Page 1 E n s u r e t o r e a d t h i s i n s t r u c t i o n m a n u a l thoroughly for safe and proper use of the product. October, 2013 DAIHEN Corporation Manual No. : 1P30137-1...
Page 3: 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 4: Important Information
MPORTANT NFORMATION Important Information Use of the Product This product is a power supply unit designed and manufactured for use in arc welding. Do not use the product for any other purposes. Safe Use of the Product For safe use of the product (hereafter referred to as welding power source), ensure to follow the instructions below: •...
Page 5: Service And Support
MPORTANT NFORMATION Service and Support See the back cover for contact numbers and mailing addresses. When contacting your dealer for service, you are required to provide the following information: • Name, address, telephone number • Product model, manufacture year, serial number, and software version number (Refer to the diagram below for product information.
Page 6: Table Of Contents
ABLE OF ONTENTS TABLE OF CONTENTS Forward ..............i CHAPTER 4 CONNECTION Important Information..........ii 4.1 Precautions for Connection Procedure Use of the Product ............ii and Grounding ..........4-1 Safe Use of the Product ........... ii 4.2 Connecting the Welding Power Source ..4-2 Copyright................
Page 7 ABLE OF ONTENTS 6.5 Memory Function of Welding 10.2 Reference Drawing ........10-3 Conditions ........... 6-9 10.2.1 Schematic diagram.......... 10-4 10.2.2 Parts layout drawing........10-6 6.5.1 Memory registration of welding conditions..6-10 6.5.2 Read out of welding conditions ....... 6-11 10.3 Materials for Setting Welding 6.5.3 Deletion of memory registration ......
Page 8 ABLE OF ONTENTS (MEMO)
Page 9: Chapter 1 Safety Information
Chapter 1 Safety Information This chapter explains the precautions on the welding power source and welding operation. 1.1 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 10: Operating Precautions
AFETY NFORMATION HAPTER AFETY RECAUTION 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. Have only trained and experienced personnel perform operation of welding power source or welding machine.
Page 11: 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 12: Precautions For Air Discharge And Use Of Respiratory Protective Equipment
AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.3 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: • 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 13: Precautions For Flammable Materials
AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.4 Precautions for flammable materials To prevent fire, explosion and rupture, ensure to follow the instructions below: • Remove all flammables within 10 m (33 ft) 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 14: Precautions For Gas Cylinder And Gas Regulator
AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.5 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 shielding gas cylinders according to the related laws, regulations and customer's standard.
Page 15: Precautions For Disassembling And Modifying The Welding Power Source
AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.7 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 precautions below: • Do not disassemble/modify the welding power source. Disassembling/modifying by customer is out of the warranty scope.
Page 16: Principal Safety Standards
AFETY NFORMATION HAPTER RINCIPAL AFETY TANDARDS 1.3 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 Arc welding equipment Part 10: Electromagnetic compatibility (EMC) requirements IEC 60974-10, from International Electro technical Commission...
Page 17: Chapter 2 Product Specification And Configuration
Chapter 2 Product Specification and Configuration This chapter explains the specification, name of each parts and configuration of the welding power source. 2.1 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. Specification/Model Welbee Inverter P500L Model...
Page 18: 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. (mm) TRAVEL SPEED METHOD adjustment MILD STEEL 0.8/1.0/ 1.2/1.6 (*2) (*3) Enable...
Page 19: External Dimensions
RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION WELDING Penetration GAS (*1) WIRE MATERIALS WIRE DIA. (mm) TRAVEL SPEED METHOD adjustment MAG (20 % CO MILD STEEL 0.8/1.0/1.2/1.6 (*2) (*1-1) MAG (10 % CO MILD STEEL 0.8/1.0/1.2 (*2) (*1-2) STAINLESS STEEL 0.8/1.0/1.2/1.6 (*2) MIG (2 % O DC WAVE...
Page 20: Rated Duty Cycle
RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 2.1.4 Rated duty cycle This section explains the rated duty cycle of the welding power source. • Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle may result in deterioration and damage to the welding power source.
Page 21: Standard Composition
RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 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 22 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • When air-cooled welding torch (with voltage detection) is used Welding power source Base metal Ground a base metal if required by local law. Supplied unit Optional Name Remarks (*1) accessories To be prepared by the customer. Gas regulator 2.2.3 Accessory (not...
Page 23 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • At TIG welding: Welding power source Base metal Supplied unit Optional Name Remarks (*1) accessories Gas regulator To be prepared by the customer. 2.2.3 Accessory (not Welding torch supplied)) Gas hose (3 m) (*2) ○...
Page 24: Accessory (Supplied)
RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • At DC STICK welding: Welding power source Base metal Supplied unit Optional Name Remarks (*1) accessories To be prepared by the customer. Welding electrode holder 2.2.3 Accessory (not supplied)) Power cable (38mm or more) (*2) ○...
Page 25: Optional Accessories
RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • Shielding gas Use a shielding gas suitable to the welding method. Name Remarks Carbon dioxide (CO ) 100 % Argon (Ar) 80 % + Carbon dioxide (CO ) 20 % MAG gas Argon (Ar) 90 % + Carbon dioxide (CO ) 10 % MIG gas...
Page 26 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 27: Part Names
RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES 2.3 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 28: Rear Panel
RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES 2.3.2 Rear panel The section explains the rear section of the welding power source. Print circuit board Connector for connecting CAN Terminal block for Blind bush Cover for external external connections (for drawing externally connections 4.5.2 Connection of connecting wire)
Page 29: 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. 3.1 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 30: Ventilation Equipment/Partial Exhaust Facility
RANSPORTATION AND NSTALLATION HAPTER EQUIRED QUIPMENT • Use an engine generator with a damper winding that has a capacity of more than twice the rated input (kVA) of the welding power source. Generally, the recovery time of the engine generator's voltage for load change is slower than that of the commercial power source.
Page 31: Installation Environment
RANSPORTATION AND NSTALLATION HAPTER NSTALLATION NVIRONMENT 3.2 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 32 RANSPORTATION AND NSTALLATION HAPTER NSTALLATION NVIRONMENT • Equipment used for calibration or measurement; • The user shall ensure that other equipment being used in the environment is compatible; • The time of day that welding or other activities are to be carried out; Methods of reducing EMC: •...
Page 33: Transportation Procedure
RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE 3.3 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 34: 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 35: Chapter 4 Connection
Chapter 4 Connection This chapter explains the procedure for connecting the welding power source. 4.1 Precautions for Connection Procedure and Grounding This section explains the precaution 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 36: Connecting The Welding Power Source
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2 Connecting the Welding Power Source This section explains the procedure for connecting the welding power source. Follow the steps below for connection of the welding power source. • Do not turn on the input power of the welding power source until confirming the completion of connection work.
Page 37: 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 38: Connection Of Wire Feeder
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.2 Connection of wire feeder This section 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 39: Connection Of Welding Torch
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.3 Connection of welding torch This section explains the procedure for connecting the welding torch. TIPS • When the air-cooled welding torch (with voltage detection) is used, refer to “4.2.4 Connection of voltage detection cable (Voltage detection cable is used)”. When air-cooled welding torch is used Wire feeder Power cable for...
Page 40: Connection Of Voltage Detection Cable (Voltage Detection Cable Is Used)
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.4 Connection of voltage detection cable (Voltage detection cable is used) This section explains the procedure for connecting the voltage detection cable. TIPS • For connection of welding torch, refer also to “4.2.3 Connection of welding torch”.
Page 41 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.4.1 Caution on connection of voltage detection cable Voltage detection cable needs to be wired so that arc voltage can be fed back with accuracy. Be sure to check the following for reducing the influence of inductance noise. •...
Page 42: Connection At Tig Welding
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.5 Connection at TIG welding • In using the welding power source for TIG welding, prepare a welding torch by the customer. • Contrary to the normal connection, the TIG welding requires connection of the welding torch to the output terminal (base metal side).
Page 43: Connection At Dc Stick Welding
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.6 Connection at DC STICK welding • In using the welding power source for DC STICK welding, prepare a welding electrode holder by the customer. • After five seconds have passed, the safety voltage(approx.15 V） is automatically provided.
Page 44: Connection Of Shielding Gas
ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.7 Connection of shielding gas This section explains the procedure for connecting the the shielding 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 45: Grounding And Connection Of Input Power Supply
ONNECTION HAPTER ROUNDING AND ONNECTION OF NPUT OWER UPPLY 4.3 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). •...
Page 46: Confirmation Of Connection
ONNECTION HAPTER ONFIRMATION OF ONNECTION Connect the power cables (3 pcs) to the output terminals of power source at facility side. ● Input cable : AWG10 (5.3 mm ) with 10 mmΦ terminal × 3 Grounding and connection of input power supply is complete. Procedure is followed by 4.4 Confirmation of Connection.
Page 47 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT 4.5.1.1 Configuration example for connection Gas shortage/wire shortage Pack wire detection circuit Gas cylinder Signal line (*1) Internal printed circuit board Case ground Robot controller Socket for Voltage detection terminal Control cable for base metal side the wire (17 core) Manipulator...
Page 48 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT 4.5.1.2 Wiring of wire feeder In the welding of DC low spatter, wiring of the wire feeder needs to be changed and voltage detection from the torch end is required. • Perform the work after turning the input power off with the switch in the switch box connected to the welding power source.
Page 49: Connection Of Automatic Machine
ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT 4.5.2 Connection of automatic machine This section explains the procedure for connection of automatic machine with the welding power source. 4.5.2.1 Wiring for connecting automatic machine The welding power source is equipped with terminal block for external connection inside the cover for external connection at the rear.
Page 50 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT • Output signal of the external connection terminal block Welding power Output signal is open collector output. Ensure to keep the source side maximum rated power of the transistor. Maximum rated power of transistor READY: DC50 V/100 mA OUT EXT1 to 4: DC50 V/100 mA Transistor...
