OTC Welbee P400L II Owner's Manual
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OTC Welbee P400L II Owner's Manual

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OWNER'S MANUAL
Welbee P400L II
P500L II
July, 2021
DAIHEN Corporation
Manual No. : P30345-1

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Summary of Contents for OTC Welbee P400L II

  • Page 1 OWNER'S MANUAL Welbee P400L II P500L II July, 2021 DAIHEN Corporation Manual No. : P30345-1...

  • Page 2: Forward

    Preliminaries Forward Thank you for your purchase of OTC's welding power source. This Owner's Manual (hereafter referred to as "this manual") explains the following points for safe use of the product. • Caution regarding the product • Welding operation/setting method •...

  • Page 3: Important Information

    If this manual is lost or damaged, immediately contact your dealer. Copyright This manual is copyrighted and all rights are reserved by OTC. Any part of the manual shall not be copied, photocopied, or reproduced without the prior consent of OTC.

  • Page 4: Table Of Contents

    ABLE OF ONTENTS TABLE OF CONTENTS Forward 4.2.3 Connection of welding torch ..... 35 Service and Support 4.2.4 Connection of voltage detection cable Important Information .
  • Page 5 ABLE OF ONTENTS 6.6.6 Welding voltage adjustment ....84 10.2.2 Parts layout drawing ......157 6.6.7 Arc characteristics adjustment .

  • Page 6: Chapter 1 Safety Information

    Chapter 1 Safety Information This chapter explains the precautions on the welding power source and welding operation. Warning Symbols The following safety warning symbols and signs are used throughout the manual to ensure proper operation of the product and to prevent from various hazards that cause serious injury and damages. Indication and explanation for the symbols are as follows: Make sure to fully understand the content before beginning operation.

  • Page 7: Safety Precaution

    AFETY NFORMATION HAPTER AFETY RECAUTION Safety Precaution This section explains the safety precautions regarding operation of the welding power source. 1.2.1 Operating precautions To prevent serious injury or accidents, ensure to follow the instructions below: • Be sure to read and understand the information in the manual before operating the product.

  • Page 8: Precautions For Power Supply And Electric Shock

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.2 Precautions for power supply and electric shock To prevent electric shock or burn injury, ensure to follow the instructions below: • Do not touch the input and output terminals and the internal live electrical parts of the welding power source.

  • Page 9: Precautions For Handling Of Plastic Parts

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.3 Precautions for handling of plastic parts Front panel, rear panel and fan of the welding power source is made from polycarbonate resin. To prevent from electric shock or fire caused by the damage on polycarbonate resin, ensure to follow the instructions below. •...

  • Page 10: Precaution For Protective Equipment

    AFETY NFORMATION HAPTER AFETY RECAUTION • To reduce the dust concentration, install a partial exhaust facility such as fume suction device, or install the collective ventilation equipment. • When it is difficult to provide a partial exhaust facility or the ventilation or exhaust facility does not give sufficient performance, ensure to use the respiratory protective equipment.

  • Page 11: Precautions For Flammable Materials

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.7 Precautions for flammable materials To prevent fire, explosion and rupture, ensure to follow the instructions below: • Remove all flammables within 33 ft (10 m) of the welding arc so that sparks and spatter do not strike flammable materials. If this is not possible, tightly cover them with noncombustible covers.

  • Page 12: Precautions For Gas Cylinder And Gas Regulator

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.8 Precautions for gas cylinder and gas regulator To prevent falling of gas cylinder, gas regulator explosion and accident caused by gas, ensure to follow the instructions below: • Use only correct shield gas cylinders according to the related laws, regulations and customer's standard.

  • Page 13: Principal Safety Standards

    AFETY NFORMATION HAPTER RINCIPAL AFETY TANDARDS Principal Safety Standards Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro technical Commission Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.

  • Page 14: Chapter 2 Product Specification And Configuration

    This chapter explains the specification, name of each part and configuration of the welding power source. Specification This section explains the specification and external dimension of the welding power source. 2.1.1 Specifications This section explains the specification of the welding power source. Welbee P400L II Welbee P500L II Specification/ Model/Welding method DC TIG DC TIG...

  • Page 15: Applicable Welding Method

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 2.1.2 Applicable welding method This section explains the applicable welding method (shield gas/wire type/welding type) and wire diameter. Standard specification WIRE DIA. [in. (mm)] WELDING Penetration GAS (*1) WIRE MATERIALS TRAVEL SPEED METHOD adjustment WB-P402L WB-P502L .030/.035/.040/...

  • Page 16: External Dimensions

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION WIRE DIA. [in. (mm)] WELDING Penetration GAS (*1) WIRE MATERIALS TRAVEL SPEED METHOD adjustment WB-P402L WB-P502L MS-MIG (100 % Ar) HARD ALUMINUM 1/16 (1.6) 1/16 (1.6) STANDARD/HIGH (*5) (*1-3) DC TIG DC STICK *1: Note that the "collective" voltage adjustment may not meet the appropriate condition if a mixing gas other than those with the following mixing ratios is used.

  • Page 17: Rated Duty Cycle

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 2.1.4 Rated duty cycle This section explains the rated duty cycle of the welding power source. • Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle may result in deterioration and damage to the welding power source.
  • Page 18 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION <Relationship between welding current and duty cycle (WB-P402L)> DC, DC TIG, three phase DC PULSE, three phase Usable range Usable range Welding current (A) Welding current (A) DC, DC TIG, DC STICK, single phase DC STICK, three phase Usable range Usable range...
  • Page 19 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION <Relationship between welding current and duty cycle (WB-P 02L)> DC TIG, DC STICK Usable range Usable range Welding current (A) Welding current (A) DC PULSE Usable range Welding current (A)

  • Page 20: Product Configuration

    RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION Product Configuration This section explains the standard or optional composition of the welding power source and parts to be prepared by customers. 2.2.1 Standard composition This section explains the standard composition of the welding power source. For equipment used in combination with the welding power source connected to robot, refer to the instruction manual of the robot controller.
  • Page 21 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • When air-cooled welding torch (with voltage detection) is used Welding power source Base metal Ground a base metal if required by local law. Required Optional Name Remarks component accessories To be prepared by the customer. Gas regulator 2.2.3 Accessory (not supplied))
  • Page 22 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION Required Optional Name Remarks component accessories Gas regulator To be prepared by the customer. Welding torch 2.2.3 Accessory (not supplied)) Gas hose [10 ft (3 m)] (*1) Included in feeder (*2) Power cable for base metal side (*1) Included in feeder To be prepared by the customer.

