Robotic Arc Welding Manual · 2018. 12. 10. · Robotic Arc Welding Manual Chapter 2 Safety page 10...

Motoman XRC 2001 Controller

Robotic ArcWelding Manualfor MotoWeld™ E350 Power Source

Part Number: 148984-1CDRevision: 0

Motoman, Incorporated 805 Liberty LaneWest Carrollton, OH 45449TEL: (937) 847-6200FAX: (937) 847-627724-Hour Service Hotline: (937) 847-3200

The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

Inc.

©2006 by MOTOMANAll Rights Reserved

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MotoWeld E350148984-1

Chapter 2

Safety

2.1 Introduction

It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries Association by requesting ANSI/RIA R15.06. The address is as follows:

Robotic Industries Association900 Victors Way

P.O. Box 3724Ann Arbor, Michigan 48106

TEL: (734) 994-6088FAX: (734) 994-3338

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel who are adequately trained to operate, program, and maintain the robot cell. The robot must not be operated by personnel who have not been trained!

We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system.

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Robotic Arc Welding ManualChapter 2 Safety

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming Safety (Section 2.6)

• Operation Safety (Section 2.7)

• Maintenance Safety (Section 2.8)

2.2 Standard Conventions

This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words:

DANGER!

WARNING!

CAUTION!

NOTE:

Pay particular attention to the information provided under these headings which are defined below (in descending order of severity).

DANGER!Information appearing under the DANGER caption concerns the protection of personnel from the immediate and imminent hazards that, if not avoided, will result in immediate, serious personal injury or loss of life in addition to equipment damage.

WARNING!Information appearing under the WARNING caption concerns the protection of personnel and equipment from potential hazards that can result in personal injury or loss of life in addition to equipment damage.

CAUTION!Information appearing under the CAUTION caption concerns the protection of personnel and equipment, software, and data from hazards that can result in minor personal injury or equipment damage.

Note: Information appearing in a Note caption provides additional information which is helpful in understanding the item being explained.

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2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows:

• Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.

• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06 safety standards, and other local codes that may pertain to the installation and use of industrial equipment. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following safety measures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.

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2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R15.06 safety standards are permitted to install the equipment.

• Identify the work envelope of each robot with floor markings, signs, and barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry into the work envelope.

• Eliminate areas where personnel might get trapped between a moving robot and other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching and maintenance procedures.

2.6 Programming Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Programming tips are as follows:

Any modifications to PART 1 of the XRC controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

Some operations require standard passwords and some require special passwords. Special passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these special passwords.

Back up all programs and jobs onto a floppy disk whenever program changes are made. To avoid loss of information, programs, or jobs, a backup must always be made before any service procedures are done and before any changes are made to options, accessories, or equipment.

The concurrent I/O (Input and Output) function allows the customer to modify the internal ladder inputs and outputs for maximum robot performance. Great care must be taken when making these modifications. Double-check all modifications under every mode of robot operation to ensure that you have not created hazards or dangerous situations that may damage the robot or other parts of the system.

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• Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to operate the system.

• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place.

• Check the E-STOP button on the teach pendant for proper operation before programming.

• Carry the teach pendant with you when you enter the workcell.

• Be sure that only the person holding the teach pendant enters the workcell.

• Test any new or modified program at low speed for at least one full cycle.

2.7 Operation Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Operation tips are as follows:

• Be sure that only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories are permitted to operate this robot system.

• Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

• Inspect the robot and work envelope to ensure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.


• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the cell.


• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

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• All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.

2.8 Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Maintenance tips are as follows:

• Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

• Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.


• Back up all your programs and jobs onto a floppy disk whenever program changes are made. A backup must always be made before any servicing or changes are made to options, accessories, or equipment to avoid loss of information, programs, or jobs.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the cell.


• Be sure all safeguards are in place.

• Use proper replacement parts.

• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

• All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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YASKAWA

MOTOWELD-E350IIINSTRUCTIONSYWE-E350-BN2

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

YASKAWA MANUAL NO. HW0481431

HW0481431

• This instruction manual is intended to explain operating instructions and maintenance procedures primarily for the MOTOWELD-E350II. The MOTOWELD-E350II has been developed following the MOTOWELD-E350. However, the welding type and some parameter meanings differ from the MOTOWELD-E350. Therefore, even those who have used the MOTOWELD-E350 must read this manual carefully and understand the contents before handling the MOTOWELD-E350II. For the wire feeder, the welding torch, and the gas regulator, read each instruction manual carefully.

• General items related to safety are listed in the Safety Manual Section 1: Safety. To ensure correct and safe operation, carefully read the Setup Manual before reading this manual.

• Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating this product.

• The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications. If such modification is made, the manual number will also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA rep-resentative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your prod-uct’s warranty.

MANDATORY

CAUTION

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Notes for Safe OperationRead this manual carefully before installation, operation, maintenance, or inspection of the MOTOWELD-E350II.In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”

“Serious injury” described above indicates loss of eyesight, injuries, burns (both due to high/low temperature), electric shock, fractures, poisoning, etc. which may cause personnel to suf-fer aftereffects, hospitalization, or prolonged out-patient medical treatment.“Moderate injury” indicates injuries, burns, or electric shock which does not require hospital-ization or prolonged out-patient medical treatment.“Damage to equipment” indicates expanded damages relating to property or equipment.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

For safe training concerning welding, utilize technical institutes held by the welding society or association, or related societies or associations, technical courses held by the headquarters or their branches, or qualifications examinations for welding technicians or engineers.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe practices.

Always be sure to follow explicitly the items listed under this heading.

Must never be performed.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING.”

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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Be sure to observe the following warnings to avoid serious injury to personnel.

• Be sure to observe the precautions in this instruction manual although this welder is designed and manufactured with sufficient consideration given to safety.

Failure to observe this warning may result in death or serious injury to personnel.

• Observe the regulations and your own references for the construction of the input power sources, selection of the installation site, handling of high-pressure gases, storage and piping, storage of manufactured prod-ucts after welding, disposal of wastes, etc.

• Do not let personnel to approach the welder or welding sites unneces-sarily.

• Any person using a pacemaker must not approach the welder or welding site under operation unless permitted by doctor.

The welder generates a magnetic field around it during current conduction, resulting in bad influence on the pacemaker.

• Clean the cooling-water path once a month when using a water-cooled torch and the cooling water circulator.

Failure to observe this warning may result in explosion or burns due to the choked path.

• In order to secure safe operations, only a trained or qualified person who has understood the welder must perform installation, maintenance and inspection, or repair of the welder.

• In order to secure safe operations, only a person that has understood this instruction manual and has knowledge and techniques to handle the welder safely must operate the welder.

• Do not use the welder for any applications other than welding.

WARNING

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Be sure to observe the following warnings and use protectors to protect yourself or other people from the fumes or gases generated at welding and short of the oxygen.

• In order to prevent gas poisoning or suffocation, be sure to ventilate sufficiently or use an inhaler, etc. when welding at a place specified by regulations such as labor safety and sanitary regulations or hypoxia preventive regulations.

• In order to prevent dust trouble or gas poisoning due to the fumes or gases, use a local air exhaust facility specified by regulations such as labor safety and sanitary regulations or dust trouble preventive regula-tions or use effective protectors for breathing.

Fumes or gases generated at welding may harm your health.

• When welding within such areas as a tank, a boiler, or a ship’s hold, be sure to ventilate sufficiently or use an inhaler, etc. in order to prevent or offset any actual or potential oxygen shortage.

Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom.

• When welding in a small space, be sure to ventilate the site sufficiently or use an inhaler. At the same time, operations must be done under trained supervisor.

Welding operations at a small space may result in short of the air, causing a person to be suffocated.

• Do not perform welding near degreasing, cleaning, or spraying opera-tions.

Failure to observe this warning may generate extremely noxious gases.

• Before welding coated steel plates, be sure to ventilate sufficiently or use protectors for breathing.

Welding such coated steel plates generates noxious fumes or gases.