Page 51 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT Cover for external connections Attaching screw Cable (vinyl) Strip the cable cover b 10 to 11 mm Blind bush Button Terminal block Attaching screw Check that input power is turned off with the disconnect switch connected to the welding power source.
Page 52: Wiring Of Voltage Detection Cable At Base Metal Side
ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL 4.6 Wiring of Voltage Detection Cable at Base Metal Side When the extension cable is 30 m or more in length in total, use of the voltage detection cable at the base metal side is recommended.
Page 53: Wiring To Welding Power Source
ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL Restore the right side panel of the wire feeder. Wiring of voltage detection cable is complete. 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.
Page 54: Wiring Example Of Voltage Detection Cable
ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL 4.6.3 Wiring example of voltage detection cable This section shows the wiring examples of the voltage detection cables at the base metal side to the base metal. 4.6.3.1 Wiring examples for plural welding stages Connect the voltage detection cable at the base metal side to the stage to which the cable on the base metal side was last connected.
Page 55: Chapter 5 Welding Operation
Chapter 5 Welding Operation This chapter explains the procedures from preparation to completion of the welding operation. 5.1 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 56: Precaution For Protective Equipment
ELDING PERATION HAPTER HECK BEFORE ELDING 5.1.2 Precaution for protective equipment For protection from arc ray generated from welding, spatter and spattering dross and hearing disorder from noise, observe the following: • Wear safety goggles with sufficient blocking effect or face shield in the work area and the surrounding.
Page 57 ELDING PERATION HAPTER HECK BEFORE ELDING Check parameter Countermeasures Check The voltage detection cables at the base metal side and the torch side The voltage detection cable should be should be wired along each other. adequately wired. Keep the voltage detection cable (base metal side) at least 10 cm away from the cable at the base metal side.
Page 58: Power On And Gas Supply
ELDING PERATION HAPTER OWER UPPLY Check parameter Countermeasures Check Ensure that the torch cable has no bending at a sharp angle. If the liner is clogged with dirt or when inched wire has flaw, replace the There should be no large feeding resistance liner with a new one.
Page 59: Wire Inching
ELDING PERATION HAPTER NCHING Turn ON the power switch of the welding power supply. Check that the flow rate adjustment knob is set to "SHUT", and press the GAS CHECK key. ⇒ The LED of the GAS CHECK key lights up, turning to the gas check status (shield gas is discharged). ⇒...
Page 60: Check And Setting Of Welding Condition
ELDING PERATION HAPTER HECK AND ETTING OF ELDING ONDITION TIPS • Wire feeding is also enabled by a remote control (optional). Turning the welding current adjustment knob can adjust the feed speed. ( Operation of Analog Remote Control (Optional)) 5.5 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).
Page 61: Performing Welding Operation
ELDING PERATION HAPTER ERFORMING ELDING PERATION 5.5.2.2 Deactivating erroneous operation prevention function Press and hold the ENTER key for approximately three seconds or more again. ⇒ The LED of the ENTER key lights off, which deactivates the erroneous operation prevention function. TIPS •...
Page 62: Operation During Welding
ELDING PERATION HAPTER ERFORMING ELDING PERATION TIPS • The displayed average value is processed by the software. Note that the value cannot be guaranteed as the control data for a measurement instrument. 5.6.2 Operation during welding This section explains the operation requiring adjustment of welding current/voltage during the welding.
Page 63 ELDING PERATION HAPTER ERFORMING ELDING PERATION Press the DISPLAY CHANGE key. ⇒ The displays on the left/right digital meters return to the display of current/voltage in welding. TIPS • When no operation is performed for approximately 5 seconds, the display will return to the one showing current/voltage in welding.
Page 64: 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. Main valve GAS CHECK key Flow rate Welding power adjustment knob source SHUT Shut off Power switch Welding power source...
Page 65: 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. 6.1 List of Welding Conditions This section explains the parameters/functions settable in the welding power source. 6.1.1 Parameter (Welding parameter) Parameter Set Range Initial Value...
Page 66: Internal Function
ELDING ONDITION HAPTER IST OF ELDING ONDITIONS 6.1.3 Internal function Details of internal function ( Setting Internal Functions) The functions with circle mark (O) on the Memory row can be stored with the welding conditions. Function Name Setting range Initial value Explanation Memory Sets the waveform control mode for voltage...
Page 67 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 Low input voltage Adjusts the low primary input voltage detection 260 to 400 320 (V)
Page 68 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Sets whether to read "1" to "10" of the welding conditions stored on the memory via the analog Reading welding conditions OFF/ON remote control: with remote control OFF: Not to read ON: Reads Sets the initial condition and crater condition as...
Page 69 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Arc loss detection time Arc start error detection time WCR output ON Used when connecting with OTC automatic OFF (fixed) delay time machine. WCR output OFF delay time Analog setting switch Pulse peak current fine...
Page 70: Function On Operation Panel
ELDING ONDITION HAPTER UNCTION ON PERATION ANEL 6.2 Function on Operation Panel This section explains the function of displays and keys arranged on the operation panel. WARNING m/min. sec. LOAD JOB No. INITIAL WELD CONDI MONITOR CONTROL -TION MAIN CONSTANT PENETRATION CONDITION SAVE m/min.
Page 71 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Name Function Select the TRAVEL SPEED to apply. (*1) • The LED of the parameter in selection lights up. TRAVEL SPEED key • Some option is invalid depending on the combination of the wire diameter, wire material, gas and the welding method.
