Yaskawa Motoman MOTOWELD X500 Instructions

MOTOWELD-X500
INSTRUCTIONS
TYPE:
YWE-X500-6N0
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
192344-1CD
2
MANUAL NO.
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Read this manual carefully and operate the MOTOWELD-X500
properly.
Thank you for purchasing the MOTOWELD-X500. The product is
the welding power source for a high performance robot of CO2/
MAG/MIG controlled by the digital inverter.
Read this manual carefully and understand the contents before
handling the MOTOWELD-X500. For the wire feeder, the welding
torch, and the gas regulator, read each instruction manual carefully.
CAUTION
•
This instruction manual is intended to explain
operating instructions and maintenance
procedures for the MOTOWELD-X500.
• To ensure the safety for installation, maintenance, service of this
welding machine, understand the machine well and allow only
trained or authorized personnel to perform the operation.
• To ensure the safety, allow only personnel who have understood
the welding machine well and have the knowledge and ability
enough to handle safely to perform the operation.
• Do not disassemble/modify the product. Doing so could cause
electric shock, injury, or damage to the product.
• After reading this manual, keep it handy and safely for future reference and read again as necessary.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of your product.
In this manual, the Notes for Safe Operation are classified as
"DANGER", "WARNING", "CAUTION" or "NOTICE".
DANGER
WARNING
CAUTION
NOTICE
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.
Indicates a potentially hazardous
situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.
Indicates a hazardous situation,
which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.
NOTICE is the preferred signal word
to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “DANGER”, “WARNING” and “CAUTION".
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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.
DANGER
Be sure to observe the following warnings to avoid serious injury to
personnel.
1. Be sure to observe the precautions in this instruction manual
although this welding power source is designed and manufactured
with sufficient consideration given to safety.
Failure to observe this warning may result in death or serious injury
to personnel.
2. 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 products after welding, disposal of wastes, etc.
3. Do not let personnel to approach the welding power source or
welding sites unnecessarily.
4. Any person using a pacemaker must not approach the welding
power source or welding site under operation unless permitted by
doctor.
The welding power source generates a magnetic field around it
during current conduction, resulting in bad influence on the
pacemaker.
5. Clean the cooling-water path once a month when using a watercooled torch and the cooling water circulator.
Failure to observe this warning may result in explosion or burns due
to the choked path.
6. In order to secure safe operations, only a trained or qualified person
who has understood the welding power source must perform
installation, maintenance and inspection, or repair of the welding
power source.
7. In order to secure safe operations, only a person that has
understood this instruction manual and has knowledge and
techniques to handle the welding power source safely must operate
the welding power source.
8. Do not use the welding power source for any applications other than
welding.
9. Do not use the welding power supply for purposes other than
welding, such as thawing frozen pipes.
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DANGER
Be sure to observe the following warnings to avoid an electric shock.
1. Never touch the input terminals, output terminals, or other charged
parts of the welding power supply.
2. Only a qualified person in electric construction should perform
grounding construction for the welding power source 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.
3. Be sure to perform installation or maintenance and inspection 10
minutes 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 turn on this input power supply until the
work is finished and the checks have been completed.
4. Use the cables having the specified thickness. Do not use any cable
of insufficient capacity or damaged or with its conductor exposed.
5. Tighten the cable connecting sections firmly and insulate them.
6. Do not use the welding power source with its case or cover
removed. Install the case and cover securely.
7. Do not extend cables between round terminals.
8. Use such protector as gloves, safety boots, and clothes with long
sleeves.
9. Do not use worn, damaged or wet gloves. Always use dry insulated
gloves.
10. Use lifelines when working at heights.
11. Perform maintenance and inspection periodically. Repair damaged
parts immediately.
12. Turn OFF all equipment input power supplies when not being used.
13. When performing AC arc welding in a small space or at heights, be
sure to use equipment to prevent critical electric shock as specified
by labor safety and sanitary regulations.
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DANGER
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.
1. 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.
2. 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
regulations or use effective protectors for breathing.
Fumes or gases generated at welding may harm your health.
If welding work is continuously performed indoors, a fit test should
be conducted once a year.
(Comprehensive measures to prevent dust hazards)
3. 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.
4. 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.
5. Do not perform welding near degreasing, cleaning, or spraying
operations.
Failure to observe this warning may generate extremely noxious
gases.
6. 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.
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DANGER
Observe the following cautions to prevent fire, explosion, or rupture.
1. 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.
2. 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.
3. Do not make hot base metals immediately after welding close to
inflammables.
4. Remove inflammables at the hidden side when welding ceiling,
floor, or wall.
Failure to observe this caution may result in fire.
5. 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.
6. Connect the cable at the base metal as close to the welding part as
possible.
7. 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.
8. Locate fire extinguishers near the welding site.
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WARNING
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 welding.
1. Wear welding mask or shaded glasses appropriate for welding.
2. Wear protective glasses to protect your eyes from spatters or slags.
Scattered spatters or slags may damage eyes or burn the skin.
3. Use such protectors as leather gloves, clothes with long sleeves,
leg covers, or leather aprons for welding.
4. Install protective curtains around the welding site to protect your
eyes from arc beams.
Arc beams may irritate eyes or burn skins.
5. Use noise protector when there is excessive noise.
Noise may damage hearing.
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WARNING
Be sure to observe the following cautions to prevent a gas cylinder from
falling or a gas regulator from rupturing.
1. 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.
2. Use the attached gas regulator or our recommended one.
3. Read carefully the instruction manual of the gas regulator and
observe the precautions before using it.
4. Hold the gas cylinder in the exclusive-use gas cylinder stand.
A gas cylinder falling may result in personal injury.
5. Do not expose the gas cylinder to high temperature.
6. Do not bring your face close to the discharging opening when
opening the valve of the gas cylinder.
7. Be sure to attach the protective cap when the gas cylinder is not
used.
8. Do not hang the welding torch over the gas cylinder or keep the
electrode away from the gas cylinder.
WARNING
The front panel of the welding power source, an input terminal cover,
the output terminal cover are produced with polycarbonate resin.
Please look after next about the handling of resin parts by all means.
1. Please do not give a shock in resin parts. It causes damage and the
trouble.
2. When resin parts become dirty, please wipe it with tender cloth
using water or the synthetic detergent which you diluted.Please do
not use an organic solvent and the chemicals containing solvents
such as thinner, benzine, the alcohol etc.It causes a crack
(breaking) and a strength drop, the change of color.
3. Organic solvent, chemicals, place where synthetic oil attaches to
and these, please do not use a welding power supply at a place
included in the atmosphere.It causes a crack (breaking) and a
strength drop, the change of color of resin parts.
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WARNING
Observe the following cautions to prevent personal injury due to
improper handling.
1. Do not use the welding power source with the case or cover
removed.
2. Only a qualified person or a person who has understood the
welding power source must remove the welding power source case
for maintenance and inspection or repair. Take preventive
measures not to let other personnel approach the welding power
source or welding sites unnecessarily by putting up a guard fence or
the like.
3. 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.
4. Please do not rotate the cooling fan in the state of removing the
cover of the cooling fan.
WARNING
Observe the following cautions to prevent personal injury by the end tip
of the welding wire.
1. 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.
2. Do not bring the welding torch end close to eyes, face, or body to
perform inching or pulling the torch switch.
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WARNING
When hanging the wire feeder, observe the
following cautions to prevent wire from being
removed from the spool shaft.
When hanging the wire feeder, remove the antifall 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.
WARNING
Observe the following cautions to prevent burns due to the arc.
If body parts such as hands and fingers directly touch the arc, burns will
result.
1. Do not put your hands and fingers near the chip and the electrodes
of the torch end during cutting operation.
2. Do not grasp near the base metal during cutting operation.
3. Turn OFF the power supply before replacing the chip or the
electrodes of the torch.
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WARNING
Observe the following cautions to prevent a fire accident caused by
deterioration of welding power source insulation.
1. Perform all welding and grinding away from welding power source
to protect welding power source from spattering and metal powder.
Spatter and metal powder inside the welding power source may
cause a deterioration of insulation resulting in accidental fire.
2. Be sure to perform maintenance and inspection periodically to
prevent deterioration of insulation caused by accumulation of dust
and dirt.
3. If spatter or metal powder enters the inside of the welding power
source, be sure to remove any dust by blowing dry compressed air
or using similar methods after turning OFF the welding power
source and switch in the switch box. Leaving dust deposited inside
may cause insulation deterioration, resulting in electric shock or fire.
WARNING
1. Please do not ride on the top plate of the welding power source.
2. Sheet metal on the surface of the welding power source might be
very hot. Please do not touch the sheet metal.
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1 Basic Specifications ........................................................................................................................ 1-1
2 Welding Power Source Installation and Connection ....................................................................... 2-1
2.1 Installation Site and Welding Power Source Environment................................................. 2-1
2.2 Precautions on Grounding ................................................................................................. 2-2
2.3 Power Supply Installed Capacity and Connection Cables................................................. 2-2
2.4 Combination with Earth Leakage Breaker ......................................................................... 2-3
2.5 Connection of Electrical System ........................................................................................ 2-4
2.6 Connection of Welding Voltage Sensing Cable ................................................................. 2-9
2.6.1 Connection in the Welding Power Source Side.................................................. 2-10
2.6.2 Connection to the Work ...................................................................................... 2-10
2.6.3 Connection example of Welding Voltage Sensing Cable ................................... 2-13
2.7 Connection of Shielding Gas System .............................................................................. 2-16
2.7.1 For Mixed Gas or Carbon Dioxide Gas Welding ................................................ 2-16
2.7.2 Installation Site and Gas Cylinder Environment ................................................. 2-16
2.8 Ambient Environment ...................................................................................................... 2-18
2.9 Precautions on Transporting............................................................................................ 2-19
3 Welding Preparation ....................................................................................................................... 3-1
4 Operations on Panel ....................................................................................................................... 4-1
4.1 Explanation of Welding power source Panel ..................................................................... 4-1
4.2 Explanation of Welding power source Panel ..................................................................... 4-6
4.2.1 Parameters confirmation method ......................................................................... 4-6
4.2.2 Changing Common (C) Parameters ..................................................................... 4-7
4.2.3 Communication Setting ........................................................................................ 4-8
4.2.4 Saving Welding Conditions................................................................................. 4-10
4.2.5 System Reset ..................................................................................................... 4-10
5 Setting in the Robot Control Unit Side ............................................................................................ 5-1
5.1 Digital Communication Setup ............................................................................................ 5-1
5.2 Welding Unit Characteristics Setup ................................................................................... 5-2
5.3 Welding power source Basic Setup ................................................................................... 5-4
5.3.1 Security Mode Change ......................................................................................... 5-5
5.3.2 Welding power source Setup Screen Display ............................. 5-6
5.3.3 Feeder Motor Selection ........................................................................................ 5-7
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5.4 Welding Method Setup....................................................................................................... 5-9
5.5 Welding Job Making......................................................................................................... 5-11
6 Welding power source Customization............................................................................................. 6-1
6.1 MOTOWELD Screen ......................................................................................................... 6-1
6.1.1 MOTOWELD Screen (Online/Offline) ................................................................... 6-1
6.1.2 Parameter Discrepancy Screen............................................................................ 6-3
6.1.3 Note and Procedure When Switching the Welding Power Source ....................... 6-3
6.2 Welder prm. Screen ........................................................................................................... 6-5
6.2.1
Gas/Wire Screen ................................................................................................. 6-5
6.2.2 Other Screen ........................................................................................................ 6-6
6.2.3 All PRM. screen .................................................................................................... 6-6
6.3 Customize Screen.............................................................................................................. 6-8
6.3.1 Start ...................................................................................................................... 6-9
6.3.2 End ..................................................................................................................... 6-10
6.3.3 Short-circuit......................................................................................................... 6-11
6.3.4 Pulse................................................................................................................... 6-12
6.3.5 Aluminum MIG Pulse Welding Characteristics ................................................... 6-14
6.3.6 Aluminum Low Pulse Setting Screen.................................................................. 6-15
6.3.7 EAGL+ Pulse Setting Screen ............................................................................. 6-16
6.3.8 Welding Current Output Characteristics ............................................................. 6-17
6.3.9 Heat And Wave Form Control (HAWC) Screen.................................................. 6-19
6.3.10 All PRM. Screen ............................................................................................... 6-20
6.4 Maintenance Screen ........................................................................................................ 6-21
6.5 External Memory.............................................................................................................. 6-22
6.5.1 Setting Contents Save ........................................................................................ 6-22
6.5.2 Setting Contents Reading................................................................................... 6-24
6.6 Other Option Functions.................................................................................................... 6-25
6.6.1 Output Voltage Out-of-range Error Detection Function ...................................... 6-25
6.6.1.1 Function Description.............................................................................. 6-25
6.6.1.2 Setting Methods .................................................................................... 6-26
6.6.1.3 Parameter Settings................................................................................ 6-27
6.6.1.4 Setting Examples .................................................................................. 6-29
6.6.1.5 Parameter screen .................................................................................. 6-32
7 Welding Operation .......................................................................................................................... 7-1
7.1 Checking the Welding Conditions ...................................................................................... 7-1
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7.2 Wire Stickout...................................................................................................................... 7-1
7.3 Direction of Welding and Torch Angle ............................................................................... 7-1
8 Precautions on Welding .................................................................................................................. 8-1
8.1 Error Detection Function.................................................................................................... 8-1
8.2 Tripped Breaker of the welding power source ................................................................... 8-1
8.3 Precautions on Welding Operation .................................................................................... 8-1
9 Location and Setting of Printed Boards .......................................................................................... 9-1
9.1 Location of Printed Boards ................................................................................................ 9-1
9.2 Internal Selecting Switches................................................................................................ 9-2
9.2.1 DIP Switch Settings for Pr(MB)-031 Board........................................................... 9-2
9.2.2 DIP Switch Settings for Pr(CR)-031 Board........................................................... 9-3
10 Maintenance and Inspection ....................................................................................................... 10-1
10.1 Cleaning of Fan Guard and Cooling Fan ....................................................................... 10-3
10.2 Replace Fuse................................................................................................................. 10-4
11 Failure Analyses ......................................................................................................................... 11-1
11.1 Confirming Setting conditions ........................................................................................ 11-1
11.2 Cause and Remedy of Welding Section Failure ............................................................ 11-3
11.3 Cause and Remedy of Failure at Electrical Circuit Section ........................................... 11-5
12 Robot Interface Signals............................................................................................................... 12-1
12.1 Specifications of Robot Digital Interface Signals ........................................................... 12-1
12.2 Description and Function of Signal Output
Terminals for Monitor............................................................................................................... 12-1
12.3 Meaning and Function of Signal for Starting Point Detecting Function
(Optional board Pr (OP2) -001) ............................................................................................... 12-2
13 Connection System Diagram ...................................................................................................... 13-1
14 Welding power source Condition File of the Robot Controller .................................................... 14-1
15 List of Service Parts .................................................................................................................... 15-1
16 List of Parameters....................................................................................................................... 16-1
16.1 List of Process Parameters............................................................................................ 16-1
16.2 List of Common Parameters .......................................................................................... 16-2
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16.3 List of D Parameters ...................................................................................................... 16-6
16.4 List of A Parameters ...................................................................................................... 16-9
16.5 List of BIT Parameters ................................................................................................. 16-10
17 List of Welding Types.................................................................................................................. 17-1
18 List of Errors................................................................................................................................ 18-1
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1
Basic Specifications
Basic Specifications
Item
Specifications
Model
MOTOWELD-X500
Type
YWE-X500-6N0 (Compliance with UL standards)
Number of Phases, Rated
Input Voltage
Three-phase, 480V 10 %
Rated Frequency
50/60 Hz common
Rated Input
31 kVA
26 kW
Welding Current Adjustment
Range
30 to 500 A (depends on the wire diameter)
Welding Voltage Adjustment
Range
12 to 45 V (depends on the wire diameter)
Rated Operational Ratio
60% (for 10 minutes)
Welding Type
CO2 short-circuit welding, MAG/MIG short-circuit welding, pulse
welding, EAGL1)
Welding Object Material
Iron, stainless steel, aluminum
Feeding Motor
Types of feeding motors can be selected among;
0: Print servomotor (Production is currently discontinued)
1: E4WD servo torch (Production is currently discontinued)
2: 4-roller servomotor
(YWE-WFR42DX2, YWE-WFX40TELC) (Default setting)
YWE-WF340MELC, YWE-WF340TELC (Production is currently discontinued)
8: EAGLX torch
9: EAGL7 torch
10: EAGL motor (Production is currently discontinued)
Wire Feeding speed
1.5 to 18 m/min
Wire Feeding
Slow-down Speed
CO2 short-circuit welding: Approx. 3 m/min
(adjustable range by panel operation: 1.5 to 6 m/min)
MAG/MIG short-circuit welding and pulse welding: Approx. 2 m/min
(adjustable range by panel operation: 1 to 4 m/min)
Wire Feeder Cable
5 m (standard), 7 m max.