WARNING

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Be sure to observe the following warnings to avoid an electric shock.

• Never touch the charged parts.

Touching the charged parts may result in critical electric shock or burns.

• Only a qualified person in electric construction should perform ground-ing construction for the welder case and base metals (to be welded) or jigs that are electrically connected to the base metals as specified in the electric facility technical reference.

• Be sure to perform installation or maintenance and inspection five min-utes after all the input power supplies are turned OFF by using switches in the switch box.

Even if the input power supply is turned OFF, the capacitor may still be charged. Be sure to confirm that charged voltage is gone before starting operations.

• Do not use any cable of insufficient capacity or damaged or with its con-ductor exposed.

• Tighten the cable connecting sections firmly and insulate them.

• Do not use the welder with its case or cover removed.

• Do not use worn, damaged or wet gloves. Always use dry insulated gloves.

• Use lifelines when working at hights.

• Perform maintenance and inspection periodically. Repair damaged parts immediately.

• Turn OFF all equipment input power supplies when not being used.

• When performing AC arc welding in a small space or at hights, be sure to use equipment to prevent critical electric shock as specified by labor safety and sanitary regulations.

WARNING

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Observe the following cautions to prevent fire, explosion, or rupture.

• Remove inflammables so that they will not get spattered. If they cannot be removed, use the inflammables with nonflammable covers.

Spatters or hot base metal immediately after welding may result in fire.

• Do not weld near flammable gases.

If arc is generated in a container (for inflammables) in which gasoline or the like is put, the container may explode.

• Do not make hot base metals immeidately after welding close to inflam-mables.

• Remove inflammables at the hidden side when welding ceiling, floor, or wall.

Failure to observe this caution may result in fire.

• Tighten and insulate the cable connections.

Imperfect cable connections or imperfect contacting section of the current path at the base metal such as iron framework may result in fire due to heat generation by current conduction.

• Connect the cable at the base metal as close to the welding part as pos-sible.

• Do not weld a gas tube having gas inside or an enclosed tank or pipe.

Welding an enclosed tank or pipe may result in rupture.

• Locate fire extinguishers near the welding site.

WARNING

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Be sure to observe the following cautions and use protectors to protect yourself or other people from arc beams, spatters, slugs or noise generated from weld-ing.

• Wear welding mask or shaded glasses appropriate for welding.

• Wear protective glasses to protect your eyes from spat-ters or slags.

Scattered spatters or slags may damage eyes or burn the skin.

• Use such protectors as leather gloves, clothes with long sleeves, leg covers, or leather aprons for welding.

• Install protective curtains around the weling site to protect your eyes from arc beams.

Arc beams may irritate eyes or burn skins.

• Use noise protector when there is excessive noise.

Noise may damage hearing.

CAUTION

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Be sure to observe the following cautions to prevent a gas cylinder from falling or a gas regulator from rupturing.

• Observe the regulations and your own references for the handling of gas cylinders.

Since a gas cylinder is filled with high pressure gas, improper handling may cause high pressure gas to blow up, resulting in personal injury.

• Use the attached gas regulator or our recommended one.

• Read carefully the instruction manual of the gas regulator and observe the precautions before using it.

• Hold the gas cylinder in the exclusive-use gas cylinder stand.

A gas cylinder falling may result in personal injury.

• Do not expose the gas cylinder to high temperature.

• Do not bring your face close to the discharging opening when opening the valve of the gas cylinder.

• Be sure to attach the protective cap when the gas cylinder is not used.

• Do not hang the welding torch over the gas cylinder or keep the elec-trode away from the gas cylinder.

Observe the following cautions to prevent personal injury due to improper handling.

• Do not use the welder with the case or cover removed.

• Only a qualified person or a person who has understood the welder must remove the welder case for maintenance and inspection or repair. Take preventive measures not to let other personnel approach the welder or welding sites unnecessarily by putting up a guard fence or the like.

• Do not contact the rotating cooling fan or feeding roll of the wire feeder with hands, fingers, hair, or clothes.

Failure to observe this caution may cause someone to be caught in the machine resulting in personal injury.

CAUTION

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Observe the following cautions to prevent personal injury by the end tip of the weld-ing wire.

• Do not peep through the chip hole to confirm that the wire is being fed.

If the wire is projected from the end tip of the welding torch, it may poke you in the eyes or face.

• Do not bring the welding torch end close to eyes, face, or body to per-form inching or pulling the torch switch.

If the wire is projected from the end tip of the welding torch, it may poke you in the eyes, face, or body.

• When hanging the wire feeder, remove the anti-fall fastening from the spool shaft and tighten.

Failure to observe this caution may cause the wire to be removed from the spool shaft, resulting in personal injury.

Observe the following cautions to prevent burns due to the plasma arc.

If body parts such as hands and fingers directly touch the plasma arc, burns will result.

• Do not put your hands and fingers near the chip and the electrodes of the torch end during cutting operation.

• Do not grasp near the base metal during cutting operation.

• Turn OFF the power supply before replacing the chip or the electrodes of the torch.

CAUTION

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Observe the following cautions to prevent a fire accident caused by deterioration of welder insulation.

• Perfom all welding and grinding away from welder to pro-tect welder from spattering and metal powder.

Spatter and metal powder inside the welder may cause a deterioration of insulation result-ing in accidental fire.

• Be sure to perform maintenance and inpsection periodically to prevent deterioration of insulation caused by accumulation of dust and dirt.

• If spatter or metal powder enters the inside of the welder, remove it by forced air sprot after turning OFF the welder and switch in the switch box.

Spatter and metal powder inside the welder may cause a deterioration of insulation result-ing in accidental fire.

CAUTION

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1 Transporting1.1 Using the Casters . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11.2 Using the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21.3 Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2 Installation2.1 Installation Site and Welder Environment . . . . . . . . 3-1

2.1.1 Wind Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12.1.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

2.2 Installation Site and Gas Cylinder Environment . . . 3-2

3 Wiring3.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13.2 Required Power Supply Facility Capacity and

Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . 4-23.3 Combination with Leakage Breaker . . . . . . . . . . . . 4-23.4 Connection of Electric System . . . . . . . . . . . . . . . . 4-3

3.4.1 Connection of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53.4.2 Connections at Welding Side . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63.4.3 Connection of Control Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

3.5 Connection of Shielding Gas System . . . . . . . . . . . 4-7

4 Gas for Welding4.1 Type of Gas Cylinder . . . . . . . . . . . . . . . . . . . . . . . 5-14.2 Quality of Gas for Welding . . . . . . . . . . . . . . . . . . . 5-14.3 Gas Regulator with Flow Meter. . . . . . . . . . . . . . . . 5-2

5 Shading Measures

6 Basic Specifications

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7 Precautions on Welding and Preparation Procedure7.1 Precautions on Welding. . . . . . . . . . . . . . . . . . . . . .8-1

7.1.1 Error Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17.1.2 Tripped Power Supply Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8-27.1.3 Precautions on Welding Operation . . . . . . . . . . . . . . . . . . . . . .8-3

7.2 Welding Preparation Procedure. . . . . . . . . . . . . . . .8-4

8 eOperations on Panel8.1 Explanation of Welder Panel . . . . . . . . . . . . . . . . .9-18.2 Settings on Welder Panel . . . . . . . . . . . . . . . . . . . .9-3

8.2.1 Changing Process Parameters . . . . . . . . . . . . . . . . . . . . . . . . .9-3 How to Change the Process Parameter Number . . . . . . . . .9-3 How to Change the P Parameter Value . . . . . . . . . . . . . . . .9-3

8.2.2 Changing Common Parameters . . . . . . . . . . . . . . . . . . . . . . . .9-4 How to Change the Common Parameter Number. . . . . . . . .9-4 How to Change the Common Parameter Value . . . . . . . . . .9-4

8.2.3 Changing Welding Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-58.2.4 Changing the Contents of User Files. . . . . . . . . . . . . . . . . . . . .9-68.2.5 Changing to the Local Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .9-68.2.6 Saving Welding Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-78.2.7 Checking the Flow Amount of Shieding Gas . . . . . . . . . . . . . . .9-78.2.8 Changing D Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8

