Page 1 YASKAWA MOTOWELD-E500-6N3 INSTRUCTIONS Upon receipt of the product and prior to initial operation, read this instruction thoroughly, and retain for future reference. 180368-1CD MANUAL NO. HW0482309 ...
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 Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the MOTOWELD-E500III. In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.” Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury to personnel.
Page 4 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 designed manufactured with sufficient consideration given to safety. Failure to observe this warning may result in death or serious injury to personnel. •...
Page 5 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 6 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 •...
Page 7 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. Do not weld near flammable gases.
Page 8 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 welding. Wear welding mask or shaded glasses appropriate • for welding. Wear protective glasses to protect your eyes from spatters or slags. •...
Page 9 CAUTION Be sure to observe the following cautions to prevent a gas cylinder from falling or a gas regulator from rupturing. Observe the regulations and your own references • for the handling of gas cylinders. Since a gas cylinder is filled with high pressure gas, improper handling may cause high pressure gas to blow up, resulting in personal injury.
Page 10 CAUTION 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 qualified person or a person who has • understood welder must remove welder case maintenance ...
Page 11 CAUTION Observe the following cautions to prevent personal injury by the end tip of the welding 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 12 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 • protect welder from spattering and metal powder. Spatter and metal powder inside the welder may cause a deterioration of insulation resulting in accidental fire.
Page 13: Table Of Contents
CONTENTS 1. Configuration and Specification・・・・・・・・・・・・ 2. Installation and Connection・・・・・・・・・・・・・・ 2.1 Place of Installation・・・・・・・・・・・・・・・・ 2.2 Precautions for Grounding・・・・・・・・・・・・・ 2.3 Required Power Supply Facility Capacity and Connection Cables・・・・・・・・・・・・・・ 2.4 Combination with Earch Leakage Breaker・・・・・・・ 2.5 Connection of Electric System・・・・・・・・・・・・ ...
Page 14: Table Of Contents
6.3 Precautions on Welding Operation・・・・・・・・・７．Built-in Functions・・・・・・・・・・・・・・・・・・ 7.1 Terminals for ARCON Signal Input for Maintenance Check・・・・・・・・・・・・・・ 7.2 Internal Selecting Switch・・・・・・・・・・・・・ 7.3 Location of Printed Boards・・・・・・・・・・・・ 7.4 How to Use the Selecting Switch・・・・・・・・・ 8. Maintenance and Inspections・・・・・・・・・・・・・ 9.
Page 15: Table Of Contents
14. Calibration for External Resistance・・・・・・・・・・・・・・・・ 14.1 Outline・・・・・・・・・・・・・・・・・・・・・・ 14.2 Procedure of Calibration for External Resistance・・・ 14.2.1 Connecting the Cable for Resistance Measurement 14.2.2 Measurring the External Resistance Value・・・・ ...
Page 16: Configuration And Specification
1 Configuration and Specification Table. 1 Rated Specifications Model MOTOWELD-E500III Type YWE−E500-6N3 Rated Input Voltage and 480V ±10% , three-phase Number of Phases Rated Frequency 50 / 60Hz 27.5kVA Rated Input 24.3kW Rated Output Current 500A Rated Output Voltage Welding Current 30 to 500A (depends on the wire diameter) Adjustment Range Welding Voltage...
Page 17 Outputs the signal corresponding to current or voltage to the robot side. Output for Arc Monitoring And also, outputs to the output terminal block for analog display. Interface for Refer to “Robot Interface Signals”. Robot Controller Voltage for Starting Point Peak value: 280V ±10% (full-wave rectification) Detecting Function (optional)
Page 18: Installation And Connection
2 Installation and Connection 2.1 Place of Installation This equipment is designed to be operated under the following conditions: In a dry indoor location spaced at least 30cm away from walls and from other surrounding articles. At a place that is not exposed direct sunlight or rain. At ambient temperatures from 0℃...
Page 19: Required Power Supply Facility Capacity
2.3 Required Power Supply Facility Capacity and Connection Cables "Table 2-1 Power Supply Capacity and Power Cables" shows the required power supply facility capacity and connection cables. The rated input voltage for the welder is three-phase, 480V. The welder supports a voltage compensation circuit so that the equipment can operate at a power voltage within ±10％...
