Daihen OTC Welbee WB-M350 Owner's Manual
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Daihen OTC Welbee WB-M350 Owner's Manual

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Welbee Inverter
OWNER'S MANUAL
Model: WB-M350
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.
CO /MAG
Welding power source
DAIHEN Corporation
2
M350
November, 2015
Manual No. : 1P30201-1

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Summary of Contents for Daihen OTC Welbee WB-M350

  • 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. November, 2015 Manual No. : 1P30201-1 DAIHEN Corporation...

  • 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

    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

    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.
  • Page 7 ABLE OF ONTENTS 6.5.3 Deletion of memory registration ... 6-12 10.3 Materials for Setting Welding Conditions ......10-6 6.6 Setting Welding Conditions .
  • 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

    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 Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.

  • 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 M350 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. [in. (mm)] TRAVEL SPEED METHOD adjustment 030 / .035 / .040 /.045 MILD STEEL (*2) (*3)

  • Page 19: 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)

  • 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 • At TIG welding: Welding power source Base metal Required Optional Name Remarks component accessories Gas regulator To be prepared by the customer. 2.2.3 Accessory (not Welding torch supplied)) Gas hose [118.1" (3 m)] (*1) Included in feeder ○...

  • Page 23: Accessory (Supplied)

    RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • At DC STICK welding: Welding power source Base metal Required Optional Name Remarks component accessories To be prepared by the customer. Welding electrode holder 2.2.3 Accessory (not supplied)) Power cable [AWG2 (38mm ) or more] (*1) ○...

  • Page 24: Accessory (Not Supplied)

    RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 2.2.3 Accessory (not supplied) This section explains the accessories to be prepared by the customer before operating the welding power source. Prepare the following: • Shielding gas Use a shielding gas suitable to the welding method. Name Remarks Carbon dioxide (CO...
  • Page 25 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION 2.2.4.2 Details on extension cables and hoses Following extension cables and hoses are optionally available. For extending the working radius, use extension cable and hose according to the working radius. • When using extension cables, roll them out. Winded extension cable may cause an unstable arc.

  • Page 26: Part Names

    RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES 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 27: 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 28 RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES 2-12...

  • 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: 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 33: 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 34: 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 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. When air-cooled welding torch is used Wire feeder Power cable for torch side When water-cooled welding torch is used Condensing water port (red collar) Feeding water port...

  • Page 40: Connection At Tig Welding

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.4 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 41: 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 42: Connection Of Shielding Gas

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.6 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 43: 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 44: Confirmation Of Connection

    ONNECTION HAPTER ONFIRMATION OF ONNECTION Connect the power cables (3 pcs) to the output terminals of power source at facility side. ) with 0.4" Φ (10 mmΦ) terminal × 3 ● Input cable : AWG6 (13.3 mm Grounding and connection of input power supply is complete. Procedure is followed by 4.4 Confirmation of Connection.
  • Page 45 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 46: 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 47 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 48 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT Cover for external connections Attaching screw Cable (vinyl) Strip the cable cover by 25/64 to 7/16" (10 to 11 mm) Blind bush Button Terminal block Attaching screw Check that input power is turned off with the disconnect switch connected to the welding power source.

  • Page 49: 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 118.1" (30 m) or more in length in total, use of the voltage detection cable at the base metal side is recommended.

  • Page 50: 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 51: 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 52 ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL 4-18...

  • Page 53: 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 54: 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 55 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 3.9" (10 cm) away from the cable at the base metal side.

  • Page 56: 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 57: 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 58: 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 59: 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 60: 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 61 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 62: Operation At Welding End

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

  • Page 63: Chapter 6 Welding Condition

    Chapter 6 Welding Condition This chapter explains the functions on the operation panel as well as how to set the welding conditions. 6.1 List of Welding Conditions This section explains the parameters/functions settable in the welding power source. 6.1.1 Parameter (Welding parameter) Set Range Initial Parameter...

  • Page 64: 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 65 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Sets the output status when an error of the alarm level is detected: Alarm setting switching OFF/ON OFF: Ineffective ON: Stops the output Low input voltage Adjusts the low primary input voltage detection 140 to 460 160 (V)
  • Page 66 ELDING ONDITION HAPTER IST OF ELDING ONDITIONS Function Name Setting range Initial value Explanation Memory Special crater sequence Sets initial time in the special crater sequence. 0.0 to 10.0 0.0 (s) ○ initial time (available when "ON" is selected in F45) Special crater sequence Sets crater time in the special crater sequence.