8.3 List of Process Parameters . . . . . . . . . . . . . . . . . . .9-98.4 List of Common Parameters . . . . . . . . . . . . . . . . .9-118.5 List of D Parameters . . . . . . . . . . . . . . . . . . . . . . .9-12

9 Welding Operation9.1 Checking the Welding Conditions . . . . . . . . . . . . .10-19.2 Wire Stickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19.3 Direction of Welding and Torch Angle . . . . . . . . . .10-29.4 Notes for Using Extension Cable. . . . . . . . . . . . . .10-2

10 Robot Interface Signals10.1 Specifications of Robot Interface Signals . . . . . .11-110.2 Meaning and Function of Signal for Starting Point

Detecting Function. . . . . . . . . . . . . . . . . . . . . . . . .11-410.3 Meaning and Function of Pr (RC2) Terminal. . . .11-5

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10.3.1 TB2 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-510.3.2 TB3 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

11 Connection System Diagram

12 Built-in Functions12.1 Terminals for ARCON Signal Input for Maintenance

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-112.2 Internal Selecting Switches . . . . . . . . . . . . . . . . 13-2

12.2.1 How to Use the Selecting Swich . . . . . . . . . . . . . . . . . . . . . 13-212.2.2 DIP Switch Settings of the Pr(CR)-002 Board . . . . . . . . . . . 13-3

DIP Switch Arrangement on the Pr (CR)-002 Board . . . . . 13-412.2.3 System Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-512.2.4 DIP Switch Settings of the Pr (MB)-010 Board . . . . . . . . . . 13-512.2.5 Jumper-pin Settings of the Pr (MB)-010 Board . . . . . . . . . . 13-6

12.3 Location of Printed Boards . . . . . . . . . . . . . . . . . 13-6

13 Adjustment of Welding Characteristics Using Process Parameters

13.1 Adjustable Welding Characteristics . . . . . . . . . . 14-113.2 Adjustment of Starting Characteristic . . . . . . . . . 14-2

13.2.1 Adjustment of Starting Pulse . . . . . . . . . . . . . . . . . . . . . . . . 14-213.2.2 Adjustment of Hot Conditions. . . . . . . . . . . . . . . . . . . . . . . . 14-3

13.3 Adjustment of Ending Characteristics. . . . . . . . . 14-413.4 Adjustment of Short-circuit Welding Characteristics. .

14-613.5 Adjustment of Pulse Welding Characteristics . . . 14-8

13.5.1 Adjustment of MAG Pulse Welding Characteristics . . . . . . . 14-813.5.2 Adjustment of MIG Pulse Welding Characteristics . . . . . . . . 14-9

13.6 Adjustment of Other Pulse Welding Characteristics .14-10

13.7 Adjustment of current output . . . . . . . . . . . . . . 14-11

14 Calibration for External Resistance14.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

xiv

HW0481431

14.2 Procedure of Calibration for External Resistance15-214.2.1 Connecting the Cable for Resistance Measurement. . . . . . .15-214.2.2 Measuring the External Resistance Value and Confirming the

Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-414.2.3 Setting the D Parameter for Calibration of External Resistance to

"Enabled". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-6

15 Welder Condition File Data of the XRC15.1 Common for All Welding Type of "Synergic" (A/%) . .

16-115.2 Common for All Welding Type of "Independent"

(A/V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-2

16 Maintenance and Inspection16.1 Daily Inspection Items . . . . . . . . . . . . . . . . . . . . .17-116.2 Quarterly to Semiannual Inspection Items . . . . .17-216.3 Annual Overhaul and Repair . . . . . . . . . . . . . . . .17-216.4 Guideline for Service Lifetime and Replacement of

Components Used . . . . . . . . . . . . . . . . . . . . . . . . .17-2

17 Fault Analyses17.1 Cause and Remedy of Welding Section Faults. .18-117.2 Cause and Remedy of Electrical Circuit Section Faults

18-6

18 List of Service Parts

xv

1.1 Using the CastersHW0481431

1 Transporting

1.1 Using the Casters

• Sling applications and crane or forklift operations must be performed by authorized personnel only.

Failure to observe this caution may result in injury or damage.

• Avoid excessive vibration or shock while transporting.

The system consists of precision components, so failure to observe this caution may adversely affect performance.

• Do not climb up on the welder or place anything on it.

Failure to observe this caution may deform the shape of the case or cause malfunction.

• Do not pass a rope directly around the welder case during transporting.

Failure to observe this caution may deform the shape of the case or cause malfunction.

• When using the casters, move the welder slowly so that it can be stopped quickly at any time.

Moving the welder with casters quickly may result in an accident due to inertia and you cannot control the direction of movement.

• Be sure to stop the welder with casters at a step and move it slowly to prevent any shock sudden.

• Do not move the welder with casters up a slope, stairs, etc.

CAUTION

CAUTION

1-1

1.2 Using the CraneHW0481431

1.2 Using the Crane

When using the crane, be sure to confirm the following points before transporting. • The welder mass is approx. 70kg. Select the wire rope suitable for the mass and angle.• Use the eyebolts for transporting and confirm that the eyebolts are tightened firmly before

transporting.Lift the welder using crane after completion of the above confirmation.

1.3 Using the Forklift

Observe the following points to use the forklift for transporting. • Confirm availability of safe operations site, and transfer the welder to the installing site.• After determinig the operation site, warnings must be placed on transport path to prevent

accidents.• Put the welder on the transporting pallet and fix firmly to prevent falling or shifting.

Employ a stopper on the casters to fix the welder. Over-tightening the cover may cause it to deform.

• Do not raise the lift excessively.• Transport the welder at yield speed when using the folklift.

Eyebolt M8

Wire rope

MOTOWELD-E350

60 degrees or more

1-2

2.1 Installation Site and Welder EnvironmentHW0481431

2 Installation

2.1 Installation Site and Welder Environment

The welder can be used under the following environmental conditions:• Dry, indoor and at least 30cm from the wall or peripheral devices• Free from direct sunlight, wind, and rain• Ambient temperature of 0 to 40°C• Altitude less than 1000m • Free from direct splash of welding spatter or metalic fine powder at grinding

2.1.1 Wind PreventionNormally, the allowable wind limit for welding using shielding gas is approx. 1.5 m/s or less. If the wind speed is higher than this limit, stop operation or take some countermeasures such as putting up a screen.Even for indoor operations, sufficient attention to the shield effect must be paid when using air tools or fans around the welder.

Fig. 1 Shielding Wind for Welding

• The welder can be moved easily by using the caster. After installation, use the stopper to fix the welder before starting operations.

CAUTION

Wind Screen

Torch

Object to be welded

2-1

2.2 Installation Site and Gas Cylinder EnvironmentHW0481431

2.1.2 VentilationThe carbon dioxide gas used as the shielding gas is decomposed by arc heating, and a small amount of carbon monoxide is generated.For operations indoor or in a container or a tank, ventilation is needed. In this case, do not use a fan to blow the air, but ventilate the accumulated gas by providing a ventilation fan or exhaust duct.

Fig. 2 Example of Ventilation

2.2 Installation Site and Gas Cylinder Environment

Handle the gas cylinder with special care since it contains high pressure gas. Refer to the instruction manual attached to the gas cylinder.Use the gas cylinder in the specified site free from direct sunlight. If you cannot help installing at the welding site, fix it vertically to the column or gas cylinder stand to prevent it from falling. Avoid heating by welding arc or the like.

Torch

Ventilating fan

Gas cylinder

Gas cylinder stand

Fix the gas cylinder to prevent it from falling.

2-2

3.1 GroundingHW0481431

3 Wiring

3.1 Grounding

Ground terminal (crimp terminal M6, 14mm2) is provided at the lower part of the rear face of the welder for safe operation. (Refer to "Fig. 3 Connections at Rear Face.")Connect the ground wire of 14mm2 or more to the terminal.If there is a pool or pond between the power supply switch gear ground and the welder ground so that the leak current is concentrated into the pool or pond, not only ground them but also connect both grounds with cable to make any leak current flow in the cable.

