing D Parameters

    HW0480311 4.2 Settings on Welding Source Panel 4.2.5 Changing D Parameters For details on the D parameter, refer to " 4.5 List of D Parameters ". D parameters specify the setting or operation conditions for the welding source by ON/OFF. The D parameters consist of D-1 parameter and D-2 parameter.

  • Page 44: Saving Welding Conditions

    HW0480311 4.2 Settings on Welding Source Panel <Example> When the parameter D1-11 is ON (enabled): Type Wire m/min Press the button "Record" for three seconds or more to save the changed values (conditions). Do not turn OFF the welding source during saving conditions. When the 7-segment LED indicators are lit again, the saving of conditions is completed.

  • Page 45: Checking The Flow Amount Of Shielding Gas

    HW0480311 4.2 Settings on Welding Source Panel 4.2.7 Checking the Flow Amount of Shielding Gas The shielding gas flow amount can be checked. Press the button "Gas" button. The LED indicator lamp above the "GAS" button lights and the gas flows for 20 seconds. Press the button again during gas checking to stop the gas flow.

  • Page 46: Monitoring Of Motor Current

    HW0480311 4.2 Settings on Welding Source Panel 4.2.9 Monitoring of Motor Current The motor current of rotating feeding motor can be displayed in the 7-segment LED indicator "Wire m/min" by setting D parameter D1-5 to "OFF". During the standby status, the 7-seg- ment LED indicator displays the command of wire feeding amount (m/min).
  • Page 47 HW0480311 4.2 Settings on Welding Source Panel The following describes how to reset the system. (1) Press the button "Common PRM Select" during standby status. The 7-segment LED indicator voltmeter (V) displays "C.00" blinking, and the 7-segment LED indi- cator "Wire m/min"...

  • Page 48: Lock Of Panel Operation

    HW0480311 4.2 Settings on Welding Source Panel 4.2.11 Lock Of Panel Operation "Lock of panel operation" is a function to invalidate the button operation so as not to operate the button of a front panel of the welding power supply by mistake. The button that can be operated with the panel operation locked is only a gas check button.
  • Page 49 HW0480311 4.2 Settings on Welding Source Panel Method of releasing "lock of panel operation" L button is pushed continuousness three times while pushing R button with the panel operation locked. Type Wire m/min Power Warning Search Auto Adj. PRM Select PRM Set Weld, Type Auto Adjustment...

  • Page 50: List Of Process

    HW0480311 4.3 List of Process Parameters List of Process Parameters The welding characteristics (start/main conditions/end) that are specified by database in the welding source can be adjusted according to your environmental conditions by changing the set values of the process parameters (P parameters). All the values are set to "100% = Operating as the characteristics in the database"...
  • Page 51 HW0480311 4.3 List of Process Parameters Display Items Description Reserved for system Do not change. MAG/MIG pulse current increas- ing speed Reserved for system Do not change. MAG/MIG pulse current decreas- ing speed Reserved for system Do not change. Aluminum MIG pulse current increasing ratio Aluminum MIG pulse current decreasing ratio...
  • Page 52 HW0480311 4.3 List of Process Parameters Display Items Description Low-pulse frequency ratio Changes the frequency based on C parameter C03. (for welding type 2.14, aluminum) E.g.) When C03=100 and P55=50%, 5.0Hz Low-pulse wire feeding speed Changes the amplitude based on C parameter C04. ratio E.g.) (for welding type 2.14, aluminum)

  • Page 53: List Of Common

    HW0480311 4.4 List of Common Parameters List of Common Parameters Common parameters (C parameters) specify the operations of the welding source. Set the parameters according to the operation conditions. Save the changed common parameters to enable common parameters. Then turn OFF the power and ON again.
  • Page 54 HW0480311 4.4 List of Common Parameters Display Default Contents Unit Description Setting Current calibration reference Reference current 2 for the user current 2 (File 3) file No.3 Reserved for system Do not change. Reserved for system Do not change. Reserved for system Do not change.
  • Page 55 HW0480311 4.5 List of D Parameters Display Default Contents Unit Description Setting Reserved for system Do not change. The initial value of the external resistance set value is the value measured under the environment for the MOTOWELD-EH500 database creation. For measurement of the external resistance value under your operation conditions, refer to "...
  • Page 56 • For synergic voltage, the voltage that Yaskawa assumes adequate is specified as 100%. Changing the synergic voltage by 10%, voltage varies by approx.about 1V. (Example: In case of 20V at 100%, it becomes 19V and 21V at 90% and 110%, respectively.
  • Page 57 HW0480311 4.5 List of D Parameters ting) with the parameters "D2-2", "D2-3", and "D2-4" set to "OFF". 4-23 HW0480311 57/129...

