YASKAWA MOTOWELD-T300D Instructions Manual
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YASKAWA MOTOWELD-T300D Instructions Manual

YASKAWA MOTOWELD-T300D Instructions Manual

Ac/dc tig welder used exclusively for motoman
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AC/DC TIG Welder Used Exclusively For MOTOMAN
MOTOWELD-T300D
INSTRUCTIONS
YWE-T30D (0)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
YASKAWA
Part Number: 158413-1CD
Revision: 0
MANUAL NO. HW0481095

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Summary of Contents for YASKAWA MOTOWELD-T300D

  • Page 1 YASKAWA AC/DC TIG Welder Used Exclusively For MOTOMAN MOTOWELD-T300D INSTRUCTIONS YWE-T30D (0) Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. Part Number: 158413-1CD Revision: 0 MANUAL NO. HW0481095...
  • 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 representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.
  • Page 3 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. 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, could result in WARNING 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 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 WARNING Be sure to observe the following warnings 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 grounding 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 CAUTION 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 7 CAUTION Observe the following cautions to prevent personal indury due to improper handling. • Do not use the welder with the case or cover removed. • Only a trained or qualified person must remove the welder case for maintenance and inspection or repair. Take preventive measures not to let other personnel approach the welder or welding sites unnecessarily by putting upa guard fence or the like.

  • Page 8: Table Of Contents

    CONTENTS Receiving ･････････････････････････････････････････････ Transporting ･･･････････････････････････････････････････ Using the Casters ･･･････････････････････････････････････････････ Using the Crane ････････････････････････････････････････････････ Using the Forklift ････････････････････････････････････････････････ Installation ････････････････････････････････････････････ Installation Site and Welder Environment ･･･････････････････････････ Installation Site and Gas Regulator Environment ････････････････････ Wiring ････････････････････････････････････････････････ Grounding ･････････････････････････････････････････････････････ Required Power Supply Facility Capacity and Connection Cables ･････...
  • Page 9 13 Welding Conditions ･････････････････････････････････････ 13.1 Selection of Welding Method ･････････････････････････････････････ 13.2 Electrode and Gas Flow Rate for Various Welding Current ･･･････････ 13.3 Welding Conditions of Stainless Steel (SUS 304) and Middle Pulse ･･･ 13.4 Conditions of Low-pulse Welding ･････････････････････････････････ 13.5 Welding Conditions of Aluminum ･････････････････････････････････...

  • Page 10: Receiving

    1 Receiving Checking Package Contents When the package arrives, check the contents for the following standard items (Any additional options ordered should be checked as well): • Welder • Attachment at installation • Hose for gas (φ6×3 m) ×1 • Hose for cooling water (φ8×5 m) ×2 •...

  • Page 11: Transporting

    2 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. • Avoid excessive vibration or shock while transporting. The system consists of precision components, so failure to observe this caution may adversely affect performance.

  • Page 12: Using The Forklift

    2.3 Using the 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 determinig the operation site, warnings must be placed on transport path to prevent accidents.

  • Page 13: Installation

    3 Installation CAUTION • The welder can be moved easily by using the caster. After installation, use the stopper to fix the welder before starting operations. 3.1 Installation Site and Welder Environment The welder can be used under the following environmental conditions: •...
  • Page 14 Gas regulator Gas regulator stand Fix the gas regulator to prevent it from falling.

  • Page 15: Wiring

    4 Wiring WARNING • Ground resistance must be 100Ω or less. The regulation specifies that the ground resistance must be 100Ω or less when the welder is used with power supply voltage 200 V. Failure to observe this warning may result in charging the case or unstable operations when the welder is not installed.

  • Page 16: Required Power Supply Facility Capacity And Connection Cables

    4.2 Required Power Supply Facility Capacity and Connection Cables CAUTION • Be sure to use cables for welding with sufficient thickness. Excessively thin cables may cause abnormal heating resulting in burn or fire. • If the output cable is extended, do not use the cable while it is still wound. Otherwise, an output resistance increase will interrupt assurance of start performance.