Grounding of Base MetalBe sure to ground the base metal at resistance of 100Ω or less, even when a base such as lumber is floated.As shown in "Fig. 4 Connections at Front Face," be sure to ground base metal at resistance of 100Ω or less individually. If it is not grounded, voltage may be generated in the base metal resulting in electric shock.Make sure that the grounding is always done individually, separated from grounding for the robot.Connect the welder and the base metal with exclusive-use base metal cable.

• Ground resistance must be 100Ω or less.

The regulation specifies that the ground resistance must be 100Ω or less when the welder is used with rated input power supply voltage 400/440/480V.Failure to observe this warning may result in charging the case or unstable operations when the welder is not installed.

• Before wiring, be sure to turn the primary power supply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in fire or electric shock.

• Wiring must be performed by authorized or certified personnel.

Failure to observe this caution may result in fire or electric shock.

WARNING

CAUTION

3-1

3.2 Required Power Supply Facility Capacity and Connection CablesHW0481431

3.2 Required Power Supply Facility Capacity and Con-nection Cables

"Table 1 Power Supply Facility Capacity and Connection Cables" shows the required power supply facility capacity and connection cables.The rated input voltage for the welder is three-phase, 400/440/480V.Although welding is possible without any problems even if power supply voltage is fluctuated within ±10% from rated input power supply voltage, use as stable a power supply as possible for proper welding. If voltage varies more than ±10% from rated input power supply voltage, proper welding conditions cannot be established, resulting in welder problems.For safe operations, be sure to attach a no-fuse breaker or a switching device with fuse for each welder.When a no-fuse breaker is used, it must satisfy rated current in Table 1 and trip at 600% cur-rent of rated current for one second or more (generally, it will be a breaker for motor). If the breaker has too small a rating or power supply voltage is too high, the breaker may trip when the welder is turned ON.

*1 Be sure to use cables for welding. Also, use cables with sufficient thickness for pulse welding or current of 250A or more.Excessively small gauge cables may result in poor welding and cause abnormal heat-ing resulting in burn or fire.

3.3 Combination with Leakage Breaker

When the welder is used in a construction site, in a place with high humidity, or on an iron plate, iron framework, or surface plate with high conductivity, a leakage breaker should be installed according to the law. In such a case, connect a leakage breaker of current sensitivity 30mA, manufactured by Hitachi, Ltd. or the equivalent for each welder. The welder may mal-function because of the inverter operations depending on the model or current sensitivity of the leakage breaker. Therefore, select a proper one for inverter drives.

Table. 1 Power Supply Facility Capacity and Connection Cables

Power Supply Facility Capacity 20kVA

Fuse Rated Current 45A

Input Cable 8mm2 or more

Exclusive-use Base Metal Cable *1 60mm2 or more

Ground Cable 14mm2 or more

3-2

3.4 Connection of Electric SystemHW0481431

3.4 Connection of Electric System

Even one imperfect contact in the connections precludes proper welding. Be sure to make a perfect connection to the base metal by using jigs.

3-3


3-4


3.4.1 Connection of Power SupplyRefer to the following figure to make proper connections.

Fig. 3 Connections at Rear Face

2CO

exceeds 35 C

Gas hose

specified in JIS-K1106.conforms to the Class 3for welding or whatUse carbon dioxide gas

the ambient temperatureDo not put this where

To wire feeder

Carbon dioxide gas

(Example: FCR-2505A)(with flow meter)Carbon dioxide gas regulator

Exhaust air

Exhaust air

The cooling fan isthe air-suction type.

3-5


3.4.2 Connections at Welding SideRefer to the following figure for proper connections.For carbon dioxide gas or MAG gas arc welding, connect the base metal to the minus cable and connect the torch (wire) to the plus cable. (This is called reverse polarity or electrode pos-itive.)

Fig. 4 Connections at Front Face

For motor: connect to CON4 at rear face.For encoder: connect to CON5 at rear face.

MOTOWELD-E350

Cover

Welding cable 60 or more

Wire feeder

Base metal

Ground resistance:100 or less

Ground cable

Exclusive-use basemetal cable

60 or more

Output terminal

Remove the output terminal.cover and connect the cableAfter connection,be sure toreattach the output terminal cover.

3-6

3.5 Connection of Shielding Gas SystemHW0481431

3.4.3 Connection of Control CableConnect the connector at rear face of the welder and the wire feeder, and the robot interface connector at rear face of the welder and the control cable (with plug) from the XRC. Securely tighten the plug until it cannnot be turned any more.

3.5 Connection of Shielding Gas System

For Mixed Gas or Carbon Dioxide Gas WeldingThe 100VAC power supply is required for a heater of carbon dioxide gas regulator. Connect the gas cylinder as follows.

1. Remove dust from the gas cylinder connecting port.2. Install the MAG/carbon dioxide common gas regulator. Check the quality of the gas

and the type of the cylinder.3. Insert one end of the supplied rubber gas hose into the outlet of the gas regulator, and

the other end into the gas terminal inlet of the wire feeder.Clamp both ends securely with hose bands.

3-7

4.1 Type of Gas CylinderHW0481431

4 Gas for Welding

4.1 Type of Gas Cylinder

Carbon dioxide gas-filled cylinders can be classified into two types: One is the general type that is not the siphon type, and the other is the siphon type.Never use siphon type gas cylinders. The provided carbon dioxide gas regulator is not appli-cable to siphon type gas cylinder. If the regulator is connected to a siphon type gas cylinder, the contents of the cylinder are not gaseous and enter the regulator as remaining liquefied. In such a case, the pressure reduction mechanism of the regulator cannot be operated.The type of gas cylinder can be distinguished by cylinder color according to the cylinder’s manufacturer. Contact the gas seller for details.The safety valve operates when the pressure goes extremely high. When the valve operates, stop operation immediately, confirm the reason, and take appropriate corrective actions to prevent that the same error from occuring again.

4.2 Quality of Gas for Welding

Moisture or impurity in the carbon dioxide gas or argon gas used to shield welding arcs adversely influences welding. High purity and low moisture gas must be used.Use MAG gas containing 80% argon and 20% carbon dioxide gas for mixed gas. The gas mix-ing ratio of MAG gas is content, which contributes to constant welding quality. Especially for pulse welding, improper pulse welding will be resulted if the argon gas ratio is less than 80%.Use carbon dioxide gas designated as “for welding” or what conforms to Class 3 specified in JIS-K1106 (moisture content 0.005% or less) or the equivalent.Avoid using carbon dioxide gas containing moisture more than 0.005%, not only for the adverse effect on welding, but also because it may cause clogging in the gas regulator if the water content freezes.

4-1

4.3 Gas Regulator with Flow MeterHW0481431

4.3 Gas Regulator with Flow Meter

Use gas regulator with flow meter suitable for the gas to be used. The following table shows the examples of the gas regulator.

*1 The power supply for the heater is not provided with the welder. Prepare a 100VAC power supply for the heater of the gas regulator.

Table. 2 Gas Regulators (with Flow Meters)

Type Applicable Gas Remarks

FCR-2505A CO2, MAG Meter: Indicates secondary pressure and flow amount.Heater: 100VAC*1, 190W

FCR-225 CO2, MAG, argon Meter: Indicates primary pressure and float-type flow amount.Heater: 100VAC*1, 190W

4-2

5-1

HW0481431

5 Shading Measures

For shaded glasses of helmets or hand shields, use filter numbers 8 to 10 of JIS T8141 for welding of thin plates since it has a weak arc beam and the arc must be seen easily. On the other hand, use numbers 10 to 13 for welding of medium-thick plates since the arc is bright.

For MAG welding, for which stronger arc light is required compared to CO2 welding, use greater filter numbers.The welder brings in ultraviolet rays stronger than that caused by manual welding. Periodi-cally check protectors for eyes and the skin. Also, be sure to always wear these protectors.