  • Page 67: Function On Operation Panel

    ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Function Name Setting range Initial value Explanation Memory No function OFF (fixed) No functions are provided. When “CRATER ON” is selected, sets the current value of the initial condition and crater condition Setting change of current in the percentage based on the current value of value (initial condition, crater OFF/ON...
  • Page 68 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Name Function Sets welding current/wire feed speed. The value in setting is displayed on the left digital CURRENT SETTING DISPLAY meter, which can be adjusted by the parameter adjustment knob. Switching the mode is SWITCH key enabled by pressing the key.
  • Page 69 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Name Function Sets the welding time when "ARC SPOT" is selected by the CRATER-FILL key. ( 6.6.4 spot time) SPOT TIME key Pressing this key makes the LED lit, enabling to adjust the welding time by the parameter adjustment knob.

  • Page 70: Welding Conditions

    ELDING ONDITION HAPTER ELDING ONDITIONS 6.3 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 71: Preparing Welding Conditions

    ELDING ONDITION HAPTER REPARING ELDING ONDITIONS 6.4 Preparing Welding Conditions This section explains the setting process of basic welding conditions. Check welding material suitable for the welding condition 10.3 Materials for Setting Welding Conditions) ↓ Setting wire material, shield gas, and TRAVEL SPEED 6.6.1 Welding mode setting) ↓...

  • Page 72: Memory Function Of Welding Conditions

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS 6.5 Memory Function of Welding Conditions This section explains the memory function of welding conditions. The welding power source is equipped with the function to register the welding conditions and reads them out for use. The number of welding conditions that are able to be registered are 100 at maximum. Single welding condition can contain the following information at registration: •...

  • Page 73: Read Out Of Welding Conditions

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Turn the parameter adjustment knob, and select the JOB No. ⇒ When there is no registration data on the selected JOB No., "- - -" is displayed on the left digital meter. ⇒...

  • Page 74: Deletion Of Memory Registration

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Turn the parameter adjustment knob, and select the JOB No. to read out. ⇒ When there is no registration data on the selected JOB No., "- - -" is displayed on the left digital meter. ⇒...
  • Page 75 ELDING ONDITION HAPTER EMORY UNCTION OF ELDING ONDITIONS Turn off the power switch. With the LOAD key and the SAVE key depressed together, turn ON the power switch. ● Depress these two keys until "dEL" is displayed on the left digital meter. Release the keys after "dEL" is LOAD displayed.

  • Page 76: Setting Welding Conditions

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6 Setting Welding Conditions This section explains how to set the welding conditions (welding mode or welding parameters). 6.6.1 Welding mode setting Available combination of the welding mode is listed in the table below. Selecting unavailable combination displays “- - -“...

  • Page 77: Setting Welding Parameter

    ELDING ONDITION HAPTER ETTING ELDING ONDITIONS CONSTANT PENETRATION key WARNING IPM. sec. LOAD JOB No. INITIAL WELD CONDI MONITOR CONTROL -TION MAIN CONSTANT PENETRATION CONDITION IPM. SAVE SYNERG. WATER SYNERG. 3 sec. INITIAL DISPLAY CRATER-FILL INDIV. POST CONDITION CONDITION CHANGE FLOW FLOW TORCH...
  • Page 78 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.2.1 Welding sequence The basic welding sequence is the process of PRE FLOW, MAIN CONDITION, and POST FLOW. To this sequence, initial condition and crater condition can be added depending on the crater setting. The welding parameters such as gas discharge time, welding current and voltage should be set to this sequence.

  • Page 79: 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"). ● Check the lighting on the LED "A" (unit of welding current). When the LED is lights off, press the "CURRENT SETTING DISPLAY SWITCH"...
  • Page 80 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS The above-mentioned mode switches in the following order by each pressing the CRATER-FILL key. "CRATER FILL OFF" - "CRATER FILL ON " - "CRATER FILL ON (REPEATED)" - "Arc Spot". 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.
  • Page 81 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.3.2 Crater "ON" (no initial condition) Select "CRATER-FILL ON" 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 82 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.3.3 Crater "ON" (with initial condition) Select "CRATER-FILL ON" 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 83 ELDING ONDITION HAPTER ETTING ELDING ONDITIONS 6.6.3.4 Crater (Repeated) Select “CRATER-FILL ON (REPEATED)” by the CRATER SWITCH key. • The torch switch operation until the crater treatment is the same with the welding of “CRATER-FILL ON”.  ( 6.6.3.2 Crater "ON" (no initial condition)) •...