  • Page 23: Accessory (Supplied)

    RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • At DC STICK welding: Welding power source Base metal Required Optional Name Remarks component accessories To be prepared by the customer. Welding electrode holder 2.2.3 Accessory (not supplied)) Power cable for welding electrode holder [AWG2 (38mm ) or more] Power cable for base metal side...

  • Page 24: Accessory (Not Supplied)

    RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 2.2.3 Accessory (not supplied) This section explains the accessories to be prepared by the customer before operating the welding power source. Prepare the following: • Gas regulator For the gas regulator, make sure to use a device for compressed gas cylinder that conforms to the specific application of the shield gas.
  • Page 25 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 2.2.4.2 Details on extension cables and hoses Following extension cables and hoses are optionally available. For extending the working radius, use extension cable and hose according to the working radius. • When using extension cables, roll them out. Winded extension cable may cause an unstable arc.

  • Page 26: Part Names

    RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES Part Names This section explains the part names of the welding power source. 2.3.1 Front panel The section explains the front section of the welding power source. Operation panel 6.2 Function on Operation Panel) Main power lamp Power switch Socket for analog remote control...

  • Page 27: Chapter 3 Transportation And Installation

    Chapter 3 Transportation and Installation This chapter explains the necessary equipment, installation environment and transportation method for installing the welding power source. Required Equipment This section explains the necessary power supply equipment for installing the welding power source and equipment for preventing lack of oxygen and dust hazard during welding.

  • Page 28: Ventilation Equipment/Partial Exhaust Facility

    RANSPORTATION AND NSTALLATION HAPTER EQUIRED QUIPMENT 3.1.1.1 Use of the engine generator and auxiliary power • To prevent the welding power source from being damaged or arc loss, follow the instructions below. When using an engine generator for the welding power source, pay attention to the following. •...

  • Page 29: Installation Environment

    RANSPORTATION AND NSTALLATION HAPTER NSTALLATION NVIRONMENT Installation Environment This section explains the installation environment of the welding power source. • For prevention from fire or damage to the welding power source, be sure to install in a location that satisfies the following environment: 3.2.1 Installation environment •...

  • Page 30: Transportation Procedure

    RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE Transportation Procedure This section explains the procedure for transportation of the welding power source. • Do not touch the input and output terminals and the internal live electrical parts of the welding power source. It may cause electric shock.

  • Page 31: Transportation With Lifting Lug

    RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE 3.3.1 Transportation with lifting lug This section explains the procedure for transportation with lifting lug such as a crane. For preventing falling of the welding power source and resulting accidents, be sure to observe the following: •...

  • Page 32: Manual Transportation With Carts

    RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE 3.3.2 Manual transportation with carts This section explains the manual procedure for transportation using equipment such as a cart. • When lifting the welding power source, make sure to hold the bottom of the welding power source by more than one person.

  • Page 33: Chapter 4 Connection

    Chapter 4 Connection This chapter explains the procedure for connecting the welding power source. Precautions for Connection Procedure and Grounding This section explains the precautions for connection and grounding procedure. For protection from serious injury or fire, observe the following: For protection from electric shock, observe the following points: •...

  • Page 34: Connection Of Cable At Output Side

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.1 Connection of cable at output side This section explains the procedure for connecting of cable at output side. • Use a grounding cable for the case, of welding power source and perform grounding. Otherwise, voltage may increase in the case or base metal which could cause electric shock.
  • Page 35 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE • WB-P502L Power cable for Welding torch side power source Output terminal (Torch side) Power cable for base metal side Base metal Output terminal (Base metal side) Ground a base metal if required by local law. Output terminal cover Remove the output terminal cover.

  • Page 36: Connection Of Wire Feeder

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.2 Connection of wire feeder This chapter explains the connecting procedure of the wire feeder. Refer also to the instruction manual of wire feeder. • When not using an analog remote control (optional accessory), do not remove the cap for the analog remote control.

  • Page 37: Connection Of Welding Torch

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.3 Connection of welding torch This section explains the procedure for connecting the welding torch. TIPS • When the air-cooled welding torch (with voltage detection) is used, refer to “4.2.4 Connection of voltage detection cable (Voltage detection cable is used)”. When air-cooled Wire feeder welding torch is used...
  • Page 38 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE Voltage detection terminal Wire feeder Voltage detection cable for base metal side Base metal Connect the torch cable and the voltage detection adapter to the wire feeder. Cut the voltage detection cable for base metal side to a suitable length. Connect the voltage detection cable for base metal side to the base metal.

  • Page 39: Connection At Tig Welding

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.4.1 Caution on connection of voltage detection cable Voltage detection cable needs to be wired so that arc voltage can be fed back with accuracy. Be sure to check the following for reducing the influence of inductance noise. •...
  • Page 40 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE Welding power source Power cable for base metal side Output terminal Power cable for Base metal (Torch side) torch side Output terminal (Base metal side) Connector Ground a base metal if Power cable for base required by local law.

  • Page 41: Connection At Dc Stick Welding

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.6 Connection at DC STICK welding • In using the welding power source for DC STICK welding, prepare a welding electrode holder by the customer. After five seconds have passed, the safety voltage (approx. 15 V) is automatically provided. •...
  • Page 42 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE • WB-P502L Welding power source Power cable for welding electrode holder side Welding electrode holder Output terminal (Torch side) Base metal Power cable for base metal side Output terminal (Base metal side) Ground a base metal if Output terminal cover required by local law.

  • Page 43: Connection Of Shield Gas

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.7 Connection of shield gas This section explains the procedure for connecting the shield gas. Refer also to the instruction manual of wire feeder. • Be sure to observe the following points to prevent from suffocation due to gas leakage or explosion.

