Daihen OTC Welbee P402L Owner's Manual
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Daihen OTC Welbee P402L Owner's Manual

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OWNER'S MANUAL
Welbee P402L
P502L
October, 2021
DAIHEN Corporation
Manual No. : P30334-2

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  • Page 1 OWNER'S MANUAL Welbee P402L P502L October, 2021 DAIHEN Corporation Manual No. : P30334-2...

  • Page 2: Forward

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

  • Page 3: Important Information

    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 4: Table Of Contents

    ABLE OF ONTENTS TABLE OF CONTENTS Forward 4.2.4 Connection of voltage detection cable Service and Support (Voltage detection cable is used) ....34 Important Information ......1 4.2.5 Connection at TIG welding .
  • Page 5 ABLE OF ONTENTS 6.6.9 Adjustment of wave frequency ....82 10.3.2 Samples of welding condition settings ... . 155 6.6.10 Welding guide .

  • Page 6: Chapter 1 Safety Information

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

  • Page 7: Safety Precaution

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

  • Page 8: Precautions For Power Supply And Electric Shock

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

  • Page 9: Precautions For Handling Of Plastic Parts

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

  • Page 10: Precaution For Protective Equipment

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

  • Page 11: Precautions For Flammable Materials

    AFETY NFORMATION HAPTER AFETY RECAUTION 1.2.7 Precautions for flammable materials To prevent fire, explosion and rupture, ensure to follow the instructions below: • Remove all flammables within 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 12: Precautions For Gas Cylinder And Gas Regulator

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

  • Page 13: Principal Safety Standards

    AFETY NFORMATION HAPTER RINCIPAL AFETY TANDARDS Principal Safety Standards Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro technical Commission Arc welding equipment Part 10: Electromagnetic compatibility (EMC) requirements IEC 60974-10, from International Electro technical Commission •...

  • Page 14: Chapter 2 Product Specification And Configuration

    Chapter 2 Product Specification and Configuration This chapter explains the specification, name of each part and configuration of the welding power source. Specification This section explains the specification and external dimension of the welding power source. 2.1.1 Specifications This section explains the specification of the welding power source. Welbee P402L Welbee P502L Specification/...

  • Page 15: Applicable Welding Process

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 2.1.2 Applicable welding process This section explains the applicable welding process (shield gas/wire type/welding type) and wire diameter. Standard specification WIRE DIA. (mm) WELDING WIRE Penetration GAS (*1) Manual/Auto. PROCESS MATERIALS adjustment WB-P402L WB-P502L 0.8/1.0/1.2 0.8/1.0/1.2/1.6 Manual (*2)/Auto.
  • Page 16 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION WIRE DIA. (mm) WELDING WIRE Penetration GAS (*1) Manual/Auto. PROCESS MATERIALS adjustment WB-P402L WB-P502L MAG (18%CO 0.8/1.0/1.2 0.8/1.0/1.2/1.6 Manual/Auto. (*1-1) MAG (10%CO 0.8/1.0/1.2 0.8/1.0/1.2 Manual/Auto. (*1-2) CrNi 0.8/1.0/1.2 0.8/1.0/1.2/1.6 Manual/Auto. MAG (2%O DC WAVE (*1-3) Cr 18 0.8/1.0/1.2...

  • Page 17: External Dimensions

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 2.1.3 External dimensions This section explains the external dimensions of the welding power source. • WB-P402L 395mm 710mm • WB-P502L 395mm 710mm 14mm...

  • Page 18: Rated Duty Cycle

    RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION 2.1.4 Rated duty cycle This section explains the rated duty cycle of the welding power source. • Use this welding power source at or under the rated duty cycle. Exceeding the rated duty cycle may result in deterioration and damage to the welding power source.
  • Page 19 RODUCT PECIFICATION AND ONFIGURATION HAPTER PECIFICATION <Relationship between welding current and duty cycle (WB-P402L)> DC, DC TIG Usable range Usable range Welding current (A) Welding current (A) DC PULSE Usable range Welding current (A) <Relationship between welding current and duty cycle (WB-P502L)> DC TIG Usable range Usable range...

  • Page 20: Product Configuration

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

  • Page 23: Accessory (Supplied)

    RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION • At MMA 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 for welding electrode holder (38mm ○...

  • 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: • Shield gas Use a shield gas suitable to the welding process. Name Remarks Carbon dioxide (CO...
  • Page 25 RODUCT PECIFICATION AND ONFIGURATION HAPTER RODUCT ONFIGURATION IFR-800DN (DeviceNet connection type) IFR-800PN (PROFINET connection type) 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. •...