Page 72: Welding Conditions
ELDING ONDITION HAPTER ELDING ONDITIONS Name Function Select air-cooled welding torch or water-cooled welding torch to be used. Switching the mode is enabled by pressing the key. TORCH key • When the LED is ON: water-cooled welding torch mode • When the LED is OFF: air-cooled welding torch mode Sets welding voltage.
Page 73: Preparing Welding Conditions
ELDING ONDITION HAPTER REPARING ELDING ONDITIONS • Synergic adjustment of voltage ( Function on Operation Panel) Using the VOLT.ADJUST key enables to automatically set the welding voltage according to the welding current. Fine adjustment of the welding voltage automatically set is also available. •...
Page 74: Memory Function Of Welding
ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS • The welding conditions (electronic data) stored by this function are susceptible to occurrence of static electricity, impact, repair, etc., and there is a possibility that the stored contents may be changed or lost. BE SURE TO MAKE A COPY FOR IMPORTANT DATA.
Page 75: Read Out Of Welding Conditions
ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Press the ENTER key. ⇒ The LED of ENTER key flashes. 3 sec. ⇒ Pressing the DISPLAY CHANGE key enables to ENTER check the value of welding parameter registered in the JOB No. to overwrite. The setting values are 3 sec.
Page 76: Deletion Of Memory Registration
ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Press the ENTER key. ⇒ The LED of ENTER key flashes. 3 sec. ⇒ Pressing the DISPLAY CHANGE key enables to ENTER check the set values of welding conditions (welding parameters) to read out. The setting values are 3 sec.
Page 77: Setting Welding Conditions
ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Turn the parameter adjustment knob, and select the JOB No. to delete. ● To delete all the registration at the same time, turn the parameter adjustment knob counterclockwise, to display "ALL" on the right digital meter. When "ALL"...
Page 78 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS WELDING Penetration GAS (*1) WIRE MATERIALS WIRE DIA. (mm) TRAVEL SPEED METHOD adjustment MILD STEEL 0.8/1.0/ 1.2/1.6 (*2) (*3) Enable MILD STEEL CORED 1.2/1.6 STANDARD (*3) Enable STAINLESS CORED 1.2/1.6 STANDARD (*3) Enable MILD STEEL 0.8/1.0/1.2/1.6 (*2) (*3) Enable...
Page 79 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS *1: Note that the "collective" voltage adjustment may not meet the appropriate condition if a mixing gas other than those with the following mixing ratios is used. *1-1: MAG gas: Argon (Ar) 80 % + Carbon dioxide (CO )20 % *1-2: MAG gas: Argon (Ar) 90 % + Carbon dioxide (CO )10 %...
Page 80: Setting Welding Parameter
ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Press the WELDING METHOD key, and select the welding method to apply. Press the WIRE MATERIALS key, and select the wire material to apply. Press the GAS key, and select the shielding gas to apply. Press the WIRE DIA.
Page 81 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.2.2 Welding parameter setting This section explains how to set the welding parameters (gas discharge time, welding current/voltage) according to the welding sequence. Parameter adjusting knob WARNING m/min. sec. JOB No. INITIAL CONDI CONTROL CURRENT SETTING -TION MAIN...
Page 82: Crater Setting
ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Set the welding voltage. ● Check the lighting on the LED "V" (unit of welding voltage). When the LED is lights off, press the "VOLTAGE SETTING DISPLAY SWITCH" key to light up the LED. ●...
Page 83 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Pattern No. Crater setting WELDING METHOD TRAVEL SPEED WIRE MATERIALS DC PULSE/ no pulse HIGH Al/Mg DC WAVE PULSE DC PULSE/ no pulse HIGH Brazing Cu Si DC WAVE PULSE DC PULSE/ no pulse HIGH Brazing Cu Al DC WAVE PULSE...
Page 84 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.3.2 Crater "ON" (no initial condition) Select "CRATER-FILL ON (no pulse) " or "CRATER-FILL ON (with pulse)" by the CRATER-FILL key to light off the LED of the INITIAL CONDITION key. • 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 85 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.3.3 Crater "ON" (with initial condition) Select "CRATER-FILL ON (no pulse) " or "CRATER-FILL ON (with pulse)" by the CRATER-FILL key to light on the LED of the INITIAL CONDITION key. • 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 86: Arc Spot Time
ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.4 Arc spot time This section explains the details of arc spot and torch switch operation. Selecting "ARC SPOT" by the CRATER-FILL key 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 87: Arc Characteristics Adjustment
ELDING ONDITION HAPTER ETTING ELDING ONDITIONS ■SYNERGIC mode Press the VOLT.ADJUST key. When the LED of the key is ON, it means the SYNERGIC mode is applied. • The welding voltage is automatically set to the values corresponding to the welding current. •...
Page 88: Adjustment Of Wave Frequency
ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.8 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.
Page 89 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS Select the welding sequence to adjust. ● Press the DISPLAY CHANGE key, and select either "INITIAL CONDITION", "MAIN CONDITION" or DISPLAY "CRATER-FILL CONDITION". CHANGE ⇒ The LED for the selected welding sequence lights up. MAIN CONDITION m/min.
Page 90: Setting Internal Functions
ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7 Setting Internal Functions This section explains how to set the internal functions with the details. The internal functions can be customized according to the using environment of the customer for further convenient use of the welding power source. 6.7.1 Setting procedure This section explains how to set the internal functions.
Page 91: Detailed Information On Internal Functions
ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Turn the parameter adjustment knob, and change the setting value. ⇒ The set value is activated as it is changed. ⇒ Pressing the F (Function) key enables to return the display to the status described in step 1. WARNING m/min.