Page 20: Connection Of Electric System
2.5 Connection of Electric System CAUTION • Open the disconnect switch of the switchgear before connecting wires between welding machine and power supply. Even one imperfect contact in the connections precludes proper welding. Be sure to make perfect connection to the base metal by using jigs. Fig.2-1 Connection of Power Supply Connection of Power Supply Refer to Fig.
Page 21 Exhaust air The cooling fan is the Air suction type. Exhaust air Fig. 2-2 Connections at the Rear Face of Welder HW0482309...
Page 22 Fig. 2 3 Connections on the Welding side HW0482309...
Page 23: Connection Of Shielding Gas System
Grounding Ground terminal (crimp terminal M6, 14 mm ) is provided at the lower part of the rear face of the welder for safe operation. Connect the ground wire of 14mm or more to the terminal. Ground resistance must be 100 Ω or less. Be sure to ground base metal at resistance of 100 Ω...
Page 24 type gas cylinder. If the regulator is connected to a siphon type gas cylinder, the contents of the cylinder are not gaseous and enter the regulator as remaining liquefied. In such a case, the pressure reduction mechanism of the regulator cannot be operated.
Page 25: Consolidation Of Ambient Condition
2.7 Consolidation of Ambient Condition 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 countermeasures such as putting up a screen. Even for indoor operations, sufficient attention to the shield effect must be paid when using air tools or fans around the welder Ventilation...
Page 26: Transporting
Helmet Hand shield Jacket must be long-sleeved. Welding gloves Foot covers Safety boots Fig. 2-7 Example of Protection 2.8 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 27 Using a Forklift Observe the following points to use the forklift for transporting. - Confirm availability of safe operations site, and transfer the welder to the installing site. - After determining the operation site, warnings must be placed on transport path to prevent accidents.
Page 28: Welding Preparation Procedure
3 Welding Preparation Procedure The following describes the preparation procedure to start actual welding. Table 3-1 Preparation for Welding Order Item Description Setting welding Set a wire suitable to the welding method. Make sure that the wire diameter of the roller of wire feeder matches the wire diameter.
Page 29 Checking the Check the settings for the voltage, current, wire feeding indicated value speed, and welding type of the digital meter on the panel on the panel face face. Check the indicated value on the panel by changing command value from the robot controller. Wire inching Adjust the welding wire by wire inching so that it can be used for welding as follows:...
Page 30: Operations On Panel
4 Operations on Panel 4.1 Explanation of Welder Panel Pressing the panel buttons during welding does not change any operation other than user file selection. Be sure to stop welding before starting the panel operations. Power Warning Search Mode Wire m/min Type P.R.M.
Page 31 The following table explains the display of the meters , and The content of the display differs according to the status as follows: Wire m/min Type Welding Welding Wire Feeding Welding Type Status Voltage Indicator Current Indicator Speed Indicator Indicator Displays Displays Displays the feeding...
Page 32 Parameters Setting When setting parameters or common parameters, the numbers and the parameter set values can be switched. The blinking indicator is the selected item. Selecting Welding Press this button during standby status to change the welding Type type (Type), and the indicator No.4 blinks. The welding type setting is confirmed with pressing of this button again, and the indicator No.4 stops blinking.
Page 33: Setting On Welder Panel
4.2 Setting on Welder Panel 4.2.1 Changing Welding Type The following describes how to change the welding type. Press the button No.12 “Weld. Type”, and the indicator No.4 “Type” blinks. Wire m/min Type Use the button No.13 “+” or “-“ to increase or decrease the value. After changing the value, press the button No.12 “Weld.
Page 34 Table 4-1. List of Weld Types Shielding Gas Wire Pulse or Wire Weld type remarks Short-circuit diameter φ0.9 3.21 φ1.0 3.24 (Ar80%, short-circuit Steel φ1.2 3.27 20%) φ1.4 3.61 φ0.9 3.19 φ1.0 3.22 (Ar80%, Steel Pulse φ1.2 3.25 20%) φ1.4 3.60 φ0.9...