(Optional: 25 m max with a cable extender)
Gas Running-in Time
Approx. 20 seconds (Can be adjusted by panel operation)
Gas Pre-flow Time
Approx. 0.06 seconds (Can be adjusted by panel operation)
Gas After-flow Time
Approx. 0.5 seconds (Can be adjusted by panel operation)
Wire-stick Prevention Time
Approx. 0.2 seconds (Can be adjusted by panel operation: 0.02 to 0.4
seconds)
Voltage for Starting Point
Detecting Function (Optional)
Peak value: 220 V 20% (full-wave rectification)
External Dimensions
[mm]
385 × 647 × 618 (width × depth × height)
(excluding the projections such as screws or eye bolts)
Mass
Approx. 68 kg
Interface for Robot Controller
Refer to chapter 12 “Robot Interface Signals” .
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1
Basic Specifications
Item
Specifications
Error Output
Outputs the arc failure signal to the robot side. (Error contents are
indicated on the welding power source panel.)
Output for Arc
Monitoring
Outputs the signal corresponding to current or voltage to the robot
side. The output terminal stand for analog indicator is also available.
Power Supply of the Heater
for the Gas Regulator
None
Standard Accessory
Fuse contained in glass tube of 1A (1 fuse)
Fuse contained in glass tube of 10A (1 fuse) for Pr(MD)-31 board
Remarks
Front panel: Written in Japanese / English / Chinese
Welding Voltage Setting
Method
Auto adjustment command / Individual command
Read from the welding unit characteristics file of the robot control
unit.
Arc Touch Start Function
Setting is made on the setting screen of the robot control unit.
User File
Number of files: 16
Adjustment of Voltage and
Current Waveform Control
Adjustable on the setting screen of the robot control unit.
1 EAGL: Enhanced Arc weldinG for Low spatter
CAUTION
•
Can not be used in combination with AC unit XACU.
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1-3
Left side Face
498.9
ON
252.0
Front Face
OFF
MOTOWELD-X500
385.0
500A YWE-X500
1204803180001
Right side Face
488.0
596.4
Top Face
31.7
37.0
出力端子
Output
Terminal
出端子
CON 8
自
源
GB15579. 1-2013
CC0 Ser.No.1204803180001
I 1max =44.3A
I 1eff =43.5A
30A/15.5V
500A/39V
X
60%
100%
I2
500A
380A
39V
U2
33V
COS. Ø 0.88 (500A)
V
DC
X500
器 B ,DC Reactor B
量 68kg TAG-097A
冷
DATE 2018.03 IP21
U 1 =380V
50/60Hz
U0
100V
Great Forward Industrial Co.,Ltd.
台 桃 市 山 䐾 三路398
No. 398, Fushin Rd.Ⅲ, Kueishan Dist,TaoYuan City,Taiwan
福峰工 股份有限公司 台
制造
3~
等 :
冷 方式
f2
Type: YWE
3 ~ f1
逆 式控制MIG/MAG
2-1 Kurosakishiroishi, Yahatanishi-ku,Kitakyushu
806-0004 Japan
母材
Base
Metal
母材
（
TM1
V
用)
OP1
EAGL MOTOR
危
DANGER
危
開
作業
前、
高電
放電
、 電源
OFF
10分以上待
。
源后要
外 板 ,需等待至少
10分 以上,以便 危 高
容器
放 。
Before opening the cover , turn off the
power switch and wait for at least 10
minutes to discharge dangerous high
voltage from the capacitor.
TAG-097D
電部
触
。
入力端子
取 付
。
Do not touch live electrical parts.
This cover shall be installed.
勿触䉰
部位,此保
上并固定。
TAG-094H
Rear Face
A
Interface For Robot(Digital)
机器人接口( 字
)
SW1
用
YASKAWA ELECTRIC CO.
電
出線
Voltage Sensing
出
For Push Motor
用
CON 6

618.0
1
591.8
647.2
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Basic Specifications
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2
2.1
2
Welding Power Source Installation and Connection
Installation Site and Welding Power Source Environment
Welding Power Source Installation and Connection
2.1
Installation Site and Welding Power Source Environment
CAUTION
•
The welding power source can be moved easily by using the caster.
After installation, use the stopper to fix the welding power source
before starting operations. Please use stays to fix the welding
power source as necessary. (See the figure below. Bolts, nuts and
metal angles are provided by customers.)
•
For precautions on transporting, see chapter 2.9 “Precautions on
Transporting” .
The welding power source can be used under the following environmental
conditions:
1. Dry, indoor and at least 30 cm from the wall or peripheral devices
2. Free from direct sunlight, wind, and rain
3. Ambient temperature of 0°C to 45°C
4. Ambient humidity of 20 % to 80 % (with no condensation)
5. Altitude less than 1000 m
6. Gases and particles are present only at the level generated by normal
arc welding
Free from direct splash of welding spatter or metallic fine powder at
grinding
7. Location not exposed to large shocks or vibrations (vibrations do not
exceed 0.5G)
8. Location with an incline of 10° or less
9. Locations that are not subject to strong electromagnetic / magnetic
fields
10. Location not exposed to combustible materials or flammable liquids or
gases
If the combustible materials cannot be removed, cover the combustibles with a noncombustible cover.
11. Locations where organic solvents, chemicals, synthetic oils, and
similar substances do not adhere and where these are not contained
in the atmosphere
These substances may cause cracking, weakening, or discoloration of
the resin parts.
12. Locations where the arc section is not exposed to wind
If the arc section is exposed to wind, implement measures to protect
from the wind such as putting up a screen.
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2.2
Welding Power Source Installation and Connection
Precautions on Grounding
MOTOWELD-X500
500A YWE-X500
1204803180001
ON
OFF
Bolt and nut
Stay
Anchor bolt
2.2
Precautions on Grounding
CAUTION
•
Be sure to turn OFF the main switch of the switchboard before
performing the grounding work.
1. Be sure to perform secure grounding work (ground resistance must be
100  or less) on the welding power source so as not to charge its
case or lead to unstable operation.
2. In the case of input voltage 480 V, connect a grounding cable of 14
mm2 or thicker to the terminal marked " GROUND " or " EARTH ".
(See fig. 2-1 “Connection Diagram of welding power source at Rear
Face” . )
3. Be sure to ground the base metal (ground resistance must be 100 
or less) as well when or any other non-conductive material is placed
under the base metal.
4. If there is a pool or pond between the grounding of the power supply
switchboard and the welding power source, the leak current is
concentrated in the pool or pond. In such a case, connect the
grounding with a cable to escape the leak current through the cable.
2.3
Power Supply Installed Capacity and Connection Cables
The rated input voltage for the welding power source is three-phase, 480
V. The welding power source supports a voltage compensation circuit so
that the equipment can operate at a power voltage within ±10 %
fluctuations of the rated value. All the same, it is recommended to use a
power supply as stable as possible. If fluctuations in power supply voltage
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2.4
Welding Power Source Installation and Connection
Combination with Earth Leakage Breaker
exceed ±10 %, welding power source conditions cannot be guaranteed
and problems may occur.
Diameter of the input cable and the fuse capacity must be in compliance
with table 2-1 “Power Supply Installed Capacity and Cables” . Install a
non-fuse breaker (NFB) or a switch with fuse for each welding power
source.
The non fuse breaker used should be the same capacity of the fuse
indicated in table 2-1, and the tripping time at 600 % of the rated current
should be one second or longer (General motor breakers satisfy these
requirements). If breaker capacity is insufficient or primary voltage is too
high, the breaker will be tripped when the welding power source is turned
ON.
Table 2-1: Power Supply Installed Capacity and Cables
Rated input voltage
480 V
Installed Capacity
35 kVA
Fuse Rated Current
60 A
(rated voltage: 480 V)
Input Cable
14 mm2 or more
Output cable
80mm2 or more *1
Grounding Cable
14 mm2 or more
CAUTION
•
2.4
*1 Be sure to use cables for welding. Also, use cables with
sufficient thickness for pulse welding or current of 250 A or more.
Small gauge cables may result in poor welding and cause abnormal
heating in burn or fire.
Combination with Earth Leakage Breaker
When the welding power source 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 proper regulations or laws. In such a case, connect a leakage breaker
of current sensitivity 30 mA for each welding power source. The welding
power source may malfunction because of the inverter operations
depending on the model or current sensitivity of the leakage breaker.
Therefore, select a proper one for inverter drives.
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2.5
Welding Power Source Installation and Connection
Connection of Electrical System
DANGER
•
2.5
Install together with a ground-fault circuit interrupter.
Connection of Electrical System
CAUTION
•
Open the disconnect switch of the switch gear before connecting
wires between welding machine and primary power supply.
Even one imperfect contact in the connections precludes proper welding.
Be sure to make perfect connection to the base metal by using jigs.
1. Connection on the welding power source Side
See fig. 2-1 “Connection Diagram of welding power source at Rear Face”
for proper connections.
• Input cable Connected bolt of the input voltage terminal is M6.
• Ground cable
2. Connection on the Welding Side
See fig. 2-2 “Connection Diagram of welding power source at Front Face”
for proper connections.
CAUTION
•
Do not insert washers, spring washers, or similar objects between
the power supply output terminal and the round terminal of the
power cable. Doing so may cause burn damage to the connection
section.
(1) Torch-side Power Cable
The torch-side power cable connects between the welding torch
and the output terminal (+) of the welding power source.
–On the welding power supply side, remove the nut, washer, and
spring washer from the power output terminal. Tighten the round
terminal, washer, spring washer, and nut of the torch-side power
cable to the power supply output terminal, in this order.
(Tightening torque: 20 N•m)
(2) Base metal-side Power Cable
The base metal-side power cable connects between the base
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2.5
Welding Power Source Installation and Connection
Connection of Electrical System
metal and the output terminal (-) of the welding power source.
–On the welding power supply side, remove the nut, washer, and
spring washer from the power output terminal. Tighten the round
terminal, washer, spring washer, and nut of the base metal side
power cable to the power supply output terminal, in this order.
(Tightening torque: 20 N•m)
(3) Base metal-Side Welding Voltage Sensing Cable
The base metal-side welding voltage sensing cable connects to
the base metal via the wire feeder cable.
<Power cables>
• The torch-side and base metal-side power cables must be
straightened. Do not use them coiled. The arc will be unstable
due to impedance.
• Do not extend the connecting cable between round terminals.
• Use dedicated cables for the torch-side and base metal-side
power cables. When attaching crimp terminals to the power
cable, use crimp terminals and dedicated tools that are compatible with the cable.
• Select a thickness for the power cable on the torch side and on
the base metal side that can safely carry the current.
Cable cross-sectional area
Welding current
Operational ratio
(10 minute cycles)
80mm²
500A
60%
430A
80%
380A
100%
3. Connection of the wire feeder cable
As shown in fig. 2-1 “Connection Diagram of welding power source at
Rear Face” connect cables to connectors at the rear face of the welding
power source. When connecting the cables, tighten the plug until it stops
rotating.
I)
Connect the wire feeder cable to the connector "CON 6".
4. Connection of control cables
As shown in fig. 2-1 connect cables to connectors at the rear face of the
welding power source. When connecting the cables, tighten the plug until
it stops rotating.
II)
Connect the welding interface cable from the robot controller to
the connector "CON 8".
III) Connect the ethernet cable to the connector written in the
table 2-2 “Connection of the robot controller side” .
Table 2-2: Connection of the robot controller side
Robot controller connector
version
YRC1000
CN106(LAN2)
YAS2.03.00( □ )-00 or later
DX200
CN104(LAN)
DN2.40.00( □ )-00 or later
DX100
CN104(LAN)
DS4.34.00( □ )-00 or later
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2.5
Welding Power Source Installation and Connection
Connection of Electrical System
* For details, refer to WELDCOM Function Operation Manual.
* When using on NX100 or earlier, relay it with Ether-Analog conversion
box. (It is necessary to arrange separately)
Reference material
• HW1485149 Ether-Analog Conversion BOX INSTRUCTIONS
Fig. 2-1: Connection Diagram of welding power source at Rear Face
The input power supply voltage must be within ±10V
from the rated input power supply voltage.
Three phase AC480V at 50/60Hz
Attach one switch for each welder.
Refer to Table 2.1 for fuse capacities.
Switch in
the switch gear
ON / OFF
OP1
Connector for EAGL feeder cable
CON8(RJ45)
Connector for robot interface(Digital)
Ground resistance
100 Ω or less
Ground cable
CON6(ASJ3102A20-27S)
Connector for wire feeder cable
SW1(L21-22A8)
Voltage sensing cable select switch
CON 6
OP1
EAGL MOTOR
CON 8
（
用
For Push Motor
用
用)
Interface For Robot(Digital)
机器人接口( 字
)
L 1 L 2 L 3 PE
TM1
SW1
電
出線
Voltage Sensing
出
出力端子
Output
Terminal
出端子
Use a cable of 22mm2
or more for grounding.
母材
Base
Metal
母材
A
Input cable
V
TM1 External,connected terminal
(Ammeter,voltmeter,wire inching)
2
22mm or more.
開
作業
前、
高電
放電
、 電源
OFF
10分以上待
。
源后要
外 板 ,需等待至少
10分 以上,以便 危 高
容器
放 。
Before opening the cover , turn off the
power switch and wait for at least 10
minutes to discharge dangerous high
voltage from the capacitor.
TAG-097D
Remove the input terminal cover,
and connect three cables surely
Please install it without forgetting
the input terminal cover after it
connects it.
YASKAWA ELECTRIC CO.
2-1 Kurosakishiroishi, Yahatanishi-ku,Kitakyushu
806-0004 Japan
逆
式控制MIG/MAG
Type: YWE
3 ~ f1
X500
CC0
自
源
Ser.No.1204803180001
GB15579. 1-2013
f2
U0
100V
3~
等 :
冷 方式
30A/15.5V
500A/39V
X
60%
100%
I2
380A
500A
39V
33V
U2
COS. Ø 0.88 (500A)
V
DC
U1 =380V
50/60Hz
I 1max =44.3A
I 1eff =43.5A
器 B ,DC Reactor B
量 68kg TAG-097A
冷
DATE 2018.03 IP21
Great Forward Industrial Co.,Ltd.
台 桃 市 山 䐾 三路398
No. 398, Fushin Rd.Ⅲ, Kueishan Dist,TaoYuan City,Taiwan
福峰工 股份有限公司 台
制造
Heater power
supply
100V
Carbon deoxide gas regulator
(with flow meter)
Rear Face
危
DANGER
危
電部
触
。
入力端子
取 付
。
Do not touch live electrical parts.
This cover shall be installed.
勿触䉰
部位,此保
上并固定。
TAG-094H
Gas cylinder
Carbon deoxide gas
CO2
Use carbon deoxide gas
for welding or what
conforms to the Class 3
specified in JIS-K1106.
Do not put this where
the ambient temperature
exceeds 35Υ.
Cover
Earth terminal
(DUWKWHUPLQDO
Input voltage terminal
L 1 L 2 L 3P E
Ground cable
Ground cable
To wire feeder
Gas hose
The main swith of power distrlbutor panel
must be tum off white wiring
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2.5
Welding Power Source Installation and Connection
Connection of Electrical System
Fig. 2-2: Connection Diagram of welding power source at Front Face
Wire feeder cable
：connect to CON6
at the rear face
Rear face of the welding power source
SW1：” Base Metal” side
MOTOWELD-X500
500A YWE-X500
1204803180001
ON
OFF
Output terminal
cover
Wire feeder cable：connect to CON6
Output terminal
Remove the output
terminal cover and
connect the cable.
After connection,
be sure to reattatch
the output terminal
cover.
Base metal-side
power cable
Torch-side power cable
80mm2 or more
80mm2 or more
Wire feeder
S-axis of robot
Torch
Gas hose
-
+
Base
metal
Base metal
Torch-side
power cable
Ground cable
Ground resistance
: 100Ω or less
Base metal-side
welding voltage
sensing cable
Base metal-side welding voltage sensing cable
5. Setting of the welding voltage sensing cable select switch
When using the welding voltage sensing cable, set the welding voltage
sensing cable select switch in the rear side of the welding power source to
the "Base Metal" side as shown in the graphic ① .