  • Page 26: Part Names

    RODUCT PECIFICATION AND ONFIGURATION HAPTER AMES Part Names This section explains the part names of the welding power source. 2.3.1 Front panel The section explains the front section of the welding power source. • WB-P402L Operation panel 6.2 Function on Operation Panel) Main power lamp Power switch Socket for analog remote control...

  • 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. • WB-P402L Connector for connecting CAN Print circuit board Cover for external connections Blind bush (for drawing externally connecting wire) Terminal block for external connections 4.5.2 Connection of...

  • Page 28: Chapter 3 Transportation And Installation

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

  • Page 29: Ventilation Equipment/Partial Exhaust Facility

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

  • Page 30: Installation Environment

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

  • Page 31: Transportation Procedure

    RANSPORTATION AND NSTALLATION HAPTER RANSPORTATION ROCEDURE • Maintenance of the arc welding equipment Close and fix all doors and covers of the welding power source. • Welding cables Do not use an unnecessarily long cable. Place a base metal cable and a torch side cable as closely as possible. •...

  • Page 32: 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 33: Chapter 4 Connection

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

  • Page 34: Connection Of Cable At Output Side

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.1 Connection of cable at output side This section explains the procedure for connecting of cable at output side. • Use a grounding cable for the case, of welding power source and perform grounding. Otherwise, voltage may increase in the case or base metal which could cause electric shock.

  • Page 35: Connection Of Wire Feeder

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

  • Page 36: 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 37 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE When air-cooled welding torch (with voltage detection) is used Voltage detection Voltage detection terminal adaptor Wire feeder Voltage detection cable for torch side Voltage detection cable for base metal side Power cable for torch side Connect the torch cable and the voltage detection adapter to the wire feeder.

  • Page 38: Connection At Tig Welding

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.4.1 Caution on connection of voltage detection cable It is necessary to wire the voltage detection line to correctly feedback the arc voltage. In order to reduce the influence of inductive interference, pay attention to the following matters. When connecting the base metal side voltage detection cable to the welding power source, also pay attention to the following matters.
  • Page 39 ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE Welding power source Power cable for base metal side Output terminal Power cable for Base metal (Torch side) torch side Output terminal Connector (Base metal side) Ground a base metal if Power cable for base required by local law.

  • Page 40: Connection At Mma Welding

    ONNECTION HAPTER ONNECTING THE ELDING OWER OURCE 4.2.6 Connection at MMA welding • In using the welding power source for MMA welding, prepare a welding electrode holder by the customer. • After five seconds have passed, the safety voltage (approx.15 V) is automatically provided. NOTE When using the welding electrode holder, the specified connector needs to be attached to •...

  • Page 41: Connection Of Shield Gas

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

  • Page 42: Power Supply

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

  • Page 43: Confirmation Of Connection

    ONNECTION HAPTER ONFIRMATION OF ONNECTION Confirmation of Connection This section explains the point of confirmation after completing all of the connections. Check for the following after the connection is complete. • No looseness in the cable connections If looseness is found, tighten it to secure the connection. •...
  • Page 44 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT Product name/Model Remarks Welding power source Connection robot controller cable Interface: IFR-101WB (optional) is also available. ( Refer to instruction manual of Interface) Wiring for wire feeder needs to be changed. Wire feeder 4.6.1 Wiring to wire feeder) Welding torch: K2331 type curved torch Uni-cord power cable:...

  • Page 45: Connection Of Automatic Machine

    ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT Use the voltage detection cable for torch side (K5416P00) with a blind bush. ● Remove the voltage detection cable (line No. 309) connected to the bracket. Restore the plates in the right side and left side of the wire feeder. Wiring for the wire feeder is complete.
  • Page 46 ONNECTION HAPTER ONNECTION OF XTERNAL QUIPMENT • Output signal of the external connection terminal block Output signal is open collector output. Ensure to keep the maximum rated power of the transistor. Welding power Maximum rated power of transistor source side READY: DC50 V/100 mA OUT EXT1 to 4: DC50 V/100 mA Transistor...

  • Page 47: Wiring Of Voltage Detection Cable At Base Metal Side

    ONNECTION HAPTER IRING OF OLTAGE ETECTION ABLE AT ETAL • The control cable drawn out from the terminal for external connection should be kept away from the welding power cable or the torch cable as much as possible. Otherwise, failure may occur due to noise during use. Do not pull out the cables other than the cable that is connected with the terminal block on •...

  • Page 48: Wiring To Wire Feeder

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

  • Page 49: Wiring Example Of Voltage Detection Cable

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

  • Page 50: Chapter 5 Welding Operation

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

  • Page 51: 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 52 ELDING PERATION HAPTER HECK BEFORE ELDING Check parameter Countermeasures Check Painted contact part could cause increased contact resistance, resulting in The contact part of jig and welding work piece decrease in arc voltage. Polish the painted contact part using a grinder to expose should not be painted.