Page 35: User Files
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 robot controller to perform welding. The P parameter cannot be changed or saved unless the user file is selected (No File status).
Page 36 The blinking digit moves as shown below with each pressing of the button No.11 “P.R.M. Set”. Wire m/min Type Wire m/min Type After changing the value, press the button No. 8 “P.R.M. Set” or leave it without doing anything for 10 seconds to return to the standby display. Press the button No.14 “Record”...
Page 37 (6) After changing the value, press the button No.9 “Common P.R.M. Select” or leave it without doing anything for 10 seconds to return to the standby display. Press the button No.14 “Record” for 3 seconds or more to save the changed value. Do not turn OFF the breaker until the LED indicator lights again when the “Record”...
Page 38: Saving Welding Conditions
(ON/OFF) can be changed. ON and OFF are switched with each pressing of the button No.13 “+” or “-“. After changing the setting, press the button No.9 “Common P.R.M. Select” or leave it without doing anything for 10 seconds to return to the standby display. <Example>...
Page 39: Checking The Flow Amount Of Shielding Gas
When the value is changed, the “Record” LED indicator starts blinking. Press the “Record” button for 3 seconds or more to save the changed value Do not turn OFF the breaker until the LED indicator lights again when the “Record” button was pressed.
Page 40: Display Of Motor Current
4.2.10 Display of Motor Current The motor current of rotating feeding motor can be displayed in “Wire m/min” indicator by setting D parameter D1-5 to OFF. During the standby status, it indicates the command of wire feeding amount (m/min). Wire m/min Type When the indicator displays the motor current, “A”...
Page 41 the setting value is four digits or more, use the button No.13 “L” to move the cursor to the indicator No.2 ammeter (A). The indicator No.2 ammeter (A) displays the number(s) above the forth digit. ＶＶＡＡＷｉｒｅｍ／ｍｉｎＷｉｒｅｍ／ｍｉｎ...
Page 42: List Of Process Parameters
4.3 List of Process Parameters When the welding type which is set in the user file is changed, the P parameter is initialized and everything becomes the value at 100 %. By changing the Process parameter set values, the welding characteristics (start/main conditions/end) that are specified by database in the welder can be adjusted according to your environmental conditions.
Page 43 Display No. Contents Display No. Contents MAG pulse current increasing Wire slow-down speed speed Reserved for system (Do not Wire speed at start change.) MAG pulse current decreasing Starting pulse peak time speed Reserved for system (Do not Reserved (Do not change.) change.) MIG pulse current increasing Starting pulse peak time...
Page 44: List Of Common Parameters
Display No. Contents Description Arc length control gain Wire feeding speed compensation ratio 1 Current output characteristic 1 (unit: %) Wire feeding speed compensation ratio 2 Current output characteristic 2 (unit: %) P64 to Reserved for system (Do not change.) P: For pulse welding (including aluminum pulse) A: For aluminum welding S: For short-circuit welding...
Page 45 Reserved for system Do not change. Reserved for system Do not change. Reserved for system Do not change. Current calibration Reference current 1 for the user file Reference current 1 No.1 (File 1) Current calibration Reference current 2 for the user file Reference current 2 No.1 (File 1)
Page 46: List Of D Parameters
4.5 List of D Parameters D parameters specify the operation conditions for the welder. Set the parameters according to the operation conditions. The D parameters are displayed as follows. Keep pressing the button No.9 “Common P.R.M. Select” and press the button No.8 "P.R.M. Select"...
Page 47 Set Timer instruction(about 2 seconds) after ARCOF instruction, since crater time is about 2 seconds. ・ For synergic voltage, the voltage that Yaskawa deems adequate is specified as 100%. Changing it by 10%, voltage varies by approx. 1V. (Example: In case of 20V at 100%, it becomes 19V and 21V at 90% and 110%, respectively.
Page 48: Welding Operation
5 Welding Operation 5.1 Checking the Welding Conditions Before starting actual welding operation, perform the test welding for the 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. 5.2 Wire Stickout The wire length from the torch tip to the arc point is called wire stickout.