When not using the welding voltage sensing cable, set the welding voltage
sensing cable select switch in the rear side of the welding power source to
the "Output terminal" side as shown in the graphic ② .
When using a welding voltage sensing cable, refer to chapter 2.6
“Connection of Welding Voltage Sensing Cable” .
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2.5
Welding Power Source Installation and Connection
Connection of Electrical System
⋇
SW1
電圧検出線
Voltage Sensing
⭥঻Ự⍻㓯
母材
Base
Metal
⇽ᶀ
出力端子
Output
Terminal
䗃出端子
⋈
SW1
電圧検出線
Voltage Sensing
⭥঻Ự⍻㓯
母材
Base
Metal
⇽ᶀ
出力端子
Output
Terminal
䗃出端子
6. Grounding
Ground terminal (crimp contact M6, 22mm2) is provided in the rightmost
terminal of the input terminal on the rear face of the welding power source
for safe operation. Connect the grounding cable of 22 mm2 or more to the
crimp contact. Ground resistance must be 100  or less.
Be sure to ground the base metal at resistance of 100  or less
individually as shown in fig. 2-2 “Connection Diagram of welding power
source at Front Face” . 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 manipulator.
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2.6
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
Also, connect the welding power source and the base metal with
exclusive-use base metal cable.
2.6
Connection of Welding Voltage Sensing Cable
When the power cable is so long (5 m or more) that the welding work is
unstable, it is advisable to use the welding voltage sensing cable.
1. Connect the base metal-side welding voltage sensing cable from the
wire feeder cable of the robot side connection part to the base metal
side. (Refer to fig. 2-3 “Connection Diagram of Welding Voltage
Sensing Cable” )
2. Connect the base metal-side welding voltage sensing cable as close to
the position where welding is performed as possible.
3. The base metal-side welding voltage sensing cable and the base
metal-side power cable must separate as far as possible. (The
distance is required 100 mm or more.)
Fig. 2-3: Connection Diagram of Welding Voltage Sensing Cable
Rear face of the welding power source
SW1：” Base Metal” side
S-axis of robot
Gas hose
Base metal
Base metal-side
welding voltage
sensing cable
Wire feeder cable
Torch-side power cable
Connection
Connection
Torch
Base metal
Connect the base metal-side
voltage sensing cable as close
to the position where welding
is performed as possible
Wire feeder cable：connect to CON6
Welding power source
Torch-side welding voltage
sensing cable
(Inside the robot)
MOTOWELD-X500
500A YWE-X500
1204803180001
+
ON
OFF
S-axis of robot
Base metal-side welding
voltage sensing cable
Base metal-side power cable
Wire feeder cable
̲
The distance is required 100mm or more
r
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2.6
2.6.1
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
Connection in the Welding Power Source Side
Set the voltage sensing cable select switch in the rear side of the welding
power source to the "Base Metal" side.
SW1
電圧検出線
Voltage Sensing
⭥঻Ự⍻㓯
2.6.2
出力端子
母材
Output
Terminal
Base
Metal
䗃出端子
⇽ᶀ
Connection to the Work
In the connection of the welding voltage sensing cable, be sure to observe
the following items.
If the following items are not observed, the amount of the spatter
generation might increase.
1. Since the torch-side welding voltage sensing cable and the base
metal-side welding voltage sensing cable are twisted inside of the wire
feeder cable, be sure to use the wire feeder cable.
2. The area S surrounded by the two welding voltage sensing cables
should be as small as possible as shown in fig. 2-4 “Welding Voltage
Sensing Circuit” . Making the inductance of the welding voltage
sensing circuit smaller reduces the effect of induction noise.
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2.6
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
Fig. 2-4: Welding Voltage Sensing Circuit
Welding power source
Torch-side welding voltage sensing cable
+
Torch
MOTOWELD-X500
500A YWE-X500
1204803180001
_
ON
OFF
Base metal
Base metal-side welding voltage sensing cable
Torch-side
welding voltage sensing cable
Welding power source
Inside of the
wire feeder cable
Torch
+
MOTOWELD-X500
500A YWE-X500
1204803180001
_
ON
Base metal
OFF
Base metal-side
welding voltage sensing cable
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2.6
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
3. When a rotation axis is used, connect the base metal-side welding
voltage sensing cables with the screw of the cover that exists in the
base of MOTOPOS (See fig. 2-5 “Connection of the Welding Voltage
Sensing Cables when using Rotation Axis and Two Welding Power
Sources” ). Do not connect the power cable and the welding voltage
sensing cable with the same part. (Do not connect the welding voltage
sensing cable with the route where the welding current flows.) Please
confirm the electrical continuity between the welding workpiece and
the screw of the cover by a circuit tester before wiring.
Fig. 2-5: Connection of the Welding Voltage Sensing Cables when using
Rotation Axis and Two Welding Power Sources
Two base metal-side
welding voltage senseing
cables
Two base metal-side
welding voltage senseing
cables
Two base metal-side
power cables
a)
Connection of the metal side welding voltage sensing cables
b)
Connection of the base metal-side
power cables
CAUTION
•
Be sure to connect the welding voltage sensing cable. If the
welding voltage sensing cable is not connected, the error "Err702:
Voltage Sensing Cable Error" may occur, and welding cannot be
performed.
•
When the welding voltage sensing cable is not used, be sure to set
the welding voltage sensing cable select switch to the "Output
terminal" side.
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2.6
2.6.3
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
Connection example of Welding Voltage Sensing Cable
1) One Robot & Multiple Bases System
The system is an example of welding voltage sensing cable of one robot
to weld the works on multiple bases.
Note 1) The distance between power cable and welding voltage sensing
cable is 100mm or more.
Note 2) The resistance between the weld on bases and base metal-side
welding voltage sensing cable must be 1Ω or less.
Fig. 2-6: Connection example of One Robot & Multiple Bases System
Robot
Welding power source
Base 1
Base 2
Base 3
Base metal-side power cable
Base metal-side welding voltage sensing cable
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2.6
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
2) Multiple Robots & One Base System
The system is an example of welding voltage sensing cable of multiple
robots to weld the work on base.
Note 1) The distance between power cable and welding voltage sensing
cable is 100mm or more.
Note 2) The resistance between the weld on base and base metal-side
welding voltage sensing cables must be 1Ω or less.
Note 3) Each base metal-side power cable and base metal-side welding
voltage sensing cable connect to different cable duct.
If connected to the same cable duct, the welding phenomenon may not be
stable.
Fig. 2-7: Connection example of Multiple Robots & One Base System
Robot 1
Welding power source 1
CON6
−
+
Base metal-side welding voltage sensing cable Robot 1 - Base
Base metal-side power cable Welding power source 1 - Base
Robot 2
Welding power source 2
Base
CON6
−
+
Base metal-side welding voltage sensing cable Robot 2 - Base
Base metal-side power cable Welding power source 2 - Base
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2.6
Welding Power Source Installation and Connection
Connection of Welding Voltage Sensing Cable
3) Multiple Robots & One Base System
The system is an example of welding voltage sensing cable of multiple
robots to weld the works on multiple bases.
Note 1) The distance between power cable and welding voltage sensing
cable is 100mm or more.
Note 2) The resistance between the weld on base and base metal-side
welding voltage sensing cables must be 1Ω or less.
Note 3) Each base metal-side power cable and base metal-side welding
voltage sensing cable connect to different cable duct.
If connected to the same cable duct, the welding phenomenon may not be
stable.
Fig. 2-8: Connection example of Multiple Robots & Multiple Bases System
Robot 1
Welding power source 1
CON6
−
+
Base metal-side welding voltage sensing cable Robot 1 - Base 1
Base metal-side power cable Welding power source 1 - Base 1
Base metal-side power cable Welding power source 1 - Base 2
Base 1
Base metal-side
welding voltage sensing cable
Base 1 - Base 2
Robot 2
Welding power source 2
CON6
Base 2
Base metal-side welding voltage sensing cable
Robot 2 - Base 2
Base metal-side power cable Welding power source 2 - Base 2
−
+
Base metal-side power cable Welding power source 2 - Base 1
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2.7
2.7
2.7.1
Welding Power Source Installation and Connection
Connection of Shielding Gas System
Connection of Shielding Gas System
For Mixed Gas or Carbon Dioxide Gas Welding
1. Remove dust from the gas cylinder connecting port. Install the MAG/
carbon dioxide common gas regulator. Check the quality of the gas
and the type of the cylinder.
2. Insert one end to the supplied rubber gas hose into the output 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. The 100 V AC power supply is required for a heater of carbon dioxide
gas regulator.
2.7.2
Installation Site and Gas Cylinder Environment
Handle the gas cylinder with special care because it contains high
pressure gas. Refer to the instruction manual attached to the gas cylinder.
Gas cylinder stand
2. 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.
Gas cylinder
1. Installation SIte of Gas Cylinder
Fig. 2-9: Installation Site of
Place the gas cylinder in a specified Gas Cylinder
gas container position that is not
exposed to direct sunlight. If the gas
cylinder is unavoidable placed at the
welding site, it must be fixed to post
or cylinder stand in an upright
position to prevent it from falling.
Also, the gas cylinder must not be
heated by a welding arc or the like.
Fix the gas cylinder to prevent
it from falling.
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2.7
Welding Power Source Installation and Connection
Connection of Shielding Gas System
DANGER
•
Never use siphon type gas cylinders. The provided carbon dioxide
gas regulator is not applicable to siphon type 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 distributor 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 occurs again.
3. Quality of Gas for Welding
Moisture or impurity in the carbon dioxide gas or argon gas used to
shield welding arcs adversely influenced 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 mixing 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 ration 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. Gas Regulator with Flow Meter
Use gas regulator with flow meter suitable for the gas to be used. The
following table show the examples of the gas regulator.
Table 2-3: Gas Regulator with Flow Meter
No.
Type
Applicable Gas
Remarks
1
FCR-2505A
CO2, MAG
Meter: Indicates secondary pressure and flow
amount
Heater: 100 VAC*1, 190 W
2
FCR-225
CO2, MAG, Ar
Meter: Indicates primary pressure and float-type
flow amount
Heater: 100 VAC*1, 190 W
*1The power supply for the heater is not provided with the welding power
source. Prepare a 100V AC power supply for the heater of the gas
regulator.
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2.8
2.8
Welding Power Source Installation and Connection
Ambient Environment
Ambient Environment
1. Wind Prevention
Normally, 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 welding.
2. Ventilation
The 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. 2-10: Shielding Wind for Welding
Fig. 2-11: Ventilation Example
Ventilating fan
Torch
Torch
Wind
Screen
Object to be welded
3. 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. Use numbers 10 to 13 for welding of
medium-hick 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 welding power source brings in ultraviolet rays stronger than that
caused by manual welding. Periodically check protectors for eyes and
the skin. Also, be sure to always wear these protectors.
When the welding power source is controlled by external control input
signal or while operating the manipulator, provided proper shade
around the welding torch.
Accidental arc generation may damage eyes or burn the skin of those
without proper protection.
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2.9
Welding Power Source Installation and Connection
Precautions on Transporting
Fig. 2-12: Protection Example
Helmet
Handshield
Jacket must be
long-sleeved.
Welding gloves
Foot covers
Safety boots
2.9
Precautions on Transporting
CAUTION
•
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 welding power source consists of precision components.
Failure to observe this caution may affect its performance.
1. Transporting with Using Casters
When using the casters, move the welding power source slowly so that
it can be stopped quickly at any time. Moving the welding power
source with casters quickly may result in an accident due to inertia,
and you cannot control the direction of movement.
Moreover, be sure to stop the welding power source with casters at a
step and move it slowly to prevent any shock sudden. Do not move
the welding power source with casters up a slope, stairs, etc.
2. Transporting with Using a Crane
When using the crane, be sure to confirm the following points before
transporting.
(1) Confirm the mass of the welding power source by referring to
chapter 1 “Basic Specifications” . Select the wire rope suitable for
the mass and angle.
(2) Use eye bolts for transporting and confirm that the eyebolts are
tightened firmly before transporting.
(3) Lift the welding power source using the crane after the above confirmation.
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2.9
Welding Power Source Installation and Connection
Precautions on Transporting
Wire rope
Eyebot M10
60 degrees
or more
MOTOWELD-X500
500A YWE-X500
1204803180001
ON
OFF
3. Transporting with Using a Forklift
Observe the following points to use the forklift for transporting.
(1) Confirm availability of safe operations site, and transfer the welding power source to the installing site.
(2) After determining the operation site, warnings must be placed on
transport path to prevent accidents.
(3) Put the welding power source on the transporting pallet and fix
firmly to prevent falling or shifting. Employ a stopper on the casters to fix the welding power source.
Over-tightening the cover may cause it to deform.
(4) Do not raise the lift excessively.
(5) Avoid excessive shock or vibration while transporting since the
system consists of precision component.
(6) Transport the welding power source at yield speed when using the
forklift.
4. Others
(1) Do not climb up on the welding power source or place anything on
it.
(2) Do not pass a rope directly around the welding power source case
during transporting. Failure to observe this caution may deform
the shape of the case or cause malfunction.
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3
Welding Preparation
Welding Preparation
The preparation procedures for welding are shown in table 3-1 “Welding
Preparation Procedure” .
Table 3-1: Welding Preparation Procedure
Step
Item
Details
1
Setting welding wire
Set a wire suitable to the welding method. 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 gear
Confirm that connections are correct, then turn ON the switch of the switch gear
of the welding power source.
4
Turning ON switches
for the welding power
source
Turn ON the power switch. The power indicator lamp lights and the built-in
cooling fans start rotating. The fan rotates at low speed after fifteen minutes
unless the welding starts. The fan automatically rotates at high speed when the
welding starts.
5
Set the communication
parameter
Set the communication parameter in the welding power source side.
C50: welding power source IP address setting (Default value: 0)
6
Saving welding
conditions
Save the conditions before turning OFF the welding power source.
Keep on pressing the "Record" button for more than three seconds to save
changes. Do not turn OFF the welding power source while saving. The 7segment LED indicators light up again at the completion of the saving. Confirm
that the 7- segment LED indicators light again.
7
Reboot the welding
power source
To validate the communication setting of the welding power source, turn OFF the
welding power source once, then turn it ON.
8
Setting at the robot
side
Set the following items in the robot side:
• Welding unit characteristics file (Voltage command type
(Auto adjustment/Individual))
• Welding power source type
• Wire feeding unit type
• Welding method
Setting is performed under the condition where the communication between the
welding power source and the robot control unit is enabled.
9
Communication check
Check to confirm that the welding current command and the welding voltage
command which were set on the robot control unit are displayed normally on the
panel.
10
Adjusting gas flow
Adjust the gas flow as follows:
(1) Press the "Gas" button on the panel of welding power source. The LED
indicator lights and the gas flows for 20 seconds. The gas automatically stops
after the 20 seconds. (The gas flow time can be set by the parameter C00.)
(2) Turn the valve of the gas cylinder counterclockwise to open.
(3) Turn the knob of the gas regulator to adjust the flow according to welding
conditions. Proper gas flow rate is 10 - 25 liters per minute. The flow rate must
be increased in proportion to the welding current (the higher the current, the
larger the flow rate).
11
End
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4.1
4
Operations on Panel
Explanation of Welding power source Panel
Operations on Panel
4.1
Explanation of Welding power source Panel
NOTE
Pressing the panel buttons during welding can change the
display.
Fig. 4-1: Welding power source Panel
7SEG_1
LED2
LED1
7SEG_2
LED4
SW4
LED9
LED7
LED8
LED3
LED5
SW5
LED6
LED10
SW6
SW1
SW2
SW3
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Rotary SW
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4.1
Operations on Panel
Explanation of Welding power source Panel
Table 4-1: Panel details
Item
Content
7SEG_1
-Welding Current
-Wire Feeding Speed
-User File Number
-Number of the parameter
Explanation
■ Status:During standby
○ Welding Current indication setting:LED1 turns ON
・Displays the set Welding Current value [A].
(Order value indication: Setting of C32=0)
・Displays the set 0.(Standby indication: Setting of C32=1)
Indicator
○ Wire Feeding Speed indication setting:LED2 turns ON
*The content of the display ・Displays the feeding amount [m/min] of the set
differs according to the status Welding Current
value.(Order value indication: Setting of C32=0)
and the setting.