  • Page 53: Power On And Gas Supply

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

  • Page 54: Wire Inching

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

  • Page 55: Check And Setting Of Welding Condition

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

  • Page 56: Performing Welding Operation

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

  • Page 57: Operation During Welding

    ELDING PERATION HAPTER ERFORMING ELDING PERATION • Other welding process • If the TIG valve controller will not be used in TIG welding, be sure to shut off the gas after completion of welding. There is a risk of suffocating if closing the gas is forgotten in case opening/closing of the gas is done manually.
  • Page 58 ELDING PERATION HAPTER ERFORMING ELDING PERATION DISPLAY CHANGE key Welding current adjustment knob Welding voltage adjustment knob Analog remote control (Optional accessories) Welding power source Parameter adjustment UNIT CHANGE key knob Press the DISPLAY CHANGE key.  The displays of the left/right digital meter switches to the set values. ...

  • Page 59: Operation At Welding End

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

  • Page 60: 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 JOB. List of Welding JOB This section explains the parameters/functions settable in the welding power source. 6.1.1 Parameter (Welding parameter) Parameter Set Range Initial Value...

  • Page 61: Internal Function

    ELDING ONDITION HAPTER IST OF ELDING 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 JOB. Function Name Setting range Initial value Explanation Memory Sets the waveform control mode for voltage detection...
  • Page 62 ELDING ONDITION HAPTER IST OF ELDING 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 260 to 400 320 (V) Adjusts the low primary input voltage detection level.
  • Page 63 ELDING ONDITION HAPTER IST OF ELDING Function Name Setting range Initial value Explanation Memory Sets crater time in the Special 2T. Special 2T crater time 0.0 to 10.0 0.0 (s) ○ (available when F45 is enabled) With the setting of "Crater" and in the welding condition (during start input holding), sets whether to adjust current by the torch switch operation: Adjusting current with torch...
  • Page 64 ELDING ONDITION HAPTER IST OF ELDING Function Name Setting range Initial value Explanation Memory L pulse peak current fine Sets the adjustment value of pulse peak current at the -150 to 150 0 (A) ○ adjustment LOW side in pulse welding. L pulse peak time fine Sets the adjustment value of pulse peak time at the -1.5 to 1.5...

  • Page 65: Function On Operation Panel

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

  • Page 66: Setting Screen

    ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Name Function Pressing this knob switches the digital meter (left/right) that needs to be set. Turning this knob changes the value of the selected parameter. Sets the welding current / wire feeder speed when the left digital meter is selected. Switching Parameter adjustment knob between welding current / wire feeder speed is enabled by pressing the UNIT CHANGE key.
  • Page 67 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL <HOME screen> <MENU screen> Cursor Displays current setting welding JOB. The screen switches every time the key is pressed. Move the cursor by turning screen Move the cursor by turning screen operation knob and select item to operation knob and select item to be changed setting.
  • Page 68 ELDING ONDITION HAPTER UNCTION ON PERATION ANEL Item Functions Select the wire material to use. • Some wire material cannot be used depending on the combination of the wire diameter, gas, welding process, and Manual/Auto. The wire material that cannot be used will not be displayed. WIRE MATERIALS 6.6.1 Welding mode setting) •...

  • Page 69: Welding Job

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

  • Page 70: Memory Function Of Welding Job

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING Memory Function of Welding JOB This section explains the memory function of welding JOB. The welding power source is equipped with the function to register the welding JOB and reads them out for use. The number of welding JOB that are able to be registered are 100 at maximum.

  • Page 71: Read Out Of Welding Job

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

  • Page 72: Deletion Of Memory Registration

    ELDING ONDITION HAPTER EMORY UNCTION OF ELDING Turn the screen operation knob (or parameter adjustment knob), and select the JOB No. to read out. ⇒ When there is no registration data on the selected JOB No., "no data" is displayed on the LCD panel and "- - - -" is displayed on the left digital meter.
  • Page 73 ELDING ONDITION HAPTER EMORY UNCTION OF ELDING Select "Delete JOB". Turn the screen operation knob and point the cursor to ● Delete JOB. Press the screen operation knob. ● ⇒ "dEL" is displayed when the system transits to the DELETE mode. ⇒...

  • Page 74: Setting Welding Job

    ELDING ONDITION HAPTER ETTING ELDING Setting Welding JOB This section explains how to set the welding JOB (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 75 ELDING ONDITION HAPTER ETTING ELDING WIRE DIA. (mm) WELDING WIRE Penetration GAS (*1) Manual/Auto. PROCESS MATERIALS adjustment WB-P402L WB-P502L MAG (18%CO 0.8/1.0/1.2 0.8/1.0/1.2/1.6 Manual/Auto. (*1-1) MAG (10%CO 0.8/1.0/1.2 0.8/1.0/1.2 Manual/Auto. (*1-2) CrNi 0.8/1.0/1.2 0.8/1.0/1.2/1.6 Manual/Auto. MAG (2%O DC WAVE (*1-3) Cr 18 0.8/1.0/1.2 0.8/1.0/1.2...