  • Page 44: Connection Of Cooling Water Circulation Device And Water Hose (In Using Water-Cooled Welding Torch)

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.8 Connection of cooling water circulation device and water hose (In using water- cooled welding torch) • WB-P402L only This section explains the procedure for connecting the cooling water circulation device and water hose. Refer also to the instruction manual of the cooling water circulation device.

  • Page 45: Grounding And Connection Of Input

    ONNECTION HAPTER ROUNDING AND ONNECTION OF NPUT OWER UPPLY Grounding and Connection of Input Power Supply This section explains the procedure for performing grounding work, connecting the welding power source and input power supply (power supply at facility side). • When the welding power source is used in a humid environment such as construction site, or location with highly conducting material such as steel plate or on steel structure, install a leakage breaker.

  • Page 46: Confirmation Of Connection

    Connection of robot This section explains the configuration example of connecting the welding power source with robots made by other manufacturer. When connecting with robots made by OTC, refer to the instruction manual of the robot controller. 4.5.1.1 Configuration example for connection...
  • Page 47 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT Product name/Model Remarks Welding power source Connection robot controller cable (optional) is also available. Interface: IFR-101WB Refer to instruction manual of Interface) Wiring for wire feeder needs to be changed. Wire feeder 4.6.1 Wiring to wire feeder) Welding torch: K2331 type curved torch Uni-cord power cable: K5369 [3.6 ft (1.1 m)], K5370 [4 ft (1.2 m)] Control cable for wire feeder: BKCPJ-1010 [33 ft (10 m)]...

  • Page 48: Connection Of Automatic Machine

    ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT 4.5.2 Connection of automatic machine This section explains the procedure for connection of automatic machine with the welding power source. 4.5.2.1 Wiring for connecting automatic machine The welding power source is equipped with terminal block for external connection inside the cover for external connection at the rear.
  • Page 49 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT • WCR output signal WCR signal is the output of relay contact. Ensure to keep the maximum rated power of the contact. Welding power Maximum rated power of relay contact Current limiting source side WCR: 125 VAC / 0.5 A, 30 VDC / 1 A at resistance load As a rough resistor indication, use at 80% of the ratings.

  • Page 50: Wiring Of Voltage Detection Cable At Base

    ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL Cover for external Cable Strip the cable cover by connections (vinyl) 25/64 to 7/16" (10 to 11 mm) Blind bush Button Terminal block Attaching screw Check that input power is turned off with the disconnect switch connected to the welding power source. Remove the attaching screws and open the cover for external connection.

  • Page 51: Wiring To Wire Feeder

    ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL 4.6.1 Wiring to wire feeder This section explains how to connect the voltage detection cable at the base metal side to the wire feeder. Wire feeder Connection part of Terminal block voltage detection cable Jointly fasten with wire 310...

  • Page 52: Wiring Example Of Voltage Detection Cable

    ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL Check that input power is turned off with the disconnect switch connected to the welding power source. Remove the output terminal cover. Connect the voltage detection cable at the base metal side to the voltage direct detection terminal at the base metal side.

  • Page 53: Chapter 5 Welding Operation

    Chapter 5 Welding Operation This chapter explains the procedures from preparation to completion of the welding operation. Precaution at Welding Operation This section explains the safety precautions for welding operation. 5.1.1 Precautions for air discharge and use of respiratory protective equipment To prevent suffocation or gas poisoning in the welding operation, ensure to follow the instructions below: •...

  • Page 54: Precaution For Protective Equipment

    This section explains the check parameters before welding. To avoid welding problems beforehand, check the parameters below when the welding environments are prepared. (These are the check parameters recommended by OTC. They also contain check parameters after power ON or after shield gas supply.) For handling the cooling water circulation device, refer to the instruction manual of the cooling water circulation device.
  • Page 55 ELDING PERATION HAPTER HECK BEFORE ELDING Check parameter Countermeasures Check Painted contact part could cause increased contact resistance, resulting in The contact part of jig and welding work piece decrease in arc voltage. Polish the painted contact part using a grinder to expose should not be painted.

  • Page 56: Power On And Gas Supply

    ELDING PERATION HAPTER OWER UPPLY Power ON and Gas Supply This section explains how to supply power and shield gas. • Handle the gas cylinder according to the related laws or regulations as well as the internal standard of the customer. Note that the gas cylinder contains a high-pressure gas.

  • Page 57: Wire Inching

    ELDING PERATION HAPTER NCHING Wire Inching This section explains the inching operation (feeding operation) of the wire. • Do not look into the tip of the welding torch during the inching operation. Do not bring the tip of the welding torch to face, eyes, or body. The wire may abruptly burst out, resulting in an injury.

  • Page 58: Check And Setting Of Welding Condition

    ELDING PERATION HAPTER HECK AND ETTING OF ELDING ONDITION Check and Setting of Welding Condition This section explains how to check the welding condition as well as how to prevent erroneous operation on the operation panel (Erroneous operation prevention function). 5.5.1 Reading welding condition Before starting the welding operation, it is necessary to set the welding conditions (such as welding current/voltage, type...

  • Page 59: Performing Welding Operation

    ELDING PERATION HAPTER ERFORMING ELDING PERATION 5.5.2.2 Deactivating erroneous operation prevention function Turn the screen operation knob again to place the cursor on “KEY LOCK”, and press the knob. The KEY LOCK will be released, and the color of “OFF” of the KEY LOCK in the MENU screen becomes inverted. The key mark in the Home Screen will disappear.

  • Page 60: Operation During Welding

    ELDING PERATION HAPTER ERFORMING ELDING PERATION • Other welding methods • If the TIG valve controller will not be used in TIG welding, be sure to shut off the gas after completion of welding. There is a risk of suffocating if closing the gas is forgotten in case opening/closing of the gas is done manually.
  • Page 61 ELDING PERATION HAPTER ERFORMING ELDING PERATION DISPLAY CHANGE key Welding current adjustment knob Welding voltage adjustment knob Analog remote control (Optional accessories) Welding power source UNIT CHANGE key Parameter adjustment knob Press the DISPLAY CHANGE key. The displays of the left/right digital meter switches to the set values. The LED for the welding sequence changes to the light-up mode.