・Displays the set 0.(Standby indication: Setting of C32=1)
○ User File Number indication setting:LED3 turns ON
・Displays the User File Number that was chosen.
■ Status:During welding, During wire inching
○ Welding Current indication setting:LED1 turns ON
・Displays the Welding Current value [A] that is fedback.
○ Wire Feeding Speed indication setting:LED2 turns ON
・Displays the feeding amount [m/min] of the motor that
is fed-back.(Setting of D04=ON)
・Displays the motor current [A] that is fed-back.
(Setting of D04=OFF)
○ User File Number indication setting:LED3 turns ON
・Displays the User File Number that was chosen.
■ Status:During setting parameter
・Displays the ”P.00”or”C.00”or”D.00”.
LED1
Welding Current[A]
indication meter setting
When the setting of the indication meter is Welding
Current, LED1 turns on.
*The indication meter is set by "SW4: indication meter
switching".
LED2
Wire Feeding Speed[m/min]
indication meter setting
When the setting of the indication meter is Weld Wire
Feeding Speed, LED2 turns on.
*The indication meter is set by "SW4: indication meter
switching".
LED3
User File Number
indication meter setting
When the setting of the indication meter is Weld Wire
Feeding Speed, LED3 turns on.
*The indication meter is set by "SW4: indication meter
switching".
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4.1
Operations on Panel
Explanation of Welding power source Panel
Table 4-1: Panel details
Item
Content
7SEG_2
-Welding Voltage
-Auto Adjustment Voltage
-Welding Type
-Value of the parameter
Explanation
■ Status:During standby
○ Welding Voltage indication setting:LED4 turns ON
・Displays the set Welding Voltage value [V].
(Order value indication: Setting of C32=0)
・Displays the set 0.(Standby indication: Setting of C32=1)
Indicator
○Auto Adjustment Voltage indication setting:LED5 turns
ON
*The content of the display
・Displays
the set auto adjustment voltage value [%].
differs according to the status
○ Welding Type indication setting:LED6 turns ON
and the setting.
・Displays the Welding Type that was chosen.
■ Status:During welding, During wire inching
○ Welding Voltage indication setting:LED4 turns ON
・Displays the Welding Voltage value [V] that is fed-back.
■ Status:During setting parameter
・Displays the Value of the parameter.
LED4
Welding Voltage[V]
indication meter setting
When the setting of the indication meter is Welding
Voltage, LED4 turns on.
*The indication meter is set by "SW4: indication meter
switching".
LED5
Auto Adjustment Voltage[%]
indication meter setting
When the setting of the indication meter is Auto Adjustment Voltage, LED5 turns on.
*The indication meter is set by "SW4: indication meter
switching".
LED6
Welding Type
indication meter setting
When the setting of the indication meter is Welding
Voltage, LED6 turns on.
*The indication meter is set by "SW4: indication meter
switching".
SW1
Auto Adjustment/Individual
(synergic/independent)
Switch
-Not used
LED7
Auto Adjustment/
Individual
setting indication
・When the voltage setting of the welding is Auto Adjustment, LED7 turns on.
・When the voltage setting of the welding is Individual,
LED7 turns on.
*Auto Adjustment/Individual are set in the robot control unit side.
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4.1
Operations on Panel
Explanation of Welding power source Panel
Table 4-1: Panel details
Item
Content
Explanation
SW2
Saving Conditions
Used to save the setting. The LED8 indicator lamp
blinks when the setting is changed.
To save the changed setting, keep pressing the
"Record" button for three seconds or more. If the
welding power source is turned OFF when the 7segment LED indicators go out, the changed setting
cannot be saved successfully. Wait until the 7-segment
LED indicators are lit again. If the welding power source
is turned OFF and back ON after the 7-segment LED
indicators are lit again (the conditions are saved), the
settings return to the status where the conditions were
saved.
Turn the welding power source OFF and back ON
without pressing this button so as not to save the
changed settings.
LED8
Indication of the Saving Con- The LED8 indicator lamp blinks when the setting is
ditions
changed.
The LED8 turns off when the Saving Conditions was
completed.
SW3
Choice of the
parameter indication
・P parameter
・C parameter
・D parameter
[1 push] P parameter indication
・Indication of 7SEG_1:P parameter number (e.g.”P.00”)
・Indication of 7SEG_2:P parameter value (e.g.”100”)
[2 push] C parameter indication
・Indication of 7SEG_1:C parameter number
(e.g.”C.00”)
・Indication of 7SEG_2:C parameter value(e.g.”020”)
[3 push] D parameter indication
・Indication of 7SEG_1:D parameter number
(e.g.”D.00”)
・Indication of 7SEG_2:C parameter value(e.g.”ON”)
[4 push] Normal indication
SW4
Indication Meter
Switching
Indication of 7SEG_1 and 7SEG_2 are replaced.
[Normal indication]
・Indication of 7SEG_1:Welding Current[A]
・Indication of 7SEG_2:Welding Voltage[V]
[1 push]
・Indication of 7SEG_1:Wire Feeding Speed[m/min]
・Indication of 7SEG_2:Auto Adjustment Voltage[%]
[2 push]
・Indication of 7SEG_1:User File Number
・Indication of 7SEG_2:Welding Type
[3 push]
Normal indication
SW5
Checking Wire Inching
Checks the wire inching.
・Wire inching is carried out interval pushing the button
LED9
Indication of the
Wire Inching
When wire inching, LED9 turns on.
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4.1
Operations on Panel
Explanation of Welding power source Panel
Table 4-1: Panel details
Item
Content
Explanation
SW6
Checking Gas
LED10
Indication of
the Gas State
Checks the gas. The LED indicator lamp lights when
pressing the "Gas" button, and the gas flows for 20
seconds. (The default setting for the gas flow time is 20
seconds. This time can be changed by C00 parameter.)
When this button is pressed again during the gas check,
the gas stops flowing.
When gas outflow, LED10 turns on.
SW7
Parameter Setting
When parameter setting indication, The Number of the
parameter and a Value of the parameter setting can be
chosen.
It is the item where a meter flashing on and off is
chosen.
Rotary SW Numerical Value
Increase and Decrease
The numerical increase and decrease can be carried
out.
The right turn：Numerical increase
The left turn：Numerical decrease
Fig. 4-2: Display switching method
Welding Current[A]
Welding Voltage[V]
Wire Feeding Speed[m/min]
Pressing the display
switching button.
User File Number
Individual Voltage[%]
Pressing the display
switching button.
Welding Type
Pressing the display
switching button.
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4.2
4.2
4.2.1
Operations on Panel
Explanation of Welding power source Panel
Explanation of Welding power source Panel
Parameters confirmation method
Fig. 4-3: Waiting screen
Parameter button
• Confirmation of the parameters [ P, C, D parameter ] can be done by
pressing the “ SW3 : Choice of the parameter indication “.
Fig. 4-4: Parameter confirmation screen
Pressing the button.
Pressing the button.
Pressing the button.
Pressing the button.
• Regarding the change of the number of each parameter: it can be
changed by rotating the " SW7 Rotary SW ".
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4.2
Operations on Panel
Explanation of Welding power source Panel
Fig. 4-5: Number selection method for each parameter
Turn to the right.
→To a number in
the plus.
Turn to the right.
→To a number in
the minus.
4.2.2
Changing Common (C) Parameters
The C parameter is the common parameters for the welding power
source.
Follow the instructions to change C parameter value as follows:
1. Press the " SW3 parameter display selection" 2 times to display C.
In this case, " 7SEG_1: C parameter number" flashes.
2. By rotating the " Rotary SW increase or decrease in the numerical
value " to set the C parameter values.
3. Press the " SW7 parameter setting.In this case, " 7SEG_2: parameter
settings " flashes.
4. By rotating the " Rotary SW increase or decrease in the numerical
value " to set the C parameter values.
5. After setting change, it will be the normal display and press twice "
SW3 parameter display selection ".
To save changes ,press and hold the condition memory button for more
than 3 seconds.
In this case, please do not turn OFF the welding power source.
Once the panel LED lights up again, it is the condition storage completion.
Other than the C parameters in the table below is the parameter change
from the robot control device. C parameters, please refer to the
chapter 16.2 “List of Common Parameters” .
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4.2
Operations on Panel
Explanation of Welding power source Panel
Table 4-2: C Parameter List panel can be changed
Display
Item
Factory
No.
Contents
setting
C23
System reset
0
When C23 is set to "204", the system is reset, returning to
the factory setting. Before executing the system reset, be
sure to memorize the changed parameters. After executing
the system reset, turn OFF the power and then turn it ON
again.
When the power is turned OFF, C23 is returned to "0".
C50
welding power source
side IP address
0
Set the fourth digit of the welding power source side IP
address. (Addition value to the reference value 210)
When the set value is 0: 192.168.255.210
When the set value is 1: 192.168.255.211
4.2.3
Communication Setting
When this unit is used in the digital communication mode, the following parameters
must be set properly.
Any changes in parameters are activated by rebooting the welding power source.
After changing any parameter setting, take condition memory, turn OFF the
welding power source, and turn ON the welding power source again.
Table 4-3: IP address setting
Display
No.
C50
Factory
setting
Item
Welding power source
side IP address
0
Contents
The 4th digit of the welding power source side IP
address is set. (Additional value of the reference
value)
- When the set value is 0: 192.168.255.210
- When the set value is 1: 192.168.255.211
In the combination of one robot control unit and one welding power source unit, the
factory setting can be used.
In the combination of one robot control unit and two or more welding power source
units, be careful not to duplicate the welding power source side IP address C50.
(Example) When one robot control unit and two welding power source units are
connected:
welding power source unit No. 1 C50=0
welding power source unit No. 2 C50=1
When the communication between the welding power source and the robot control
unit is not established, the following display is shown.
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4.2
Operations on Panel
Explanation of Welding power source Panel
Fig. 4-6: Relationship between robot controller and welding power source
communication status and panel display
CAUTION
If data communication is not established, check the following items:
•
Check to confirm that the power of the robot controller is turned ON.
•
Check to confirm that the communication cable between the robot
controller and the welding power source is properly connected.
•
Check to confirm that the proper communication cable is used.
When the Ethernet hub is used, use the Ethernet straight cable
between the LAN port of the controller and the hub and the Ethernet
cross cable between the hub and the Welding power source.When
the Ethernet hub is not used, use the Ethernet cross cable.
•
Check to confirm that the communication setting of the robot
controller is properly set.
•
Check to confirm that the communication setting (C50) of the
welding power source is properly set.
If the communication setting is changed, perform condition memory
and turn OFF the welding power source, then turn it ON again.
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4.2
4.2.4
Operations on Panel
Explanation of Welding power source Panel
Saving Welding Conditions
Since the normal parameters to be changed from the robot controller,
operation of the condition storage button is not required.
However, for specific parameters, and the conditions stored in the after
parameter change in the panel.
The following describes how to save the settings.
1. To change the parameter settings.When the set value is changed, "
LED8: Saving Conditions " flashes.
2. When " SW2 " is pressed for 3 seconds or more, "7SEG_1" and "
7SEG_2 " are displayed as " " -SA " " VE- " "
• Please do not turn off the power supply of the welding machine
during storage. Save does not run successfully.
3. After conditions save of the end, it will return to the display at the time
of the condition storage.
4. Make sure that the condition storage has been completed, to turn off
the power supply of the welding machine at a time, please turn on the
power of welding power source again.
Saving Conditions will be complete.
CAUTION
•
4.2.5
For P parameters, the changed data are validated at the same time
the change is made. However, when the welding type is changed or
the power supply switch of the welding power source is turned OFF,
the changed data will be lost.
System Reset
System Reset initializes all the setting data in the welding power source.
Reset the system only when the software is updated.
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4.2
Operations on Panel
Explanation of Welding power source Panel
CAUTION
•
Be sure that executing System Reset initializes all the internal data.
If some parameters must be retained, write them down on a sheet
of paper before System Reset. The data cannot be restored after
the system reset operation.
•
After System Reset, set the welding method and parameters using
the robot control unit. If the welding is performed without setting the
welding method, the error "Err602 (Welding method not set)" is
output.
The following describes how to reset the system.
1. Press: "SW3 parameter display selection" twice, to display the C
parameters. In this case, "7SEG_1: C parameter number" flashes.
2. "Rotary SW: numerical increase or decrease" Rotate the to display the
"C23".
3. And press: "SW7 parameter setting". In this case, "7SEG_2:
parameter settings" flashes.
4. "Rotary SW: numerical increase or decrease" is rotated, and then the
parameter setting value to "204". When it becomes C23= 204, system
reset is performed.
5. “7SEG_1 ", the display of" 7SEG_2 "is," "---" "---" "," "will be displayed
in the order of SyS" "rSt" ".
6. When the "" SyS "" rSt "" is displayed, please turn off the power switch
of the welding power source. This will be the completion of
initialization.
7. Again, please turn on the power switch of the welding power source.
Parameter is returned to the factory default initial state.
System Reset will be complete.
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4.2
Operations on Panel
Explanation of Welding power source Panel
Fig. 4-7: Procedure of the system reset
After selecting the C23,
Press the rotary switch button.
Automatic in the system reset
by-204 became a point
Panel display when the
system is reset.
Ẑ---,---ẑ→ẐSYS,rStẑ
- 7segLED the
selection is changed
- 204 to change
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5.1
5
Setting in the Robot Control Unit Side
Digital Communication Setup
Setting in the Robot Control Unit Side
5.1
Digital Communication Setup
With the program pendent of the robot control unit, set the following items.
Welding unit characteristics setup
Welding power basic setup
The characteristics (voltage command type) of
the welding unit to be used are set.
(5.2 Welding Characteristics Setup)
The welding power type and the motor model
are set.
(5.3 Welding Power Basic Setup)
Welding method setup
The welding method to be used and the
parameters are set.
(5.4 Welding Method Setup)
Welding job making
The welding job to be used is made.
(5.5 Welding Job Making)
CAUTION
•
To perform the welding power source setup, turn ON the welding
power source to be online (communication enable state).
•
The welding method is not set before shipping. Be sure to set a
welding method.
•
If communication is disable, "welding power source: Ethernet
communication error" is displayed in the lower side of the screen.
Be sure to check to confirm that this is not displayed before performing
the welding power source setup.
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5.2
Setting in the Robot Control Unit Side
Welding Unit Characteristics Setup
Fig. 5-1: Welding power source :Ethernet Communication Error Display
5.2
Welding Unit Characteristics Setup
Select the welding unit characteristics file for the X500 ("MOTOWELD-E
series 500A" class). For the voltage command type, there are the auto
adjustment setting and the individual setting. Select one between them
Operation
1
Description
Select [ARC WELDING] 
[POWER SOURCE COND.] on
the Main Menu.
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5.2
Operation
2
Select [DATA]  [READING].
3
Set the characteristics of the
welding power source to be used.
Select the welding characteristics
file of the auto adjustment setting
or the individual setting according
to the voltage command type.
Setting in the Robot Control Unit Side
Welding Unit Characteristics Setup
Description
For the X500, select the auto
adjustment data or the individual
data of "MOTOWELD- E Series
500A class".
4
Change the setting from "Not
completed" to "DONE".
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5.3
5.3
Setting in the Robot Control Unit Side
Welding power source Basic Setup
Welding power source Basic Setup
Basic setup of the welding power source is performed. Change the
security mode of the robot control unit to the administrator mode. In the
editor mode, setup cannot be made and only browsing is allowed.
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5.3
5.3.1
Setting in the Robot Control Unit Side
Welding power source Basic Setup
Security Mode Change
Operation
1
Select [SYSTEM INFO] 
[SECURITY] on the Main Menu,
and set the security mode to
[MANAGEMENT MODE]. Enter the
password of the administrator
mode.
2
The display indicates the
administrator mode.
Description
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5.3
5.3.2
Setting in the Robot Control Unit Side
Welding power source Basic Setup
Welding power source Setup Screen Display
Operation
1
Select [ARC WELDING]  [ARC
START COND.] on the Main Menu.
2
Select [OTHER] tab of the ARC
START COND. screen, and press
[Welder setting] button.
3
The MOTOWELD screen is
displayed.
Description
When the communication with the
welding power source is
established, the welding power
source type and voltage command
are automatically acquired from the
welding power source and they are
set.
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5.3
5.3.3
Setting in the Robot Control Unit Side
Welding power source Basic Setup
Feeder Motor Selection
By changing the C parameter C09 value, the feeder motor selection can
be changed.