  • Page 58: Direction Of Welding And Torch

    HW0480311 5.1 Checking the Welding Conditions 5 Welding Operation Checking the Welding Conditions Before starting actual welding operation, perform the test welding for welding conditions to check if the welding performance is satisfactory. Remove oil, rust, oil paint, water, and foreign matter generated by gas-cutting to prevent the surface pore and blowhole.

  • Page 59: Precautions On Using Extension

    HW0480311 5.4 Precautions on Using Extension Cable Fig. 10 Direction of Welding and Torch Angle Precautions on Using Extension Cable When an extension cable is used, actual output between the torch and the base metal decreases because of voltage drop in the cable. To prevent this, set the command value of welding voltage adjustment higher than the target voltage value to compensate for the output voltage drop.

  • Page 60: Error Detection

    Overcurrent flows in the primary • Check if the output cable is overcurrent control circuit. short-circuited or grounded. • The power circuit may be bro- ken. Contact your Yaskawa representative. Err110 Voltage The welding voltage is not Contact your Yaskawa represen- detector error detected.
  • Page 61 • Check the DIP switch setting of setting error board is not correctly set. PR(CR)-008 board. • PR(CR)-008 board may be bro- ken. Contact your Yaskawa representative. Err304 to Improper Nonconformity in the model set- The setting of hardware or soft-...
  • Page 62 HW0480311 6.1 Error Detection Function Table. 5 List of Error Display Contents Error No. Item Contents Remedy Err701 Output over- Overcurrent flows in the second- Confirm the following. current ary control circuit. • Check that the torch cable or power cable is not grounded. •...

  • Page 63: Tripped Power Supply

    6.2 Tripped Power Supply Switch Tripped Power Supply Switch If the power supply switch is tripped, do not turn it ON again. Contact your Yaskawa representative. If the power is turned ON again with the power supply switch tripped, the problem may be compounded and may affect the welding.
  • Page 64 HW0480311 6.3 Precautions on Welding Operation 4. Power switch operation The inverter welding source is the forced air-suction cooling type. Do not turn OFF the power supply switch until the cooling fan completely stops after completion of the oper- ation. To prevent electric shock, never disconnect or connect the cables for the weld- ing source, the wire feeder, the welding torch, etc.

  • Page 65: Internal Selecting

    HW0480311 7.1 Internal Selecting Switches 7 Built-in Functions Internal Selecting Switches The internal selecting switches are set as follows before shipping. The internal switches are not allowed for change since the switches are prepared for adjuste- ment and maintenace performed by manufacturers. Table.

  • Page 66: Location Of Printed

    HW0480311 7.2 Location of Printed Boards Pr (CR)-008 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 DSW1 DSW2 DSW3...
  • Page 67 HW0480311 7.2 Location of Printed Boards Fig. 15 Location of Printed Board Pr(MB)-021 and Pr(CR)-008 To Replace , Remove two screws at a control panel Printed Board Pr(MB)-021 and Pr(CR)-008 and open a control panel. HW0480311 67/129...

  • Page 68: Dip Switch Settings For Pr(Mb)-021 Board

    HW0480311 7.2 Location of Printed Boards 7.2.1 DIP Switch Settings for Pr(MB)-021 Board The DIP switch settings for Pr(MB)-021 board are for manintenance. Do not change these settings. Table. 8 Settings of DIP Switches Setting 7.2.2 Jumper-pin Settings of the Pr(MB)-021 Board The settings of the Pr(MB)-021 board are for maintenance.

  • Page 69: Daily Inspection

    HW0480311 8.1 Daily Inspection Items 8 Maintenance and Inspection WARNING • 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.