Page 49: Notes For Using Extension Cable
5.4 Notes for Using Extension Cable When an extension cable is used, actual output between the torch and the welded object decreases because of voltage drop in the cable. To prevent this, set the welding voltage adjustment command value higher than the target voltage value to compensate for the output voltage drop.
Page 50: Precautions On Welding
This is not a fault. Err1 Input overcurrent Overcurrent flows in the The power circuit may be broken. primary control circuit. Contact your Yaskawa representative. Err2 Output overcurrent Output overcurrent flows Check that the torch or power cable is in the secondary control grounded.
Page 51: Tripped Power Supply Switch
6.2 Tripped Power Supply Switch If the power supply switch is tripped, do not turn it ON again. Contact your Yaskawa representative. If the power were to be turned ON again, the problem may be compounded and may affect the welding.
Page 52 Power Supply Switch Operation The inverter welder 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 operations. To prevent electric shock, never disconnect or connect the cables for the welder, the wire feeder, or the welding torch while the power is ON.
Page 53: Built-In Functions
7 Built-in Functions 7.1 Terminals for ARCON Signal Input for Maintenance Check The terminals are provided on the printed board Pr (MB)-011 that can be seen on the top when the cover is removed. Do not use terminals other than “Arc Start” terminal to prevent malfunction.
Page 54 Table 7-1 Internal Selecting Switches on the Pr (CR)-002 Board Default Meaning Remarks Switch Setting Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved...
Page 55: Location Of Printed Boards
7.3 Location of Printed Boards Top View of the Welder with Upper Cover Removed Fig. 7-2 View from the Front of the Welder 7.3.1 DIP Switch Settings of the Pr (MB)-011Board The settings of the Pr (MB)-011 board are for maintenance. Do not change these settings. Table 7-2 Settings of DIP Switches Setting HW0482309...
Page 56: How To Use The Selecting Switch
7.3.2 Jumper-pin Settings of the Pr (MB)-011 Board The settings of the Pr (MB)-011 board are for maintenance. Do not change these settings. Table 7-3 Settings of Jumper Pins Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved DJ10 Reserved...
Page 57: Maintenance And Inspections
8 Maintenance and Inspection CAUTION Before maintenance or inspection, or wiring, be sure to turn OFF the • switch in the input side switch gear. Failure to observe this warning may result in electric shock or injury. • For internal inspection immediately after using the welder, the capacitor in the power supply may be changed.
Page 58 Guideline for Service Lifetime and Replacement of Components Used The welder is composed of many components. Unless all these components operate normally, the welder cannot utilize its essential functions. Therefore, it is absolutely necessary to find 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 59: Fault Analyses
If the equipment does not function properly even after the above check, contact your Yaskawa representative to investigate the cause and to repair as soon as possible. Afterwards, take proper corrective action with the following sections.
Page 60 Item Checking Contents Check that correct print-type servomotor (for motor) or minertia servomotor (for servo torch) is selected. Improper selection results in the incorrect display of the wire feeding amount, which is different from the actual wire feeding Motor selection amount, and the motor runaway (running at the maximum speed).
Page 61: Cause And Remedy Of Welding Section Faults
9.2 Cause and Remedy of Welding Section Faults Table 9-2 Fault Analyses for Welding Section Fault Cause Remedy Excessive oil, rust, or paint Carefully remove the adherent adheres to the base metal. substances to clean the base metal. Oil adheres to the welding wire. Carefully store and handle the Or rust occurs.
Page 62 Table 9-2 Fault Analyses for Welding Section Fault Cause Remedy Power supply voltage excessively Use a different power supply from fluctuates. that of other machines that cause power supply voltage fluctuation. Or increase the power supply transformer capacity. Chip hole diameter becomes Replace the chip.
Page 63 Table 9-2 Fault Analyses for Welding Section Fault Cause Remedy Excessive spatters The welding conditions are not Increase or decrease the settings correct. of the welding voltage and current values to adjust the welding conditions. Welding wire is not suitable for the Check if a welding wire suitable for shielding gas.