Fig. 5 Example of Protection

• When the welder is controlled by external control input signal or while operating the manipulator, provide proper shade around the welding torch.

Accidental arc generation may damage eyes or burn the skin of those without proper pro-tection.

CAUTION

Jacket must be long-sleeved.

Helmet

Hand shield

Foot covers

Safety boots

Welding gloves

HW0481431

6 Basic Specifications

The following table shows the welder specifications.

Item Specifications

Model MOTOWELD-E350II

Type YWE-E350-BN2

Number of Phases, Rated Input Voltage

Three-phase, 400/440/480 (Change by terminal) ±10%

Rated Frequency 50/60Hz common

Rated Input 18kVA

15kW

Rated Output Current 30 to 350A (depends on the wire diameter)

Rated Output Voltage 12 to 36V (depends on the wire diameter)

Rated Operational Ratio 60% (for 10 minutes)

Wire Feeding Wire feeding speed: 1.5 to 18m/minServomotor: Print servomoter (standard)

(common for two-axis drive and four-axis drive)Encoder cable: 5m (standard), 7m max.Minertia servomotor applicable for servo torch

Output Setting Analog Input

0 to 14V (Indication of voltage, current, or wire feeding speed that are set to the panel)

Welding Type CO2 short-circuit welding, MAG/MIG short-circuit welding, pulse welding

Welding Object Material Iron, stainless steel, aluminium (Refer to the “Type” on the panel for details.)

Welding Voltage Setting Method

Synergic or independent Can be switched by D1 parameter 13.

User File Number of files: 3"Panel" or "robot" can be switched by D1 parameter 11.

Adjustment of Voltage and Current Waveform Control

Can be changed by P parameter in the user file.

Error Output Output with the arc failure signal on the robot side. (Error contents are indicated on the panel.)

Arc Start Control Switched every welding type. Can be adjusted by parameter.

Arc Touch Start Function Available for aluminium welding using the servo torch.

Gas Pre-flow Time 0.06 seconds (Can be switched by panel operation: 65 seconds max.)

6-1

HW0481680

Gas After-flow Time Approx. 0.5 seconds (Can be switched by panel operation: 65 seconds max.)

Wire-stick Prevention Time

Approx. 0.4 seconds (Can be adjusted by panel operation: 0.1to 0.6 sec-onds)

Wire Feeding Slow-down Speed

Approx. 2m/min (Can be adjusted by panel operation: 0.3 to 6m/min)

Output for Arc Monitoring

Outputs the signal corresponding to current or voltage to the robot side.The output terminal stand for analog indication is also available.

Interface for Manipulator Refer to "10 Robot Interface Signals."

Voltage for Starting Point Detecing Function (Optional)

Peak value: 220V ±20% (full-wave rectification)

External Dimensions [mm]

360 x 605 x 605 (width x depth x height)(excluding the projections such as screws or eyebolts)

Power Supply of the Heater for the Gas Regulator

None

Mass Approx. 70kg

Standard Accesory Fuse contained in glass tube of 5A (1 fuse)

Remarks Front face panel: Written in English

Item Specifications

6-2

7.1 Precautions on WeldingHW0481431

7 Precautions on Welding and Prepara-tion Procedure

The following describes the precautions on welding and the preparation procedure.

7.1 Precautions on Welding

7.1.1 Error DetectionError detection is performed for the following items, and the welder is automatically stopped when an error is detected.If an error occurs, the "Warning" lamp lights or blinks and the error number is displayed in the digital meter on the panel face. For the contents of errors, refer to the following table.At error detection, an arc failure signal is output at the robot side.

Table. 3 List of Error Display Contents

Error No. Item Contents Remedy

Err0 System reset System reset status Status display at system reset. This is not a fault.

Err1 Input overcur-rent

Overcurrent flows in the primary control circuit.

The power circuit may be broken. Contact your Yaskawa represen-tative.

Err2 Output over-current

Output overcurrent flows in the secondary control circuit.

Check that the torch or power cable is grounded.

Err3 Input over-voltage

Primary input voltage exceeding ・480V:more than 552V・440V:more than 506V・400V:more than 460Vis applied continuously for 2 sec-ondes

check the input voltage.

Err4 Excessive temperature

The temperature in the primary or secondary control circuit exceeds the specified value of the welder.

Check the ambient temperature (40°C or less) and operational ratio (60%).

Err5 Input under-voltage

Primary input voltage is・480V:lower than 432V・440V:lower than 396V・400V:lower than 360Vcontinuously for 2 seconds

Check the input voltage.

7-1


7.1.2 Tripped Power Supply SwitchIf the power supply switch is tripped, do not turn it ON again. Contact your Yaskawa represen-tative. If the power were to be turned ON again, the problem may be compounded and may affect the welding.

Err7 Open single-phase

At least one of the three phases of the primary input power supply is not connected.

Check the voltage between phases of the primary input power supply.

Err8 Improper model setting of DIP switch

PR(CR)-002 DIP switch is not correctly set.

Check the DIP switch setting.

Err9 Improper sys-tem reset set-ting

Err10 Improper feeding amount

There is a certain difference between the feeding amount command value and the feed-back from the encoder.

Check that the encoder cable of the feeder is not disconnected or that the wire load is not exces-sively heavy.

Err11 Communica-tions error

A communications error between the CPU and the DSP occurs.

The board may be broken. Con-tact your Yaskawa representa-tive.

Err12 to 14 Memory check error

The data in the welder internal memory (ROM, RAM, EEPROM) is not correct.

The data may not have been cor-rectly saved when the welding conditions are recorded because of a power failure, etc. Reset the system. If it still does not work, the board may be broken. Con-tact your Yaskawa representa-tive.

Err15 Starting sig-nal error

Arc starting signal is input before the welder’s main power supply starts up.

Check again the operation timing or signal cable connections. The same error may occur at momen-tary power failure.

Table. 3 List of Error Display Contents

Error No. Item Contents Remedy

7-2


7.1.3 Precautions on Welding OperationCheck the following precautions when before starting welding.

• Do not weld on a wet earth floor or metallic floor to avoid electric shock. Also avoid weld-ing where there are inflammables to prevent fire due to scattering of heated spatter or slag.

• The welding current flows to the wire while welding. Be careful that the welding voltage still remains for two seconds after the welding ends due to the two-second delay set for the welder. Also, do not touch the welding wire during the starting point detection (optional function) since the voltage of approx. 300V is applied to the wire.

• If a conduit is extremely bent, wire cannot be smoothly fed, and thus the set welding con-ditions may be altered. To prevent this, place conduit as straight as possible.

• If welding is done at a current exceeding the rated output current, internal parts of the welder may be burnt. Allowable operational ratio for a current under the rated value is cal-culated as follows:

Allowable operational ratio = Rated operational ratio × [ ]2%

• The inverter welder is the forced air-suction cooling type. Do not turn OFF the power sup-ply switch until the cooling fan completely stops after completion of the operations. To prevent electric shock, never disconnect or connect the cables for the welder, the wire feeder, or the welding torch while the power is ON. Make sure that the power supply switch of the welder is turned OFF after the operation.

• The cooling fan starts rotating as soon as the power supply is turned ON. Then, the fan stops if approx. five minutes passes without arc start. However, the fan restarts rotating when welding starts, and it stops approx. 15 minutes after the welding ends.

• Stretch a protective curtain for workers and others to protect from arc light, spatter, and slag.

• The welder cannot be used for gouging other than CO2/MAG welding.• Noise may be generated over the radio when welding.

When listening to the radio, keep the radio as far as possible from the welder. When a radio is not on battery but on a 100 VAC power supply, do not bring the welding torch close to the 100 VAC cable.