  • Page 84: 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 85: 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 86: 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 87: 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 IPM.
  • Page 88 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Setting Parameter 5 (Automatic machine 3) 0 (Semi-automatic) 1 (Automatic machine 1) 2 (Automatic machine 2) (*6) After short-circuiting the pins [3]-[4] operation stop Cancellation of terminals on the Short-circuit the operation stop terminal pins [3]-[4] on the external connection operation stop external connection terminal block TM3.
  • Page 89 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS *5: For the applicable plug of analog remote control receptacles: See specification DPC25-6A/Part No. 4730-009. *6: If you want to use Automatic machine 3, conditions will change for the following functions. • F5 (Maximum external command voltage) : Fixed to "10.0V" •...
  • Page 90 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.4 F6: Upslope time When the difference between the initial current and welding current is large, the wire may burn up at the change of the conditions. In this case, adjust the time period changing from the initial current to the welding current (upslope time) longer.
  • Page 91 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.9 F11: Fine adjustment of welding conditions memory When the analog remote control (optionally available) is used, fine adjustment of the welding current and welding voltage of welding condition stored on the welding condition memory is available. This function is effective when the internal function F4 (Auto/Semi-auto mode) is set to "0".
  • Page 92 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.11 F14/F15: Start control (time/current) adjustment Set the time and current for start control to be performed at the time of welding start. Depending on the welding conditions and set current value, the appropriate time and current for start control are determined;...
  • Page 93 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.13 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 94 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.17 F22: Operation sound switching Set the operation sound not to be emitted. • [ON]: Pressing any key on the operation panel enables to sound the operation sound. • [OFF]: Pressing any key on the operation panel does not enable to sound any operation sound. 6.7.2.18 F23: Sleep mode switching time When the welding power source is not operated for a fixed period of time, it can be turned into the sleep mode.
  • Page 95 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. –...
  • Page 96 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 97 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.) ON (close) OFF (open) ON (close) ON (close) OFF (open) ON (close) ON (close) ON (close) ON (close) ON (close) ON (close) ON (close) The external input terminal without the setting "5"...
  • Page 98 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 99 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.22 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.
  • Page 100 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS NOTE • Do not carelessly change the setting of this function. 6.7.2.25 F43: CAN ID When multiple welding power sources are connected with a PC monitoring system, set ID for CAN. 6.7.2.26 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 101 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.27 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 102 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.28 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 103 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.29 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 104 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 105 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.33 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 106: 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 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. 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 108 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 109: 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 110: 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 111: 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 112 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 113 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 114 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 115: 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 116: 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 117 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Column Item Description Unit Column Item Description Unit Welding feeding 3.9 IPM Double click wld_feed CriIsetStep2 1(A) Ｖ ＡＶ speed [0.1(m/min)] adjustment value Crater feeding 3.9 IPM cre_feed reserve Reserved Ｗ ＡＷ speed [0.1(m/min)] Checksum reserve...

  • Page 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124 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 125: Daily Inspection

    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 126: 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 127: Periodical Replacement Parts

    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 128 AINTENANCE AND NSPECTION HAPTER NSULATION ESISTANCE EASUREMENT AND ITHSTAND OLTAGE – 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)-(E1), TR2(C2)-(E2), TR4(C2)-(E2), TR5(C1)-(E1), TR5(C2)-(E2). –...

  • Page 129: 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 130 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 131 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error 500 Lack of water pressure (*1) • Check for water leakage from the cooling water hose and ensure that sufficient cooling water is available. When using the air-cooled torch, check that LED of the TORCH key on the operation panel is off.

  • Page 132: 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 133 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 134 ROUBLESHOOTING HAPTER ROUBLESHOOTING...

  • Page 135: 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 136: Reference Drawing

    EFERENCE ATERIALS HAPTER EFERENCE RAWING Code Part No. Product Name Specifications Q’ty Remarks 100-0234 Carbon resistor RD20S 1kΩJ 100-2224 Metal film resistor RPM200Z A2.5ohm J ZOO 100-2225 Metal film resistor RPM200Z A20ohm J ZOO C1 to 4 100-1433 Ceramic capacitor DE0805E222Z2K C5,6 100-1434...

  • Page 137: Schematic Diagram

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.1 Schematic diagram 10-3...
  • Page 138 EFERENCE ATERIALS HAPTER EFERENCE RAWING 10-4...

  • Page 139: Parts Layout Drawing

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.2 Parts layout drawing 10-5...
  • Page 140 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 141 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Plate Leg length Wire diameter Current Voltage Travel speed gas flow rate thickness L [in. (mm)] [in. (mm) Φ] [IPM (cm/min)] [CFH (L/min)] t [in. (mm)] 1/8 to 9/64 .035 to .045 20 to 24 32 to 42 12 ga.
  • Page 142 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Example for welding conditions of I shape butt (without backing plate) Plate gas flow rate Root opening Wire diameter Current Voltage Travel speed Number thickness g [in. (mm)] [in. (mm) Φ] [IPM (cm/min)] of layers [CFH (L/min)] t [in.
  • Page 143 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS Plate Root Wire Travel Root face thickness opening diameter Current Voltage speed Number of flow rate Bevel shape h [in. layers t [in. g [in. [in. (mm) [IPM (cm/ [CFH (L/ (mm)] (mm)] (mm)] Φ]...
  • Page 144 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING ONDITIONS 10.3.2.2 Example of MAG short arc welding Material: Mild steel Gas: Ar + CO mixed gas (10 to 15 L/min) Plate thickness Wire diameter Current Voltage Travel speed Joint shape t [in. (mm)] [in.

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