  • Page 17: Combination With Leakage Breaker

    4.3 Combination with Leakage Breaker When the welder is used in a construction site, in a place with high humidity, or on an iron plate, iron framework, or surface plate with high conductivity, a leakage breaker should be installed according to the law. In such a case, connect a leakage breaker of current sensitivity 30 mA for each welder.
  • Page 18 ■ Precautions on Wiring of High DC Voltage Start Method The followng shows a case where the water cooled torch is used. Cooling water circulator: Use the circulator for high DC voltage. Insulate from the floor or other faces by using an insulation cover Cooling water path: Insulate even if the circulator is...
  • Page 19 ■ Connection of Power Supply Refer to “Fig. 4.1 Connections at Rear Face” to make proper connections. The 200/220-V selector switch is provided at the rear face. Can be switched by rated input Input terminal 1 見出し 2（見出し 1 は欠番） 200/220-V selector switch.
  • Page 20 ■ Connections at Welding Side Refer to “Fig. 4.2 Connections at Front Face” for proper connections. The welder is a high DC voltage start type which applies DC voltage between the electrode and the base metal. If insulation is not made between the electrode and the base metal, the welder is hard to start.
  • Page 21 1 見出し 2 （見出し 1 は欠番） 本文 2 1.1 見出し 3 本文 3 ■ 見出し 4 Output terminal cover 本文 4 Base metal (+) terminal 見出し 5 Torch (-) terminal 本文 5 1. 見出し 6 Wire feeder connector Gas output terminal To cooling water Cooling water exhaust terminal...

  • Page 22: Gas For Welding

    5 Gas for Welding 5.1 Quality of Gas for Welding In the TIG welding method, argon gas is mainly used as shielding gas. Water or any impurities in the gas adversely affects welding. Use the gas of high purity with little water content. 5.2 Gas Pressure Adjuster and Flow Meter Use gas pressure adjuster and flow meter suitable for the gas to be used.

  • Page 23: Shading Measures

    6 Shading Measures CAUTION • When the welder is controlled by external control input signal, provide proper shade around the welding torch. Accidental arc generation may damage eyes or burn the skin of those without proper protection. For shaded glasses of helments 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.

  • Page 24: Precautions On Welding And Preparation Procedure

    ) or more. When a air cooling torch is used, confirm that the air/water cooling changeover switch is correct. Input Current Exceeded Lights. The internal circuit malfunctions or the element is Lights continuously. defective. Contact your Yaskawa representative. Fig. 7.1 Display of Fault Monitor Indicator Lamp...
  • Page 25 ■ Precautions on Welding Check the following precautions when welding. • Welding must be done on the concrete floor as long as possible. Do not weld on a wet earth floor or metallic floor to avoid electric shock. Also avoid welding where there are inflammables or exposure to wind.
  • Page 26 • Since TIG welding puts out strong ultraviolet rays, protect eyes, neck, or hands with shaded glasses, helmet, or gloves. • When the torch parts are inspected or replaced, be sure to turn OFF the power supply switch. Pressing the torch switch by mistake may cause an electric shock. •...

  • Page 27: Welding Preparation Procedure

    7.2 Welding Preparation Procedure The following describes the preparation procedure to start actual welding. The numbers in the circles in the table correspond to the numbers in “Fig. 7.2 Operation Functions.” Table 7.2 Welding Preparation Procedure Step Item Details Confirm the connections. Confirm again that there is no defect in the connections.
  • Page 28 Table 7.2 Welding Preparation Procedure (Continued) Step Item Details Use the knob ⑤ to set the pulse frequency. Set the pulse frequency and pulse width. The inner side is “Low Pulse,” and the outer side is “Middle Pulses.” The pulse frequency is 1/T (second) (Hz). Then set the pulse width Tp by the knob ⑥.
  • Page 29 ⑦ Gas adjustment Pulse frequency adjustment selector switch ③ knob ⑤ Panel/remote selector switch ② Pulse selector switch ④ MOTOWELD-T300D Power supply switch ① Torch selector switch (air/water) ⑬ Output terminal cover ⑲ Wire feeder connector ⑩ Cooling water outlet terminal ⑫...