  • Page 76: Setting Welding Job

    ELDING ONDITION HAPTER ETTING ELDING 6.6.2 Setting welding JOB Set the welding JOB with setting screen and screen operation knob. Select "WELDING PROCESS" on the HOME screen. ● Turn the screen operation knob and point the cursor to the WELDING PROCESS (Eg. DC PULSE). Press the screen operation knob.
  • Page 77 ELDING ONDITION HAPTER ETTING ELDING MAIN POST FLOW CONDITION FLOW START CRATER-FILL CONDITION CONDITION Each sequence process has the following description: Process Description PRE FLOW It is the sequence to discharge gas before the welding starts. START CONDITION It is the sequence to process the welding start. MAIN CONDITION It is the welding sequence.

  • Page 78: Crater Setting

    ELDING ONDITION HAPTER ETTING ELDING ⇒ The set parameter is displayed on the left digital meter. TIPS • In the setting of welding current, the wire feed speed automatically set according to the welding current can be checked. Press the UNIT CHANGE key to light off the LED of the key ("...
  • Page 79 ELDING ONDITION HAPTER ETTING ELDING 6.6.4.1 2T (Crater "OFF") Select "2T" by the 2T/4T menu. • In synchronous to the ON/OFF operation of the torch switch, the welding starts/stops. Torch switch Pre-flow Post-flow Gas flow No-load voltage Anti-stick time Output voltage Slow-down speed Wire feeding speed Welding current...
  • Page 80 ELDING ONDITION HAPTER ETTING ELDING 6.6.4.2 4T (Crater "ON") (no start condition) Select "4T" by the 2T/4T menu and select "START CONDITION OFF" by the Start Condition menu. • Carry out twice the ON/OFF operation of the torch switch and carry out the welding operation. In the second ON operation, the welding sequence is carried out by the crater current.
  • Page 81 ELDING ONDITION HAPTER ETTING ELDING 6.6.4.3 4T (Crater "ON") (with Start Condition) Select "4T" by the 2T/4T menu and select "START CONDITION ON" by the Start Condition menu. • Carry out twice the ON/OFF operation of the torch switch and carry out the welding operation. The operation from the first ON to OFF enables the welding by the initial current, and the second ON operation enables the welding by the crater current.

  • Page 82: Arc Spot Time

    ELDING ONDITION HAPTER ETTING ELDING 6.6.5 Arc spot time This section explains the details of arc spot and torch switch operation. Selecting "ARC SPOT" by the 2T/4T menu allows the machine in the main mode. • In this mode, the torch switch remains to be ON for welding operation. When the arc spot time elapses, the welding automatically stops.

  • Page 83: Welding Voltage Adjustment

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

  • Page 84: Penetration Control Adjustment

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

  • Page 85: 6.6.10 Welding Guide

    ELDING ONDITION HAPTER ETTING ELDING Press the WAVE FRQ key. ⇒ The LED for the WAVE FRQ key lights up. ⇒ The wave frequency setting value appears on the left digital meter. Turn the parameter adjustment knob, and change the setting value. Adjust the value between 0.5 to 32 Hz.
  • Page 86 ELDING ONDITION HAPTER ETTING ELDING Turn the screen operation knob and select "WELD JOINT", then press the screen operation knob. ⇒ The color of the selected parameter will be inverted on the display. Select the weld joint that needs to be changed. ●...