  • Page 62: Operation At Welding End

    ELDING PERATION HAPTER ERFORMING ELDING PERATION 5.6.3 Operation at welding end This section explains the supply stop procedure of power/shield gas after the welding end. GAS CHECK key Main valve Flow rate Welding power adjustment knob source SHUT Shut off Power switch Welding power source...

  • Page 63: Chapter 6 Welding Condition

    Chapter 6 Welding Condition This chapter explains the functions on the operation panel as well as how to set the welding conditions. List of Welding Conditions This section explains the parameters/functions settable in the welding power source. 6.1.1 Parameter (Welding parameter) Parameter Set Range Initial Value...

  • Page 64: Internal Function

    0: Semi-automatic machine 1: Automatic machine 1 Auto/Semi-auto mode 0/1/2/3/4 2: Automatic machine 2 3: Almega (OTC’s robots) specification 4: Almega (OTC’s robots) specification (for high speed communication) Maximum external command Sets the maximum value of voltage supplied when 10.0/14.0/15.0 15.0 (V) voltage current/voltage command is externally input.
  • Page 65 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Sets the output status when an error of the alarm level is detected: Alarm setting switching OFF/ON OFF: Ineffective ON: Stops the output 140 to 460 160 (V) (*1) Low input voltage...
  • Page 66 ON: Feeds without slow down speed Arc loss detection time Arc start error detection time WCR output ON OFF (fixed) Used when connecting with OTC automatic machine. delay time WCR output OFF delay time Analog setting switch Pulse peak current fine...
  • Page 67 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory L pulse peak current fine Sets the adjustment value of pulse peak current at the -150 to 150 0 (A) adjustment LOW side in pulse welding. L pulse peak time fine Sets the adjustment value of pulse peak time at the -1.5 to 1.5...

  • Page 68: Function On Operation Panel

    ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Function Name Setting range Initial value Explanation Memory Current display adjustment -20 to 20 0 (%) (GAIN) These functions are for adjusting current value displayed on the digital meter. Current display adjustment -20 to 20 0 (A) (OFFSET) Voltage display adjustment...

  • Page 69: Setting Screen

    When the LED is ON: water-cooled welding torch mode • When the LED is OFF: air-cooled welding torch mode Terminals for service use Terminals for the OTC service use. For variety of registered data, writes to or reads from the USB memory. ( Chapter 7 Administrator...
  • Page 70 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL <HOME screen> <MENU screen> Cursor Displays current setting welding conditions. The screen switches every time the key is pressed. Move the cursor by turning screen Move the cursor by turning screen operation knob and select item to operation knob and select item to be changed setting.
  • Page 71 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Item Functions Select the gas to use. • Some gas cannot be used depending on the combination of the wire material, wire diameter, welding method, and TRAVEL SPEED. The gas that cannot be used will not be displayed. 6.6.1 Welding mode setting) •...

  • Page 72: Welding Conditions

    ELDING ONDITION HAPTER ELDING ONDITIONS Welding Conditions This section explains basic welding conditions with useful functions. 6.3.1 Basic welding conditions This section explains the basic welding conditions. To carry out the welding operation, the followings should be considered: • Plate thickness and materials of welding material •...

  • Page 73: Memory Function Of Welding Conditions

    BE SURE TO MAKE A COPY FOR IMPORTANT DATA. • Please note that OTC will not be liable for any alteration or loss of electronic information. • The memory function of welding condition is not available if the welding method is "DC TIG"...

  • Page 74: Read Out Of Welding Conditions

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Turn the screen operation knob (or parameter adjustment knob), and select a JOB No. ⇒ When there is no registration data on the selected JOB No, “no data” is displayed on the LCD panel, and “- - - -” is displayed on the left digital meter.

  • Page 75: Deletion Of Memory Registration

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Turn the screen operation knob (or parameter adjustment knob), and select the JOB No. to read out. ⇒ When there is no registration data on the selected JOB No., “no data” is displayed on the LCD panel and "- - - -" is displayed on the left digital meter.
  • Page 76 ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Select “Delete JOB”. Turn the screen operation knob and point the cursor to ● Delete JOB. Press the screen operation knob. ● ⇒ "dEL" is displayed when the system transits to the DELETE mode.

  • Page 77: Setting Welding Conditions

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Setting Welding Conditions This section explains how to set the welding conditions (welding mode or welding parameters). 6.6.1 Welding mode setting Available combination of the welding mode is listed in the table below. Selecting unavailable combination displays “- - -“...
  • Page 78 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS WIRE DIA. [in. (mm)] WELDING Penetration GAS (*1) WIRE MATERIALS TRAVEL SPEED METHOD adjustment WB-P402L WB-P502L .030/.035/.040/ .030/.035/.040/.045 (20% CO MILD STEEL .045/.052/ 1/16 STANDARD/HIGH (0.8/0.9/1.0/1.2) (*1-1) (0.8/0.9/1.0/1.2/1.4/1.6) STAINLESS STEEL .030/.035/.045 .030/.035/.045/ 1/16 STANDARD/HIGH DC WAVE (*3) (0.8/0.9/1.2)

  • Page 79: Setting Welding Conditions

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.2 Setting welding conditions Set the welding conditions with setting screen and screen operation knob. Select "WELDING METHOD" on the HOME screen. Turn the screen operation knob and point the cursor to the ● WELDING METHOD (Eg.
  • Page 80 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS MAIN POST FLOW CONDITION FLOW INITIAL CRATER-FILL CONDITION CONDITION Each sequence process has the following description: Process Description PRE FLOW It is the sequence to discharge gas before the welding starts. INITIAL CONDITION It is the sequence to process the welding start. MAIN CONDITION It is the welding sequence.