Table. 4 Allowable Operational Ratio of the Welder of 350 Ampere(with Rated Operational Rate of 60%)

Welding Current

(A)

Allowable Operational Rate

(%)

Allowable Continuous Welding Time Welding Pause Time

350 60 6 minutes or less 4 minutes or more




270 100 Continuous welding possible -

Rated currentOperating current

7-3

7.2 Welding Preparation ProcedureHW0481431

7.2 Welding Preparation Procedure

The following describes the preparation procedure to start actual welding. Refer to "8 eOper-ations on Panel" for operations using the welder’s panel.

Table. 5 Welding Preparation Procedure

Step Item Details

1Setting welding wire Set a wire suitable to the welding type to the wire

feeder. Make sure that the diameter of the roller of wire feeder matches the wire diameter.

2 Checking torch Confirm that a contact tip suitable to the diameter of the wire is installed on the torch.

3 Turning ON the switch in the switch gearConfirm that connections are correct , then turn ON the switch of the switch gear of the welder.

4

Turning ON switches for welders Turn ON the power switch. The power indicator lamp lights and the built-in cooling fan starts. The fan stops unless the arc does not start for approx. five minutes. The fan automatically restarts when the arc starts.

5 Checking “Synergic” or “Indepen-dent”Check the “Synergic” or “Independent” for the welder.

6 Setting at the robot side Set the files related to the welder (including “Synergic” or “Independent” selection).

7

Selecting welding type(Select the welding type accord-ing to the type of shielding gas and wire, or short-circuit/pulse. Selectable types are written on the nameplate on the front face of the panel.)

Set the welding type number to the Type on the panel face. The available welding types are written on the nameplate attached on the front face of the welder panel.(Welding types other than written are not available. To use those types other than written, upgrading of the software is required. Contact your Yaskawa represen-tative.)Also, select the feeding motor (print servo or servo torch).

8

Checking the indicated value on the panel face

Check the settings for the voltage, current, wire feed-ing speed, and welding type of the digital meter on the panel face. Check the operation of the panel by changing the command value from the XRC.

9

Wire inching Press the inching button on the programming pendant of the XRC, and do not release the button until wire comes out from the end of the torch. The wire feeding speed can be modified by using the welding current control signal from the XRC.

7-4

7.2 Welding Preparation ProcedureHW0481431

When step1 to 11 have been finished, the preparation has been completed.

10

Adjusting gas flow 1. Press the "Gas" button on the panel of welder.The LED indicator lights and the gas flows for 20 seconds. The gas automatically stops after the 20 seconds.

2. Turn the valve of the gas cylinder counterclock-wise to open.

3. Turn the knob of the gas regulator to adjust the flow according to welding conditions. Proper gas flow rate is 10 to 25 liters per minute. The flow rate must be increased in proportion to the welding cur-rent.

11

Saving welding conditions Save the conditions before turning OFF the welder.Press the "Record" button of the panel to save the conditions.Confirm that the LED indicator lights again after sav-ing.

Table. 5 Welding Preparation Procedure

Step Item Details

7-5

8.1 Explanation of Welder PanelHW0481431

8 eOperations on Panel

8.1 Explanation of Welder Panel

Fig. 6 Welder Panel

During standby status: Displays the set welding voltage value (V).During welding: Displays the welding voltage value (V) that is fed-back.During setting: Displays the parameter number.During standby status: Displays the set welding current value (A). During welding: Displays the welding current value (A) that is fed-back.During setting: Normally displays "---." When the touch start is selected for weld-

ing other than aluminum welding, displays "-."During standby status: Displays the wire feeding amount (m/min) of the set welding cur-

rent value.During inching or welding: Displays the feeding amount (m/min) of the motor that is fed-

back.During setting: Displays the P parameter ratio (%) or C or D parameter value (in

decimal).Displays the welding type. Lights when the power supply switch is turned ON. Lights or blinks when an error occurs. The error number is displayed on the digital meter.Lights while the starting point detecting function is used. (Effective only when the optional board for the starting point detecting function is mounted.)When this button is pressed during standby status, display changes to the parameter setting display. "P.00" appears in display , and the parameter set value appears in display .

Pressing the panel buttons during welding does not change any operation other than user file selection. Be sure to stop welding before starting the panel operations.

NOTE

Search

Power

Warning

PRM Set Weld Type

File No 2File No 3

User File Select

File No 1

TypeWire m min

do not turn off the breaker before LED re-lighting.

PRM Select

Record Gas

LocalCommon PRM Select

Warning:When the record switch is pushed,

V A

8-1

8.1 Explanation of Welder PanelHW0481431

Pressing it again returns to the standby display. (Effective only when the user file is selected.)When this button is pressed during standby status, display changes to the common param-eter setting display. "C.00" appears in display , and the common parameter set value appears in display . Pressing it again returns to the standby display.Switches the remote mode and the local mode. The LED indicator lights in the local mode. • Remote mode: Voltage/current command is given by the operations at the robot side.• Local mode: Voltage/current command is given by the operations on the welder panel.

When setting parameters or common parameters, the numbers and the parameter set val-ues can be switched. The blinking display is the selected item.Selects the welding type. Used to change the settings. Press "L" or "R" to move the digit. Press "+" or "-" to increase or decrease the value.The LED indicator blinks when the setting is changed.To save the changed setting, keep pressing the button for 3 seconds or more. The LED indicator lights and the changed setting is saved. Refer to for the selection of saving des-tination.The indicators on the panel are extinguished while the data is being saved. If the power supply is turned OFF during this time, the data cannot be correctly saved. Wait until the indicators lights again.Turning OFF and ON the welder after the indicators light again returns to the status where the conditions were saved.The changed settings will not be saved when the power supply is turned OFF and ON with-out pressing this button.Checks the gas. The LED indicator lights when pressing this button, and the gas flows for 20 seconds. Pressing the button again during gas checking, the gas stops flowing.Selects the file to save the contents of the changed settings. Each time the button is pressed, the LED indicator for the file number is changed.

11

12

13

14

16

15

16

8-2

8.2 Settings on Welder PanelHW0481431

8.2 Settings on Welder Panel

8.2.1 Changing Process ParametersProcess parameters can be changed only when the user file is selected. For details on the Process parameters, refer to "8.3 List of Process Parameters."

How to Change the Process Parameter Number1. Press "P.R.M. Select" button during standby status.

voltmeter (V) displays "P.00" blinking, and ammeter (A) displays the parameter set value lighting.

2. Press "L" or "R" button to change the number of the blinking digits to one.3. Using "L" or "R" button, move the blinking digit to the number to be changed.

Pressing "L" button moves to the left while "R" moves to the right.4. Use "+" or "-" button to increase or decrease the value.5. After changing the value, press "P.R.M. Select" button or leave it without doing any-

thing for 10 seconds to return to the standby display.

How to Change the P Parameter ValueIn this modification, the internal data of the selected welding type are multiplied by the modifi-cation ratio.

To multiply the internal data of parameter 00 of welding type 325 by 200%:

1. Press "P.R.M. Select" button during standby status. voltmeter (V) displays "P.00" blinking, and "Wire m/min" (WF) displays the param-

eter value lighting.2. Press "P.R.M. Set" button, and the parameter value display of "Wire m/min" (WF)

blinks.3. Press "L" or "R" button to change the number of blinking digits to one. 4. Using "L" or "R" button, move the blinking digit to the number to be changed.

Pressing "L" button moves to the left while "R" moves to the right.5. Use "+" or "-" button to increase or decrease the value in the range between 10 and

200%.6. After changing the value, press "P.R.M. Set" button, and the parameter number

blinks.7. Press "P.R.M. Select" button or leave it without doing anything for 10 seconds to

return to the standby display.To save the changed contents, refer to "8.2.6 Saving Welding Conditions."

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13

P. 00

TypeWFAV

200 325

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13

13

13

13

11

8-3


8.2.2 Changing Common ParametersFor details on the common parameters, refer to "8.4 List of Common Parameters."

How to Change the Common Parameter Number1. Press "Common PRM Select" button during standby status.

voltmeter (V) displays "C.00" blinking, and "Wire m/min" (WF) displays the param-eter value lighting.