  • Page 87: Setting Internal Functions

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

  • Page 88: Detailed Information On Internal Functions

    ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Turn the parameter adjustment knob, and change the setting value. ⇒ The set value is activated as it is changed. Press the CANCEL key. ⇒ The setting of internal function completes, and the LCD display returns to MENU. 6.7.2 Detailed information on internal functions This section explains the detailed information of internal functions in the order of function No.
  • Page 89 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.3 F4: Auto/Semi-auto mode In combining the welding power source with a robot or an automatic machine, set I/O (interface) of the welding source according to the application. For the settings "0" to "2", refer to the table below. The settings "3" and "4" are the modes specifically for the use with OTC robots.
  • Page 90 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.4 F5: Maximum external command voltage When the internal function F4 (Auto/Semi-auto mode) is used with the setting of "1", set the maximum value of command voltage input from outside. Select either from 10 V, 14 V, or 15 V. The below charts show the relationship between current/voltage command voltage and welding current/voltage.
  • Page 91 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.7 F8: Welding result display time Set the time period for the output current and voltage to be displayed on the left/right digital meters in a flashing mode after the completion of welding. Set the display time in the flashing mode. The value of display time is the average value for 1 second immediately before the completion of welding.
  • Page 92 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS – Internal function F44 (Reading welding JOB with remote control) is set to "ON" (enabled); – Internal function F45 (Special 2T) is set to "ON" (enabled); – Internal function F48 (Adjusting current with torch switch) is set to "ON" (enabled); or –...
  • Page 93 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.14 F16: Slowdown speed adjustment Slow-down speed is the speed to slowly feed the wire from the time of the machine start to the time of arc start. The slowdown speed is automatically set to an appropriate speed depending on the welding process and wire diameter; meanwhile, it can be adjusted through this function if manual setting is preferred.
  • Page 94 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.19 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. • [0]: disables the function. • [1] to [10]: enables the function.
  • Page 95 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS – Each pressing the UNIT CHANGE key, the wire feed speed display and the welding current display switches alternatively. Switch to the welding current display, and set the welding current in the unit of 1 A. –...
  • Page 96 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS JOB No. Function (external input terminal) (Registration No.) F29(IN-EXT1) F30(IN-EXT2) F31(IN-EXT3) F32(IN-EXT4) OFF (open) OFF (open) OFF (open) OFF (open) ON (close) OFF (open) OFF (open) OFF (open) OFF (open) ON (close) OFF (open) OFF (open) ON (close) ON (close)
  • Page 97 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 98 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.23 F33: Spatter suppression rate display Any shift in detecting [Squeeze] leads to spatter generation. This function enables to check the inhabitation ratio (%) of [Squeeze] detection from the welding start to the welding completion. •...
  • Page 99 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.25 F35: Saving the correction value of low spatter function 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 100 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.27 F38: Arc voltage detection switching Sets the combination of enabling or disabling the voltage direct detection terminal on the base metal side of the welding power source and voltage detection terminal of the wire feeder. Extending the power cable without the cable at the base metal side can cause extraordinary volume of spatter.
  • Page 101 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.31 F44: Reading welding JOB with remote control Sets whether to read the welding condition registered to the memory by the analog remote control (optional) or not. This function is effective when the internal function F4 (Auto/Semi-auto mode) is set to "0". •...
  • Page 102 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Torch switch Post-flow Pre-flow Gas flow No-load voltage Anti-stick time Output voltage Slow-down speed Wire feeding speed Welding current Crater-fill current Start current Welding current Crater-fil Main welding Start condition Set the time by F46 Set the time by F47 (0.0 to 10.0 seconds) (0.0 to 10.0 seconds)
  • Page 103 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS Example: In the setting examples of Crater setting: ON; Start condition: OFF; Welding current: 100 A; Crater current: 60 A; F48: "ON"; F49:"-10"; and F50: "20", the following diagram is available: Within Double Within 0.3 sec.
  • Page 104 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS TIPS • When this function is set to [ON], automatically the setting of "4T/Crater repeat" is selected, disabling other welding modes. (The 2T/4T menu does not work.) • Single-clicking operation should be within 0.3 seconds. •...
  • Page 105 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.38 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 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS During the anti-stick period, regardless of the function value, WCR output OFF delay time (approx. 0.02 seconds) for anti-stick must be set. The timing chart of WCR output ON delay and WCR output OFF delay is shown below. Torch switch Open Open...
  • Page 107 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.46 F61: Pulse peak time fine adjustment This function allows fine adjustment of the standard pulse peak time; by setting the adjustment value, finely adjusted pulse peak time can be obtained. Moreover, in the pulse condition of the wave pulse welding at HIGH side, fine adjustment is available to the standard pulse peak time at HIGH side by setting the adjustment value.
  • Page 108 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.51 F66: Feeding amplitude ratio adjustment This function sets the feed amplitude ratio of wire (amplitude change of wire feed speed) in the wave pulse welding. When the wave frequency is under 5 Hz, the wire feed speed is adjusted. By fine adjusting the amplitude of this feed speed, optimized welding result for the specific purpose can be obtained.
  • Page 109 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.56 F71: Interval function This function repeats arc ON/OFF to control the heat input. • "ON": Enables the function. When this function is enabled, ": Interval" will be displayed at the end of CRATER-FILL CONDITION in the Home screen, and internal functions F72 and F73 will be enabled.
  • Page 110 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.62 F80: Switching of CAN communication speed Set the connection speed of the CAN connection. Set to "0" to use the Digital panel, Digital pull torch, Digital middle feeder and Intelli torch. This function is effective when any one of "0" (Semi-auto mode), "1" (Automatic machine 1 mode), and "2" (Automatic machine 2 mode) is selected for F4 (Auto/Semi-auto mode).
  • Page 111 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.66 F84: Automatic pulse adjustment Sets the pulse mode that has the pulse automatic adjustment function. This function is available when set to the following welding process. Manual/Auto. Welding process Wire material Auto. DC PULSE In pulse welding, spatter generation will increase when the welding voltage is set at a low value and welding is carried out in a way that short-circuit will occur moderately.
  • Page 112 ELDING ONDITION HAPTER ETTING NTERNAL UNCTIONS 6.7.2.68 F86/F87: Current display adjustment (GAIN/OFFSET) Set the adjustment value (gain/offset) when the current display value on the left digital meter is different from the actual current value. The current value displayed on the digital meter is obtained by software processing of the average value of outputs; therefore, it may not be consistent with the value indicated on a needle meter, etc.