  • Page 81: Crater Setting

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Turn the parameter adjustment knob to set the welding current. ● ⇒ The set parameter is displayed on the left digital meter. TIPS • In the setting of welding current, the wire feed speed automatically set according to the welding current can be checked.
  • Page 82 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.4.1 Crater "OFF" Select "CRATER OFF" by the CRATER-FILL menu. • In synchronous to the ON/OFF operation of the torch switch, the welding starts/stops. Torch switch Pre-flow Post-flow Gas flow No-load voltage Anti-stick time Output voltage Slow-down speed Wire feeding speed...
  • Page 83 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.4.2 Crater "ON" (no initial condition) Select "CRATER-FILL ON" by the CRATER-FILL menu and select "INITIAL CONDITION OFF" by the INITIAL CONDITION menu. • Carry out twice the ON/OFF operation of the torch switch and carry out the welding operation. In the second ON operation, the welding sequence is carried out by the crater current.
  • Page 84 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.4.3 Crater "ON" (with initial condition) Select "CRATER-FILL ON" by the CRATER-FILL menu and select "INITIAL CONDITION ON" by the INITIAL CONDITION menu. • Carry out twice the ON/OFF operation of the torch switch and carry out the welding operation. The operation from the first ON to OFF enables the welding by the initial current, and the second ON operation enables the welding by the crater current.

  • Page 85: Arc Spot Time

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.5 Arc spot time This section explains the details of arc spot and torch switch operation. Selecting "ARC SPOT" by the CRATER-FILL menu allows the machine in the main mode. • In this mode, the torch switch remains to be ON for welding operation. When the arc spot time elapses, the welding automatically stops.

  • Page 86: Welding Voltage Adjustment

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.6 Welding voltage adjustment This section explains how to adjust the welding voltage. The adjustment of welding voltage can be carried out either by the SYNERGIC mode or INDIVIDUAL mode. TIPS • Some conditions such as synergic condition does not meet the appropriate level if a mixing gas ratio of shield gas is not the specified value.

  • Page 87: Penetration Control Adjustment

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.8 Penetration control adjustment This section explains how to adjust the penetration control. Using the constant penetration function enables to automatically adjust the wire feed speed so that the constant welding current can be assured even when the wire feeding length changes.

  • Page 88: Welding Guide

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Press the WAVE FRQ key. ⇒ The LED for the WAVE FRQ key lights up. ⇒ The wave frequency setting value appears on the left digital meter. Turn the parameter adjustment knob, and change the setting value. Adjust the value between 0.5 to 32 Hz.
  • Page 89 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Turn the screen operation knob and select "WELD JOINT", then press the screen operation knob. ⇒ The color of the selected parameter will be inverted on the display. Select the weld joint that needs to be changed. Turn the screen operation knob to place the cursor on the ●...

  • Page 90: Setting Internal Functions

    ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Setting Internal Functions This section explains how to set the internal functions with the details. The internal functions can be customized according to the using environment of the customer for further convenient use of the welding power source. 6.7.1 Setting procedure This section explains how to set the internal functions.

  • Page 91: Detailed Information On Internal Functions

    ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Turn the parameter adjustment knob, and change the setting value. ⇒ The set value is activated as it is changed. Press the CANCEL key. ⇒ The setting of internal function completes, and the LCD display returns to MENU. 6.7.2 Detailed information on internal functions This section explains the detailed information of internal functions in the order of function No.
  • Page 92 For the settings "0" to "2", refer to the table below. The settings "3" and "4" are the modes specifically for the use with OTC robots. For details, refer to the instruction manual of the robot controller.
  • Page 93 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.4 F5: Maximum external command voltage When the internal function F4 (Auto/Semi-auto mode) is used with the setting of "1", set the maximum value of command voltage input from outside. Select either from 10 V, 14 V, or 15 V. The below charts show the relationship between current/voltage command voltage and welding current/voltage.
  • Page 94 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.7 F8: Welding result display time Set the time period for the output current and voltage to be displayed on the left/right digital meters in a flashing mode after the completion of welding. Set the display time in the flashing mode. The value of display time is the average value for 1 second immediately before the completion of welding.
  • Page 95 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS – Internal function F44 (Reading welding condition with remote control) is set to "ON" (enabled); – Internal function F45 (Special crater sequence) is set to "ON" (enabled); – Internal function F48 (Adjusting current with torch switch) is set to "ON" (enabled); or –...
  • Page 96 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.14 F16: Slowdown speed adjustment Slow-down speed is the speed to slowly feed the wire from the time of the machine start to the time of arc start. The slowdown speed is automatically set to an appropriate speed depending on the welding method and wire diameter; meanwhile, it can be adjusted through this function if manual setting is preferred.
  • Page 97 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.18 F21: Maximum cooling fan operation The cooling fan can be rotated at the maximum rotation speed at all time. • [ON]: The cooling fan rotates at the maximum rotation speed at all time. Even when it is set to [ON], ensure not to exceed the specified duty cycle.
  • Page 98 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS <Command voltage - Welding current characteristic> 984 (25) 14 V 787 (20) 10 V 15 V 591 (15) 394 (10) 197 (5) External command voltage (V) TIPS • The wire feed speed with the maximum command voltage is 866 IPM (22 m/min). (Depending on the welding mode, the wire feed speed does not always reach 866 IPM (22 m/ min)) •...
  • Page 99 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • F31: set the function of IN-EXT3 ("7" to "9") on the external connection terminal block TM3. • F32: set the function of IN-EXT4 ("8" to "9") on the external connection terminal block TM3. For the details of external connection terminal block;...
  • Page 100 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS *5: Even after reading out the welding condition by this function, welding method can be changed either via the front panel or by the "DC/PULSE switch" of the external input terminal. In this case, the welding condition is newly read out when the signal of external input terminal to which this function is allocated to has any change again.
  • Page 101 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.24 F33: Inhibition ratio display for [Squeeze] detection Any shift in detecting [Squeeze] leads to spatter generation. This function enables to check the inhabitation ratio (%) of [Squeeze] detection from the welding start to the welding completion. •...
  • Page 102 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.26 F35: Saving [Squeeze] detection sensitivity Sets whether to return the sensitivity corrected by F34 (Automatic correction of [Squeeze] detection sensitivity) to the initial value when welding completes or maintain it after welding completes. •...
  • Page 103 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.28 F38: Arc voltage direct detection switching Sets the combination of enabling or disabling the voltage direct detection terminal on the base metal side of the welding power source and voltage detection terminal of the wire feeder. Extending the power cable without the cable at the base metal side can cause extraordinary volume of spatter.
  • Page 104 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.32 F44: Reading welding conditions with remote control Sets whether to read the welding condition registered to the memory by the analog remote control (optional) or not. This function is effective when the internal function F4 (Auto/Semi-auto mode) is set to "0". •...
  • Page 105 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Torch switch Post-flow Pre-flow Gas flow No-load voltage Anti-stick time Output voltage Slow-down speed Wire feeding speed Welding current Crater-fill current Initial current Welding current Crater-fil Main welding Initial condition Set the time by F46 Set the time by F47 (0.0 to 10.0 seconds) (0.0 to 10.0 seconds)
  • Page 106 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Example: In the setting examples of Crater setting: ON; Initial condition: OFF; Welding current: 100 A; Crater current: 60 A; F48: "ON"; F49:"-10"; and F50: "20", the following diagram is available: Within Double Within 0.3 sec.
  • Page 107 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS TIPS • When this function is set to [ON], automatically the setting of "CRATER-FILL ON (Repeat)" is selected, disabling other welding modes. (The CRATER-FILL menu does not work.) • Single-clicking operation should be within 0.3 seconds. •...
  • Page 108 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.39 F53: Sampling speed of data log function Selects the data sampling interval in using data log function. The relationship between the setting value and the data sampling is as follows: Setting Sampling interval 10 ms 100 ms For data log function;...
  • Page 109 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.43 F61: Fine adjustment of pulse peak time This function allows fine adjustment of the standard pulse peak time; by setting the adjustment value, finely adjusted pulse peak time can be obtained. Moreover, in the pulse condition of the wave pulse welding at HIGH side, fine adjustment is available to the standard pulse peak time at HIGH side by setting the adjustment value.
  • Page 110 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.48 F66: Adjustment of feed amplitude ratio This function sets the feed amplitude ratio of wire (amplitude change of wire feed speed) in the wave pulse welding. When the wave frequency is under 5 Hz, the wire feed speed is adjusted. By fine adjusting the amplitude of this feed speed, optimized welding result for the specific purpose can be obtained.
  • Page 111 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.53 F71: Interval welding function This function repeats arc ON/OFF to control the heat input. • “ON”: Enables the function. When this function is enabled, “: Interval” will be displayed at the end of CRATER-FILL CONDITION in the Home Screen, and internal functions F72 and F73 will be enabled.
  • Page 112 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.59 F80: Switching of CAN communication speed Set the connection speed of the CAN connection. Set to "0" to use the Digital panel, Push-Pull torch, Inline Assist feeder and Intelli torch. This function is effective when any one of “0” (Semi-auto mode), “1” (Automatic machine 1 mode), and “2” (Automatic machine 2 mode) is selected for F4 (Auto/Semi-auto mode).
  • Page 113 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.63 F84: Pulse automatic adjustment Sets the pulse mode that has the pulse automatic adjustment function. This function is available when set to the following welding method. Travel speed Welding method Wire material MILD STEEL HIGH DC pulse In pulse welding, spatter generation will increase when the welding voltage is set at a low value and welding is carried...
  • Page 114 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.65 F86/F87: Current display adjustment (GAIN/OFFSET) Set the adjustment value (gain/offset) when the current display value on the left digital meter is different from the actual current value. The current value displayed on the digital meter is obtained by software processing of the average value of outputs; therefore, it may not be consistent with the value indicated on a needle meter, etc.

