OTC Welbee P400 II Owner's Manual
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OTC Welbee P400 II Owner's Manual

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OWNER'S MANUAL
Welbee P400 II
June, 2021
DAIHEN Corporation
DAIHEN Corporation
Manual No. : P30344-1

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Summary of Contents for OTC Welbee P400 II

  • Page 1 OWNER'S MANUAL Welbee P400 II June, 2021 DAIHEN Corporation DAIHEN Corporation Manual No. : P30344-1...

  • 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 ..... 31 Service and Support 4.2.4 Connection at TIG welding ..... . 31 Important Information .
  • Page 5 ABLE OF ONTENTS 6.6.10 Welding guide ....... 77 6.7 Setting Internal Functions....79 6.7.1 Setting procedure .

  • 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 Disassembling And Modifying The Welding Power Source

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.4 Precautions for disassembling and modifying the welding power source 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.

  • Page 10: Precaution For Protective Equipment

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.6 Precaution for protective equipment 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: 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 P400 II Specification/ Number of phase/ Three phase Single phase Welding method...

  • 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 WELDING Penetration GAS (*1) WIRE MATERIALS WIRE DIA. [in. (mm)] TRAVEL SPEED METHOD adjustment .030/.035/.040/.045 MILD STEEL STANDARD (*2)/HIGH...

  • Page 16: External Dimensions

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 2.1.3 External dimensions 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) 2.1.4 Rated duty cycle This section explains the rated duty cycle of the welding power source. •...
  • Page 17 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION <Relationship between welding current and duty cycle> DC/DC TIG, three phase DC/DC TIG/DC STICK, single phase Usable range Usable range Welding current (A) Welding current (A) DC PULSE, single phase DC PULSE, three phase Usable range Usable range Welding current (A)

  • Page 18: 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 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. 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...

  • Page 20: 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 21: 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 22 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 23: 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 wire feeder...

  • Page 24: 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 25: Ventilation Equipment/Partial Exhaust Facility

    RANSPORTATION AND NSTALLATION HAPTER EQUIRED QUIPMENT • Be sure to use a single welding power source with a single engine generator. If more than two welding power sources are combined, output voltage will become unstable with a likely result of arc loss. Use the auxiliary power of engine welder with an improved voltage waveform.

  • Page 26: 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 27: 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 28: 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 29: 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 30: 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 31: 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 32: 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 33: 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. 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...
  • Page 34 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 35: Connection At Dc Stick Welding

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.5 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 36: Grounding And Connection Of Input

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE • Be sure to observe the following points to prevent from suffocation due to gas leakage or explosion. – Be sure to turn off the shield gas at the main tap when the welding power source is not in use.

  • Page 37: Power Supply

    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 38: 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 39: Connection Of Automatic Machine

    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)]...
  • Page 40 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 41 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT 4.5.2.2 Connection of terminal for external connection 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 42: Wiring Of Voltage Detection Cable At Base Metal Side

    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. Wiring of Voltage Detection Cable at Base Metal Side 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 43: Wiring To Welding Power Source

    ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL 4.6.2 Wiring to welding power source 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. Welding power source Terminal for voltage direct detection at base metal side...

  • Page 44: 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 45: 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 46 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 47: 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 48: 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 49: 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 50: 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 51: 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 52 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 53: 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 54: 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) Set Range Parameter Initial Value...

  • Page 55: 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 56 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Low input voltage Adjusts the low primary input voltage detection level. 140 to 460 160 (V) detection level Sets the operation mode of cooling fan: Maximum cooling fan operation OFF/ON OFF: Economical operation...
  • Page 57 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Sets current increase/decrease volume by double- Current increase and -100 to 100 0 (A) clicking of the torch switch. (available when "ON" is decrease by double-clicking selected in F48) With the setting of "Crater,"...
  • Page 58 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Sets the current value of the crater condition in the Setting of current value (crater 10 to 300 100 (%) percentage based on the current value of the welding condition) condition.

  • Page 59: Function On Operation Panel

    ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Function on Operation Panel This section explains the function of displays and keys arranged on the operation panel. 6.2.1 Operation panel DISPLAY CHANGE key UNIT CHANGE key Parameter adjusting knob Screen operation knob Name Function Displays various information.

  • Page 60: 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 61 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 62 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 63: 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 64: Preparing 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 65: Memory Registration Of Welding Conditions

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS TIPS Use of the internal function (F44) enables to read out the registered welding condition by the • analog remote control (optional). ( Setting Internal Functions) • Use of the internal function (F11) enables to finely adjust the current/voltage values read out from the memory by the analog remote control (optional).