  • Page 113: Operation Of Analog Remote Control

    ELDING ONDITION HAPTER PERATION OF NALOG EMOTE ONTROL PTIONAL Operation of Analog Remote Control (Optional) This section explains the functions of knobs and buttons arranged for the analog remote controller (optional) as well as their operation. Since the setting at the analog remote control is preferred when connected, it is not possible to set this condition on the operation panel of welding power source.

  • Page 114: (Optional)

    ELDING ONDITION HAPTER PERATION OF NALOG EMOTE ONTROL PTIONAL The functions which can be assigned to the switching knob are as follows. Position of switching knob F2 setting Functions No function ― ― ― 4T/Crater DC Crater setting（ 6.6.4 Crater setting） 4T/Crater DC Pulse Gas check（...

  • 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 JOB. Protection of Welding JOB This section explains the protection function (password function) of welding JOB. When the function is enabled, ( 5.5.2 Preventing erroneous operation on operation panel), a password will be requested to disable the erroneous operation prevention function.
  • Page 116 DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING Turn the screen operation knob to select "Password Setting", and press the knob. If a password has already been set, the Password Input ● screen will be displayed on the LCD panel. To change the password, delete the password with the operation from the step 3 of "7.1.2 Disabling erroneous operation prevention"...

  • Page 117: Disabling Erroneous Operation Prevention

    DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING Turn the screen operation knob to select "OK" (color inversion display). • To cancel setting of the password, turn OFF the power switch. 2 3 5 Check that the password is correct and press the screen operation knob. ...
  • Page 118 DMINISTRATOR UNCTIONS HAPTER ROTECTION OF ELDING Press the screen operation knob, enter the password of the selected digit, and press the knob.  The number is confirmed, and the display will change from color inversion display to digit selection display. •...

  • Page 119: Welding Result Control Function

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

  • Page 120: Details Of Welding Control Items

    DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION Select the desired monitor No. Turning the screen operation knob (or parameter ● adjustment knob) will change the tens place digit of monitor No. (Example: "P10" -> "P20" -> "P30" -> "P40") ● Pressing the screen operation knob will change the ones place digit of monitor No.
  • Page 121 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION *2: If "Disabled" is selected and the target is achieved, next welding cannot start until any key on the operation panel is pressed. 7.2.2.2 Wire consumption Wire consumption is controlled according to the setting range. •...
  • Page 122 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION The set values and operations when the target is achieved are the same as those of the "P12" function. "P12 (Operation at the time when the target number of welding points is achieved)" ( 7.2.2.1 Number of welding point) 7.2.2.4...
  • Page 123 DMINISTRATOR UNCTIONS HAPTER ELDING ESULT ONTROL UNCTION 7.2.2.5 Total operating time Total operation time and total welding time are managed according to the display range. • P50 (Cumulative total operation time) The operation time of welding power source is counted at all time and accumulated as total operation time. The setting range of count value is between 0 and 9999 hours.

  • Page 124: Data Backup (Utilization Of Data)

    Compatibility of the following USB flash drives has been confirmed. Model No.: SFU22048E3BP2TO-I-MS-121-STD (swissbit) Part No.: 100-1820 • There is software allowing you to easily display waveforms and edit welding JOB. You can download it from our home page. URL: https://www.daihen.co.jp/en/products/welder/software/...

  • Page 125: Setting Of Welding Job/Internal Functions

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.1 Setting of welding JOB/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 JOB set with the operation panel will not be saved.

  • Page 126: Simplified Data Log Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Item Description Unit Item Description Unit L pulse peak lpls_pkt_adj 0.1 (ms) Interval Interval function 0/1(OFF/ON) time fine adjustment L base current Interval function Arc-ON lpls_bsi_adj 1 (A) Interval_ON 0.01(s) fine adjustment time Wave pulse Interval function Arc-OFF wave_feed_adj...

  • Page 127: Failure Log Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Welding current [A] Welding current [V] Time [msec] Feeding rate [m/min] Start of welding TIPS The length of time that can be used for recording depends on the sampling speed. If the • sampling speed is set to 100 ms, data of approximately five hours can be recorded.