C09: 0 Print servomotor (Production is currently discontinued)
C09: 1 E4WD servo torch (Production is currently discontinued)
C09: 2 Mechanical servo
YWE-WFR42DX2, YWE-WFX40TELC (Default setting)
YWE-WF340MELC, YWE-WF340TELC (Production is currently discontinued)
C09: 8 EAGLX torch
C09: 9 EAGL7 torch
C09: 10 EAGL motor (Production is currently discontinued)
Table 5-1: Feeder Unit Setup Screen
Operation
1
Press [Welder prm.] button on the
MOTOWELD screen.
2
Select [Gas/Wire] tab of the Welder
prm. screen, and set feeder unit
from Feeder Type (C09).
After the setup, be sure to press
[SAVE].
3
Turn OFF the welding power source
and turn ON it again.
Description
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5.3
Setting in the Robot Control Unit Side
Welding power source Basic Setup
CAUTION
•
If the feeder unit setup is made erroneously, the wire cannot be fed
at the instructed wire feeding speed, resulting in defective welding.
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5.4
5.4
Setting in the Robot Control Unit Side
Welding Method Setup
Welding Method Setup
Please refer chapter 17 “List of Welding Types” .
The welding method has not been set before shipping. When welding is
performed with a user file which has no setting of welding method,
Welding method not set Err602 is generated. Be sure to set the welding
method before executing welding.
Operation
1
Select [ARC WELDING]  [ARC
START COND.] on the Main Menu.
2
Press [Welder setting] button of the
[OTHER] tab.
Description
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5.4
Setting in the Robot Control Unit Side
Welding Method Setup
Operation
3
Select the welding power source
user file to be used from the
welding method list, and press
[Weld type] button.
The user file describes the setup
content of the parameter for
optional welding method.
Max. 16 welding power source user
files can be registered.
4
Select the wire type, the wire
diameter, the shield gas, and the
pulse, select the welding method to
be used among the displayed
welding methods, and press
[SAVE] button.
If there are two or more welding
method options, select one from
the list.
If the welding method is not
displayed, it means there is no
corresponding welding method.
Description
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5.5
5.5
Setting in the Robot Control Unit Side
Welding Job Making
Welding Job Making
Operation
1
Select [JOB] on the Main
Menu.
2
A job is made and [ARCON] is
registered at the start point of
welding.
In this case, the setting method of
ARCON is made as the welding
start condition file [ASF#(x)].
Description
* x: Optional file number
3
Press the direct open button on the
ARCON command on the job
screen to display the welding start
condition screen, and select the
other tab.
Set the [Weld user file No:] as the
welding power source user file
number which was set in
" " The user file number to be used
is in the range of 1 to 16.
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5.5
4
Setting in the Robot Control Unit Side
Welding Job Making
Operation
Description
Press the welding power source
setup button and check the welding
method registered in the user file.
(Example: When "1" is selected as the user file number in the welding
start condition file, "Weld No.10" of the welding power source user file
1 is used.)
With the above procedure, setup of the welding power source digital
communication is completed.
CAUTION
•
The user file is changed to the number which was specified with the
user file number when executing the ARCON command. On the
welding power source panel, the welding method which was
registered in the selected user file is displayed.
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6.1
6
Welding power source Customization
6.1
6.1.1
Welding power source Customization
MOTOWELD Screen
MOTOWELD Screen
MOTOWELD Screen (Online/Offline)

Online Mode
The welding power source is ON and the communication is established.
Use this online mode normally to change the welding power source
setting.

Offline Mode
The offline mode is used when there is no welding power source or when
the communication with the welding power source is not established.
In the offline mode, the welding power source parameter can be set by the
robot control unit alone. To reflect the set contents on the welding power
source, switch to the online mode and execute the auto adjustment writing
to the welding power source. If the auto adjustment writing to the welding
power source is not executed, the parameter set content of the welding
power source and that of the robot control unit may be out of
synchronization and welding setting may be invalid.
The setup items on the MOTOWELD screen are described.
Fig. 6-1: MOTOWELD Screen (Online)
1
2
3
4
5
7
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6.1
Welding power source Customization
MOTOWELD Screen
Fig. 6-2: MOTOWELD Screen (Offline)
1
2
3
5
7
10
4
6
8
9
11
Description
1
Welder
Set the power type.
When the communication with the welding power source is established, the
welding power source type is automatically acquired from the welding
power source and it is set.
2
Welder No.
Select the welding power source No. connected to the robot control unit.
When there is only one welding power source, "1" is displayed.
When there are two welding power sources, select between "1" and "2."
3
Weld-V:synergic
Check the setup status of the auto adjustment or the individual setup.
Selection of the auto adjustment setting or the individual setting is switched
by reading the welding unit characteristics file.
4
Feeder Type
The setting status of the feeder unit is displayed.
Set the feeder unit from [ ⑥ Welder prm.].
5
Maintenance
The display shifts to the maintenance menu.
6
Welder prm.
The display shifts to the adjustment menu for the motor and gas.
7
Weld type
The list of the set user files (16 files) is shown.
8
Weld type
Set the welding method in the user file selected in the welding method list.
The display shifts to the welding method selection menu.
9
Customize
The display shifts to the Customize screen.
Used to change the welding parameter from the default value.
If the selected user file number is not registered, it cannot be selected.
10
OFFLINE
Indicates the communication status with the welding power source.
When the communication with the welding power source is established:
No display is shown.
When the communication with the welding power source is not established:
"Offline" is displayed.
When the operation is performed in the offline mode, the set contents are
not reflected on the welding power source. To set the content which is set
in the offline to the welding power source, turn ON the welding power
source to establish the communication and execute data writing (Robot
controller Welding power source).
11
to ONLINE
Displayed during the offline mode.
When the offline shift button is pressed under the state where the
communication with the Welding power source is established, the display
shifts to the online mode.
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6.1
Welding power source Customization
MOTOWELD Screen
The welding power source setting can be edited either in the online mode
or in the offline mode.
6.1.2
Parameter Discrepancy Screen
When setting the welding power source in the digital communication,
parameters of the welding power source are read by the robot control unit
and edited and written into the welding power source.
When opening the welding power source setting screen, the parameter
setting of the robot control unit and that of the welding power source are
compared. If they are out of synchronization, the dialog shown in fig. 6-3
“Parameter Discrepancy Screen” is displayed.
To validate the setting in the robot control unit side, execute "Robot
controller Welder".
To validate the setting in the welding power source side, execute "Welder
 Robot controller".
Fig. 6-3: Parameter Discrepancy Screen
6.1.3
Note and Procedure When Switching the Welding Power Source
When switching the welding power source, use the following procedure to
write parameters from the robot control unit into the welding power source.
If the parameters are not written, Err602 is output when executing the
ARCON command since the welding method has not been set before
shipping.
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6.1
Welding power source Customization
MOTOWELD Screen
Operation
1
Select [ARC WELDING]  [ARC
START COND.] on the Main Menu.
2
Select [OTHER] tab of the ARC
START COND. screen, and then
press [Welder setting].
3
The parameter discrepancy screen
is displayed.
Execute "Robot controller 
Welder".
Description
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6.2
6.2
6.2.1
Welding power source Customization
Welder prm. Screen
Welder prm. Screen
Gas/Wire Screen
Fig. 6-4: Gas/Wire Screen
Description
1
Feeder Type (C09)
Set the feeder unit model.
C09: 0 Print servomotor (Production is currently discontinued)
C09: 1 E4WD servo torch (Production is currently discontinued)
C09: 2 Mechanical servo
(YWE-WFR42DX2, YWE-WFX40TELC) (Default setting)
YWE-WF340MELC, YWE-WF340TELC (Production is currently
discontinued)
C09: 8 EAGLX torch
C09: 9 EAGL7 torch
C09: 10 EAGL motor (Production is currently discontinued)
2
Gas pre-flow time (C01)
Set the gas pre-flow time. (Set time range: 0 sec - 1 sec)
During gas pre-flowing, the robot stops at the arc start point.
3
Gas after-flow time (C02)
Set the gas after-flow time. (Set time range: 0.1 sec - 10 sec)
4
Gas check time (C00)
Set the gas adjustment time in the welding power source side. (Unit: sec,
Default: 20 sec)
When the gas adjustment button of the welding power source is pressed,
the LED lights up. When the set time passes, gas flow is automatically
stopped. When the gas adjustment button is pressed again during gas
check, shielding gas is stopped.
5
Motor curr. warning (C25)
When the motor current of the feeder motor exceeds the alarm level C25,
the wire feeding speed indicator blinks. Welding operation and wire
inching operation are not interrupted by this alarm.
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6.2
6.2.2
Welding power source Customization
Welder prm. Screen
Other Screen
This menu is to set the welding power source panel display, the output
current monitor parameter, the external resistors, etc.
Please refer the list of parameters.
Fig. 6-5: Other Screen
6.2.3
All PRM. screen
For parameters C and D, the number is specified and the value is entered.
This menu is used to set parameters which are not described in
chapter 6.2.2 “Other Screen” .
Press the list display button to select between parameter C and parameter
D.
For parameter D, press the ON/OFF select button to change the setting.
Please press the save.
Fig. 6-6: Parameter C Menu
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6.2
Welding power source Customization
Welder prm. Screen
Fig. 6-7: Parameter D Menu
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6.3
6.3
Welding power source Customization
Customize Screen
Customize Screen
Fig. 6-8: Customize Screen
The welding parameters of the welding power source can be changed.
The following welding characteristics can be adjusted by the welling
parameters.
①
Start
②
③
End
Short
④
Pulse
⑤
Other characteristics
Characteristics from arc on to
stabilization of the welding conditions.
From arc off to deletion of arc.
Characteristics of welding during shortcircuit welding.
Characteristics of welding during pulse
welding.
Current output characteristics.
The parameters of start, short-circuit (pulse), and end are changed by
changing the above tab.
After changing the tab, press [SAVE] button in the lower side to reflect the
change to the welding power source user file.
The welding characteristics of the digital inverter welding power source
MOTOWELD-X500 are determined by the database loaded in the welding
power source. The characteristics value can be changed to 10% - 200%
of the database value by adjustment the P parameter. Normally the
characteristics value of the database can be used. If, however, there is
any need for changing the characteristics depending on the environmental
conditions or preferences, adjust as follows referring to the descriptions
below.
The factory setting when shipping is "100 (%) = Operate according to the
database characteristics."
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6.3
6.3.1
Welding power source Customization
Customize Screen
Start
The parameters on the initial generation of arc when arc is on.
Fig. 6-9: Start/End Screen
Parameter No.
Meaning
Adjustment reference
P00
Wire speed until the wire reaches the
work.
The wire lead tip is left  Decrease
No arc is generated  Increase
P01
Wire speed of returning when arc is
generated until the wire reaches the
work. (Valid at touch start only)
Greater spatter at arc start  Increase
Arc flaming at arc start  Decrease
P02
Peak current of the pulse current
flowing for generation of arc.
Greater spatter at arc start  Increase
Arc flaming at arc start  Decrease
P04
Peak time of the pulse current flowing
for generation of arc.
P05
Average current of the hot condition
for stabilizing the melt pool.
Greater spatter at arc start  Decrease
Greater arc flaming at arc start  Increase
P06
Average voltage of the hot condition
for stabilizing the melt pool.
Greater spatter at arc start  Increase
Arc flaming at arc start  Decrease
P07
Output time of the hot condition for
stabilizing the melt pool.
Melts and Drops at arc start  Decrease
Considerable time for stabilizing arc  Increase
P43
Shift time from the hot condition to
this condition.
Melts and Drops at arc start  Decrease
Considerable time for stabilizing arc  Increase
*Touch start
Touch start is an arc start method in which the wire is pulled away
from the base material after contact between the wire and the base
material to generate an arc.
At the time of arc start, if there is a lot of wire repulsion, enable
touch start.
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6.3
6.3.2
Welding power source Customization
Customize Screen
End
Characteristics parameters after turning off arc until arc is extinguished
completely.
Fig. 6-10: End Screen
Parameter No.
Meaning
Adjustment reference
P11
Average current for crater
process after turning OFF arc
(Only when the end process is
enable)
Crater makes a hole.  Decrease
Crater is not covered.  Increase
P12
Average voltage for crater
process after turning OFF arc
(Only when the end process is
enable)
P13
Time for crater process after
turning OFF arc (Only when the
end process is enable)
P14
Average current for adjusting
flaming after welding
P15
Average voltage for adjusting
flaming after welding
P16
Arc time for adjusting flaming
after welding
P20
Time for preventing the wire from
adhering to the work
The wire melts and adheres to the work.  Increase
Arc is generated in a section other than the welding
section when air cutting.  Decrease
P44
Shift time from this condition to
the crater condition (Only when
the end process is enable)
Crater makes a hole.  Decrease
Crater is not covered.  Increase
The wire adheres to the chip.  Decrease
The wire adheres to the work.  Increase
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6.3
6.3.3
Welding power source Customization
Customize Screen
Short-circuit
"Soft arc" mode and "Hard arc" mode are presetted for simple adjustment.
• Soft arc: Use this mode to reduce spatters. Do not use this mode
when the welding is not stable or when high-speed welding is
applied.
• Hard arc: Use this mode when the welding is not stable or when the
high-speed welding is applied.
For detailed adjustment, choose "Professional" mode and set the
parameters below to change the short-circuit welding characteristics.
Fig. 6-11: Short Screen
Parameter No.
Meaning
Adjustment reference
P08
Peak current of the pulse
P10
Peak time of the pulse
Arc flaming  Decrease
Arc spatter  Increase
P24
Sensitivity of necking
Change P24 arbitrary and adjust the arc
P37
Current rising speed (First half) when
short-circuiting
Much spatter  Decrease
Unstable arc  Increase
P38
Current rising speed (Latter half)
when short-circuiting
P47
Target value of short-circuit current
Much spatter  Decrease
Unstable arc  Increase
P33
Arc current decrease speed
No drop, long-term arc  Increase
Unstable arc  Increase
Bead is made flat with stainless steel
 Decrease
Long-term short-circuit  Decrease
Drop of melted metal  Increase
P64
Welding voltage adjustment
correction
Output voltage is greater than command
voltage Decrease
Output voltage is smaller than command
voltage Increase
(Reference: 10% per volt)
*Automatic correction of output voltage
Enable when automatically matching the output voltage and the command
voltage.
(Software version Ver1.20-010-F or later)
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6.3
6.3.4
Welding power source Customization
Customize Screen
Pulse
Parameters of characteristics of the MAG/MIG pulse welding which uses
mixed gas with Ar 98% or less.
Parameters A00 - A02 are adjusted by adding parameter values to the
database values.
To adjust with the conventional P parameter ratio (P08 - P10), refer to
chapter 6.3.10 “All PRM. Screen” .
Fig. 6-12: MAG Pulse Screen
Parameter No.
Range
Meaning
Adjustment reference
A00
-100 A to +150 A
Pulse peak current for droplet
transfer
Much spatter  Increase
Much flaming  Decrease
A01
-50 A to +150 A
Base current for maintaining arc
A02
-1.0 ms to +2.0 ms
Pulse peak time for droplet transfer
P31
10 to 200%
Pulse current rise speed
Arc flaming  Decrease
Arc spatter  Increase
P33
10 to 200%
Pulse current fall speed
Arc flaming  Increase
Arc spatter  Decrease
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6.3
Welding power source Customization
Customize Screen
Fig. 6-13: Arc Length Control
Arc length vibration great
Arc length control
gain too much
NG
Welding direction
OK
Arc length 1
Arc length control gain
P61
NG
Arc length following problem
Arc length gain
insufficient
Parameter No.
P61
Transient state
Steady state
Meaning
Adjustment reference
Arc length control gain in pulse
welding
Ark length following problem  Increase
Arc length vibration  Decrease
CAUTION
•
If there is a following problem of robot with COMARC (arc sensor),
increase the arc length gain (target: P61=110 - 120%).
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6.3
6.3.5
Welding power source Customization
Customize Screen
Aluminum MIG Pulse Welding Characteristics
Characteristic parameters of the aluminum MIG pulse welding under the
condition.
Parameters A00 - A02 are adjusted by adding parameter values to the
database values.
To adjust with the conventional P parameter ratio (P08 - P10), refer to
chapter 6.3.10 “All PRM. Screen” .
Fig. 6-14: Aluminum MIG Pulse Screen
Parameter No.