  • Page 66: Read Out Of Welding Conditions

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS 6.5.2 Read out of welding conditions This section explains how to read out the welding conditions registered in the memory. TIPS The current welding condition set on the operation panel is overwritten by the welding •...

  • Page 67: Deletion Of Memory Registration

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS 6.5.3 Deletion of memory registration This section explains how to delete the welding conditions registered to the memory. NOTE • The deleted data cannot be restored. Before deleting the stored welding condition, carefully check the welding JOB No.

  • Page 68: Setting Welding Conditions

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Press the screen operation knob. The display "dEL" on the left digital meter starts flashing. To cancel the deletion, turn off the power switch. • Press the screen operation knob. The welding condition of the selected JOB No. is deleted, and "End"...
  • Page 69 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS WELDING Penetration GAS (*1) WIRE MATERIALS WIRE DIA. [in. (mm)] TRAVEL SPEED METHOD adjustment .030/.035/.040/.045/.052 MILD STEEL STANDARD/HIGH Enable MAG (20 % CO (0.8/0.9/1.0/1.2/1.4) (*1-1) METAL CORED .045(1.2) STANDARD Enable .030/.035/.045 STAINLESS STEEL (*3) STANDARD/HIGH Enable (0.8/0.9/1.2)

  • Page 70: Setting Welding Conditions

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.2 Setting welding conditions Set the welding conditions with HOME 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 71: Setting Welding Parameter

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.3 Setting welding parameter This section explains how to set the welding parameter (gas discharge time, welding current/voltage). The welding parameters are set according to the welding sequence. 6.6.3.1 Welding sequence The basic welding sequence is the process of PRE FLOW, MAIN CONDITION, and POST FLOW. To this sequence, initial condition and crater-fill condition can be added depending on the crater setting.

  • Page 72: Crater Setting

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Set the welding current. Press the DISPLAY CHANGE key, and select the LED of "MAIN CONDITION" (or "INITIAL CONDITION" or ● "CRATER-FILL CONDITION"). When the LED above the 7-segment display (for current adjustment) is off, press the parameter adjustment knob ●...
  • Page 73 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS TIPS Even in the Crater-fill off mode, using the internal function (F45) enables to carry out the • welding process in the initial condition before the main welding, and the welding process in the Crater condition after the main welding. ( 6.7.2.28 F45/F46/F47: Special crater sequence (effective/initial standard time setting/crater standard time setting))
  • Page 74 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 75 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 76: 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 77: Arc Characteristics Adjustment

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS ■ SYNERGIC mode Press the VOLT. ADJUST menu. When the SYNERGIC is selected, it means the SYNERGIC mode is applied. • The welding voltage is automatically set to the values corresponding to the welding current. •...

  • Page 78: Adjustment Of Wave Frequency

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.9 Adjustment of wave frequency This section explains how to adjust the wave frequency. In wave pulse welding, cyclically accumulating two separate unit pulse conditions at low frequency enables to obtain continuous weld bead looking like rows of fish scales. Aluminum welding makes a ripple bead using an overlap method.

  • Page 79: 6.6.10 Welding Guide

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Turn the parameter adjustment knob, and change the setting value. Adjust the value between 0.5 to 32 Hz. ● Press the WAVE FRQ key or the DISPLAY CHANGE key. Adjustment of wave frequency is complete. 6.6.10 Welding guide By setting the "WELD JOINT"...
  • Page 80 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Turn the screen operation knob to select the plate thickness value, and press the knob. ▲ and ▼ will be displayed above and below the plate thickness value, and the value becomes adjustable. Welding current will be set automatically according to the WELD JOINT and plate thickness.