Page 64: Cause And Remedy Of Electrical Circuit Section Faults
Table 9-2 Fault Analyses for Welding Section Fault Cause Remedy Burnback occurs. The welding torch operations are The wire stickout of the welding (The welding wire sticks not correct. wire is too short. to the end tip of the Extend it a little. Change the chip.) welding torch angle.
Page 65 List of Erro Contents Display”. The power supply switch is tripped Input diode is broken. Contact your and the power is not turned ON. Yaskawa representative. Main circuit transistor (IGBT) is broken. Shielding gas cannot be adjusted or The gas solenoid valve turns Investigate the gas stopped.
Page 66: 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. Connection System Diagram." Correspo nding Pin Signal Direction Function...
Page 67 start instruction is released.) • Even if the welder is in error status (outputting an error), the arc failure is output. Relays and outputs the signal which shows Contact Gas-pressur S – E pressure shortage of the shielding gas for the output W→R e shortage...
Page 68: Meaning And Function Of Pr(Rc2) Terminal
10.2 Meaning and Function of Pr (RC2) Terminal The following describes the line number of the connection terminal stand and corresponding signals. TB2 Terminal Connection Signal Directi Terminal Function Meaning on *1 Stand Line Ammeter Outputs W→R terminal 600A, 60mA. Directly Voltmeter outputs the...
Page 69 TB3 Terminal Connecti Signal Directio Signal Function Terminal Meaning n *1 Form Block Cable No. Contact Reserved output Common Contact Reserved input Indicates the Contact shortage of Wire input welding wire OP→W shortage (Valid at remaining closed) amount. Indicates the Contact shortage of input...
Page 70: Meaning And Function Of Signal
10.3 Meaning and Function of Signal for Starting Point Detecting Function The starting point detection function is an optional function. The optional board Pr (OP) is required (not included in standard package). The following table shows the correspondence of the line number and signal of the terminal stand for connection.
Page 71 11 Connection System Diagram The figure below shows the connection system diagram of the MOTOWELD-E500III. HW0482309...
Page 72: Diagnosis Function
12 Diagnosis Function MOTOWELD-E500III has a Diagnosis mode to confirm the DIP switch set status, software version, and the occurrence status and the number of occurrence of welder errors. 12.1 Starting up the Welder in the Diagnosis Mode To start up the welder in the Diagnosis mode, turn OFF the main power of MOTOWELD-E500III once, and turn ON the main power again while pressing the “Record”...
Page 73 −Power −Warning −Search Mode Wire m/min Type P.R.M. Select P.R.M. Set Weld. Type AW/Set V/Set −File No.1 Common P.R.M. Select ＋ −File No.2 Fig. 12.1.2 MOTOWELD-E500III Diagnosis Mode The displayed information can be changed by “+” and “-“ buttons on the MOTOWELD-E500III front panel.
Page 74: Confirmation Of The Dip Switch Set Status
12.2 Confirmation of the DIP Switch Set Status By using “d-1” to “d-4” information which is displayed in the Diagnosis mode, the DIP switch set status on the Pr (CR) board of welder inside can be confirmed without removing the cover of welder.
Page 75: Confirmation Of The Software Version
12.3 Confirmation of the Software Version By using “C-1”, “C-2”, and “C-3” information which is displayed in the Diagnosis mode, the software version which is loaded in the welder can be confirmed. C-1: Main CPU 1 Software Version C-2: Sub CPU 2 Software Version C-3: Memory Software Version The software version is displayed as shown below.
Page 76: Confirmation Of Welder Error Occurrence Status
12.4 Confirmation of Welder Error Occurrence Status By using “E-1” and “E-2” information which is displayed in the Diagnosis mode, the welder error occurrence status can be confirmed. To confirm the occurrence status of welder errors, the error occurrence status has to be saved in the EEPROM of the welder inside by the “Record”...