2. Press "L" or "R" button to change the number of blinking digits to one. 3. Using "L" or "R" button, move the blinking digit to the number to be changed.

Pressing "L" button moves to the left while "R" moves to the right.4. Use "+" or "-" button to increase or decrease the value.5. After changing the value, press "Common PRM Select" button or leave it without

doing anything for 10 seconds to return to the standby display.

How to Change the Common Parameter ValueIn this modification, the internal data related to the whole unit of the welder are directly changed.

To change the internal data of common parameter 00 to 640:

1. Press "Common PRM Select" button during standby status. voltmeter (V) displays "C.00" blinking, and "Wire m/min" (WF) displays the param-

eter value lighting.2. Press "P.R.M. Set" button, and the parameter value display of "Wire m/min" (WF)

blinks.3. Press "L" or "R" button to change the number of blinking digits to one.4. Using "L" or "R" button, move the blinking digit to the number to be changed.

Pressing "L" button moves to the left while "R" moves to the right. The number(s) above the forth digit is/are displayed in ammeter (A).

5. Use "+" or "-" button to increase or decrease the value in the range between 1 and 1000.

6. After changing the value, press "Common PRM Select" button, and the common parameter number blinks.

7. Press "Common PRM Select" button or leave it without doing anything for 10 sec-onds to return to the standby display.

To save the changed contents, refer to "8.2.6 Saving Welding Conditions."

13

13

13

13

C. 00

TypeWFAV

640

11

13

13

13

13

8-4


8.2.3 Changing Welding TypeThe following describes how to change the welding type.

1. Press "Weld. Type" button. The display "Type" blinks. 2. Press "L" or "R" button to change the number of blinking digits to one.3. Using "L" or "R" button, move the blinking digit to the number to be changed.

Pressing "L" button moves to the left while "R" moves to the right.4. Use "+" or "-" button to increase or decrease the value.5. After changing the value, press "Weld. Type" button or leave it without doing any-

thing for 10 seconds, and "Type" lights.To save the changed contents, refer to "8.2.6 Saving Welding Conditions."

The welding types available for software version 201-000 are listed on the nameplate attached to the front panel of the welder.

Fig. 7 Nameplate on the Welder Front Panel

Welding types other than listed on the nameplate are not available. To perform any welding type other than listed, the software version of the welder must be up-graded. Contact your Yaskawa representative to up-grade the software version.

WELD TYPE SELECTION

WELD TYPE GAS

MATERIAL WIRE_DIA PULSE/SHORT

WELD TYPE GAS

MATERIAL WIRE_DIA PULSE/SHORT

2.12 A Al 1.2 P 3.37 C Fe 1.2 S2.14 A Al 1.2 LP 3.38 M1 Fe 0.6 S3.16 M1 Fe 0.8 P 5.39 M4 Sus 0.6 S3.18 M1 Fe 0.8 S 5.40 M1 Sus 0.8 P3.19 M1 Fe 0.9 P 5.41 M4 Sus 0.8 S3.21 M1 Fe 0.9 S 5.42 M3 Sus 1.0 P3.22 M1 Fe 1.0 P 4.43 M2 Sus 1.2 P3.24 M1 Fe 1.0 S 5.44 M3 Sus 1.2 P3.25 M1 Fe 1.2 P 5.45 M3 Sus 0.8 P3.26 M1 Fe 1.2 P2 5.46 M3 Sus 0.9 P3.27 M1 Fe 1.2 S5.28 M1 Sus 0.9 P5.29 M4 Sus 0.9 S5.30 M1 Sus 1.0 P5.31 M4 Sus 1.0 S5.32 M1 Sus 1.2 P5.33 M4 Sus 1.2 S3.34 C Fe 0.8 S3.35 C Fe 0.9 S3.36 C Fe 1.0 S2:Al(5000) 3:Fe4:FLUX5:SUS

M1:Ar 80 + CO2 20M2:Ar 95 + CO2 5M3:Ar 98 + CO2 2M4:Ar 98 + O2 2C:CO2 100% A:Ar 100%

S:SHORTP :PULSE P2:WEAK PULSELP:LOW PULSE

Using improper welding type will result in unstable welding, which causes excessive spat-ters or imperfect bead appearance. Before starting welding, confirm that the welding type has been correctly selected.

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12

NOTE

8-5


8.2.4 Changing the Contents of User Files The conditions changed by the P parameter concerning any welding type are saved in the user file.Also, the user file can be called up from the XRC to perform welding.

The following describes how to change the contents of user files.1. Use the "User File Select" button to select File No. 1, 2, or 3 in the remote mode.2. Press the "Weld. Type" button to change the welding type.

For the changing type, refer to "8.2.3 Changing Welding Type."3. Press the "P.R.M. Select" button to display the P parameter number.

For the changing type, refer to "8.2.1 Changing Process Parameters."When the conditions are changed, the "Record" LED indicator blinks. To save the changed contents, refer to "8.2.6 Saving Welding Conditions."

8.2.5 Changing to the Local ModeSelect either one of user file F1, 2, or 3 and press the "Local" button, and the "Local" LED indi-cator lights.The voltage command value, current command value (wire feeding command value), or weld-ing type can be changed by operation on the panel, separated from the robot side.

• With the "V/Set" arrow button (parameter selection), the voltage command value can be changed.

• With the "A.W/S" arrow button (parameter selection), the current command value can be changed.

In the Local mode, welding can be performed with the welding voltage and current command values on the panel face.

When the value is changed, the "Record" LED indicator blinks. To save the changed contents, refer to "8.2.6 Saving Welding Conditions."

8-6


8.2.6 Saving Welding Conditions

When the parameter set value is changed by the operations on the panel, "Record" LED indicator blinks.

The following describes how to save the settings.1. Referring to "8.2.4 Changing the Contents of User Files," specify the file number

where the data are to be saved.2. Press "Record" button for 3 seconds or more, and the panel LED indicators are

extinguished. Only "Record" LED indicator lights.3. After the indicators light again, turn OFF and ON the welder.

The display returns to the status where the conditions were saved.

8.2.7 Checking the Flow Amount of Shieding Gas The shielding gas flow amount can be checked.

Press the "Gas" button.The LED indicator lights and the gas flows for 20 seconds.Press the button again during gas checking to stop the gas flow.

• While the data is being saved, the panel LED indicators are extinguished. If the power supply is turned OFF while the LED indicators are extinguished, the data cannot be cor-rectly saved. Confirm that the panel LED indicators light again before turning OFF the power supply.

• The changed data are overwritten on the data of the file where the data is to be stored.• For P parameters, the changed data has been validated at the same time the change is

made. However, when the welding type is changed or the power supply switch of the welder is turned OFF, the changed data will be lost.

14

14

14

NOTE

8-7


8.2.8 Changing D ParametersFor details on the D parameters, refer to "8.5 List of D Parameters."The following describes how to change the D parameter number.

1. Press "P.R.M. Select" button and "Common PRM Select" button simultaneously during standby status.

voltmeter (V) displays "d-1" blinking, ammeter (A) displays the soft switch number blinking, and "Wire (m/min)" displays ON or OFF blinking.

2. Press "P.R.M. Set" button, and voltmeter (V) stops blinking. 3. Use "+" or "-" button to switch "d-1" and "d-2."4. Press "P.R.M. Set" button, and ammeter (A) stops blinking. 5. Use "+" or "-" button to change the soft switch number (1 to 16). 6. Press "P.R.M. Set" button again, and "Wire (m/min)" stops blinking. 7. Use "+" or "-" button again to switch ON and OFF.8. After changing the value, press "P.R.M. Select" button or leave it without doing any-

thing for 10 seconds to return to the standby display.

When soft switch d-1 No. 11 is ON (enabled):

To save the changed contents, refer to "8.2.6 Saving Welding Conditions."