  • Page 115: Operation Of Analog Remote Control

    ELDING ONDITION HAPTER PERATION OF NALOG EMOTE ONTROL PTIONAL Operation of Analog Remote Control (Optional) This section explains the functions of knobs and buttons arranged for the analog remote controller (optional) as well as their operation. Since the setting at the analog remote control is preferred when connected, it is not possible to set this condition on the operation panel of welding power source.
  • Page 116 ELDING ONDITION HAPTER PERATION OF NALOG EMOTE ONTROL PTIONAL The functions which can be assigned to the switching knob are as follows. Position of switching knob F2 setting Functions No function CRATER-FILL ON CRATER-FILL ON CRATER-FILL OFF Crater setting（ 6.6.4 Crater setting） (with pulse) (No pulse Gas check（...

  • Page 117: Chapter 7 Administrator Functions

    Chapter 7 Administrator Functions This chapter explains the functions used by administrators such as protection and initialization of welding conditions. Protection of Welding Conditions This section explains the protection function (password function) of welding conditions. When the function is enabled, 5.5.2 Preventing erroneous operation on operation panel), a password will be requested to disable the erroneous operation prevention function.
  • Page 118 DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING ONDITIONS Turn the screen operation knob to select “Password Setting”, and press the knob. If a password has already been set, the Password Input ● screen will be displayed on the LCD panel. To change the password, delete the password with the operation from the step 3 of “7.1.2 Disabling erroneous operation prevention”...

  • Page 119: Disabling Erroneous Operation Prevention

    DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING ONDITIONS Turn the screen operation knob to select “OK” (color inversion display). • To cancel setting of the password, turn OFF the power switch. 2 3 5 Check that the password is correct and press the screen operation knob. The password has been set.
  • Page 120 DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING ONDITIONS Press the screen operation knob, enter the password of the selected digit, and press the knob. The number is confirmed, and the display will change from color inversion display to digit selection display. •...

  • Page 121: Welding Result Control Function

    DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION Welding Result Control Function This section explains about the welding result control function. The function enables the management of the items below. Welding control Monitor Initial Setting range Explanation parameter value Cumulative number of welding points (number of times) Number of welding 0 to 9999 Target value of welding points (number of times)

  • Page 122: Details Of Welding Control Items

    DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION Select the desired monitor No. Turning the screen operation knob (or parameter ● adjustment knob) will change the tens place digit of monitor No. (Example: "P10" -> "P20" -> "P30" -> "P40") Pressing the screen operation knob will change the ones ●...
  • Page 123 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION *2: If Disabled is selected and the target is achieved ne t welding cannot start until any ey on the operation panel is pressed. 7.2.2.2 Wire consumption Wire consumption is controlled according to the setting range. •...
  • Page 124 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION • P31 (Target total welding time) Select the target value of total welding time in the range from 0 to 9999 minutes. When the "P30" count value reaches the total welding time specified here, an alarm displays indicating that the target is achieved.
  • Page 125 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION - When the torch switch is set to “ON” while an alarm is displayed to start welding (only when P46 is set to "0") - When operation is stopped by releasing 3-4 (operation stop terminal) on the external connection terminal block TM3 during alarm indication, and then the operation stop is canceled by short-circuiting these terminals (only when F4 setting is "1"...