  • Page 70: Bimonthly To Semiannual Inspection

    HW0480311 8.2 Bimonthly to Semiannual Inspection Items Bimonthly to Semiannual Inspection Items Perform the following: (1) Removal of dust and dirt Remove dust and dirt by spraying dry compressed air. Carefully clean spaces between the transformer and reactor windings, and semiconductors. To clean circuit boards, use the exclusive-use dust remover device.

  • Page 71: Components Used

    HW0480311 8.4 Guideline for Service Lifetime and Replacement of Components Used Guideline for Service Lifetime and Replacement of Components Used The welding source is composed of many components. Unless all these components operate normally, the welding source cannot utilize its essential functions. Therefore, it is absolutely necessary to find any sign leading to a failure of a component or device as early as possible according to the periodical inspection and take proper corrective action.
  • Page 72 HW0480311 8.5 Replace Fuse Replace Fuse If any fault shown below occurs,Check fuse.If Fuse blown again after replace fuse,Contact your Yaskawa representative. Table. 10 Fuse Item Fault Fuse 10A blown.(purple • Although the start signal is ON or the wire inching signal is color) ON,Motor does not operate.

  • Page 73: Confirming Setting

    Table. 11 Check Items ", " Table. 12 Failure Analyses for Welding Section ", and " Table. 13 Fault Analyses for Electrical Circuit Section ". If the equipment does not function properly even after the corrective action, contact your Yaskawa representative to investigate the cause and to repair as soon as possible.
  • Page 74 HW0480311 9.1 Confirming Setting conditions Table. 11 Check Items Item Contents Synergic/ Check if synergic/independent (auto adjustment/individual) selection of the welding Independent source is the same as that on the robot side. Synergic/Independent of the welding selection source can be set by the panel button "Auto Adjustment/Individual"...

  • Page 75: Cause And Remedy Of Welding Section Failure

    HW0480311 9.2 Cause and Remedy of Welding Section Failure Cause and Remedy of Welding Section Failure Table. 12 Failure Analyses for Welding Section Fault Cause Remedy Blowholes Excessive oil, rust, or paint Carefully remove the adherent substances to and pits adheres to the base metal.
  • Page 76 HW0480311 9.2 Cause and Remedy of Welding Section Failure Table. 12 Failure Analyses for Welding Section Fault Cause Remedy Arc is Power supply voltage exces- Use a different power supply from that of other unstable. sively fluctuates. machines that cause power supply voltage fluctua- tion.
  • Page 77 HW0480311 9.2 Cause and Remedy of Welding Section Failure Table. 12 Failure Analyses for Welding Section Fault Cause Remedy Bead form Manipulation of electrode is not Change the welding torch angle a little. Employ is bad and correct. the forward welding method and practice so that the appear- welding torch can constantly aim at a target.
  • Page 78 HW0480311 9.3 Cause and Remedy of Failure at Electrical Circuit Section Cause and Remedy of Failure at Electrical Circuit Section Table. 13 Fault Analyses for Electrical Circuit Section Failure Cause Remedy Power supply indicator lamp does Power supply indicator lamp Check contacting sec- not light even if the power supply failure, improper contact...
  • Page 79 See " Table. 5 List of meter Display Contents ". Error Display Contents ". The power supply switch is Damage to the input diode Contact your Yaskawa tripped and the power is not representative. Damage to the main circuit turned ON. transistor (IGBT)

  • Page 80: Specifications Of Robot Interface

    HW0480311 10.1 Specifications of Robot Interface Signals 10 Robot Interface Signals 10.1 Specifications of Robot Interface Signals The following table shows the correspondence of the pin number and the signal of connector CON3 (26 pins). For signal systems, refer to “11. Conncetion System Diagram.” Pin No.
  • Page 81 HW0480311 10.1 Specifications of Robot Interface Signals Pin No. Direct Correspon Signal Signal Function ding to Meaning Form Connector → P - E Arc occur- 1. The signal is output when the current Contact (COM) rence detec- output is detected continuously for 16 ms tion (Valid at after the gas pre-flow upon receiving...
  • Page 82 HW0480311 10.1 Specifications of Robot Interface Signals Pin No. Direct Correspon Signal Signal Function ding to Meaning Form Connector → U - V Monitoring Sends the monitoring signal of the output Analog output for voltage. voltage output volt- 3V/60V(66V for 66V or more) Note: When using the arc monitoring function, refer to "...