  • Page 81: 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 82: 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 the MENU screen. 6.7.2 Detailed information on internal functions This section explains the detailed information of internal functions in the order of function No.
  • Page 83 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 84 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 85 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.9 F10: Motor overcurrent detection level Set the over current detection level for the current flowing to the wire feed motor. If contact resistance of the wire feeding line section increases due to liner wear / tip defect, etc., motor current increases (when the feeding roller does not slip).
  • Page 86 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.11 F13: Turbo start The welding power source has the turbo start function using capacitor discharge in order to obtain smooth welding start. • [ON]: enables the function. • [OFF]: disables the function. TIPS If wire burning is too strong at the welding start, set this function to [OFF] to disable the turbo •...
  • Page 87 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.14 F17/F18: Anti-stick time/voltage adjustment 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 88 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.18 F22: SUS EX pulse switching Two types of welding performances can be selected in pulse welding of stainless steel. This function is available when WELDING METHOD is set to "DC" or "DC WAVE PULSE" and wire material is set to "STAINLESS STEEL"...
  • Page 89 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 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)) • The minimum wire feed speed is approximately 24 to 79 IPM (0.6 to 2.0 m/min).
  • Page 90 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS The functions allocable to F29 to F32 are as follows: Setting Function name Explanation No function is allocated. Gas valve Causing short circuit between terminals opens the gas valve. (*1) Inching Causing short circuit between terminals starts inching. When inching operation is performed after short circuit is caused between terminals are short-circuited, Retract the wire feeding motor reverses to retract the wire.
  • Page 91 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS *7: The "DC/PULSE switch" function and the "WAVE PULSE/PULSE switch" function can be used together. According to the combination of external input terminal signals, welding method is optimized. The relationship between the welding method and the signal is as follows: External input terminal Welding method...
  • Page 92 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.23 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 93 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.27 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 94 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.28 F45/F46/F47: Special crater sequence (effective/initial standard time setting/crater standard time setting) Incorporates initial condition and crater condition in the "No crater" sequence. • Setting the internal function F45 to [ON] enables to carry out the initial welding/crater treatment set by F46/F47 even in the welding of "No crater"...
  • Page 95 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.29 F48: Adjusting current with torch switch Increases/decreases the welding current by the torch switch operation. • [ON]: the setting of "CRATER-FILL ON" is selected, enabling to increase or decrease welding current by single- clicking or double-clicking the torch switch in the period of welding condition (during start input holding) •...
  • Page 96 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.30 F49: Current increase and decrease by single-clicking To increase/decrease the welding current by the torch switch operation, set the current increase/ decrease volume at single-clicking. This function is available when the internal function F48 (Adjusting current with torch switch) is set to [ON].
  • Page 97 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS – Either of the internal functions F29 to F32 (External input terminal setting) is set to either "4" (Start) or "5" (Loading welding condition). 6.7.2.33 F52: Data type of data log function This function enables to select data to save when using the data log function. The patterns of data which can be saved are as shown in the below table.
  • Page 98 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.37 F60: Fine adjustment of pulse peak current This function allows fine adjustment of the standard pulse peak current; by setting the adjustment value, finely adjusted pulse peak current 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 current at HIGH side by setting the adjustment value.
  • Page 99 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.40 F63: Fine adjustment of L pulse peak current This function allows fine adjustment of the standard pulse peak current at LOW side in the pulse condition of the wave pulse welding; by setting the adjustment value, finely adjusted pulse peak current at LOW side can be obtained. Set the adjustment value in the range of -150 to 150 A.
  • Page 100 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.44 F67: Setting change of current value (initial condition, crater condition) When "CRATER ON" is selected, the current value of the initial condition and the crater condition can be set in percentage based on the current value of the welding condition. •...
  • Page 101 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.49 F72: Setting Arc-ON time (Interval function) Sets the arc-ON time in the Interval welding function. • Set the arc-ON time in the range of 020 to 9.99 seconds. 6.7.2.50 F73: Setting Arc-OFF time (Interval function) Sets the arc-OFF time in the Interval welding function.
  • Page 102 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.55 F81: TIG Mode torch switch setting Even if DC TIG is selected as welding method, operating the torch switch of the torch connected to the wire feeder can start or end welding. Normally, in DC TIG, torch detective voltage is always applied to the torch electrode, and then, arc starts when the electrode touches the base metal.
  • Page 103 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.58 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 HIGH DC pulse MILD STEEL In pulse welding, spatter generation will increase when the welding voltage is set at a low value and welding is carried...
  • Page 104 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.59 F85: Adjustment amount of pulse automatic adjustment The currently retained adjustment amount of pulse automatic adjustment can be checked. In addition, the adjustment amount can be changed manually. • Setting range of the value: -9.99 to 9.99. TIPS The adjustment amount is set in a way that the appropriate welding is possible when the value is "0".

  • Page 105: 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 106 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 setting（ 6.6.4 Crater setting） CRATER-FILL OFF (with pulse) (No pulse)

  • Page 107: 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 108 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 109: 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 110 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 111: 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 112: 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 113 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. 7.2.2.2 Wire consumption Wire consumption is controlled according to the setting range. •...
  • Page 114 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 115 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 116: 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 117: 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 118: Simplified Data Log Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Item Description Unit Item Description Unit Initial arc length adjustment Base current fine pls_bsi_adj 1(A) pre_uni_fset value 0.1(±) adjustment (when MS-MIG is selected) Crater arc length L pulse peak lpls_pki_adj 1(A) cre_uni_fset adjustment value 0.1(±) current fine adjustment (when MS-MIG is selected)

  • Page 119: Failure Log Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA When DAIHEN_OTC_Welbee\DAT\DAT00001 folder is already existing, "DAT00002" folder will be created below the "DAIHEN_OTC_Welbee\DAT" folder and folder for the consecutive number will per created for each simplified data log. 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"...