  • Page 126: Data Backup (Utilization Of Data)

    • The backup data (electronic information) may be altered or lost when affected by static electricity, impact or repair work. Important information should also be stored as printed document. Please note that OTC will not be liable for any alteration or loss of electronic information. TIPS For the USB flash drive, use the version 1.0.

  • Page 127: Setting Of Welding Conditions/Internal Functions

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.1 Setting of welding conditions/internal functions The following contents can be stored in the "DAIHEN_OTC_WELDING_PRAMETER.CSV" file. • All the welding condition data recorded in memory • The internal function values at the time of data backup The current welding conditions set with the operation panel will not be saved.

  • Page 128: Simplified Data Log Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Item Description Unit Item Description Unit Crater arc length L pulse pea lpls p i adj 1 (A) cre uni fset adjustment value 0.1( ) current fine adjustment (when MS-MIG is selected) L pulse pea lpls p t adj 0.1 (ms) Interval...

  • Page 129: Failure Log Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Example: The data will be output as below when the internal function F52 is set to "1" (detected values of welding current, welding voltage and feeding speed) and F53 to "2" (100 ms). Time [msec] Welding current [A] Welding current [V]...

  • Page 130: Welding Result Control Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.4 Welding Result Control Function The following contents can be saved in the file "DAIHEN_WELDING_MONITOR_DATA_MACHINE_***.CSV ". • Welding machine identification Number • Cumulative values of Welding result control function The values of internal function F77(Welding result control function identifications numbers) enters into "***" in the end of filename.
  • Page 131 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Select the data to back up. Turn the screen operation knob further counterclockwise ● to display the data to back up on the right digital meter. The display changes in order of "ALL" -> "1" -> "2" -> "3" - >...

  • Page 132: Importing Backup Data

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.6 Importing backup data This section explains how to import the backup data. NOTE • The data stored in the welding power source will be overwritten by the backup data. Make sure of it before overwriting. Turn ON the power switch.

  • Page 133: Initializing Welding Conditions And Internal Functions

    DMINISTRATOR UNCTIONS HAPTER NITIALIZING ELDING ONDITIONS AND NTERNAL UNCTIONS Press the screen operation knob. Importing the backup data starts. During backup, the display of right digital meter changes. When importing is completed, "End" will be displayed on the right digital meter. Initializing Welding Conditions and Internal Functions This section explains how to initialize the welding conditions and internal functions.

  • Page 134: Checking The Software Version And Serial Number

    DMINISTRATOR UNCTIONS HAPTER HECKING THE OFTWARE ERSION AND ERIAL UMBER Checking the Software Version and Serial Number This section explains how to check the software version installed in the welding power source. The software version is managed as below. P##### ### ### ### Product Extended version Main version...

  • Page 135: Calibration Mode

    DMINISTRATOR UNCTIONS HAPTER ALIBRATION Calibration Mode The calibration mode can be used to calibrate the current and the voltage values indicated on the digital meter of the welding power source as well as the actual output current and voltage values. TIPS •...

  • Page 136: Adjustment Of Output Voltage

    DMINISTRATOR UNCTIONS HAPTER ALIBRATION Turn the screen operation knob to select the “CALIBRATION MODE”, and press the knob. “cAL cAL” is displayed on the operation panel. Set the current setting as follows. WB-P402L: 400 A ● WB-P502L: 500 A Turn ON the torch switch, and measure the output voltage. After measuring the output voltage, turn OFF the torch switch.
  • Page 137 DMINISTRATOR UNCTIONS HAPTER ALIBRATION While both DISPLAY CHANGE keys are pressed at the same time, turn ON the power switch. The USER MENU will be displayed on the LCD panel. Turn the screen operation knob to select "CALIBRATION MODE", and press the knob. "cAL cAL"...

  • Page 138: System Setting

    DMINISTRATOR UNCTIONS HAPTER YSTEM ETTING System Setting Sets the “Font Size” of the Home Screen as well as the “LCD Background” and “Language” of all screens. Select “SYSTEM SETTING” on the MENU screen. Turn the screen operation knob to place the cursor on ●...

  • Page 139: Chapter 8 Maintenance And Inspection

    Chapter 8 Maintenance and Inspection This chapter explains the daily and periodical inspection of the welding power source. Precautions for Maintenance and Inspection This section explains the precautions for maintenance and inspection work. To prevent electric shock or burn injury, ensure to follow the instructions below: •...
  • Page 140 Important information should also be stored as printed document. Please note that OTC will not be liable for any alteration or loss of electronic information. • When cleaning the welding power source, do not expose the cooling fan directly to compressed air.

  • Page 141: Daily Inspection

    AINTENANCE AND NSPECTION HAPTER AILY NSPECTION Daily Inspection This section explains the daily inspection of the welding power source. Perform daily inspection for the following items in the table. The front and rear panels and the fan of the welding power source is made from polycarbonate resin. To prevent from electric shock or fire caused by the damage on polycarbonate resin, ensure to follow the instructions below.
  • Page 142 AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION Periodical inspection item Inspection work Grounding wire Each cable (Primary power cable for facility side, Refer to the description for the same item in "8.2 Daily Inspection ". • cables for base metal side/torch side, torch cable, voltage detection cable, etc.) Check that there is no deterioration, damage or other abnormality in consumable parts of the...

  • Page 143: Periodical Replacement Parts

    AINTENANCE AND NSPECTION HAPTER ERIODICAL EPLACEMENT ARTS Periodical Replacement Parts This section explains the parts to be replaced periodically. • Printed circuit board PCB7 ( 10.1 Parts List) The printed circuit board PCB7 inside the welding power source has a high voltage electrolysis capacitor. The high voltage electrolysis capacitor supplies stable direct current to the inverter circuit, but its performance will degrade year by year.

  • Page 144: Insulation Resistance Measurement And Withstand Voltage Test

    AINTENANCE AND NSPECTION HAPTER NSULATION ESISTANCE EASUREMENT AND ITHSTAND OLTAGE Insulation Resistance Measurement and Withstand Voltage Test If insulation resistance measurement and withstand voltage test is necessary, please contact your dealer. • The customer MUST NOT perform the withstand voltage test. If withstand voltage test is necessary, ensure to contact your dealer.