Page 77 The saved occurrence status of welder error is displayed as follows in the Diagnosis mode. Error No.: 5 4 3 2 1 0 Error No.: 15 14 13 12 11 10 9 8 Fig. 12.4.2 Display of Welder Error Occurrence Status The error occurrence status is displayed by bits: - “E-1”...
Page 78: Confirming The Number Of Welder Error
12.5 Confirming the Number of Welder Error Occurrence By using “Err.1” to “Err.15” information which is displayed in the Diagnosis mode, the number of errors occurred in the welder can be confirmed. The number of welder error occurrence is automatically saved. The saved number of welder error occurrence is displayed as follows in the Diagnosis mode.
Page 79: Clear Of Error Record
12.6 Clear of Error Record To delete the number of welder error occurrence, clear the error record. The followings explain how to clear the error record. −Power −Warning −Search Mode Type Wire m/min P.R.M. Select Weld. Type P.R.M. Set AW/Set V/Set −File No.1 Common P.R.M.
Page 80: Adjustment Of Welding Characteristics
13 Adjustment of Welding Characteristics Using Process Parameters By changing the Process parameter set values by panel operations, the welding characteristics of the digital inverter welder MOTOWELD-E500III can be adjusted. The welding characteristics are specified by the database incorporated into the welder. The characteristic values can be changed in the range between 10% and 200% of the database values.
Page 81: Adjustment Of Starting Characteristics
13.2 Adjustment of Starting Characteristic 13.2.1 Adjustment of Starting Pulse These parameters can change the characteristics related to the first arc start at ARCON signal. Parameter Meaning Guideline of Adjustment Wire speed until the wire contacts the - When scrap of the wire tip end remains: base metal.
Page 82: Adjustment Ofhot Conditions
13.2.2 Adjustment of Hot Conditions These parameters can change the hot condition characteristics that is given before transition to the main current after the first arc start at ARCON signal. Parameter Meaning Guideline of Adjustment Average current of hot conditions to - For excessive repelling: stabilize the molten pool Decrease the value.
Page 83: Adjustment Of Ending Characteristics
13.3 Adjustment of Ending Characteristics These parameters can change the characteristics from when ARCOF signal is input until arc disappears. Parameter Meaning Guideline of Adjustment Average current for crater processing after - When craters make holes: ARCOF signal is input (VALID when D1 Decrease the value.
Page 84 End conditions Burning conditions Sphere-drip pulse Wire-stick prevention Main conditions Adjustment of Voltage only Wire stop Sphere at end tip Average current Ｐ１８ Sphere-drip pulse peak time under main conditions (Commanded from Ｐ１１ the robot side) Average end current Sphere-drip pulse peak current 球滴パルスピーク電流...
Page 85: Adjustment Of Short-Circuit Welding Characteristics
13.4 Adjustment of Short-circuit Welding Characteristics These parameters can change the short-circuit welding characteristics under the main conditions. Parameter Meaning Guideline of Adjustment Current increasing speed at - For excessive spatters: short-circuit(first half) Decrease the value. - For unstable arc: Current increasing speed at Increase the value.
Page 86: Adjustment Of Pulse Welding
13.5 Adjustment of Pulse Welding Characteristics 13.5.1 Adjustment of MAG Pulse Welding Characteristics These parameters can change the characteristics under the main conditions for MAG pulse welding using mixed gas having Ar 98% or less. Parameter Meaning Guideline of Adjustment - For excessive spatters: Pulse peak current for droplet Increase the value.
Page 87: Adjustment Of Mig Pulse Welding
13.5.2 Adjustment of MIG Pulse Welding Characteristics These parameters can change the characteristics under the main conditions for MIG pulse welding using mixed gas having Ar 100%. Parameter Meaning Guideline of Adjustment Pulse peak current for droplet transition - For excessive spatters: Increase the value.
Page 88 13.6 Adjustment of Other Pulse Welding Characteristics Parameter Meaning Guideline of Adjustment - For arc length oscillation: Gain of the constant control for arc Decrease the value. length at pulse welding - For improper arc length follow-up: Increase the value. Arc length oscillation: large アーク長振動大...