Range
Meaning
Adjustment reference
A00
-100 A to +150 A
Pulse peak current for droplet
transfer
Much spatter  Increase
Much flaming  Decrease
A01
-50 A to +150 A
Base current for maintaining arc
A02
-1.0 ms to +2.0 ms
Pulse peak time for droplet transfer
P35
10 to 200%
Pulse current rise speed
Arc flaming  Decrease
Arc spatter  Increase
P36
10 to 200%
Pulse current fall speed
Arc flaming  Increase
Arc spatter  Decrease
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6.3
6.3.6
Welding power source Customization
Customize Screen
Aluminum Low Pulse Setting Screen
This screen is displayed when the Aluminum Low Pulse 2 welding method
is selected for aluminum MIG pulse welding. This parameter is used to
change the welding current in this condition to form scaled beads. This
function is available only for EAGLX torches and EAGL7 torches. (C09=8
or C09= 9)
To change the parameters of pulse welding characteristics in this condition
for aluminum MIG pulse welding, refer to chapter 6.3.5 “Aluminum MIG
Pulse Welding Characteristics”
Fig. 6-15: Aluminum Low Pulse Setting Screen
Parameter No.
Range
Meaning
P55
1.0 Hz to 20.0 Hz
Low pulse frequency
P56
10 % to 100 %
T_H ratio
A10
30 A to 100 A
Average current value I_L of T_L section
Frequency/pulse ratio calculation
Input the command welding speed and command current value, and press
the Calculate button to calculate the recommended values for the above
parameters.
Waveform information
Displays information on the cycle and each current value.
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6.3
6.3.7
Welding power source Customization
Customize Screen
EAGL+ Pulse Setting Screen
This screen is displayed when selecting a EAGLX welding method.
However, it is not displayed when the gas used is CO2. Combining the
EAGL welding method and pulse welding enables adjustment of heat
input and formation of aluminum scaled beads. To enable this function,
insert a check mark to select the "EAGL+ Pulse (enable/disable) (bit 3-1)"
check box.
This function is only available with the EAGLX torch. (C09=8)
This function is available with robot controller software version
YAS5.20.00A-00 and later.
If the software has been upgraded from a version earlier than
YAS5.20.00A-00 to a supported version (YAS5.20.00A-00 or later), the
following parameter of the robot controller must be changed after
upgrading. Please change the parameter before using the function.
Change parameter: S2C1696=1
Parameters A00 to A02 are adjusted by adding the parameter values to
the database values.
To change the parameters of the EAGL welding short-circuit welding
characteristics in this condition, refer to chapter 6.3.3 “Short-circuit” .
Fig. 6-16: EAGL+ Pulse Setting Screen
Parameter No.
Range
Meaning
P55
1.0 Hz to 20.0 Hz
EAGL+ pulse frequency
P56
10 % to 100 %
T_H ratio
A11
30 A to 300 A
Average current value I_L of T_L section
A00
-150 A to 150 A
Pulse peak current for droplet transfer
A01
-50 A to 150 A
Base current for maintaining arc
A02
-1.0 ms to 2.0 ms
Pulse peak time for droplet transfer
Waveform information calculation
By inputting the command current value, information on the cycle and
each current value is displayed.
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6.3
6.3.8
Welding power source Customization
Customize Screen
Welding Current Output Characteristics
Fig. 6-17: Curr. Character Screen
Correction by
parameter P62
Interpolation between
calibration 1 and 2
Wire feed
speed
command
Correction by
parameter P63
Wire feed amount
after correction
P63
Wire feed amount
before correction
P62
Calibration current 1
Example: 150A
Calibration current 2
Example: 250A
Welding current command
(Panel display current)
Parameter No.
Meaning
Adjustment reference
P62
Welding current output
characteristics 1
The wire feed amount is adjusted so
that the actual welding current value
coincides with the welding current
command.
The actual welding current value is large. 
Decrease
The actual welding current value is small. 
Increase
P63
Welding current output
characteristics 2
The wire feed amount is adjusted so
that the actual welding current value
coincides with the welding current
command.
The actual welding current value is large. 
Decrease
The actual welding current value is small. 
Increase
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6.3
Welding power source Customization
Customize Screen
The welding current output adjustment (coincidence of the welding current
command and the welding current feedback value) can be made by
setting P62 and P63.
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6.3
6.3.9
Welding power source Customization
Customize Screen
Heat And Wave Form Control (HAWC) Screen
The Heat And Wave Form Control (HAWC) is the function that
automatically adjusts the wire feeder speed so that the heat input is
consistently provided at constant rate even when the length of wire
stickout is changed due to strained base metal.
Usually, if the length of wire stickout is changed, the welding current is
changed, and then the heat input (melting) of a base metal and bead width
are changed. If the heat input wave control is enabled, the welding
current is kept at constant rate, and then this helps to keep a certain
amount of the heat input (melting) of a base metal and bead width.
Fig. 6-18: HAWC Screen
CAUTION
•
If the heat input wave control is enabled, the amount of spatter may
increase.
•
If an arc sensor or the aluminum welding is carried out, disable the
Heat And Wave Form Control.
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6.3
6.3.10
Welding power source Customization
Customize Screen
All PRM. Screen
For the user file parameter, specify the number and enter the value.
Use this setting to set parameters which are not described from
chapter 6.3.1 “Start” to chapter 6.3.7 “EAGL+ Pulse Setting Screen” .
Fig. 6-19: All PRM. Screen.
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6.4
6.4
Welding power source Customization
Maintenance Screen
Maintenance Screen
Fig. 6-20: Maintenance Screen
Description
1
All write
(Robot controller 
welder)
Execute when the welding power source is changed or when the system is
reset.
All the set parameters saved in the Robot controller are written into the
welding power source.
2
All read
(welder Robot
controller)
The welding power source setting is saved in the Robot controller.
3
Welder info.
The software version of the welding power source.
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6.5
6.5
Welding power source Customization
External Memory
External Memory
The welding power source setting can be saved to or read from the
external memory (compact flash or USB memory) of the Robot controller.
There are following two kinds of setting files of the welding power source.
• Welding method condition file: WELDTYPE.CND
• Digital welding power source characteristics: DIG_WELD.DAT
6.5.1
Setting Contents Save
Operation
1
Select [EX. MEMORY]  [SAVE] on
the Main Menu.
2
Select [FILE/GENERAL DATA].
Description
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6.5
Welding power source Customization
External Memory
Operation
3
Description
Select [WELD TYPE] and [DIGITAL
WELDER CONDITION], and
execute the save process.
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6.5
6.5.2
Welding power source Customization
External Memory
Setting Contents Reading
Operation
1
Select [EX. MEMORY]  [LOAD]
on the main menu.
2
Select [FILE/GENERAL DATA].
3
Select [WELD TYPE] and [DIGITAL
WELDER CONDITION], and
execute the load process.
Description
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6.6
6.6
6.6.1
Welding power source Customization
Other Option Functions
Other Option Functions
Output Voltage Out-of-range Error Detection Function
The output voltage out-of-range error detection function delivers an alarm
when the welding voltage that is fed back during welding deviates from the
command voltage.
The voltage difference (ΔV) that was set by the user based on the
command voltage is monitored to prevent welding that deviates from the
command.
The following requirements must be met to enable the output voltage out-of-range error detection function.
NOTE
• Welder X500: CPUVer.1.20-055-F or later
• The controller YRC1000: YAS4.31.00-00 or later
6.6.1.1
Function Description
As shown in the figure below, an alarm (Err780/Err781 or Err782/Err783)
is delivered when the average welding voltage during welding, which is
fed back during the determination validity period (during main welding),
exceeds the error detection range (ΔV1, ΔV2) that was set by the user.
④
Determination ⑤ Average calculation
start standby
time
time
Voltage
⑧Determination validity period
Err782: OUTSIDE OF VOLTAGE SETTING FORCED STOP (High)
Err780: OUTSIDE OF VOLTAGE SETTING (High)
③Command voltage
⑥ Average output
voltage value
ΔV1
ΔV2
ΔV1
ΔV2
Err781: OUTSIDE OF VOLTAGE SETTING (Low)
Err783: OUTSIDE OF VOLTAGE SETTING FORCED STOP (Low)
Time
(ms)
①ARCON
②Main welding transition
⑦Determination start
No.
Item
Description
1
ARCON
ARCON command
2
Main welding
transition
Arc stabilization period
3
Command voltage
Voltage value in welding file and ARCON command
4
Determination start
standby time
―
5
Average calculation Average calculation time
time
6
Average output
voltage value
Moving average of welding voltage that was fed
back during welding
7
Determination start
Error detection determination start
8
Determination
validity period
Error detection determination validity range
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6.6
6.6.1.2
Welding power source Customization
Other Option Functions
Setting Methods
Parameter settings can be set as a collective setting or as individual
settings by changing parameter D.
Parameter
D-3-12
Setting
method
Setting description
OFF
Collective
setting
This applies the same conditions to all
welding files.
ON
Individual
settings
This configures settings individually for each
welding file and each ARCON command.
For the error OUTSIDE OF VOLTAGE SETTING (Err780/Err781), the
stopping conditions when an alarm is delivered can be changed. The
conditions are shown below.
* The error OUTSIDE OF VOLTAGE SETTING FORCED STOP (Err782/
Err783) can use an immediate stop only.
Parameter
Function
Function description
C74
0
Error stop after
welding is
completed
When an error is detected, an error is
delivered after welding is completed, and the
robot is stopped.
1
Immediate stop
When an error is detected, the robot comes
to an immediate stop.
(Robot stops at its current position.)
2
Error disabled
No error is delivered.
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6.6
6.6.1.3
Welding power source Customization
Other Option Functions
Parameter Settings

Collective setting
The parameters for the collective setting method are shown below.
Collective setting【D-3-12︓OFF】
Determination
Average calculation time
start standby
【C72】
time
Voltage(V)
Determination validity period
Err782: OUTSIDE OF VOLTAGE SETTING FORCED STOP (High)
Err780: OUTSIDE OF VOLTAGE SETTING (High)
Command voltage
Average output
voltage value
ΔV1︓ 【C73】
ΔV2︓ 【C75】
ΔV1︓ 【C73】
ΔV2︓ 【C75】
Err781: OUTSIDE OF VOLTAGE SETTING (Low)
Err783: OUTSIDE OF VOLTAGE SETTING FORCED STOP (Low)
Time
(ms)
ARCON
Main welding transition
Determination start
Parameter Initial Setting Units
value value
Function description
D-3-12
OFF
OFF
-
OFF: Collective setting
(This is individual settings if set to ON.)
C72
10
0 to
999
100ms Average calculation time
(This is set to 1s when setting value= 0.)
C73
50
0 to
999
0.1V
Judgment range for error (Err780 &
Err781)
(Error disabled when setting value= 0.)
C74
2
0
-
Error stop after welding is completed
C75
100
1
Immediate stop
2
Error disabled
0 to
999
6-27
0.1V
Judgment range for error (Err782 &
Err783)
(This is set to 10V when setting value=
0.)
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6.6

Welding power source Customization
Other Option Functions
Individual settings
The setting of the judgment range for error can be set for each user file.
The parameters for the individual settings method are shown below.
Individual settings【D-3-12︓ON】
Determination
Average calculation
start standby
time 【C72】
time
Voltage(V)
Determination validity period
Err782: OUTSIDE OF VOLTAGE SETTING FORCED STOP (High)
Err780: OUTSIDE OF VOLTAGE SETTING (High)
Command voltage
Average output
voltage value
ΔV1︓ 【A6】
ΔV2︓ 【C75】
ΔV1︓ 【A6】
ΔV2︓ 【C75】
Err781: OUTSIDE OF VOLTAGE SETTING (Low)
Err783: OUTSIDE OF VOLTAGE SETTING FORCED STOP (Low)
Time
(ms)
ARCON
Main welding transition
Determination start
Parameter Initial
value
Setting Units
value
Function description
D-3-12
OFF
ON
-
ON: Individual settings
(This is collective setting if set to OFF.)
C72
10
0 to
999
100ms Average calculation time
(This is set to 1s when setting value= 0.)
A6
0
0 to
100
0.1V
C74
2
0
-
C75
100
Judgment range for error (Err780 &
Err781)
(Error disabled when setting value= 0 or
less.)
Error stop after welding is completed
1
Immediate stop
2
Error disabled
0 to
999
6-28
0.1V
Judgment range for error (Err782 &
Err783)
(This is set to 10V when setting value=
0.)
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6.6
6.6.1.4
Welding power source Customization
Other Option Functions
Setting Examples
<C74: 0 (when stopped after welding)>
If the welding voltage during welding that is fed back exceeds the value
set by C73 (initial value: ±5V) with respect to the command voltage, an
error OUTSIDE OF VOLTAGE SETTING (Err780/Err781) is delivered after
welding is performed to the welding end point (until arc-off).
Parameter
Function description
Setting
value
Units
C72
Average calculation time
10
100ms
C73
Judgment range for error (Err780 & Err781) 50
(Collective setting)
0.1V
A6
Judgment range for error (Err780 & Err781) 50
(Individual settings)
0.1V
C74
Judge mode of the outside of voltage
setting error (Err780 & Err781)
C75
Judgment range for error (Err782 & Err783) 100
0 (Stop after welding
is completed)
0.1V
Determination validity period
Err780:Detection
Err780:Delivery
C75 : 100 (+10V)
C73 : 50 (+5V)
A6 : 50 (+5V)
Command
voltage value
Average output
voltage value
C73 : 50 (-5V)
A6 : 50 (-5V)
C75 : 100 (-10V)
Time (ms)
Determination start
Arc off
Determination validity period
Err781:Delivery
C75 : 100 (+10V)
C73 : 50 (+5V)
A6 : 50 (+5V)
Average output
Command
voltage value voltage value
C73 : 50 (-5V)
A6 : 50 (-5V)
C75 : 100 (-10V)
Err781:Detection
Time (ms)
Determination start
Arc off
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6.6
Welding power source Customization
Other Option Functions
<C74: 1 (when immediate stop is performed)>
If the welding voltage during welding that is fed back exceeds the value
set by C73 (initial value: ±5V) with respect to the command voltage, an
alarm is immediately occurred, and an error OUTSIDE OF VOLTAGE
SETTING (Err780/Err781) is delivered.
Parameter Function description
Initial
value
Units
C72
Average calculation time
10
100ms
C73
Judgment range for error (Err780 & Err781) 50
(Collective setting)
0.1V
A6
Judgment range for error (Err780 & Err781) 50
(Individual settings)
0.1V
C74
Judge mode of the outside of voltage
setting error (Err780 & Err781)
C75
Judgment range for error (Err782 & Err783) 100
1 (Immediate stop)
0.1V
Determination validity period
Err780:Delivery
C75 : 100 (+10V)
C73 : 50 (+5V)
A6 : 50 (+5V)
Command
voltage value
Average output
voltage value
C73 : 50 (-5V)
A6 : 50 (-5V)
C75 : 100 (-10V)
Time (ms)
Determination start
Determination validity period
C75︓100 (+10V)
C73︓50 (+5V)
A6︓50 (+5V)
Command voltage value
Err781:Delivery
C73︓50 (-5V)
A6︓50 (-5V)
Average output voltage value
C75︓100 (-10V)
Time (ms)
Determination start
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6.6
Welding power source Customization
Other Option Functions
<When C75 is exceeded (when forced stop is performed)>
If the welding voltage during welding that is fed back exceeds the value
set by C75 (initial value: ±10V) with respect to the command voltage, a
forced stop is performed, and an error OUTSIDE OF VOLTAGE SETTING
FORCED STOP (Err782/Err783) is delivered.
* Even if C74: 0 (Stop after welding) is set, if the forced stop range is
exceeded, the robot stops immediately at that point and delivers an error
OUTSIDE OF VOLTAGE SETTING FORCED STOP (Err782/Err783).
Parameter Function description
Initial
value
Units
C72
Average calculation time
10
100ms
C73
Judgment range for error (Err780 & Err781) 50
(Collective setting)
0.1V
A6
Judgment range for error (Err780 & Err781) 50
(Individual settings)
0.1V
C74
Judge mode of the outside of voltage
setting error (Err780 & Err781)
C75
Judgment range for error (Err782 & Err783) 100
0 (Stop after welding
is completed.)
0.1V
Determination validity period Err782:Delivery
C75 : 100 (+10V)
Err780:Detection
C73 : 50 (+5V)
A6 : 50 (+5V)
Command
voltage value
C73 : 50 (-5V)
A6 : 50 (-5V)
Average output voltage value
C75 : 100 (-10V)
Time (ms)
Determination start
Determination validity period
C75 : 100 (+10V)
C73 : 50 (+5V）
A6 : 50 (+5V）
Command voltage value
Err781:Detection
Average output
voltage value
Err783:Delivery
C73 : 50 (-5V）
A6 : 50 (-5V）
C75 : 100 (-10V)
Time (ms)
Determination start
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6.6
6.6.1.5
Welding power source Customization
Other Option Functions
Parameter screen

Collective setting
(1) Security mode change
Operation
1
Description
Select [SYSTEM INFO] →
[SECURITY] on the Main Menu, and
set the security mode to
[MANAGEMENT MODE].
