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OTC Welbee M350 II Owner's Manual
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OTC Welbee M350 II Owner's Manual

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OWNER'S MANUAL
Welbee M350 II
M500 II
July, 2021
DAIHEN Corporation
Manual No. : P30355-1

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Sihle
May 23, 2025

What component can cause lack of phase

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1 comments:
Mr. Anderson
May 25, 2025

The component that can cause a lack of phase in the OTC Welbee M350 II is the power supply. The unit requires a three-phase power source (208/230/460 V ±10%), and a lack of any one phase can lead to operational issues.

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Summary of Contents for OTC Welbee M350 II

  • Page 1 OWNER'S MANUAL Welbee M350 II M500 II July, 2021 DAIHEN Corporation Manual No. : P30355-1...
  • Page 2 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 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 6 This chapter explains the precautions on the welding power source and welding operation. 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 AFETY NFORMATION HAPTER AFETY RECAUTION This section explains the safety precautions regarding operation of the welding power source. 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 AFETY NFORMATION HAPTER AFETY RECAUTION 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. • Have a qualified electrical engineer ground the case of the welding power source and base metal or jig electrically connected in accordance with local regulation.
  • Page 9 AFETY NFORMATION HAPTER AFETY RECAUTION To prevent electrical shock, fire, injury from malfunction and error in the welding power source, ensure to follow the instructions below: • Do not disassemble/modify the welding power source. Disassembling/modifying by customer is out of the warranty scope. To prevent suffocation or gas poisoning in the welding operation, ensure to follow the instructions below: •...
  • Page 10 AFETY NFORMATION HAPTER AFETY RECAUTION For protection from arc ray generated from welding, spattering dross and hearing disorder from noise, observe the following: • When welding or watching a welder work, wear face shield with a proper shade of filter (See ANSI Z 49.1 listed in PRINCIPAL SAFETY STANDARDS) to protect the face and eyes.
  • Page 11 AFETY NFORMATION HAPTER AFETY RECAUTION 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 AFETY NFORMATION HAPTER AFETY RECAUTION 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. Gas cylinder contains compressed gas.
  • Page 13 AFETY NFORMATION HAPTER RINCIPAL AFETY TANDARDS 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. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
  • Page 14 This chapter explains the specification, name of each parts and configuration of the welding power source. This section explains the specification and external dimension of the welding power source. This chapter explains the specification of the welding power source. Welbee M350 II Welbee M500 II Specification/Model/...
  • Page 15 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 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-M352 WB-M502 .030 / .035 / .040 / .045 .035 / .040 / .045 / .052 / 1/16 MILD STEEL STANDARD (*2)/HIGH...
  • Page 16 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION This section explains the external dimensions of the welding power source. 15.6" (395 mm) 28.0" (710 mm) 12.6" (320 mm) 18.1" (460 mm) 3.9" (100 mm) This section explains the rated duty cycle of the welding power source. •...
  • Page 17 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION • Use the welding power source within its usable range by observing the duty cycle for the welding current. <Relationship between welding current and duty cycle (WB-M352)> – Three phase DC, DC TIG DC STICK Usable range Usable range Welding current (A)
  • Page 18 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION This section explains the standard or optional composition of the welding power source and parts to be prepared by customers. 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 19 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • At TIG welding: Welding power source Base metal Required Optional Name Remarks component accessories Gas regulator To be prepared by the customer. 2.2.3 Accessory (not supplied)) Welding torch Gas hose [10 ft (3 m)] (*1) Included in feeder (*2) Power cable for base metal side (*1) Included in feeder...
  • Page 20 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 21 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 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 22 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 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 23 RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES This section explains the part names of the welding power source. 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 Socket for wire feeder Output terminal (Base metal side)
  • Page 24 This chapter explains the necessary equipment, installation environment and transportation method for installing the welding power source. 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. For installing the welding power source, power source equipment and protective device that meet the following ratings are required.
  • Page 25 RANSPORTATION AND NSTALLATION HAPTER EQUIRED QUIPMENT • 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. • Set the output voltage of the engine generator to the voltage range between 400 and 420 V at no-load welding operation.
  • Page 26 RANSPORTATION AND NSTALLATION HAPTER NSTALLATION NVIRONMENT 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: •...
  • Page 27 RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE 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 28 RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE 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: • For operation of a crane or hoisting, make sure that a qualified personnel operate them with attention to the surrounding area for safety.
  • Page 29 RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE 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. If attempting to lift by holding the front plastic part, top cover, side plates, it may cause back pain, deformation or damage to the welding power source.
  • Page 30 This chapter explains the procedure for connecting the welding power source. 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: Wear protective equipment such as protective gloves, safety shoes and long-sleeve clothes.
  • Page 31 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 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 32 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE • WB-M502 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 33 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 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 34 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE This section explains the procedure for connecting the welding torch. When air-cooled Wire feeder welding torch is used When water-cooled welding torch is used Torch cable Condensing water port (red collar) Feeding water Condensing water port (blue collar) hose (red)