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11

13

11

13

d-1

TypeWFAV

ON11

8-8

8.3 List of Process ParametersHW0481431

8.3 List of Process Parameters

By changing the Process parameter set values, the welding characteristics (start/main condi-tions/end) that are specified by database in the welder can be adjusted according to your envi-ronmental conditions.All the values are set to "100% = Operating as the characteristics in the database" when shipped.If the adjustment of welding characteristics is required, refer to "13 Adjustment of Welding Characteristics Using Process Parameters."

Display No.*1

ContentsDisplay No.*1

Contents

P00 C Wire slow-down speed P18 C Sphere-drip pulse peak time

P01 C Wire speed at start P19 - Reserved (Do not change.)

P02 C Starting pulse peak current P20 C Wire-stick prevention time

P03 - Reserved (Do not change.) P21 - Reserved (Do not change.)

P04 C Starting pulse peak time P22 - Reserved (Do not change.)

P05 C Average value of hot current P23 - Reserved (Do not change.)

P06 C Average value of hot voltage P24 - Reserved (Do not change.)

P07 C Hot time P25 - Reserved (Do not change.)

P08 P Pulse current P26 P Base current 1st target value

P09 P Base current P27 - Reserved (Do not change.)

P10 P Pulse time P28 - Reserved (Do not change.)

P11 C Average current at endingVALID when D1 parameter 4=ON

P29 - Reserved (Do not change.)

P12 C Average voltage at ending P30 - Reserved (Do not change.)

P13 C End time P31 P MAG pulse current increasing speed 1

P14 C Average current value at burning P32 P MAG pulse current increasing speed 2

P15 C Average voltage value at burning P33 P MAG pulse current decreasing speed 1

P16 C Burning time P34 P MAG pulse current decreasing time

P17 C Sphere-drip pulse peak current P35 P MIG pulse current increasing ratio

8-9

8.3 List of Process ParametersHW0481431

*1 P: For pulse welding (including aluminum pulse)A: For aluminum weldingS: For short-circuit weldingC: Common for all the welding types

P36 P MIG pulse current decreasing ratio P50 S Arc control 2

P37 S Short-circuit current increasing speed 1 P51 S Arc control 3

P38 S Short-circuit current increasing speed 2 P52 - Reserved (Do not change.)

P39 P Base time P53 - Reserved (Do not change.)

P40 P Pulse current target value P54 - Reserved (Do not change.)



P43 A Hot slope time P57 - Reserved (Do not change.)

P44 A Ending slope timeVALID when D1 parame-ter 4=ON

P58 - Reserved (Do not change.)



P47 - Reserved (Do not change.) P61 P Arc length control gain

P48 - Reserved (Do not change.) P62 C Current value adjust

P49 S Arc control 1

Display No.*1

ContentsDisplay No.*1

Contents

8-10

8.4 List of Common ParametersHW0481431

8.4 List of Common Parameters

Common parameters specify the operations of the welder. Set the parameters according to the operation conditions.

*1 Validated when the welder power supply is turned OFF and ON after the conditions are saved.

*2 The initial value of the external resistance set value is the value measured under the environment for the MOTOWELD-E350II database creation. For measurement of the external resistance value under your operation conditions, refer to "14 Calibration for External Resistance."

Dis-play No.

Contents Default Setting Unit Description

C00 Gas check time 20 s −

C01 Gas pre-flow time 56 ms Gas flowing time before welding output starts (minimum: 56 ms)

C02 Gas after-flow time 500 ms Gas flowing time after welding output completes

C03 Low-pulse frequency (for weld-ing type 2.14, aluminum) 30 0.1Hz Low-pulse frequency

C04 Low-pulse amplitude (for weld-ing type 2.14, aluminum) 10 %Low-pulse wire feeding speed amplitude

C05Current at low-pulse accelera-tion (for welding type 2.14, alu-minum)

100 % Current at low-pulse accelera-tion

C06Current at low-pulse decelera-tion (for welding type 2.14, alu-minum)

100 % Current at low-pulse decelera-tion

C07 Digital meter displayed speed 1000 msTime for average moving for dis-play of current/voltage digital meter

C08 External resistance set value *1 505 *2 ×10-5Ω

Electric resistance value of welding current path such as power cable, jig stand con-nected to welder

C09 Motor setting *1 0 -

Motor selection0: Print-type servomotor 1: Minertia servomotor for servo

torch

8-11

8.5 List of D ParametersHW0481431

8.5 List of D Parameters

D parameters specify the operation conditions for the welder. Set the parameters according to the operation conditions.The D parameters are displayed by pressing the P parameter button ("P.R.M Select") and C parameter button ("Common PRM Select") simultaneously.

D-1

Display No. Contents ON OFF

Default Setting

1 Reserved − − OFF

2 Power supply FF compen-sation Enabled Disabled ON

3 Wire slow-down Enabled Disabled ON

4 End event End condition process-ing enabled Disabled OFF



7 Current/voltage command Analog commandCommunications (unused) ON




11 File switching Switched at robot side Switched on panel OFF


13 Voltage adjustment Independent adjustment Synergic adjustment OFF

14 Arc length control P Pulse arc length control enabled Disabled ON



8-12

8.5 List of D ParametersHW0481431

*1 Validated when the welder power supply is turned OFF and ON after the conditions are saved.

*2 The direction in which the wire is fed to the base metal is the positive direction. When aluminum welding is selected for "Type," note that these parameter settings are reversed (positive direction at OFF). Aluminum welding is performed with "Touch arc start enabled" set, assuming that the servo torch is used.

• For aluminum welding, set end event "D-1 4" to "enabled" (ON) since automatic crater processing is effective.

• For synergic voltage, the voltage that Yaskawa deems adequate is specified as 100%. Changing it by 10%, voltage varies by approx. 1V. (Example: In case of 20V at 100%, it becomes 19V and 21V at 90% and 110%, respectively. The percentage (%) can be changed in the range between 50% and 150% (±5V).) The percentage (%) that is set at robot synergic voltage is displayed on the welder in the unit of V.

• To validate the calibration for the external resistance value, the external resistance value must be measured. For measurement of the external resistance value under your opera-tion conditions, refer to "14 Calibration for External Resistance."

D-2

Display No. Item ON OFF

Default Setting

1External resistance cali-bration *1

Compensated with external resistance value set to C.08 parameter

Disabled OFF

2Retracting directionUser file 1*2

Positive direction Negative direction OFF





5 and after

Reserved for system (Do not change.) − − OFF

8-13

9.1 Checking the Welding ConditionsHW0481431

9 Welding Operation

9.1 Checking the Welding Conditions

Before starting actual welding operation, perform the test welding for the welding conditions to check if the welding performance is satisfactory. Remove oil, rust, oil paint, water, and foreign matter generated by gas-cutting to prevent the surface pore and blowhole.

9.2 Wire Stickout

The wire length from the torch tip to the arc point is called wire stickout. Keep this length con-stant during welding.

The wire stickout is:15mm for wire diameter of 1.2mm10 to 15mm for wire diameter of 0.9mm

9-1

9.3 Direction of Welding and Torch AngleHW0481680

9.3 Direction of Welding and Torch Angle

There are two types of welding available: backhand welding (same as manual welding), in which the torch is tilted by 10° to 15° in the direction of welding, and forward welding, in which welding is carried out in the same state but in the opposite direction. The forward welding is more popular in robot welding because it results in better gas shielding and the welding can be performed viewing the welding line.

Fig. 8 Direction of Welding and Torch Angle

9.4 Notes for Using Extension Cable

When an extension cable is used, actual output between the torch and the welded object decreases because of voltage drop in the cable. To prevent this, set the welding voltage adjustment command value higher than the target voltage value to compensate for the output voltage drop. Fig. 9 shows a refernce for the voltage drop along an extension cable. Use the one-class thicker extension cable to keep stable welding voltage.

Nozzle

Backhand welding

Torch

Base metal

Gas

Forward welding

Forward welding is preferred in CO2/MAG welding.

Wire stickout

10° to 15°

9-2

9.4 Notes for Using Extension CableHW0481431

If an extension cable is used for pulse welding, the response for the pulse waveform control may be delayed, which may prevent the spatter-

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