  • Page 145: Chapter 9 Troubleshooting

    F19: Switching alarm setting) Check the error code displayed and take an appropriate action according to the table below. (If the welding power source is combined with robots manufactured by OTC, see the instruction manual of the robot controller.) • Before inspecting the welding power source, make sure to read "8.1 Precautions for Maintenance and Inspection".
  • Page 146 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error • Check that the WIRE INCH key (or inching button) is not pressed. • If the internal functions F29 to F32 are set to "2" (inching), check also the Inching was active when the power switch connections of the terminal blocks for external connection.
  • Page 147 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error • Check that the input voltage for primary side is the range of (208/230/460 V WB-M352: The input voltage for primary ±10%). side was out of allowable range from 265 to 320 V (*1) •...
  • Page 148 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error • Check that the tip at the end of torch is not contacting the base metal. An over current was detected at the output •...

  • Page 149: Troubleshooting

    ROUBLESHOOTING HAPTER ROUBLESHOOTING Error code Error cause Action and how to cancel error Fieldbus Communication Error: No Connection • Contact your dealer. 950 CAN Bus Off Error • Turn off the power switches of all other CAN-connected welding power sources, then turn on the power switches and check the setting of internal function F43.
  • Page 150 ROUBLESHOOTING HAPTER ROUBLESHOOTING Problem Possible cause Corrective action Arc does not generate even when Connection of the torch cable is Securely connect the torch cable. the setting of welding conditions is loose. correct. The torch switch is broken. Check that the torch switch works normally. (w/o no-load voltage) Check that the setting of internal functions F4 is correct.

  • Page 151: Chapter 10Reference Materials

    Chapter 10 Reference Materials This chapter contains the parts list of welding power source, and reference materials for setting the welding conditions. 10.1 Parts List This section shows the parts list of welding power source. • When placing an order, provide your dealer with the necessary information: the model name of welding power source, the name of the part to be replaced, and the part number (or specifications if part has no number).
  • Page 152 EFERENCE ATERIALS HAPTER ARTS Q’ty Code Part No. Product Name Specifications Remarks WB-P402L WB-P502L R5 to 10 100-0234 Carbon resistor R5 to RD20S 1 k J 10,20,21 R11,12 100-1430 Metal film resistor RPM200Z 5 R11 to 14 R13,14 4508-317 Carbon resistor RD1/2S 3 k J 100-1431 Winding resistor SMR 220 W 1.6...
  • Page 153 EFERENCE ATERIALS HAPTER EFERENCE RAWING Q’ty Code Part No. Product Name Specifications Remarks WB-P402L WB-P502L P30344W02 Operation panel sheet P30344W02 W-W03636 W-W03636 For P30086G01 4734-007 DIX BE 50/70 Receptacle 100-1836 EDZ120b(B)-1(ROHS) W-W03829 Handle cover W-W03829 For NF 4739-476 W-W02814 For CON1,2 Parameter adjusting 4735-038 Knob...

  • Page 154: Spare Parts List

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.1 Schematic diagram • WB-P402L...
  • Page 155 EFERENCE ATERIALS HAPTER EFERENCE RAWING...
  • Page 156 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-P502L...
  • Page 157 EFERENCE ATERIALS HAPTER EFERENCE RAWING...
  • Page 158 EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.2 Parts layout drawing • WB-P402L...

  • Page 159: Parts Layout Drawing

    EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-P502L...
  • Page 160 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10.3 Materials for Setting Welding Conditions This section provides reference information for setting the welding conditions. 10.3.1 Guide for changing welding conditions This section gives examples of the problems that can occur due to improper welding conditions. Problem Symptom •...

  • Page 161: Guide For Changing Welding Conditions

    EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Plate gas flow rate Leg length Wire diameter Current Voltage Travel speed thickness L [in. (mm)] [in. (mm) ] [IPM (cm/min)] [CFH (L/min)] t [in. (mm)] 15/64 to 9/32 14 to 16 32 to 42 23/64 (9.0) .045 (1.2)
  • Page 162 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Example for welding conditions of I shape butt (without backing plate) Plate gas flow rate Root opening Wire diameter Current Voltage Travel speed Number of thickness g [in. (mm)] [in. (mm) ] [IPM (cm/min)] [CFH (L/min)] layers...
  • Page 163 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Root Wire Travel Plate opening Root face diameter Current Voltage speed flow rate Number of thickness Bevel shape g [in. h [in. (mm)] [in. (mm) [IPM layers [CFH t [in. (mm)] (mm)] (cm/min)] (L/min)] 12 to 14...
  • Page 164 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10.3.2.2 Example for welding conditions of wire CO with flux Example for welding conditions of horizontal fillet Leg length Wire diameter Current Voltage Travel speed t [in. (mm)] [in. (mm) ] [IPM (cm/min)] .045 (1.2) 20 (50) 5/32 (4)
  • Page 165 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10.3.2.4 Example for welding conditions of pulse MAG Example for welding conditions of horizontal fillet Plate Travel speed Leg length Number Current Voltage thickness Aim angle and position [IPM (cm/ [in. (mm)] of layers t [in.
  • Page 166 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Example for both side welding conditions of downward butt welding (STANDARD mode) Plate Number Current Voltage Travel speed thickness Bevel shape of layers [IPM (cm/min)] t [in. (mm)] 25 to 26 12 (30) 15/64 (6.0) 26 to 27 12 (30)
  • Page 167 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Plate Number Current Voltage Travel speed thickness Bevel shape of layers [IPM (cm/min)] t [in. (mm)] 24 to 25 10 (25) 3/4 (19.0) 29 to 30 10 (25) 29 to 30 10 (25) Root path oscillation width: 0.1 in.
  • Page 168 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10.3.2.5 Example for welding conditions of aluminum pulse MIG Example welding conditions of I shape butt Plate Wire feeding Wire diameter Current Voltage Travel speed Gas flow rate thickness length [in. (mm) ] [IPM (cm/min)] [CFH (L/min)] t [in.

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