  • Page 35 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE Welding power source Power cable for base metal side Output terminal (Base metal side) Power cable for base metal Power cable for side torch side Base metal Output terminal (Torch side) Connector Power cable for Ground a base metal if torch side required by local law.
  • Page 36 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 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. • WB-M352 NOTE When using the welding electrode holder, the specified connector needs to be attached to...
  • Page 37 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE • WB-M502 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 38 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 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 39 ONNECTION HAPTER ROUNDING AND ONNECTION OF NPUT OWER UPPLY 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 40 This section explains the method for connecting the welding power source with automatic machines. 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. Gas shortage/wire shortage...
  • Page 41 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 42 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT Input signal of the external connection terminal block Use switches and relays with contact capacity of 24 V/10 mA or more for connecting with the input terminal. DC24 V Approx. 5 mA Welding power source side Contact capacity 24 V/10 mA or more...
  • Page 43 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT This section explains the procedure for connection to the terminal for external connection. To prevent electric shock, ensure to follow the instructions below: Wiring should be performed by qualified persons or persons familiar with the welding machine.
  • Page 44 ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL Check the wiring and place the cover for external connection back to the welding power source. When the extension cable is 99 ft (30 m) or more in length in total, use of the voltage detection cable at the base metal side is recommended.
  • Page 45 ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL This section explains how to connect the voltage detection cable at the base metal side to the voltage direct detection terminal at the base metal side of the welding power source. •...
  • Page 46 ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL This section shows the wiring examples of the voltage detection cables at the base metal side to the base metal. Connect the base metal side voltage detection cable cable to the stage farthest from the base metal side power cable which connects to the base metal terminal of the welding power supply, away from the base metal side cable.
  • Page 47 This chapter explains the procedures from preparation to completion of the welding operation. This section explains the safety precautions for welding operation. To prevent suffocation or gas poisoning in the welding operation, ensure to follow the instructions below: When welding is required in tank, boiler, reaction tower, or hold of a ship, closed space, or any other places of poor ventilation, ensure to provide ventilation equipment.
  • Page 48 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 49 ELDING PERATION HAPTER HECK BEFORE ELDING Check parameter Countermeasures Check There should be no loose connections of the Use a proper tool to ensure connection. cables. There should be no dirt such as oil or spatter Wipe off dirt so that the metal face of connection terminal or connection part is fully adhering on the connection terminals or exposed.
  • Page 50 ELDING PERATION HAPTER OWER UPPLY 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. Wrong operation may cause gas explosion, resulting in serious physical injury.
  • Page 51 ELDING PERATION HAPTER NCHING 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 52 ELDING PERATION HAPTER HECK AND ETTING OF ELDING ONDITION 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). Before starting the welding operation, it is necessary to set the welding conditions (such as welding current/voltage, type of shield gas, and wire type/wire diameter).
  • Page 53 ELDING PERATION HAPTER ERFORMING ELDING PERATION 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 54 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 55 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 56 ELDING PERATION HAPTER ERFORMING ELDING PERATION 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 Input power supply Cover Close the main tap of the shield gas.
  • Page 57 This chapter explains the functions on the operation panel as well as how to set the welding conditions. This section explains the parameters/functions settable in the welding power source. Parameter Set Range Initial Value Descriptions Pre-flow time 0 to 10 sec 0.1 sec Set the gas discharge time before welding starts.
  • Page 58 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 59 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 60 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Sets current increase/decrease volume by single Current increase and -100 to 100 0 (A) clicking of the torch switch. (available when "ON" is decrease by single-clicking selected in F48) Sets current increase/decrease volume by double Current increase and...
  • Page 61 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Setting arc-ON time 0.20 to 9.99 1.00 (s) Sets the arc-ON time in the Interval welding function. (Interval function) Setting arc-OFF time 0.20 to 9.99 1.00 (s) Sets the arc-OFF time in the Interval welding (Interval function)
  • Page 62 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL This section explains the function of displays and keys arranged on the operation panel. DISPLAY CHANGE key UNIT CHANGE key Parameter adjusting knob Screen operation knob Name Function Displays various information. • The welding current is displayed in welding, and the LED of "A" lights up. Left digital meter •...
  • Page 63 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 64 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 65 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 66 ELDING ONDITION HAPTER ELDING ONDITIONS This section explains basic welding conditions with useful functions. 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 67 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 68 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 69 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 70 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 71 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS This section explains how to set the welding conditions (welding mode or welding parameters). Depending on the type of shield gas, wire material, etc., there are modes that can be combined and modes that cannot be combined.
  • Page 72 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Select "WELDING METHOD" to be changed. ● Turn the screen operation knob and point the cursor to the changing item. ● Press the screen operation knob. ⇒ Change of the welding method is confirmed, and the screen returns to the HOME screen.
  • Page 73 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS This section explains how to set the welding parameters (gas discharge time, welding current/voltage) according to the welding sequence. INITIAL CONDITION MAIN CONDITION POST FLOW PRE FLOW DISPLAY CHANGE key CRATER-FILL CONDITION UNIT CHANGE key Parameter adjustment knob Screen operation knob Set the gas discharge time.