Page 92 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Setting Parameter 0 (Semi-automatic) 1 (Automatic machine 1) 2 (Automatic machine 2) After short-circuiting the pins [3]-[4] operation stop Cancellation of operation terminals on the external Short-circuit the operation stop terminal pins [3]-[4] on the stop connection terminal block external connection terminal block TM3.
Page 93 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.3 F5: Maximum external command voltage When the internal function F4 (Auto/Semi-auto mode) is used with the setting of "1", set the maximum value of command voltage input from outside. Select either from 10 V, 14 V, or 15 V. The below charts show the relationship between current/voltage command voltage and welding current/voltage.
Page 94 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.7 F9: Analog remote control scale Change the setting of the scale plate of analog remote control when using the optional analog remote control. Rated output current of welding power Applicable scale and scale plate source 350 A 350/200...
Page 95 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); ‒ Internal function F45 (Special crater sequence) is set to "ON" (enabled); ‒ Internal function F48 (Adjusting current with torch switch) is set to "ON" (enabled); or ‒ Internal function F51 (Special crater repeat) is set to "ON" (enabled); or ‒ Either of the internal functions F29 to F32 (External input terminal setting) is set to either "4" (Start) or "5" (Loading welding condition). ‒ Internal function F4 (Auto/Semi-auto mode) is set to a value other than "0" (Semi-auto mode). 6.7.2.10 F12: Operation time of water-cooled pump Sets the operation time of water-cooled pump after welding ends.
Page 96 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.12 F16: Slowdown speed adjustment Slow-down speed is the speed to slowly feed the wire from the time of the machine start to the time of arc start. The slowdown speed is automatically set to an appropriate speed depending on the welding method and wire diameter;...
Page 97 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.15 F20: Low input voltage detection level Set the low input voltage detection level on the primary side. When the input voltage is lower than the set value, an error code is displayed. Set the value in the range of 260 to 400 V. TIPS •...
Page 98 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.19 F24: Wire feeding speed setting The welding current can be automatically set based on the wire feed speed. • [ON]: enables the function. ‒ The welding power source is automatically set based on the wire feed speed. ‒ Even when the welding mode is changed by the GAS key, the welding current is automatically set based on the set wire feed speed. ‒ Each pressing the CURRENT SETTING DISPLAY SWITCH key, the wire feed speed display and the welding current display switches alternatively. Switch to the wire feed speed display, and set the feed speed in the unit of 0.1 m/min. ‒ Switching to the welding current display can check the welding current value automatically set.
Page 99 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.20 F25 to F28: External output terminal setting (reserved) The external output terminals (OUT-EXT1 to EXT4 on the external output terminal TM4) are used in connection with the automatic machines of other manufacturers. 6.7.2.21 F29 to F32: External input terminal setting Set the function of external input terminals.
Page 100 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS JOB No. Function (external input terminal) (Registration F29(IN-EXT1) F30(IN-EXT2) F31(IN-EXT3) F32(IN-EXT4) No.) OFF (open) OFF (open) OFF (open) ON (close) ON (close) OFF (open) OFF (open) ON (close) OFF (open) ON (close) OFF (open) ON (close) ON (close) ON (close)
Page 101 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 102 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS TIPS • In short arc welding where short-circuiting and arc are repeated, most of spatter is generated when short-circuit is caused and immediately before arc generation. In the latter timing which is immediately before arc generation, a phenomenon called [Squeeze] shown in the below figure occurs on the wire.
Page 103 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.24 F35: Saving [Squeeze] detection sensitivity Sets whether to return the sensitivity corrected by F34 (Automatic correction of [Squeeze] detection sensitivity) to the initial value when welding completes or maintain it after welding completes. •...
Page 104 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.26 F38: Arc voltage direct detection switching Sets the status of the voltage direct detection terminal on the base metal side of the welding power source or 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 or erroneous pulse welding.
Page 105 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS NOTE • Do not carelessly change the setting of this function. 6.7.2.29 F43: CAN ID When multiple welding power sources are connected with a PC monitoring system, set ID for CAN. 6.7.2.30 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.
Page 106 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.31 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 107 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.32 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) If this function is enabled, the LED of "CRATER-FILL ON"...
Page 108 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.33 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 109 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Example: In the setting examples of Initial welding current: 80 A; Main welding current: 100 A; and Crater current: 60 A, the following diagram is available: Single (within 0.3 sec.) Press 0.3 sec. or more Torch switch 100 A 100 A...
Page 110 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.37 F53: Sampling speed of data log function Selects the data sampling interval in using data log function. The relationship between the setting value and the data sampling is as follows: Setting Sampling interval 10 ms 100 ms For data log function;...
Page 111 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS • For optimum fine adjustment: For fine adjustment of unit pulse condition, first adjust the pulse peak time. ‒ When large droplet and unstable arc (droplet transfer) occurs, adjust to a longer pulse peak time. ‒ Adjust to a shorter pulse peak time when tip of wire becomes sharp and extremely strong arc occurs. For more improvement, adjust the pulse peak current following the same steps as pulse peak time adjustment.