Enter the password of the
administrator mode.
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6.6
Welding power source Customization
Other Option Functions
(2) Parameter change (Parameter D)
Operation
1
Select [ARC WELDING] → [ARC
START COND.] on the Main Menu.
2
Select [OTHER] tab of the ARC
START COND. screen, and press
[Welder setting] button.
3
The MOTOWELD screen is
displayed.
Press [Welder prm.] button.
Description
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6.6
Welding power source Customization
Other Option Functions
Operation
Description
The Welder prm. screen is displayed.
Select [All PRM.] tab.
4
Select [D prm.] from the drop-down
list in the All PRM. screen.
Check that the parameter list screen
is in the parameter D display, and
enter the collective setting
parameters.
For details, refer to
chapter 6.6.1.3 “Parameter
Settings” (collective setting).
Parameter
Initial
value
Setting
value
D-3-12
OFF
OFF
To change a parameter, press [ON/
OFF] with the parameter to be
changed selected, and change to ON
or OFF.
(3) Writing completion
Operation
1
Description
Select [SAVE] to complete the
parameter change.
If the parameter C or D is changed,
be sure to select [SAVE].
→If writing is not completed, the data
changes will not be applied.
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6.6
Welding power source Customization
Other Option Functions
(4) Parameter change (Parameter C)
Operation
1
Description
Select [C prm.] from the drop-down
list in the All PRM. screen.
Check that the parameter list screen
is in the parameter C display, and
enter the collective setting
parameters.
For details, refer to
chapter 6.6.1.3 “Parameter
Settings” (collective setting).
Parameter Initial
value
Setting
value
C72
10
0 to 999
C73
50
0 to 999
C74
2
0
1
2
C75
100
0 to 999
(5) Writing completion
Operation
1
Description
Select [SAVE] to complete the
parameter change.
If the parameter C or D is changed,
be sure to select [SAVE].
→If writing is not completed, the data
changes will not be applied.
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6.6

Welding power source Customization
Other Option Functions
Individual settings
(1) Security mode change
Operation
1
Description
Select [SYSTEM INFO] →
[SECURITY] on the Main Menu, and
set the security mode to
[MANAGEMENT MODE].
Enter the password of the
administrator mode.
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6.6
Welding power source Customization
Other Option Functions
(2) Parameter change (Parameter D)
Operation
1
Select [ARC WELDING] → [ARC
START COND.] on the Main Menu.
2
Select [OTHER] tab of the ARC
START COND. screen, and press
[Welder setting] button.
3
The MOTOWELD screen is
displayed.
Press [Welder prm.] button.
Description
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6.6
Welding power source Customization
Other Option Functions
Operation
Description
The Welder prm. screen is displayed.
Select [All PRM.] tab.
4
Select [D prm.] from the drop-down
list in the All PRM. screen.
Check that the parameter list screen
is in the parameter D display, and
enter the individual setting
parameters.
For details,
chapter 6.6.1.3 “Parameter
Settings” (individual settings).
Parameter Initial Setting
value value
D-3-12
OFF
ON
To change a parameter, press [ON/
OFF] select button with the
parameter to be changed selected,
and change to ON or OFF.
(3) Writing completion
Operation
1
Description
Select [SAVE] to complete the
parameter change.
If the parameter C or D is changed,
be sure to select [SAVE].
→If writing is not completed, the data
changes will not be applied.
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6.6
Welding power source Customization
Other Option Functions
(4) Parameter change (Parameter C)
Operation
1
Description
Select [C prm.] from the drop-down
list in the All PRM. screen.
Check that the parameter list screen
is in the parameter C display, and
enter the individual setting
parameters.
For details, refer to
chapter 6.6.1.3 “Parameter
Settings” (individual settings).
Parameter Initial
value
Setting
value
C72
10
0 to
999
C74
2
0
1
2
C75
100
0 to
999
(5) Writing completion
Operation
1
Description
Select [SAVE] to complete the
parameter change.
If the parameter C or D is changed,
be sure to select [SAVE].
→If writing is not completed, the data
changes will not be applied.
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6.6
Welding power source Customization
Other Option Functions
(6) Parameter change (Parameter A)
Operation
Description
1
Press [Customize] button on the
MOTOWELD screen.
2
Select [A prm.] from the drop-down
list in the All PRM. screen.
Check that the parameter list screen
is in the parameter A display, and
enter the individual setting
parameters.
For details, refer to
chapter 6.6.1.3 “Parameter
Settings” (individual settings).
Parameter Initial
value
Setting
value
A6
0 to
100
0
(7) Writing completion
Operation
1
Description
Select [SAVE] to complete the
parameter change.
If the parameter A or P is changed,
be sure to select [SAVE].
→If writing is not completed, the data
changes will not be applied.
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7.1
Welding Operation
7.1
Checking the Welding Conditions
Before starting actual welding operation, perform the test welding for
welding conditions to check if the welding performance is satisfactory.
Remove oil, rust, oil paint, water, and foreign matter generated by gascutting to prevent the surface pore and blow hole.
7.2
Wire Stickout
The wire length from the torch tip to the arc point is called wire stickout.
Keep this length constant during welding.
The standard length (  ) of wire stickout varies depending on the wire
diameter. When the wire diameter is 1.2 mm, the standard length of wire
stickout is 15 mm. When the wire diameter is 0.9 mm, the standard
length of wire stickout is between 10 and 15 mm.
Direction of Welding and Torch Angle
There are two welding types: backhand welding (same as manual
welding), in which the torch is tilted by 0 to 10 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. 7-1: Direction of Welding and Torch Angle
0° 10°
stick
out
Torch
Wire
7.3
Forward
welding
Nozzle
Backhand
welding
l
7
Welding Operation
Checking the Welding Conditions
Gas
Base metal
Forward welding is preferred in CO2/MAG welding.
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8.1
8
Precautions on Welding
Error Detection Function
Precautions on Welding
8.1
Error Detection Function
Error detection is performed for the items listed in chapter 18 “List of
Errors” , and the welding power source stops automatically when an error
is detected.
Please refer to chapter 18 for the details.
8.2
Tripped Breaker of the welding power source
If the breaker of the welding power source is tripped, do not turn it ON
again. Contact your YASKAWA representative. If the power is turned ON
again with the power supply switch tripped, the problem may be
compounded and may affect the welding.
8.3
Precautions on Welding Operation
Check the following precautions before starting welding.
1. The welding wire is electrically charged during welding. Be careful that
the welding voltage still remains for one seconds after the welding
ends due to the two-second delay set for the welding power source.
Also, do not touch the welding wire during the starting point detection
(optional function) since the voltage of approx. 200 V is applied to the
wire.
2. If a conduit cable is extremely bent, the welding wire cannot be
smoothly fed, and thus the set welding conditions may be altered. To
prevent this, place conduit as straight as possible.
3. If welding is performed at a current exceeding the rated output current,
internal parts of the welding power source may be burnt. Allowable
operational ratio for a current under the rated value is calculated as
follows:
Allowable operational ratio
Rated current
= Rated operational ratio 
] 2%
Operating current
Table 8-1: Allowable Operational Ratio of the welding power source of 500 Ampere
(with Rated Operational Ratio of 60%)
Welding
Current
(A)
500
460
430
400
380
Allowable
Operational Ratio
(%)
60
70
80
90
100
Allowable Continuous
Welding Time
Welding Pause Time
6 minutes or less
7 minutes or less
8 minutes or less
9 minutes or less
Continuous welding possible
4 minutes or more
3 minutes or more
2 minutes or more
1 minutes or more
-
4. Power switch operation
The inverter welding power source is the forced air-suction cooling
type. After welding, do not turn OFF the power supply switch before
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8.3
Precautions on Welding
Precautions on Welding Operation
the cooling fans except top one stop completely.
To prevent electric shock, never disconnect or connect the cables for
the welding power source, the wire feeder, the welding torch, etc. while
the power is ON. Make sure that the power supply switch of the
welding power source is turned OFF after the operation.
5. Cooling fan
The cooling fan start rotating as soon as the welding power source is
turned ON. The fan rotates at low speed if approx. 15 minutes passes
without start welding. The fan rotates at high speed when welding
starts, and it rotates at low speed after approx. 15 minutes from the
welding ends.
6. Stretch a protective curtain around the welding operation space for
workers and others to protect from arc light, spatter, and slag.
7. Installation Environment
Do not weld on a wet earth floor or metallic floor to avoid electric
shock. Also avoid welding where there are inflammables to prevent
fire due to scattering of heated spatter or slag.
8. The welding power source cannot be used for gouging other than
CO2/MAG welding.
9. Radio disturbance
Noise may be generated over the radio during welding.
When listening to the radio, keep the radio as far as possible from the
welding power source. 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.
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9.1
9
Location and Setting of Printed Boards
Location of Printed Boards
Location and Setting of Printed Boards
9.1
Location of Printed Boards
The printed boards are located under the top cover of the welding power
source.
CAUTION
•
Whenever performing work where the printed circuit board will be
touched, use electrostatic gloves and take other measures to
prevent electrostatic discharge. Otherwise, the electronic
components could be damaged.
Front Face
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9.2
9.2
9.2.1
Location and Setting of Printed Boards
Internal Selecting Switches
Internal Selecting Switches
DIP Switch Settings for Pr(MB)-031 Board
The internal selecting switches are set as follows before shipping.
The internal switches except SW1 are not allowed to change settings
since the switches are prepared for adjustment and maintenance
performed by manufacturers.
Table 9-1: Settings of DIP Switches for Pr(MB)-031 Board
DSW
Default Setting
Spare
350A (X350)
500A(X500)
1
OFF
OFF
2
ON
ON
3
ON
ON
4
OFF
OFF
SW3
● side
● opposite side
Current capacity
setting switch
SW5
● side
● opposite side
Added after Rev.D
SW1
● side
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9.2
9.2.2
Location and Setting of Printed Boards
Internal Selecting Switches
DIP Switch Settings for Pr(CR)-031 Board
The internal selecting switches are set as follows before shipping.
The internal switches are not allowed for change since the switches are
prepared for adjustment and maintenance performed by manufacturers.
Table 9-2: Settings of DIP Switches for Pr(CR)-031Board
DSW
SW301
Default Setting
X350-CC0
X350-6N0
X500-CC0
X500-6N0
1
OFF
ON
OFF
ON
2
OFF
OFF
ON
ON
3
ON
ON
ON
ON
4
OFF
OFF
OFF
OFF
CAUTION
•
Be sure not to switch the selecting switch which is designated as
"switch disabled" by mistake. Failure to observe this caution may
result in a trouble.
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Maintenance and Inspection
10 Maintenance and Inspection
Perform periodical maintenance and inspection for safe and efficient
operations of the welding
source.
Before maintenance or inspection, or wiring, be sure to turn OFF the
switch in the switchgear on the input side. For internal inspection
immediately after using the welding power source, the capacitor in the
welding power source may be charged. Wait for approx. 10 minutes and
remove the cover for inspection.
CAUTION
•
Wait for the temperature inside the welding power supply to cool
down before performing maintenance and inspection.
Immediately after welding, main circuit components such as DC
reactors and heat sinks are hot. Unintentional contact with these
parts could cause burns.
•
When cleaning the welding power supply, do not blow dry
compressed air directly onto the cooling fan. Dust could get inside
the cooling fan or the bearings could wear down due to the high
speed rotation of the cooling fan.
•
When using a vacuum cleaner to remove dust adhering to the
welding power supply, do not suction the cooling fan directly.
The grease that lubricates the cooling fan bearings may also be
sucked out, leading to cooling fan failure and reduced service life.
Table 10-1: Maintenance and Inspection Items
Daily inspection items
Bimonthly to semiannual inspection items
(1) The switches operate without fail.
(2) The cooling fan rotates smoothly by turning ON/OFF
the power supply switch and draws the air in from the
rear face.
(3) There is no abnormal vibration, beat, or odor. There
is no leakage of gas.
(4) The cable connecting section is not excessively
heated.
(5) The power cable and its connecting section are not
excessively heated.
(6) There is no damage on the connection cable such
as a cable on the input side or on the base metal side,
resulting in imperfect insulation.
(7) Each connecting section is tightened securely.
(1) Removal of dust and dirt
Remove dust and dirt by spraying dry compressed air.
Carefully clean spaces between the transformer and
reactor windings, and semiconductors.
To clean circuit boards, use the exclusive-use dust
remover device.
(2) Inspection of electric connecting sections
Check that the bolts are firmly tightened and rust or the
like does not deteriorate the contacts in the connecting
sections with the external wiring such as input/output
terminals or with the internal wiring. Retighten the bolts
if necessary or use a file to remove rust, if any, so that
the metallic faces contact with each other.
(3) Inspection of ground line
Confirm that the case is grounded properly.
Annual overhaul and repair
Carry out the integrated repair such as replacement of defective components, case repair, and reinforcement of
insulation deteriorated parts. When replacing defective components, replace them with the components which
are ordered at monthly inspection. Insulation resistance must be 1 M or more between the control unit circuit
and the case; if it is less than 1 M, the insulation of the deteriorated part must be repaired.
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Maintenance and Inspection
Table 10-2: Lifetime of Parts
Lifetime of welding power source parts
The welding power source is composed of many components. Unless all these components operate normally,
the welding power source cannot utilize its essential functions. Therefore, it is absolutely necessary to find any
sign leading to a failure of a component or device as early as possible according to the periodical inspection and
take proper corrective action.
These components cannot be used continuously for ever. Even under normal operation status, they are apt to
have variation of the characteristics or malfunction after the life elapses.
Therefore, it is recommended that the components be replaced periodically so that the welding power source can
operate at optimum performance.
Normally, refer to the following guideline of the component replacement when the welding power source is used
in the rated specifications (8 hours a day, 250 days a year).
① Electrolytic capacitor: Approx. 5 years
② Cooling fan: Approx. 5 years
③ Breakers, relays: Depends on how often they are used. It is recommended that they be replaced
approximately every 5 years.
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Maintenance and Inspection
10.1 Cleaning of Fan Guard and Cooling Fan
10.1
Cleaning of Fan Guard and Cooling Fan
The fan guard prevents large foreign objects from entering the welding
power source.
The air suction power into the welding power source, however, gets
weakened as the welding power source operates and the fan guard and
the cooling fan get contaminated. As a result of this, the temperature in
the welding power source may increase and the component life may be
shortened.
It is recommended to clean the fan guard and the cooling fan once every
two months periodically in order to maximize the product life.
The fan guard and the cooling fan installed in the rear face of the welding
power source as illustrated in fig. 10.1 “Cleaning of Fan Guard and
Cooling Fan” . Clean the fan guard and the cooling fan by following
procedures below.
1. Remove the Screw1.
2. Loosen the screw 2, and remove the fan guard and the cooling fan.
3. Clean the fan guard and the cooling fan.
When cleaning the cooling fan, wipe off any dust with a dry cloth.
Do not blow dry compressed air on the cooling fan.
4. Tighten the screw 2 to set the fan guard and the cooling fan in place.
5. Tighten the screw 1 to mount the fan guard and the cooling fan to the
welding power source rear side.
Fig. 10-1: Cleaning of Fan Guard and Cooling Fan
Re
Sc
F
Sc
rew
G
an
ua
Me
1
w
re
tal
e
ste
l
C
li
oo
ng
Fa
C
ar
ov
er
n
rd
2
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Maintenance and Inspection
10.2 Replace Fuse
10.2
Replace Fuse
When the following phenomenon occurs, check the fuse. When the
new fuse has blown out again even after replacing, please contact
your YASKAWA representative.
Table 10-3: Fuse
Item
Fuse 10A blown.
Fault
• Although the start signal is ON or the wire inching signal is ON,Motor does
not operate.
• Cooling fan does not rotate.
Fuse 1A blown.
• Although power switch is ON,the Digital Meter does not display.