  • Page 74 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Set the welding voltage. ● When the LED above the 7-segment display (for voltage adjustment) is off, press the parameter adjustment knob to light up the LED. ● Turn the parameter adjustment knob to set the welding voltage. At SYNERGIC mode: fine adjustment is carried out based on the welding voltage automatically set according to the welding current.
  • Page 75 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 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 Welding current Welding current...
  • Page 76 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 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 77 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Select “CRATER-FILL ON (Repeat)” by the CRATER FILL menu. • The torch switch operation until the crater treatment is the same with the welding of “CRATER-FILL ON”. ( 6.6.4.2 Crater "ON" (no initial condition)) •...
  • Page 78 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 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 79 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 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 80 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 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 81 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Select the weld joint that needs to be changed. ● Turn the screen operation knob to place the cursor on the parameter that needs to be set, and press the knob. ⇒ Change of the weld joint is confirmed, and the screen returns to the WELDING GUIDE screen.
  • Page 82 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 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. This section explains how to set the internal functions.
  • Page 83 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 the MENU screen. This section explains the detailed information of internal functions in the order of function No.
  • Page 84 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 85 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 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 86 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 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 87 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • In the following cases, this function cannot be used: – Welding conditions are not registered to the memory; – Analog remote control (optional) is not connected to the welding power source; – Internal function F44 (Reading welding condition with remote control) is set to "ON" (enabled); –...
  • Page 88 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Set the anti-stick time/voltage, which is the anti-stick processing time and voltage. Optimum setting of the anti-stick time/ voltage enables to obtain the following effects: • At the welding completion, wire adhesion to the base material can be prevented. •...
  • Page 89 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS When the welding power source is not operated for a fixed period of time, it can be turned into the sleep mode. • [0]: disables the function. • [1] to [10]: enables the function. Set the transition time to the sleep mode in the range of 1 to 10.
  • Page 90 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • [OFF]: disables the function. – The wire feed speed is automatically set based on the welding current. – Even when the welding mode is changed by the GAS menu, the wire feed speed is automatically set based on the set welding current.
  • Page 91 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS *4: Combination of the external input terminals enables to read out the welding conditions of the JOB No. 1 to 16 (Registration No. 1 to 16) registered on the memory. The corresponding JOB No. are as shown in the below table. JOB No.
  • Page 92 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Example: In the setting examples of F29: "5" ; F30: "0" ; F31: "5" ; and F32: "0" , the following diagram is available: Do not change condition within 40 msec Switch IN-EXT1 and 3 More than 100 msec before before and 100 msec after torch within 40 msec.
  • Page 93 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS TIPS • Use the voltage detection cable (optionally available) when the total length of the extension cable is 99 ft (30 m) or longer. • When using wire feeder CM-7403, water-cooled welding torch cannot be used. Accordingly, arc voltage direct detection switch cannot be activated even with this function set to "1".
  • Page 94 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • [OFF]: disables the function. • In the following cases, this function cannot be used: – Welding conditions are not registered to the memory; – Analog remote control (optional) is not connected to the welding power source; –...
  • Page 95 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • In the following cases, this function cannot be used: – Internal function F11 (Fine adjustment of welding conditions memory) is set to "1" to "30" (enabled); – Internal function F44 (Reading welding condition with remote control) is set to "ON" (enabled); –...
  • Page 96 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • In the following cases, this function cannot be used: – An analog remote control (optional) is connected. – Internal function F11 (Fine adjustment of welding conditions memory) is set to "1" to "30" (enabled); –...
  • Page 97 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • In the following cases, this function cannot be used: – Internal function F11 (Fine adjustment of welding conditions memory) is set to "1" to "30" (enabled); – Internal function F44 (Reading welding condition with remote control) is set to "ON" (enabled); –...
  • Page 98 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS The current value of the initial condition can be set in percentage based on the current value of the welding condition. • Setting range of current value (initial condition): 10 % to 300 ％ The current value of the crater condition can be set in percentage based on the current value of welding condition.
  • Page 99 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Sets whether or not to output the error code when welding is not performed for a certain time after the pre-flow to avoid an unexpected torch switch operation. • [ON]: If welding is not performed for five seconds after the pre-flow, Error code “E-011” is displayed on the left and right digital meters and the output of the welding power source stops.
  • Page 100 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 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 101 ELDING ONDITION HAPTER PERATION OF NALOG EMOTE ONTROL PTIONAL 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 102 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 OFF CRATER-FILL ON Crater setting（ 6.6.4 Crater setting） (Repeat) Gas check（...
  • Page 103 This chapter explains the functions used by administrators such as protection and initialization 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 104 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 105 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 106 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. To cancel deleting the password, press the "CANCEL"...