Page 112 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.44 F64: Fine adjustment of L pulse peak time This function allows fine adjustment of the standard pulse peak time at LOW side in the pulse condition of the wave pulse welding; by setting the adjustment value, finely adjusted pulse peak time at LOW side can be obtained.
Page 113 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.47 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 114: Operation Of Analog Remote Control (Optional)
ELDING ONDITION HAPTER PERATION OF NALOG EMOTE ONTROL PTIONAL 6.8 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 115: Chapter 7 Administrator Functions
Chapter 7 Administrator Functions This chapter explains the functions used by administrators such as protection and initialization of welding conditions. 7.1 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 panela password will be requested to disable the erroneous operation prevention function.
Page 116 DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING ONDITIONS Turn off the power switch. Press and hold the F (function) key and the ENTER key simultaneously and turn on the power switch. ● Hold the two keys pressed down until "Loc" is displayed on the left digital meter.
Page 117: Disabling Erroneous Operation Prevention
DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING ONDITIONS 7.1.2 Disabling erroneous operation prevention This section explains how to disable the password-protected erroneous operation prevention function. • To change the password on the way, press the DISPLAY CHANGE key and move the digit position to the hundreds place.
Page 118: Welding Result Control Function
DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION 7.2 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 999 Target value of welding points (number of times)
Page 119: Details Of Welding Control Items
DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION With the parameter adjusting knob and the WELD MONITOR key, select the desired monitor No. ● Turning the parameter adjusting knob will change the tens place digit of monitor No. (Example: "P10" - WELD >...
Page 120 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION Set value Operation The count value is cleared when the target is achieved (*1) Operation is continued after the target is achieved (*2) Enable Enable Enable Enable Disabled Disabled The count value is cleared when the power is turned on *1: When an alarm is displayed, pressing any key of the operation panel can also clear the count value.
Page 121 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION 7.2.2.3 Total welding time The total welding time is controlled according to the setting range. • P30 (Cumulative total welding time) Every interval from the start of current flowing triggered by the torch switch ON to the stop of output triggered by the torch switch OFF is counted and accumulated as welding time.
Page 122 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION • P45 (WARNING judgment time) Select the time to judge the event as an error in the range from 0 to 100 seconds when the average current/ voltage (average per second) during welding is out of the allowable tolerance range. When the out-of-range state becomes longer than the time specified here, an alarm displays.
Page 123: Data Backup (Utilization Of Data)
• Compatibility of the following USB flash drives has been confirmed. Model No.: SFU22048E3BF2SA-W-D0-111-STD (swissbit) Model No.: SFU22048E1BP2TO-W-D0-111-STD (swissbit) • There is software allowing you to easily display waveforms and edit welding conditions. You can download it from our home page. URL: http://www.daihen.co.jp/yosetsu/other/download.html...
Page 124: 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 125 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Column Item Description Unit Column Item Description Unit Pulse peak current pls_pki_adj 1(A) CreIsetPer (reserved) ＳＡＳ fine adjustment Pulse peak time Torch switch pls_pkt_adj 0.1(ms) TsCrickIset 0/1(OFF/ON) ＴＡＴ fine adjustment current adjustment Base current fine Single click pls_bsi_adj...
Page 126: Simplified Data Log Function
DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.2 Simplified data log function The welding status can be checked on a computer by sampling the data during welding and backing them up in the USB memory. Only three of the following data can be sampled. •...
Page 127: Failure Log Function
DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.3 Failure log function It is possible to record the latest ten error codes. (The data and time of occurrence will not be recorded.) The failure log data will be recorded in the "DAIHEN_OTC_WELDING_ABN.CSV" file. The leftmost record in the table shows the latest failure log and the records are older as they are closer to the right side.
Page 128: Importing Backup Data
DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Press the LOAD key. ⇒ The LED of ENTER key flashes. LOAD 3 sec. ENTER Press the ENTER key. ⇒ Data backup starts. During backup, the display of 3 sec. right digital meter changes. ENTER ⇒...
Page 129: Initializing Welding Conditions And Internal Functions
DMINISTRATOR UNCTIONS HAPTER NITIALIZING ELDING ONDITIONS AND NTERNAL UNCTIONS Turn the parameter adjusting knob counterclockwise to display "USb" on the left digital meter. Select the data to import. ● Turn the parameter adjusting knob further counterclockwise to display the data to import on the right digital meter.
Page 130: Checking Software Version
DMINISTRATOR UNCTIONS HAPTER HECKING OFTWARE ERSION Turn off the power switch. Press and hold the F (function) key and GAS CHECK key simultaneously and turn on the power switch. ● Hold the two keys pressed down until "End" is displayed on the left/right digital meters. ⇒...
Page 131: Chapter 8 Maintenance And Inspection