  • Page 30: Basic Specifications

    Failure to observe this caution may result in electric shock. The following table shows the welder specifications. Table 8.1 Welder Specifications Model YWE-T30D(0) Name MOTOWELD-T300D Rated Output Current 300 A Rated Input Voltage Three-phase 200/220 V ±10% Rated Input Frequency...
  • Page 31 3. When the water cooled torch is used for the welder, tap water cannot be used. Use the cooling water circulator of the cooling water path insulation type exclusive for the high DC voltage start method. The cooling water path including the water cooled torch and the current path at the torch side must be insulated from the ground.

  • Page 32: External Dimensions

    8.2 External Dimensions...

  • Page 33: Interface Signals

    9 Interface Signals Connector CON2 for Manipulator (17 Pins) Pin No. Corresponding to Meaning Function Direction* Signal Form Connector Welding current Detects that the welder current flows. W→R Photocoupler output (CON2) detection signal (Current detection at ON) output Pulse Detects the pulse current period at pulse W→R Photocoupler output (CON2)

  • Page 34: Connector Con1 For Wire Feeder (4 Pins)

    9.3 Connector CON1 for Wire Feeder (4 Pins) Pin No. Corresponding Meaning Function Direction* Signal Form to Connector W→F − Motor control Motor control voltage reference of wire (CON1) voltage feeder ∗ F indicates the wire feeder side while W indicates the welder side. Note: Connector model is as follows: ・Welder side: NCS-304RF (made by Nanaboshi Electric Mfg.
  • Page 35 ■ Relation between Analog Voltage and Weld Wire Feeding Speed Analog Voltage (V) Feeding 0.13 0.44 1.28 1.86 2.29 2.87 3.29 3.76 4.22 4.71 5.14 5.54 6.07 6.53 Speed (m/min) Weld wire feeder type: YWE-WFT40-12 Analog Voltage (V)
  • Page 36 ■ Relation between AC Output Voltage and Feedback Voltage Output Voltage (V) 2.38 Feedback Voltage (V) • No-load voltage = 75V • No-load feedvack voltage = 5.9V • No-load DC high voltage = 6.9kV 2.38 Output Voltage (V)

  • Page 37: Built-In Functions

    10 Built-in Functions 10.1 Terminals for Automatic Machine The following outlines the functions and usages of the terminals on the printed board Pr (IF). Line No. 171 173 146 147 Terminal Start signal Current detection signal Pulse synchronization signal Emergency stop signal Name Details Starts when circuit is...

  • Page 38: Internal Adjusting Knob Functions

    10.2 Internal Adjusting Knob Functions Adjustment of Pre-flow Time (VR14) Pre-flow time can be adjuted in the range of approx.0.1 to 0.5 second. The factory setting is 0.2 second. If it should be longer, use the knob VR14 on printed board Pr (MB2) to set the proper time.

  • Page 39: Internal Indicator Lamp

    The following lists the selector switches on printed board Pr (MD5). SW No. Factory Contents Setting Manufacturer’s settings. Cannot be selected. Manufacturer’s settings. Cannot be selected. ∗ Printed on the board. 10.4 Internal Indicator Lamp Indicator lamps (LED) on each board indicate the control circuit operations. Board Name Operation Pr (MB2)
  • Page 40 F2: Fuse 10 A F3: Fuse 8 A (For motor circuit) (Rear side) Magnetic valve selector switch (Short) (Long) Wire feeder selector switch (Front side) The following diagrams show the selector switches on the printed board. Replace the shortcircuit cap as described below. How to Operate Jumper Pin Type Selector Switch in Board Note: To operate the adjusting volumes or selector...