  • Page 107: Table Of Contents

    DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION 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 108 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 place digit of monitor No.

  • Page 109: Number Of Welding Point

    DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION *2: If "Disabled" is selected and the target is achieved, next welding cannot start until any key on the operation panel is pressed. Wire consumption is controlled according to the setting range. • P20 (Cumulative wire consumption used in welding) Wire consumption [lbs (kg)] used in welding is measured and counted.

  • Page 110: P41

    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 111: P50

    DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION • Alarm signal output function to external output terminal If the average current/voltage (average per second) during welding falls outside the tolerance range set by "P41" to "P44", the external output terminals set by the internal functions will be shorted. ( 6.7.2.20 F25 to F28: External output terminal setting）...
  • Page 112 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. 1.1 or 2.0 with backward compatibility.
  • Page 113 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA The current welding conditions set with the operation panel will not be saved. (If necessar , record them in memor beforehand.) The welding condition data recorded in the memor will be output in the wa that the JOB Nos. (registration Nos.) are displa ed in a vertical line and the parameter values in a hori ontall line.
  • Page 114 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA The internal function setting data will be output below the JOB Nos. (registration Nos.) Function setting data TIPS It is not possible to separately save the welding condition data recorded in memory and the internal function setting data.
  • Page 115 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA TIPS The length of time that can be used for recording depends on the sampling speed. If the sampling speed is set to 100 ms, data of approximately five hours can be recorded. When the data exceeds the capacity, they will be deleted in order from the oldest.
  • Page 116 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA This section explains how to back up the data such as welding conditions. The data can be backed up in a USB flash drive. TIPS The USB flash drive to be used should be formatted as FAT32. If it is formatted as FAT16 or NTFS, reformat it to FAT32.
  • Page 117 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Press the screen operation knob. Data backup starts. During backup, the display of right digital meter changes. When backup is completed, "End" will be displayed on the right digital meter. 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.
  • Page 118 DMINISTRATOR UNCTIONS HAPTER NITIALIZING ELDING ONDITIONS AND NTERNAL UNCTIONS Press the screen operation knob. Flashing of the left/right digital meter displays will stop, and the display changes to the light-up mode. Press the screen operation knob. Importing the backup data starts. During backup, the display of right digital meter changes.
  • Page 119 DMINISTRATOR UNCTIONS HAPTER HECKING THE OFTWARE ERSION AND ERIAL UMBER 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 Minor version There are two methods for checking: Checking at the LCD panel, and checking at the digital meter.
  • Page 120 DMINISTRATOR UNCTIONS HAPTER ALIBRATION The calibration mode can be used to calibrate the current and the voltage values indicated on the digital meter of the welding source as well as the actual output current and voltage values. TIPS To calibrate the current and/or voltage value with this function, the followings are necessary: WB-M352: Calibrated voltmeter and ammeter, a resistance load, and a cable with a cross- section of 38 mm or more...
  • Page 121 DMINISTRATOR UNCTIONS HAPTER ALIBRATION Turn the screen operation knob to select "CALIBRATION MODE", and press the knob. “cAL cAL” is displayed on the operation panel. Set the current setting as follows. ● WB-M352: 350 A WB-M502: 500 A Turn ON the torch switch, and measure the output voltage. ●...