Chapter 8 Maintenance and Inspection This chapter explains the daily and periodical inspection of the welding power source. 8.1 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 132 AINTENANCE AND NSPECTION HAPTER RECAUTIONS FOR AINTENANCE AND NSPECTION To prevent damage and problem of the welding power source and loss of the data, ensure to follow the instructions below: • The welding conditions (electronic data) stored by this function are susceptible to occurrence of static electricity, impact, repair, etc., and there is a possibility that the stored contents may be changed or lost.
Page 133: Daily Inspection
AINTENANCE AND NSPECTION HAPTER AILY NSPECTION 8.2 Daily Inspection This section explains the daily inspection of the welding power source. Perform daily inspection for the following items in the table. Front and rear panel 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 134: Periodical Inspection
AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION 8.3 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 135: Periodical Replacement Parts
AINTENANCE AND NSPECTION HAPTER ERIODICAL EPLACEMENT ARTS 8.4 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 136 AINTENANCE AND NSPECTION HAPTER NSULATION ESISTANCE EASUREMENT AND ITHSTAND OLTAGE ‒ Short-circuit the positive (+) and the negative ( - ) sides of the output terminal. ‒ Unground all the case grounding cables (line No.80, total of 6 positions) and insulate them with insulation tape. ‒ For DR1, 2 and 4, short-circuit the AC side and positive (+) output side and the AC side and negative ( - ) output side respectively. ‒ Short-circuit between TR1 (C1) and (E1C2), TR1 (E1C2) and (E2), TR3 (C2) and (E2). ‒ Apply NF. ‒ After finishing insulation resistance measurement, return the above to the original state. • After finishing insulation resistance measurement, it is necessary to remove the shortcircuit cables and return the welding power source to the original state. If the power is turned on without returning it to the original state, the welding power source will burn out.
Page 137: Chapter 9 Troubleshooting
Chapter 9 Troubleshooting This chapter explains the typical troubleshooting for the welding power source. The cause of problems can be categorized as below: • Mechanical problems (e.g., problems of driving mechanism of the wire feeder) • Electric and control problems •...
Page 138 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error 000 There is no load between the • Identify the cause of no load between the STOP terminals (3-4) of the terminal STOP terminals (*1) block TM3 for external connection.
Page 139 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error 700 An over current was detected at • Check that the chip at the end of torch is not contacting the base metal. the output side of the welding •...
Page 140: Troubleshooting
ROUBLESHOOTING HAPTER ROUBLESHOOTING 9.2 Troubleshooting This section explains the typical problems other than the error codes, their causes, and how to cope with them. Check the table below before requesting repair service. • Before inspecting the welding power source, make sure to read "8.1 Precautions for Maintenance and Inspection".
Page 141 ROUBLESHOOTING HAPTER ROUBLESHOOTING Problem Possible cause Corrective action The erroneous prevention The welding conditions cannot function to prevent malfunction be set with the operation panel. Press and hold the ENTER key three seconds or of the operation panel is The welding mode does not more to disable the erroneous operation prevention enabled.
Page 142 ROUBLESHOOTING HAPTER ROUBLESHOOTING...
Page 143: Chapter 10 Reference Materials
Chapter 10 Reference Materials This chapter contains the parts list of welding power source, reference materials for setting the welding conditions, and related regulations for use of the welding power source. 10.1 Parts List This section shows the parts list of welding power source. •...
Page 144 EFERENCE ATERIALS HAPTER ARTS Code Part No. Product Name Specifications Q’ty Remarks R15a,b 100-1431 Wire wound resistor W-W03824(SMR 220W 1.6Ω) 100-0662 Thermistor EC2F103A2-40113 R19a, b 100-1432 Winding resistor FHN50 471J/RO R20,21 100-0234 Carbon resistor RD20S 1KΩJ TR3,4 100-1571 Winding resistor CS1P 100ΩJ 4509-918 Carbon resistor...
Page 145 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. 10-3...
Page 146 EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.1 Schematic diagram 10-4...
Page 147 EFERENCE ATERIALS HAPTER EFERENCE RAWING 10-5...
Page 148 EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.2 Parts layout drawing 10-6...
Page 149 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 150 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Plate Leg length Wire diameter Current Voltage Travel speed gas flow rate thickness L (mm) (mmΦ) (cm/min) (L/min) t(mm) 5.0 to 6.0 250 to 280 26 to 29 40 to 50 15 to 20 6.0 to 7.0 280 to 300 29 to 32...
Page 151 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Example for welding conditions of single and double grooves Plate Root Wire Travel Root face Current Voltage Number of thickness Bevel shape opening diameter speed flow rate h(mm) layers t(mm) g(mm) (mmΦ) (cm/min) (L/min) 300 to 350...
Page 152 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 L(mm) (mmΦ) (cm/min) 10.3.2.3 Example of MAG short arc welding Material: Mild steel Gas: Ar + CO mixed gas (10 to 15 L/min)
Page 153 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 Number Current Voltage Travel speed thickness length Aim angle and position of layers (cm/min) t(mm) (mm) 3 to 4 26 to 27 26 to 27...
Page 154 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 (cm/min) t(mm) 25 to 26 26 to 27 29 to 30 30 to 31 30 to 31 12.0...
Page 155 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Plate Number Current Voltage Travel speed thickness Bevel shape of layers (cm/min) t(mm) 180 to 190 24 to 25 12.0 25 to 26 26 to 27 24 to 25 19.0 29 to 30 29 to 30 Root path oscillation width: 2 mm Number of oscillation: 120 times/min.
Page 156 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Number Current Voltage Bevel shape Remarks of layers 100 to 200 20 to 22 No oscillation 2 to 8 24 to 25 No oscillation 9 to 12 24 to 25 No oscillation 10.3.2.5 Example for welding conditions of aluminum pulse MIG Example welding conditions of I shape butt Plate...
Page 157 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 Wire diameter Current Voltage Travel speed Wire feeding Gas flow rate thickness (mmΦ) (cm/min) length (mm) (L/min) t(mm)
Page 158 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10-16...