Page 89: Adjustment Of Current Output Characteristics
13.7 Adjustment of Current Output Characteristics Parameter Meaning Guideline of Adjustment - When real welding current value is higher than the welding current Welding current output characteristic 1 command: (150A or less: default setting) Decrease the value. Refer to example Change the wire feeding amount so that in the figure below.
Page 90: Calibration For External Resistance
14 Calibration for External Resistance To automatically change the synergic voltage according to the variation of the operation conditions, the MOTOWELD-E500III has a function to calibrate the resistance of the power cable or jig stand connected to the welder. At independent voltage setting, this function is also effective to judge whether the resistance of the power cable or jig stand is correct.
Page 91: Procedure Of Calibration For External Resistance
14.2 Procedure of Calibration for External Resistance 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.) 2. Measure the external resistance value and confirm the display. (Refer to 14.2.2 and 14.2.3.) 3.
Page 92 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 resistance 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. For the cable for measurement, use a conductor of 38 mm ×...
Page 93 14.2.2 Measuring the External Resistance Value The external resistance is measured by panel operations. The following describes how to measure the resistance value. 1. Enter the resistance measurement mode as follows: With the "Weld.Type" button pressed, turn ON the welder main power supply. The welder starts up in the resistance measurement mode.
Page 94 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. Record the value of “C.08” parameter in advance since the result of the measurement is over written.
Page 95: Display Of External Resistance Setting Parameter
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 display of external resistance setting parameter as follows: Press the "Common PRM Select" button to display the setting of common parameters. Pressing the "+"...
Page 96: Setting Thed Parameter For Calibration
14.2.4 Setting the D Parameter for Calibration of External Resistance to “Enabled" To validate the calibration for the external resistance, setting using D parameter is required. 1. Display the parameter to set calibration for external resistance as follows: With the " Common PRM Select " button pressed, Press the "P.R.M. Select" button. The D parameter setting display appears.
Page 97 3. Save the setting as follows: If the setting is not saved, the changed data will be lost when the main power supply is turned OFF. Press the “Record” button for 3 seconds or more. The status of the LED indicator lamp above the “Record” button changes from blinking to lit, and then the meter displays are extinguished.
Page 98: Overview Of The Welding Current Calibration Function
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 99: Procedure Of Welding Current Calibration
15.2 Procedure of Welding Current Calibration The main procedure of welding current calibration is as follows; 1. Starting up of the Welding Current Calibration mode 2. Welding by the current calibration 1 3. Confirming the result of calibration 1 4. Welding by the current calibration 2 5.
Page 100 Perform the setting of the welding current command to be calibrated from the robot controller side, and weld for 6 seconds or more. The calibration operation allows the measurement of ratio of the welding current command and the actual welding current value based on the welding current value of 2 seconds to 6 seconds after welding start.
Page 101 The calibration operation allows the measurement of ratio of the welding current command and the actual welding current value based on the welding current value of 2 seconds to 6 seconds after welding start. The “Record” lamp blinks when the calibration measurement is confirmed If the welding time is less than 6 seconds, the “Record”...
Page 102: 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. When the user file No.1 is selected: Display Items Initial Value Contents Compensation ratio 1 for wire Current output characteristic 1 feeding speed Unit: % Compensation ratio 2 for wire...
Page 103: Common For All Welding Type Of "Synergic"(A/%)
16 Welder Condition File Data of Robot Controller The welder condition file data for MOTOWELD-E500III is different from the data of MOTOWELD-E350II. 16.1 Common for All Welding Type of “Synergic” (A/%) Wire-stick prevention processing time: 0.1 seconds Arc failure confirming time: 0.6 seconds Command Voltage (V) Welding Current (A) Command Voltage (V) Welding Voltage (%) 0.00 0.00...
Page 104: Setting Of Arc Monitoring Function
17 Setting of Arc Monitoring Function For using the arc monitoring function at the robot side, the setting of parameters for the robot controller is required. The parameters for the robot controller are as shown below. 17.1 For the Robot Controller: NX Parameter Items Set Value...