  • Page 83: Meaning And Function Of Pr(Rc2)-001 Terminal

    HW0480311 10.2 Meaning and Function of Pr(RC2)-001 Terminal 10.2 Meaning and Function of Pr(RC2)-001 Terminal The following describe the cable number of the connection terminal block and corresponding signals. 10.2.1 TB2 Terminal Connection Directi Terminal Signal Function Block Cable Meaning Ammeter Outputs 600A, →...

  • Page 84: Tb3 Terminal

    HW0480311 10.2 Meaning and Function of Pr(RC2)-001 Terminal 10.2.2 TB3 Terminal Connection Directi Terminal Signal Function Signal Form Block Cable Meaning This signal monitors the motor current of At normal Motor wire feeding and W→ time: Open current alerts that the motor At warning: warning current exceeds the...

  • Page 85: Detecting Function (Optional Board Pr(Op)-003 Eh500])

    HW0480311 10.3 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr(OP)-003 [EH500]) 10.3 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr(OP)-003 [EH500]) CAUTION • The starting point detection function is an optional function. The optional board Pr(OP)-003 [EH500] is included when the starting point detection function is ordered, that is, not included in standard package.
  • Page 86 HW0480311 10.3 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr(OP)-003 [EH500]) Connection Direc- Terminal Signal Function Signal Form Block Cable Meaning tion → Monitoring Monitoring signal for output volt- Analog voltage output for out- put voltage 5V/50V (For arc sensor) →...
  • Page 87 HW0480311 11 Connection System Diagram 11-1 HW0480311 87/129...

  • Page 88: Starting Up Welding Source In Diagnosis Mode

    HW0480311 12.1 Starting up Welding Source in Diagnosis Mode 12 Diagnosis Function MOTOWELD-EH500 has a Diagnosis mode to confirm the software version, the number of occurrence of welding source error, and DIP switch set status. 12.1 Starting up Welding Source in Diagnosis Mode To start up the welding source in the Diagnosis mode, turn OFF the main power of MOTOWELD-EH500 once, and turn ON the main power again while pressing the "Record"...
  • Page 89 HW0480311 12.1 Starting up Welding Source in Diagnosis Mode The information which is displayed in the 7-segment LED indicator can be changed with using the buttons "+" or "-" on the MOTOWELD-EH500 front panel. The displayed contents are "d-*" : DIP switch set status changed with the buttons "C-*"...

  • Page 90: Confirmation Of Dip Switch Set Status

    HW0480311 12.2 Confirmation of DIP Switch Set Status 12.2 Confirmation of DIP Switch Set Status By referring to the information: "d-1" to "d-4" which is displayed in the Diagnosis mode, the setting status of DIP switch on the PR(CR)-008 board of welding source inside can be confirmed without removing the cover of the welding source.

  • Page 91: Confirmation Of Software

    HW0480311 12.3 Confirmation of Software Version 12.3 Confirmation of Software Version By referring to the information: "C-1", "C-2", and "C-3" which is displayed in the Diagnosis mode, the software version which is loaded in the welding source can be confirmed. •...
  • Page 92 HW0480311 12.4 Confirmation of the Number of Welding Source Errors 12.4 Confirmation of the Number of Welding Source Errors By referring to the information: "Err.001" to "Err.999" which is displayed in the Diagnosis mode, the number of errors which occurred in the welding source can be confirmed. NOTE The number of welding source errors is automatically saved.

  • Page 93: End Of Diagnosis

    HW0480311 12.5 Clear of Error Record 12.5 Clear of Error Record To delete the number of welding source errors, perform the clear operation of the error record. The following explain how to clear the error record. Wire m/min Type Power Warning Search Auto Adj.

  • Page 94: Adjustable Welding

    HW0480311 13.1 Adjustable Welding Characteristics 13 Process Parameters (Adjustment of Welding Characteristics) Welding characteristics of the digital inverter welding source: MOTOWELD-EH500 are speci- fied by database in the welding source. The values of welding characteristics, however, can be changed to 10 to 200 % of the database values with using process parameters (P parame- ters).