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Otc welbee wb-p500l

Daihen OTC Welbee P500L Owner's Manual

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Important Information

Chapter 1 Safety Information

Warning Symbols

Safety Precaution

Principal Safety Standards

Chapter 2 Product Specification and Configuration

Specification

Product Configuration

Part Names

Chapter 3 Transportation and Installation

Required Equipment

Installation Environment

Transportation Procedure

Chapter 4 Connection

Precautions for Connection Procedure and Grounding

Connecting the Welding Power Source

Grounding and Connection of Input Power Supply

Confirmation of Connection

Connection of External Equipment

Wiring of Voltage Detection Cable at Base Metal Side

Chapter 5 Welding Operation

Precaution at Welding Operation

Check before Welding

Power on and Gas Supply

Wire Inching

Check and Setting of Welding Condition

Performing Welding Operation

Chapter 6 Welding Condition

List of Welding Conditions

Function on Operation Panel

Welding Conditions

Preparing Welding Conditions

Memory Function of Welding

Setting Welding Conditions

Setting Internal Functions

Operation of Analog Remote Control (Optional)

Chapter 7 Administrator Functions

Protection of Welding Conditions

Welding Result Control Function

Data Backup (Utilization of Data)

Initializing Welding Conditions and Internal Functions

Checking Software Version

Chapter 8 Maintenance and Inspection

Precautions for Maintenance and Inspection

Daily Inspection

Periodical Inspection

Periodical Replacement Parts

Insulation Resistance Measurement and Withstand Voltage Test

Chapter 9 Troubleshooting

Action in Case of Error

Troubleshooting

Chapter 10 Reference Materials

Parts List

Quick Links

Troubleshooting

Need help?

Questions and answers

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