  • Page 41: Maintenance And Inspection

    11 Maintenance and Inspection WARNING • Before maintenance or 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 warnig may result in electric shock or injury. •...
  • Page 42 ■ Quarterly to Semiannual Inspection Items Perform the following: • 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. • Inspection of electric connecting sections Check that the bolts are firmly tightened and rust or the like does not deteriorate the contacts in the connecting sections with the external wiring such as input/output terminals or with the internal wiring.

  • Page 43: Fault Analyses

    12 Fault Analyses WARNING • Before maintenance, inspection, or wiring, be sure to turn OFF the switch on the primary side switch gear and put up a warning sign. (ex. DO NOT TURN THE POWER ON.) Failure to observe this warnig may result in electric shock or injury. CAUTION •...
  • Page 44 Table 12.2 Fault Analyses Fault Cause Remedy Power supply indicator lamp does not Indicator lamp NL failure, improper Check contacting sections. Replace the contact indicator lamp NL. light even if the switch in the switch gear is turned ON. Improper primary input contact Check the connections.
  • Page 45 Table 12.2 Fault Analyses (Continued) Fault Cause Remedy − Arc does not start. High voltage is not Refer to No. 4. obtained. Gas does not Gas flow stops by Gas circuit failure Check the printed board (MB2). stop. turning OFF the power supply switch.

  • Page 49: Welding Conditions

    13 Welding Conditions Use the following table as the guideline for welding. 13.1 Selection of Welding Method Table 13.1 Selection of Welding Method Welding Method AC TIG Combined TIG* Material Type Mild steel 2.3 mmt or less □ 2.3 mmt or more □...

  • Page 50: Electrode And Gas Flow Rate For Various Welding Current

    13.2 Electrode and Gas Flow Rate for Various Welding Current Table 13.2 Welding Current and Gas Flow Rate for Electrode Diameter Electrode Welding Current (A) Argon Diameter Flow Rate (φmm) (Litter/ Electrode Electrode min) Negative Positive 5 to 15 4 to 15 3 to 7 －...

  • Page 51: Welding Conditions Of Stainless Steel (Sus 304) And Middle Pulse

    13.3 Welding Conditions of Stainless Steel (SUS 304) and Middle Pulse Table 13.3 Welding Conditions of Stainless Steel (SUS 304) DC Electrode Negative Butt Welding Plate Electrode Filler Rod Welding Argon Gas Number of Thickness Diameter Diameter Current Flow Rate Layers Groove Form (mm)
  • Page 52 Table 13.4 Conditions of Middle-pulse Welding Average Pulse Base Pulse Pulse Current Current Current Frequency Width (%) Material Joint Form Remarks (Hz) Excellent arc concentricity can be obtained at Stainless 250 to 500 Hz. Steel − − SUS 304 As pulse frequency is high, the bead width becomes...

  • Page 53: Conditions Of Low-Pulse Welding

    13.4 Conditions of Low-pulse Welding Table 13.5 Typical Flat or Butt Low-pulse Welding Pulse Conditions Wire Feeding Joint Form Pulse Base Pulse Pulse Welding Speed Current Current Frequency Width Speed (mm) (mm/min) (Hz) (mm/min) Mild Steel spcc Stainless Steel Copper Titanium Shielding gas : Ar (10 litters/min) Electrode : 3.2 mm...
  • Page 54 Table 13.6 Conditions of Low-pulse Welding for Various Joints Low-pulse Conditions Joint Material Joint Form Welding Pulse Base Pulse Pulse Speed Current Current Frequency Width (mm/min) (Hz) Stainless Butt Stainless Copper, stainless Horizontal, Stainless edge t=0.3 Stainless t=0.5...

  • Page 55: Welding Conditions Of Aluminum

    13.5Welding Conditions of Aluminum Table 13.7 Welding Conditions of Aluminum - AC Butt Welding Plate Electrode Filler Rod Welding Argon Gas Number of Thickness Diameter Diameter Current (A) Flowrate Layers Groove Form (mm) (φmm) (φmm) (Litter/min) 0 to 1.6 40 to 60 6 to 7 (a) or (b) 1.6 to 2.4...