  • Page 95: Adjustment Of Start Pulse

    HW0480311 13.2 Adjustment of Arc Start Characteristics 13.2 Adjustment of Arc Start Characteristics 13.2.1 Adjustment of Start Pulse The following parameters change the characteristics related to the first arc start at ARCON signal. Parameter Meaning Guideline of Adjustment Wire speed until the wire contacts -When scrap of the wire tip end remains;...

  • Page 96: Adjustment Of Hot Characteristics

    HW0480311 13.2 Adjustment of Arc Start Characteristics 13.2.2 Adjustment of Hot Characteristics The following parameters change the hot characteristics before transition to the main current after the first arc start at ARCON signal. Parameter Meaning Guideline of Adjustment Average current of hot char- -For excessive arc burning;...

  • Page 97: Adjustment Of Arc End

    HW0480311 13.3 Adjustment of Arc End Characteristics 13.3 Adjustment of Arc End Characteristics The following parameters change the characteristics from when ARCOF signal is input until arc disappears. Parameter Meaning Guideline of Adjustment Average current for crater processing after VALID -When craters are not ARCOF signal is input when D...
  • Page 98 HW0480311 13.3 Adjustment of Arc End Characteristics Wire-stick prevention End conditions Burning conditions Droplet pulse Main conditions Adjustment of sphere at end tip Wire stop Voltage only Average current under main conditions Droplet pulse peak time (Instructed from the robot side) Average end current Droplet pulse peak current End slope time...
  • Page 99 HW0480311 13.4 Adjustment of Short-circuit Welding Characteristics 13.4 Adjustment of Short-circuit Welding Characteris- tics The following parameters change the short-circuit welding characteristics under the main welding characteristics. Parameter Meaning Guideline of Adjustment Current increasing speed -For unstable arc; Increase the value. at short-circuit (first half) -For excessive spatters;...

  • Page 100: Adjustment Of Mag/Mig Pulse Welding Characteristics

    HW0480311 13.5 Adjustment of Pulse Welding Characteristics 13.5 Adjustment of Pulse Welding Characteristics 13.5.1 Adjustment of MAG/MIG Pulse Welding Characteris- tics The following parameters change the pulse welding characteristics under the main character- istics for MAG/MIG pulse welding using mixed gas with Ar 98% or less. Parameter Meaning Guideline of Adjustment...

  • Page 101: Adjustment Of Mig Pulse Welding Characteristics

    HW0480311 13.5 Adjustment of Pulse Welding Characteristics 13.5.2 Adjustment of MIG Pulse Welding Characteristics The following parameters change the pulse welding characteristics under the main character- istics for aluminum MIG welding. Parameter Meaning Guideline of Adjustment Pulse peak current for droplet transition -For excessive spatters;...
  • Page 102 HW0480311 13.6 Adjustment of Other Pulse Welding Characteristics 13.6 Adjustment of Other Pulse Welding Characteristics Parameter Meaning Guideline of Adjustment Gain of the constant control for arc length -For improper arc length follow-up: at pulse welding Increase the value. -For arc length oscillation: Decrease the value.

  • Page 103: Adjustment Of Current Output

    HW0480311 13.7 Adjustment of Current Output Characteristics 13.7 Adjustment of Current Output Characteristics Parameter Meaning Guideline of Adjustment Welding current output characteristic 1 - When real welding current value is (150 A or less: default setting) higher than the welding current com- Changes the wire feeding amount so mand: Decrease the value.

  • Page 104: Outline Of External Resistance Calibration

    HW0480311 14.1 Outline of External Resistance Calibration 14 Calibration for External Resistance The MOTOWELD-EH500 has a function to compensate for the voltage drop due to cable extension, etc. This function is effective only when short-circuit welding is selected. 14.1 Outline of External Resistance Calibration Since the negative (-) side power cable and jig stand connecting the welding source and the base metal to be welded contain electric resistance, voltage applied between the torch and the base metal drops by several volts compared with the voltage output from the welding...