  • Page 122 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 123 DMINISTRATOR UNCTIONS HAPTER YSTEM ETTING 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 “SYSTEM SETTING”, and press the knob.
  • Page 124 This chapter explains the daily and periodical inspection of the welding power source. This section explains the precautions for maintenance and inspection work. 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 125 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 126 AINTENANCE AND NSPECTION HAPTER AILY NSPECTION 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 127 AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION Periodical inspection item Inspection work Grounding wire Each cables Refer to the description for the same item in "8.2 Daily Inspection". (Primary power cable for facility side, 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 Welding torch...
  • Page 128 AINTENANCE AND NSPECTION HAPTER ERIODICAL EPLACEMENT ARTS 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 129 AINTENANCE AND NSPECTION HAPTER NSULATION ESISTANCE EASUREMENT AND ITHSTAND OLTAGE 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. Insulation resistance measurement should be conducted by qualified persons or persons familiar with the welding machine.
  • Page 130 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 131 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 132 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 133 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 134 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 135 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 136 This chapter contains the parts list of welding power source, and reference materials for setting the welding conditions. 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 137 EFERENCE ATERIALS HAPTER ARTS Q’ty Code Part No. Product Name Specifications Remarks WB-M352 WB-M502 R5 to 10 100-0234 Carbon resistor R5 to 10, RD20S 1k J 20, 21 R11, 12 100-1430 Metal film resistor RPM200Z 5 R11 to 14 4509-916 Cement resistor T20SH 2.2 J 100-0234 Carbon resistor...
  • Page 138 EFERENCE ATERIALS HAPTER EFERENCE RAWING Q’ty Code Part No. Product Name Specifications Remarks WB-M352 WB-M502 W-W03636 W-W03636 For P30086G01 100-2456 CX0058 Receptacle 100-1836 EDZ120b(B)-1(ROHS) W-W03829 Handle cover W-W03829 For NF 100-1736 Handle cover 899-35054-001 4739-476 W-W02814 For CON1, 2 Parameter 4735-038 Knob K-100 22RSB...
  • Page 139 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-M352...
  • Page 140 EFERENCE ATERIALS HAPTER EFERENCE RAWING...
  • Page 141 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-M502...
  • Page 142 EFERENCE ATERIALS HAPTER EFERENCE RAWING...
  • Page 143 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-M352...
  • Page 144 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-M502...
  • Page 145 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS This section provides reference information for setting the welding conditions. This section gives examples of the problems that can occur due to improper welding conditions. Problem Symptom • The arc length becomes long. The wire feeding length is too long.
  • Page 146 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS gas flow rate Plate thickness Leg length Wire diameter Current Voltage Travel speed t [in. (mm)] L [in. (mm)] [in. (mm) ] [IPM (cm/min)] [CFH (L/min)] 9/32 to 5/16 12 to 14 42 to 53 15/32 (12.0) .045 (1.2)
  • Page 147 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Example for welding conditions of single and double grooves Plate Root Root face Wire Current Voltage Travel speed Number of thickness Bevel shape opening h [in. diameter flow rate [IPM (cm/min)] layers t [in.
  • Page 148 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Material: Mild steel Gas: Ar + CO mixed gas [21 to 32 CFH (10 to 15 L/min)] Plate thickness Wire diameter Current Voltage Travel speed Joint shape t [in. (mm)] [in. (mm) ] [in.

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Welbee m500 ii