Page 105: For The Robot Controller: Xrc
17.2 For the Robot Controller: XRC Parameter Items Set Value Remarks Arc monitoring function: Magnification of current S2C283 200 For welder 1 conversion Arc monitoring function: Current offset S2C284 0 For welder 1 Arc monitoring function: Magnification of voltage S2C285 200 For welder 1 conversion Arc monitoring function: Voltage offset...
Page 106: Operation By External Remote Mode
18 Operation by External Remote Mode The external remote operations are available for MOTOWELD-E500III as follows: 1. Gas check 2. Switch of user files For external remote operations, connect contacts (dry contacts) to the pin terminals which come from adjacent to the connector on the robot controller side of welding command cable. Pin terminal for gas check (GAS) Pin terminals for user files switching (OP1, OP2) Pin terminal COM...
Page 107: Switch Of User Files
18.2 Switch of User Files Perform the setting as follows to select the user files by external command. 1. Set the D parameter D1-11=ON to save conditions. 2. Connect the contacts to the pin terminals “OP1”, “OP2”, and “COM”, which come from adjacent to the connector of the welding command cable.
Page 108: List Of Service Parts
19 List of Service Parts Front Face Table 19-1 List of YWE-E500-6N3 Service Parts (Front Face) Item Qty per Parts Code No. Parts Name Welder DTB30505 Eyebolt M8 6N3E50510 Front panel GF30513 Cover (top) GF30514 Side cover (right) GF30515 Side cover (left) GP430521 Terminal cover BN2E35590...
Page 109 Base Section Table 19-2 List of YWE-E500-6N3 Service Parts (Base Section) Item Qty per Parts Code No. Parts Name Welder ６N3E50002 Transformer (1) ６N3E50003 Transformer (2) AJ3E50004 DC reactor AJ3E50500 Base AJ2S35533 Terminal seat (bottom) DTR35534 Terminal DTR35535 Terminal seat (top) AJ3E50662 Ground terminal seat ...
Page 110 Right Side Face Table 19-3 List of YWE-E500-6N3 Service Parts (Right Side Face) Item Qty per Parts Code No. Parts Name Welder DTE50008 Shunt 600A-60mV AJ3E50536 Current-limiting reactor AJ3E50541 Diode 91197 Plate DTVT50739 Thermal guard (85°C) DTJ15982 Line filter AJ3E50918 Fan guard AJ0E35919 Cooling fan...
Page 111 Left Side Face HW0482309...
Page 112 Table. 19-4 YWE-E500-6N3 Service Parts (Left Side Face) Item Qty per Parts Code No. Parts Name Welder ６N3E50012 Fuse free breaker AJ3E50021 PC board set (DR)-006 910816 Aluminum electro capacitor 6N3E50717 Diode bridge 6N3E50730 IGBT ADVT50739 Thermal guard (90°C) 6N3E50741 Snubber mold 6N3E50750 FFB holder...
Page 113 Power Source SW Top Face Table. 19-5 YWE-E500-6N3 Service Parts (Top Face) Item Qty per Parts Code No. Parts Name Welder 6N3E50001 Control transformer (for motor) AJ3E50022 PC board set (PS)-004 AJ3E50024 PC board set (MB)-011 AJ3E50026 PC board set (SD)-004 AJ0E35027 PC board set (RC2) AJ0E35028...
Page 114 Rear Face Table. 19-5 YWE-E500-6N3 Service Parts (Rear Face) Item Qty per Parts Code No. Parts Name Welder AJ0E35102 Connector (4 pins) AJ0E35114 Connector (6 pins) 6N3E50512 Rear cover plate DTR35630 Ground terminal AJ2S35825 Connector (26 pins) 6N2A30905 Cable Clamp ...
Page 115 49-8166-90103 YASKAWA ELECTRIC KOREA CORPORATION 1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea Phone 82-53-745-7844 82-2-784-8495 YASKAWA ELECTRIC (SINGAPORE) PTE. LTD. 151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore Phone 65-6282-3003 65-6289-3003 YASKAWA ELECTRIC (MALAYSIA) SDN. BHD. No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia...

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YASKAWA MOTOWELD-E500-6N3 Instruction Manual

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