  • Page 105: Procedure Of External Resistance Calibration

    HW0480311 14.2 Procedure of External Resistance Calibration 14.2 Procedure of External Resistance Calibration The following outlines how to calibrate the external resistance. For details, refer to the following sections. 1. Connect the cable for resistance measurement. (Refer to " 14.2.1 Connecting the Cable for Resistance Measurement ".) 2.
  • Page 106 HW0480311 14.2 Procedure of External Resistance Calibration To measure the external resistance value, move the manipulator so that the torch will be close to the jig stand. Then, use the cable for resistor measurement to connect the torch tip end and the jig stand where base metal to be welded is set, as shown in the following figure.

  • Page 107: Measuring The External Resistance Value

    HW0480311 14.2 Procedure of External Resistance Calibration 14.2.2 Measuring the External Resistance Value The external resistance is measured by panel operations. The following describe how to measure the resistance value. 1. Start-up of the resistance measurement mode With the "Weld.Type" button pressed, turn ON the welding source main power supply. The welding source starts up in the resistance measurement mode.
  • Page 108 HW0480311 14.2 Procedure of External Resistance Calibration 2. Output of current for the resistance measurement CAUTION • Do not touch, the power cable, torch, or jig stand while current for the resistance measurement is being output. Failure to observe this caution may result in electric shock. (1) Record the value of parameter C08 in advance since the result of the measurement is overwritten.

  • Page 109: Display Of External Resistance Setting Parameter

    HW0480311 14.2 Procedure of External Resistance Calibration 14.2.3 Display of External Resistance Setting Parameter Press the "Weld.Type" button to end the external resistance measurement mode and returns to the normal welding mode. Confirm the measured external resistance value with the parameter C08 as follows: (1) Press the "Common PRM Select"...
  • Page 110 HW0480311 14.2 Procedure of External Resistance Calibration 2. Change the parameter that sets calibration of external resistance to "enabled" as fol- lows: (1) Press the "PRM Set" button twice and the display "oFF" starts blinking. (2) While the display is blinking, press the "+" button to change the display from "oFF" to "on".
  • Page 111 The welding current command value may be different from the actual welding current if the wire extension is out of standard value, the welding voltage command value is set entirely different from the synergic voltage which is specified as 100 % and Yaskawa deems to be adequate, or the P parameter value is changed.

  • Page 112: Procedure Of Welding Current Calibration

    HW0480311 15.2 Procedure of Welding Current Calibration 15.2 Procedure of Welding Current Calibration The main procedures of welding current calibration are as follows; 1. Starting up the welding source in the Welding Current Calibration mode 2. Welding by the current calibration 1 3.
  • Page 113 HW0480311 15.2 Procedure of Welding Current Calibration (2) Set the welding current command to be calibrated from the robot controller side, and perform welding for six seconds or more. Set the welding current command value so that the command value of the current calibra- NOTE tion 1 is lower than that of the current calibration 2.
  • Page 114 HW0480311 15.2 Procedure of Welding Current Calibration (2) If the 7-segment LED indicators of "A" and "Wire" on the panel blink, the current cal- ibration 2 is in standby state. Type Wire m/min (3) Set the welding current command to be calibrated from the robot controller side, and perform welding for six seconds or more.
  • Page 115 HW0480311 15.2 Procedure of Welding Current Calibration 6. Saving the conditions of calibration results After confirming the calibration result, keep pressing the "Record" button for three sec- 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.
  • Page 116 HW0480311 15.3 Parameters for Welding Current Calibration Function 15.3 Parameters for Welding Current Calibration Function The following tables show the parameters which are used for the welding current calibration function. Parameters used when the user file No.1 is selected Display No. Item Initial Value Content...
  • Page 117 0.00 0.00 Since the MOTOWELD-EH500 uses a print-type servomotor for its standard model, the motor stops within 0.1 seconds. To reduce the manipulator’s cycle time, Yaskawa recom- SUPPLE -MENT mends that the wire-stick monitoring time on the robot side be set short.
  • Page 118 HW0480311 17 Setting of Arc Monitoring Function For using the arc monitoring function on the robot side, the setting of parameters for the robot controller as shown below is required. NOTE Parameters to be set are different according to the type of robot controller. For the Robot Controller: NX Parameter No.
  • Page 119 HW0480311 For the Robot Controller: XRC Parameter No. Item Remarks Value S2C283 For welder 1 Arc monitoring function: Magnification of current conversion S2C284 Arc monitoring function: Current offset For welder 1 S2C285 Arc monitoring function: Magnification of voltage For welder 1 conversion S2C286 Arc monitoring function: Voltage offset...