  • Page 128: Welding Result Control Function

    DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA 7.3.4 Welding Result Control Function The following contents can be saved in the file "DAIHEN_WELDING_MONITOR_DATA_MACHINE_***.CSV ". • Welding machine identification Number • Cumulative values of Welding result control function The values of internal function F77(Welding result control function identifications numbers) enters into "***" in the end of filename.
  • Page 129 DMINISTRATOR UNCTIONS HAPTER ACKUP TILIZATION OF DATA Select the data to back up. Turn the screen operation knob further counterclockwise ● to display the data to back up on the right digital meter.  The display changes in order of "ALL" -> "1" -> "2" -> "3" - >...

  • Page 130: Importing Backup Data

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

  • Page 131: Initializing Welding Job And Internal

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

  • Page 132: Checking The Software Version And Serial Number

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

  • Page 133: Calibration Mode

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

  • Page 134: Adjustment Of Output Voltage

    DMINISTRATOR UNCTIONS HAPTER ALIBRATION Turn the screen operation knob to select the "CALIBRATION MODE", and press the knob.  "cAL cAL" is displayed on the operation panel. Set the current setting as follows. ● WB-P402L: 400 A WB-P502L: 500 A Turn ON the torch switch, and measure the output voltage.
  • Page 135 DMINISTRATOR UNCTIONS HAPTER ALIBRATION Connect an external voltmeter and a voltage detection line to both ends of the resistance load (if no load is applied, connect to the output terminal). While both DISPLAY CHANGE keys are pressed at the same time, turn ON the power switch. ...

  • Page 136: System Setting

    DMINISTRATOR UNCTIONS HAPTER YSTEM ETTING System Setting Sets the "LCD Background" and the "Language" of all screens. Select "SYSTEM SETTING" on the MENU screen. Turn the screen operation knob to place the cursor on ● "SYSTEM SETTING", and press the knob. ...

  • Page 137: Chapter 8 Maintenance And Inspection

    Chapter 8 Maintenance and Inspection This chapter explains the daily and periodical inspection of the welding power source. Precautions for Maintenance and Inspection This section explains the precautions for maintenance and inspection work. To prevent electric shock or burn injury, ensure to follow the instructions below: •...

  • Page 138: Daily Inspection

    AINTENANCE AND NSPECTION HAPTER AILY NSPECTION • The welding JOB (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. Important information should also be stored as printed document.

  • Page 139: Periodical Inspection

    AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION Periodical Inspection This section explains the periodical inspection of the welding power source. Check the items in the table below every three (3) to six (6) months. • Before performing maintenance and inspection, read the instructions in "8.1 Precautions for Maintenance and Inspection"...
  • Page 140 AINTENANCE AND NSPECTION HAPTER ERIODICAL NSPECTION Periodical inspection item Inspection work Dust accumulating on the fin or winding of heat sink can cause insufficient heat radiation. • Remove the left side panel and fan frame and check the dirt inside. If there is heavy dirt, blow the fin and coils of heat sink directly with compressed air to remove dust inside.

  • Page 141: Periodical Replacement Parts

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

  • Page 142: Withstand Voltage Test

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

  • Page 143: 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 144 ROUBLESHOOTING HAPTER CTION IN ASE OF RROR Error code Error cause Action and how to cancel error There is no load between the STOP • Identify the cause of no load between the STOP terminals (3-4) of the terminal block terminals (*1) TM3 for external connection.

  • Page 145: Troubleshooting

    ROUBLESHOOTING HAPTER ROUBLESHOOTING Error code Error cause Action and how to cancel error An over current was detected at the • Check that the tip at the end of torch is not contacting the base metal. output side of the welding power •...
  • Page 146 ROUBLESHOOTING HAPTER ROUBLESHOOTING Problem Possible cause Corrective action Check that the setting of internal functions F29 to F32 is Setting/handling of the external correct. ( 6.7.2.22 F29 to F32: External input terminal inputs is not correct. setting) Shield gas does not stop flowing. Check that there is no abnormality in the cables The external input cables are connected to the external input terminal block.

  • Page 147: Chapter 10 Reference Materials

    Chapter 10 Reference Materials This chapter contains the parts list of welding power source, and reference materials for setting the welding JOB. 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 148 EFERENCE ATERIALS HAPTER ARTS Q’ty Code Part No. Product Name Specifications Remarks WB-P402L WB-P502L 100-2321 Ferrite core TW70W (R311019) 100-0618 Ferrite core HM2AT4815 100-2321 Ferrite core TW70W (R311019) 100-1950 Ferrite core TW70W(R402715) 100-2321 Ferrite core TW70W (R311019) 100-0618 Ferrite core HM2AT4815 100-1950 Ferrite core...
  • Page 149 EFERENCE ATERIALS HAPTER ARTS Q’ty Code Part No. Product Name Specifications Remarks WB-P402L WB-P502L DCV2 K5791C00 Power supply K5791C00 Output DC48 V PCB1 P30099P00 Printed circuit board P30099P00 (*1) 4341-206 Relay G6A-274P DC24 V With PCB1 PCB2 P30304R00 Printed circuit board P30304R00 100-2518 Encoder...