  • Page 120: 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 121 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 122: 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 123: 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 124: 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 125: 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 126: Adjustment Of Output Voltage

    DMINISTRATOR UNCTIONS HAPTER ALIBRATION Correct the difference between the measured value and the set value by using the values of internal functions F39 and F40. When the value of F39 is "1", it is equivalent to the output current 1 A. To increases the output current, increase ●...
  • Page 127 DMINISTRATOR UNCTIONS HAPTER ALIBRATION Turn ON the torch switch, and confirm the difference between the output voltage displayed on the voltmeter and the voltage displayed on the operation panel. Correct the difference by using the values of internal functions F41 and F42 so that the difference is within the range of ±0.1 V.

  • Page 128: 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 129: 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 130: Daily Inspection

    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 131: Periodical Inspection

    AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION Periodical Inspection This section explains the periodical inspection of the welding power source. Check the items in the table below every three (3) to six (6) months. • Before performing maintenance and inspection, read the instructions in "8.1 Precautions for Maintenance and Inspection"...
  • Page 132 AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION Periodical inspection item Inspection work Dust accumulating on the fin or winding of heat sink can cause insufficient heat radiation. • Remove the left side panel and fan frame and check the dirt inside. If there is heavy dirt, blow the fin and coils of heat sink directly with compressed air to remove dust inside.

  • Page 133: 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 134: 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 135: 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 136 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 connections Inching was active when the power of the terminal blocks for external connection.
  • Page 137 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 in the following range. The input voltage for primary side 208/230/460 V ±10% exceeded the allowable range (*1) •...
  • Page 138 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 •...

  • Page 139: Troubleshooting

    ROUBLESHOOTING HAPTER ROUBLESHOOTING Error code Error cause Action and how to cancel error Fieldbus Communication Error: Watchdog Fieldbus Communication Error: NAK Resending Over • Contact your dealer. Fieldbus Communication Error: No Connection 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 140 ROUBLESHOOTING HAPTER ROUBLESHOOTING Problem Possible cause Corrective action Check that the setting of internal functions F29 to F32 is Setting/handling of the external correct. ( 6.7.2.22 F29 to F32: External input terminal inputs is not correct. setting) Shield gas does not stop flowing. Check that there is no abnormality in the cables The external input cables are connected to the external input terminal block.

  • Page 141: 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 142 EFERENCE ATERIALS HAPTER ARTS Code Part No. Product Name Specifications Q’ty Remarks 4514-206 Film capacitor US20X472JAASA 100-2227 Film capacitor US20X682JAASA CON1 100-1435 Receptacle DPC25-10BP CON2 4730-010 Receptacle DPC25-6BP-Z 4739-141 Terminal board T-3 (Black) 100-2228 Input terminal block DSTB22-04 DCV1 K5791B00 Power supply K5791B00 Output DC24V...

  • Page 143: 10.2 Reference Drawing

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2 Reference Drawing This section contains the schematic diagram and the parts layout drawing of the welding power source.

  • Page 144: 10.2.1 Schematic Diagram

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.1 Schematic diagram...
  • Page 145 EFERENCE ATERIALS HAPTER EFERENCE RAWING...

  • Page 146: 10.2.2 Parts Layout Drawing

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.2 Parts layout drawing...

  • Page 147: 10.3 Materials For Setting Welding Conditions

    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 148 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 149 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 150 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 151 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 152 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 153 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Example for welding conditions of single side welding (HIGH mode) Plate Number Current Voltage Travel speed thickness Bevel shape of layers [IPM (cm/min)] t [in. (mm)] 1/8 (3.2) 24 to 25 20 (50) 23 to 24 10 (25) 15/64 (6.0)
  • Page 154 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Number Current Voltage Bevel shape Remarks of layers 20 to 21 Oscillation Upward 21 to 22 Oscillation 21 to 22 Oscillation 21 to 22 Oscillation 21 to 22 Oscillation 19 to 20 Oscillation 100 to 200 20 to 22...
  • Page 155 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10.3.2.6 Example for short welding conditions of aluminum MIG Example for welding conditions of I shape butt Plate thickness Wire diameter Current Voltage Travel speed Wire feeding length Gas flow rate t [in. (mm)] [in.

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