  • Page 120: Switch Of User

    HW0480311 18.1 Gas Check 18 Operation by External Remote Mode The external remote operations are available for MOTOWELD-EH500 as follows: 1. Gas check 2. Switch of user files For external remote operations, connect contacts (dry contacts) to the pin terminals which emerge from adjacent to the connector on the robot controller side of welding command cable.
  • Page 121 HW0480311 18.2 Switch of User Files 18.2 Switch of User Files Perform the settings as follows to select a user file by external command. 1. Set the D parameter D1-11 to "ON". Then save conditions by referring to " 4.2.6 Sav- ing Welding Conditions ".
  • Page 122 HW0480311 19 List of Service Parts Fig. 33 YWE-EH500-6N0 Front Face Table. 14 List of YWE-EH500-6N0 Service Parts (Front Face) Item Q’ty per Parts Code No. Parts Name Welding Source DTB30505 Eyebolt M8 2ECEL3510 Front panel 2ECEL3511 Control panel 6N2A30513...
  • Page 123 HW0480311 Fig. 34 YWE-EH500-6N0 Base Section Table. 15 List of YWE-EH500-6N0 Service Parts (Base Section) Item Q’ty per Parts Code No. Parts Name Welding Source 6N0EH5001 Control transformer (for motor) 6N3E50002 Transformer(1) 6N3E50003 Transformer(2) AJ3E50004 DC reactor 6N3EH5500 Base AJ2S35533...
  • Page 124 HW0480311 Fig. 33 YWE-EH500-6N0 Right Face Table. 16 List of YWE-EH500-6N0 Service Parts (Right Face) Item Q’ty per Parts Code No. Parts Name Welding Source DTE50008 Shunt 600A-60mV 6N3EH5536 Current-limiting reactor AJ3E50541 Diode 91197 Plate ° DTVT50739 Thermal guard (85...
  • Page 125 HW0480311 Fig. 34 YWE-EH500-6N0 Left Face Table. 17 List of YWE-EH500-6N0 Service Parts (Left Face) Item Q’ty per Parts Code No. Parts Name Welding Source 6N3E50012 Fuse-free breaker 6N3E50021 PC board set (DR)-006 910816 Aluminium electro capacitor 6N3E50717 Diode bridge...
  • Page 126 HW0480311 Fig. 37 YWE-EH500-6N0 Partition Board Table. 18 List of YWE-EH500-6N0 Service Parts (Partition Board) Item Q’ty per Parts Code No. Parts Name Welding Source 6N0EH5022 PC board set (PS)-008 AJ0EL3024 PC board set (MB)-021 AJ0EL3026 PC board set (SD)-006...
  • Page 127 HW0480311 Fig. 38 YWE-EH500-6N0 Rear Face Table. 19 List of YWE-EH500-6N0 Service Parts (Rear Face) Item Q’ty per Parts Code No. Parts Name Welding Source AJ0E35102 Connector (4 pins) AJ0E35114 Connector (6 pins) 6N0EH5905 Rear cover plate AJ2S35825 Connector (26 pins)
  • Page 128 HW0480311 Fig. 39 YWE-EH500-6N0 Filter Unit Table. 20 List of YWE-EH500-6N0 Service Parts (Filter Unit) Item Q’ty per Parts Code No. Parts Name Welding Source 6N0EH5516 Filter cover set 6N0EH5919 Cooling fan 6N0EH5986 Filter case 19-7 HW0480311 128/129...
  • Page 129 +49-8166-90-103 YASKAWA ELECTRIC KOREA CORPORATION 1F, Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea Phone +82-53-382-7844 +82-53-382-7845 YASKAWA ELECTRIC (SINGAPORE) PTE. LTD. 151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741 Phone +65-6282-3003 +65-6289-3003 YASKAWA ELECTRIC (MALAYSIA) SDN. BHD. Unit 47-1 and 2. Jalan PJU 5/9, Dataran Sunway, Kota Damansara, 47810, Petailng Jaya Selangor, Malaysia...

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