  • Page 150: 10.1.2 Spare Parts List

    EFERENCE ATERIALS HAPTER EFERENCE RAWING Analog remote control parts list (K5804S00) (Optional) Code Part No. Product Name Specifications Q’ty Remarks Iset, Vset 4501-039 RV24YN20SB 5kΩ Variable resistor 100-0487 RD20S 12ΩJ Carbon resistor 4531-710 Diode D1N60 INCH 4250-077 Push switch A2A-4R 4735-013 Knob K-2195 (middle)

  • Page 151: 10.2.1 Schematic Diagram

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.1 Schematic diagram • WB-P402L...
  • Page 152 EFERENCE ATERIALS HAPTER EFERENCE RAWING...
  • Page 153 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-P502L...
  • Page 154 EFERENCE ATERIALS HAPTER EFERENCE RAWING...

  • Page 155: 10.2.2 Parts Layout Drawing

    EFERENCE ATERIALS HAPTER EFERENCE RAWING 10.2.2 Parts layout drawing • WB-P402L...
  • Page 156 EFERENCE ATERIALS HAPTER EFERENCE RAWING • WB-P502L...

  • Page 157: 10.3 Materials For Setting Welding Job

    EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING 10.3 Materials for Setting Welding JOB This section provides reference information for setting the welding JOB. 10.3.1 Guide for changing welding JOB This section gives examples of the problems that can occur due to improper welding JOB. Problem Symptom •...
  • Page 158 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING Plate Wire Leg length Wire diameter Current Voltage Manual/Auto. Gas flow rate thickness consumption L (mm) (mmΦ) (cm/min) (L/min) t (mm) (g/min) 2.3 to 2.8 2.8 to 3.4 3.0 to 4.0 130 to 170 19 to 21 45 to 55 15 to 20...
  • Page 159 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING Plate Wire Root opening Wire diameter Current Voltage Manual/Auto. Gas flow rate Number of thickness consumption g (mm) (mmΦ) (cm/min) (L/min) layers t (mm) (g/min) 2.0 to 2.5 1.0 to 1.2 130 to 150 19 to 21 40 to 50 10 to 15...
  • Page 160 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING Example for welding JOB of lap fillet Aim position Wire Plate thickness Wire diameter Current Voltage Manual/Auto. Gas flow rate Aim position consumption t (mm) (mmΦ) (cm/min) (L/min) (g/min) 1.8 to 2.1 80 to 100 18 to 19 45 to 55 10 to 15...
  • Page 161 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING 10.3.2.3 Example of MAG short arc welding Material: Mild steel Gas: Ar + CO mixed gas (10 to 15 L/min) Plate Wire Wire diameter Current Voltage Manual/Auto. Gas flow rate Joint shape thickness consumption (mmΦ) (mm)
  • Page 162 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING Example for welding JOB of downward welding Plate Wire Manual/ Wire Shape of Current Voltage thickness diameter Auto. consumption Remarks joint weld t (mm) (mmΦ) (cm/min) (g/min) Butt 22 to 23 Check back bead appearance Leg length: 4 - 5mm, Throat depth: 2.5mm Fillet 21 to 22...
  • Page 163 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING Example for welding JOB of single side welding (Auto. mode) Wire Plate Manual/ Wire Number Current Voltage Gas flow thickness diameter Bevel shape Auto. consumption of layers rate (L/min) t (mm) (cm/min) (g/min) (mmΦ) 24 to 25 15 to 20...
  • Page 164 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING Manual/ Wire Number Current Voltage Gas flow Bevel shape Auto. consumption Remarks of layers rate (L/min) (cm/min) (g/min) 20 to 21 25 to 30 15 to 20 2.2 to 2.7 Oscillation Upward 21 to 22 25 to 30 15 to 20 2.2 to 2.7...
  • Page 165 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING 10.3.2.6 Example for short welding JOB of aluminum MIG Example for welding JOB of I shape butt Plate Gas flow Wire Wire diameter Current Voltage Manual/Auto. Wire feeding thickness rate consumption (mmΦ) (cm/min) length (mm) t (mm) (L/min)
  • Page 166 EFERENCE ATERIALS HAPTER ATERIALS FOR ETTING ELDING...

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