  • Page 56: Connection Diagrams

    14 Connection Diagrams 14.1 Connection System Diagram...
  • Page 57 Current detection output signal Start signal...

  • Page 58: External Signal System Diagram

    14.2External Signal System Diagram Welder Manipulator Control Panel 200/220 VAC, 3 phases, 50/60 Hz input Welding current I Approx. 0 to 9 V Base current I Start signal (Operates at contact ON. 24 VDC, 0.1 A or more) Current detection output signal (Contact rated capacity: 24 VDC 50 mA or less) Pulse synchronous output signal (Photocoupler rated capacity: 30 VDC 20 mA or less.

  • Page 59: Lists Of Service Components

    15 Lists of Service Components...
  • Page 60 Fig. 15.1 YWE-T30D Front Face Fig. 15.2 YWE-T30D Rear Face...
  • Page 61 Table 15.1 List of YWE-T30D Service Components (Front Face) Item Component Component Name Drawing No. (Model No.) Q'ty per Code No. Welder Specifications 68W3023944…6 895564 Ammeter 910172 Fuse in glass tube (3A) J821BAR03 911632 Fuse holder FH001F − 68W3031229-B…B T30A0027 Pr (CR4) 68W3031229-B…C T30D0027...
  • Page 62 Table 15.2 List of YWE-T30D Service Components (Rear Face) Item Component Component Name Drawing No. (Model Q'ty per Welder Code No. No.) Specifications T30A0106 17-core MS3102A20-29S J833R17CS T30A0512 Rear cover plate 68W3031310-B…B 68W4047343-A…1 DPL80535 Chain 68W2009476…1 DTR35537 Input terminal cover DTR35630 Ground terminal J816R1405...
  • Page 63 Fig. 15.3 YWE-T30D Right Side Fade Fig. 15.3 YWE-T30A, D(0) Right Side Face...
  • Page 64 Table 15.3 List of YWE-T30D Service Components (Right Side Face) Item Component Component Name Drawing No. (Model No.) Q'ty per Code No. Welder Specifications 68W3030577XB…B T30A0520 Front cover 895537 Diode RM250HA-10F 0J3120005 68W4048994X……1 GP4T30547 Magnet catch 68W3030234-A…2 GF30570 Heat sink (R) 68W4040776…3 ADH30574 Mounting base...
  • Page 65 Fig. 15.4 YWE-T30D Left Side Face...
  • Page 66 Table 15.4 YWE-T30D Service Components (Left Side Face) Item Component Component Name Drawing No. (Model No.) Q'ty per Welder Code No. Specifications 68W3031474…A T30A0034 Printed board set (HV2) 68W4047387XA…2 895660 Printed board set (SL) 68W4047387XA…2 895661 Printed board set (SW) 68W3024255X…B DTR35041 FM100A...
  • Page 67 Fig. 15.5 YWE-T30D Base Section...
  • Page 68 Table 15.5 YWE-T30D Service Components (Base Section) Item Component Component Name Drawing No. (Model No.) Q'ty per Code No. Welder Specifications 68W4039440X…A DTD35001 Control transformer (4) for motor 68W9019421 to 22…B GP430002 Transformer 68W9019252…A DC reactor GP3T30004 68W3031317…1 T30A0005 Control transformer (1) Base 68W3031198-A…A T30A0500...
  • Page 69 Fig. 15.6 YWE-T30D Compartment Barrier Section...
  • Page 70 Table 15.6 List of YWE-T30D Service Components Item Component Component Name Drawing No. (Model No.) Q'ty per Code No. Welder Specifications − 68W9019638 to 640…A+B 895662 Printed board set (AC9) T30A0023 Printed board set (IF) 68W3031013-B…B 68W3031496…A T30A0024 Printed board set (MB2) 68W9018715…A+B 911956 Printed board set (DR5)

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