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Maintenance and Inspection
10.2 Replace Fuse
Fig. 10-2: Fuse
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Maintenance and Inspection
10.2 Replace Fuse
DO NOT OPERATE
UNDER LOAD
DO NOT OPERATE
UNDER LOAD
10.3 X 38
32A 600VAC
10.3 X 38
32A 600VAC
t en d
Fuse Holder
t en d
Fig. 10-3: Fuse holder
Open
Fuse 1A
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Failure Analyses
11.1 Confirming Setting conditions
11 Failure Analyses
Confirm that the junctions between the metal receptacle and the cable,
and the connectors on the printed boards are connected securely. If the
equipment does not function properly even after the corrective action,
contact your YASKAWA representative to investigate the cause and to
repair as soon as possible.
1. Before maintenance, inspection, or wiring, be sure to turn OFF the
switch in the primary side switch gear. Failure to observe this warning
may result in electric shock or injury.
2. To connect a nylon connector, insert the connector after matching the
connector number and confirm that it is locked. Do not apply excessive
force to the printed board when inserting the connector.
Never change the positions of the internal wiring or modify the
connections. Failure to observe this caution may result in device
problems.
11.1
Confirming Setting conditions
If any fault occurs, check the following items.
Table 11-1: Check Items
Item
Contents
Welding type
Check if the welding type suitable for material and the wire diameter or shielding gas has
been selected.
Parameter
Check that changing of parameters does not lead to the error in welding operation. After
recording the changed parameters, return the data to the initial values and check how welding
is performed.
Welding Voltage
Setting Method
Auto adjustment
/ Individual
Check if "Auto adjustment / Individual" selection of the welding power source is the same as
that on the robot side. When "Auto adjustment" is selected, the LED indicator "Auto Adj."
lights. If the setting is different from that on the robot side, incorrect welding voltage value is
displayed on the panel. Furthermore, if the welding power source condition files of the robot
are not correctly set, the robot command values are not correctly displayed on the welding
power source panel.
Motor
selection
Confirm the set value of C parameter C09 to check if the motor is correctly selected. (0: Print
servo 1: Servo torch, 2: 4-roller servo (YWE-WFR42DX2, YWE-WF-X40TELC, YWE-WF340MELC, YWE-WF-340TELC), 8: EAGLX torch, 9: EAGL7 torch, 10: EAGL)
If the motor is not correctly selected, the wire is not fed as instructed by the command value
and welding performance becomes unsatisfactory. If the correct EAGL motor is not selected,
the motor's rotation will be reversed and make welding impossible.
Voltage
detection wire
If the voltage detection wire is disconnected, the 7-segment LED indicator for welding voltage
 on the welding power source panel displays approx. 0 V. Then the error ERR702 "Voltage
detection wire error" is displayed on the 7-segment LED indicators. Check if the voltage
detection wire is correctly connected.
P Parameters
cannot be
changed.
P parameters can be changed only in the robot control unit side.
User files cannot
be selected.
The user file can be changed only in the robot control unit side.
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Failure Analyses
11.1 Confirming Setting conditions
Table 11-1: Check Items
Item
Contents
Record of
conditions
After selecting the welding type or changing the parameter, save conditions before turning
OFF the welding power source power supply. Before recording conditions, be sure not to
select other welding type while the user file is being adjusted because the changed data on P
parameters are deleted.
Wire feeder
cable
When the wire feeder cable is damaged, or the cable is not connected properly, the wire
feeding speed may become excessively fast. In addition, the 7-segment LED indicator for
wire feeding speed ③ displays 0 and the error Err501 "Improper feeding amount" is issued.
Check the condition of the wire feeder cable.
Shielding gas
Check if the shielding gas suitable for the welding type is selected. For pulse welding, the
argon ratio must exceed 80% to execute one pulse per drop. If short-circuit occurs
excessively during pulse welding, check the argon ratio.
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Failure Analyses
11.2 Cause and Remedy of Welding Section Failure
11.2
Cause and Remedy of Welding Section Failure
Table 11-2: Failure Analyses for Welding Section
Fault
Cause
Remedy
Blowholes and
pits occur.
Excessive oil, rust, or paint adheres
to the base metal.
Carefully remove the adherent substances to clean the
base metal.
Oil adheres to the welding wire. Or
rust occurs.
Carefully store and handle the welding wire. Remove the
oil or rust from the feeding roller or conduit.
Sufficient shielding gas does not
flow.
Check for gas leakage. Also check that the gas regulator
has been correctly adjusted and the gas cylinder is not
empty.
Gas shielding in the welding section
does not properly work due to wind,
etc.
When the wind blows hard, stop the operation or use a
screen, etc. to help block the wind.
Spatters adhere to the nozzle and
the gas does not flow out smoothly.
Often remove the spatters from the nozzle and apply
spatter preventive agent to the interior of the nozzle.
The quality of the shielding gas is
poor.
Replace the shielding gas with one of better quality.
The nozzle is too far from the arc
point.
Keep the proper length of the wire stickout (10 mm to 15
mm) to perform welding. Increase the gas flow amount.
Arc is unstable. Power supply voltage excessively
fluctuates.
Use a different power supply from that of other machines
that cause power supply voltage fluctuation. Or increase
the power supply transformer capacity.
Chip hole diameter becomes larger
and worn.
Replace the chip. (Use a genuine chip.)
Welding wire is not fed smoothly.
Remove the dust or iron powder choking up the feeding
roller section or conduit.
Check that the conduit is not excessively bent and that
the liner, contact tip, and feeding roller match the wire
diameter.
Voltage between phases of the 3Use a different power supply from that of other machines
phase power supply is not balanced. that cause the imbalance. Or increase the power supply
transformer capacity.
Excessive
spatters
The welding conditions are not
correct.
Use the test arc to increase or decrease the settings of
the welding current value and voltage value.
Unstable arc tends to occur when
thin-plate or small-current welding is
performed only with carbon dioxide
gas.
Use gas mixed with carbon dioxide gas and argon gas to
improve the arc behavior.
The connecting section is loose.
Check each terminal connection and the connections with
the base metal. Securely re-tighten if necessary.
Voltage drop is excessive with the
extension cable.
Shorten the extension cable’s length.
Use a thicker cable. Use the extension cable without
bending it.
The polarities of the secondary
terminal are inverted.
Correct the connection of + and -.
Jig current conduction is poor.
Correct the contact between the jig and the base metal.
The welding conditions are not
correct.
Increase or decrease the settings of the welding voltage
and current values to adjust the welding conditions.
Welding wire is not suitable for the
shielding gas.
Check if a welding wire suitable for the welding type is
used.
The status of the base metal is poor. Check the groove forms or dirt of the base metal.
Replace them with one of higher accuracy.
The welding section is distorted.
Check each terminal connection and the connections with
base metal. Polish the contacting face and tighten them
securely.
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Failure Analyses
11.2 Cause and Remedy of Welding Section Failure
Table 11-2: Failure Analyses for Welding Section
Fault
Cause
Remedy
Bead form is
bad and the
appearance is
poor.
Manipulation of electrode is not
correct.
Change the welding torch angle a little. Employ the
forward welding method and practice so that welding
torch can constantly aim at a target. Or change the
welding speed.
The shielding gas has a problem.
Since the gas flow amount is not sufficient, let the gas
flow 10 to 25 litters per minute, and mix argon gas if
necessary. Or use a gas of better quality.
The welding conditions are not
correct.
Increase or decrease the settings of the welding voltage
or current value a little.
Welding current conduction is not
perfect.
Check the connections and the current conduction
contacting section of the base metal to confirm the
current conduction.
The connection cable is too thin.
Replace the cables at the 3-phase input side and base
metal side with those of sufficient thickness.
The welding conditions are not
correct.
Check that the welding voltage set value is not too small
or that the wire feeding speed set value is not too large.
Arc-start is
poor.
The status of the base metal is poor. Check that dirt or insulating material does not adhere to
the base metal or slugs do not remain on it.
The welding torch operations are not The wire stickout of the welding wire is too long. Shorten
correct.
it a little. Change the welding torch angle. Or slow down
the welding speed.
The power cable is wired with the
cable being winded.
Burnback
occurs.
(The welding
wire sticks to
the end of the
contact tip.)
Wire the power cable as straight as possible.
The welding torch operations are not The wire stickout of the welding wire is too short. Extend
correct.
it a little. Change the welding torch angle.
The welding conditions are not
correct.
Check that the welding voltage set value is not too large
or that the wire feeding set value is not too small.
Contact tips are defective.
Check that the contact tip hole is worn and its inner
diameter has become too big. Also check for defect on
the tip inner side.
Welding current conduction is not
perfect.
Check the connections and the current conduction
contacting section of the base metal to confirm the
current conduction.
The welding wire almost buckles.
Pull the welding wire from the inside of the conduit and
pass the welding wire again through the conduit.
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Failure Analyses
11.3 Cause and Remedy of Failure at Electrical Circuit Section
11.3
Cause and Remedy of Failure at Electrical Circuit Section
Table 11-3: Fault Analyses for Electrical Circuit Section
No.
Failure
Cause
Remedy
1
No image is displayed in the operation
panel even if the power supply switch
is turned ON.
Fuse (1A) blown
Investigate the cause and
replace the fuse.
Input voltage is wrong
Check the Input voltage
The cooling fan
does not rotate
even if the
power supply
switch is turned
ON.
Defect in the cooling fan, control
circuit or SW power +24 V supply
Check and replace the
cooling fan and the printed
board Pr(MB)-031 and
Pr(MD)-31.
Fuse (10 A) on the Pr(MD)-31
board blown
Investigate the cause and
replace the fuse.
Input voltage is wrong
Check the Input voltage
Fuse (1A) blown
Investigate the cause and
replace the fuse.
The start signal is not sent to the
welding power source.
• In the case of digital
communication
Check the communication
setting in the welding power
source side and in the robot
control unit side.
Check to confirm that the
communication cable is
securely connected.
2
Power lamp lights
Power lamp
does not light
3
The welding power source does not
start although the start signal is turned
ON..
4
Although the
start signal is
ON, only the
motor does not
operate.
Voltage is applied to Motor failure
the motor terminals
(between #G and #H
of the connector
CON6)
The voltage is not
applied to the motor
terminals (between
#G and #H of the
connector CON6).
Replace the motor.
Disconnection of the wire feeder
cable, or improper contact of the
connector
Replace the device control
cable or check contacting
sections.
Fuse (10A) on the board Pr(MD)31 blown
Upon investigating the error
cause, replace the fuse (10A)
on the printed board Pr(MD)31.
Printed board Pr(MD)-31 failure
Check and replace the
printed board Pr(MD)-31.
5
Welding current Welding current
Commands sent from the robot
cannot be
command cannot be side is not normal.
changed.
changed from the
robot side.
• In the case of digital
communication
Check the communication
setting in the welding power
source side and in the robot
control unit side.
Check to confirm that the
communication cable is
securely connected.
6
Welding voltage Welding voltage
The analog command sent from
command cannot be the robot side is not normal.
cannot be
changed from the
changed.
robot side.
• In the case of digital
communication
Check the communication
setting in the welding power
source side and in the robot
control unit side.
Check to confirm that the
communication cable is
securely connected.
7
Error indication on the digital meter
See chapter 18.
See chapter 18 “List of Errors” .
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Failure Analyses
11.3 Cause and Remedy of Failure at Electrical Circuit Section
Table 11-3: Fault Analyses for Electrical Circuit Section
No.
Failure
8
The power supply switch is tripped and Damage to the input diode
the power is not turned ON.
Damage to the main circuit
transistor (IGBT)
Contact your YASKAWA
representative.
9
Shielding gas cannot be adjusted or
stopped.
Investigate the gas system.
10
The starting point detection cannot be
detected.
Cause
Failure of the gas solenoid valve
Remedy
Fuse (10 A) on the board Pr(MD)- Upon investigating the error
31 blown
cause, replace the fuse (10
A) on the printed board
Pr(MD)-31.
Failure of the printed board
Pr(MD)-31
Check or replace the printed
board Pr(MD)-31.
The starting point detection
command is not sent to the
welding power source or the
power supply for starting point I/F
is not supplied to the welding
power source.
Check the connection signal
cable.
The starting point detection signal
is not sent from the welding
power source.
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Robot Interface Signals
12.1 Specifications of Robot Digital Interface Signals
12 Robot Interface Signals
12.1
Specifications of Robot Digital Interface Signals
Communication with the robot control unit is made through an Ethernet
cable. Connect the Ethernet connector to connector CON8.
Item
Content
Communication cable
Ethernet cable (Category 5 or above, with shield)
Direct connection: Cross cable
Hub connection: A straight cable is used between the LAN port of the
controller and the hub, and a cross cable is used between the hub
and the welding power supply.
Communication speed
100 Mbaud
Connector
RJ45/IP67
12.2
Description and Function of Signal Output
Terminals for Monitor
The following shows the correspondence between the signals and the
cable numbers of the connection terminal block.
TM1
① ② ③ ④ ⑤ ⑥ ⑦ ⑧
A
V
"R" indicates the robot side while "W" indicates the welding power
source side.
No.
Signal Description
Function
Direction
1
Ammeter terminal*1
Outputs 600 A/ 60 mV.
WR
Voltmeter terminal*1
Directly outputs the output
voltage.
WR
5
―
―
―
6
―
7
―
―
―
8
―
2
3
4
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Robot Interface Signals
12.3 Meaning and Function of Signal for Starting Point Detecting Function
(Optional board Pr (OP2) -001)
*1
The external meters connected to the terminals are analog meters of ammeter (600 A/ 60 mV) and voltmeter (75
V).
CAUTION
•
12.3
The output voltage (600 A/60 mV) of the ammeter terminal is
different from the 350A power supply
Meaning and Function of Signal for Starting Point
Detecting Function
(Optional board Pr (OP2) -001)
Read this section only when the starting point detection function is used.
The following table shows the cable number of connection terminal block
and corresponding signals.
It tells in WELDCOM function for the search command.
No. Connection
Terminal Block
Cable No.
Signal Meaning Function
Direction
*1
Signal Form
1
520
Power supply
for starting point
detection I/F
Power supply for starting point
detecting instruction and sending /
receiving of the starting point
detection signal
RW
+24V10%,
current capacity of
30mA or more
2
521
Starting point
detection signal
The signal is output when the output
"+" (torch side) of welding power
source drops to approx. 0V while the
starting point detecting instruction is
ON.
WR
Transistor output
(ON when 0V),
sink current of
50mA or less
3
522
Common
Power cable on 0V side of the power
supply for starting point detection I/F.
RW
4
523
*1
"R" indicates the robot side while "W" indicates the welding power source side.
CAUTION
•
The starting point detection function is an optional function. The
optional board Pr(OP2)-001 is included when the starting point
detection function is ordered, that is, not included in standard
package.
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L1
L2
L3
PE
(8AWG)
2P Connector
(33051)
2P Connector
(30305)
FG
CORE x 3
FAN SP
AC FAN 2
FAN SP
AC FAN 1
C
3P
NFB
1
CR-1
8
30305
(306)
(8AWG)
(8AWG)
305
304
30305
(305)
(8AWG)
306
531
256
531
2571
5311
257
531
2581
5311
258
Pr (CR) - 031_6N0
200V-Conne ctor
F2
0.01uF/250Vac
33051(305)
33051(306)
Pr(VR)GF002-1
F1
302
301
(8AWG)
FG
303
(8AWG)
AC 480V
CN2
1
1
1
CN4
CN5
6
1
CN6
Pr(PT)-GF007
CN3
6
6
D RU
+15F
G ND
CN1
305A
0V
307A
HI
LO
FAN
CON1
6P
0V
240V
240V
306B
0V
200V
5A
230V
4A
22V
CON3
4P
0.23A
19V
25V
Pr(RF)-31
RF2-2,3
Pr(RF)-31
RF2-1
TR1
CON2
6P
1
D RV
7
6
256
257
258
531
1
1
3
2
1
2
1
4
+
TR1
200V
311 (6AWG)
MB30
MB5
5
IF31
PS29
1
MB1
5
1
MCR
AC /L
AC/N
PW_2
CN1
1
CN1
5 1
Pr(MD) - 31
MD6
1
1
1
AC /L
MB4
6
2
4
1
CN1
5
TB1
CN2
6
PW_2
Pr(FE)-GF008
Pr(GD)GF002C
IF32 5
FG
FG3
1
Pr(GD)GF002A
G3
Pr(GD)GF002D
Pr(GD)GF002B
S2
1
Pr (MB) - 31
POWER2
1
4
- TB2
+
Pr(MB) -31
MB5+MCR
309
(6AWG)
AC/N
DCL1
PW_1
CN2
G3
G ND
+15VD
+5V
Pr(DL)-GF008
TB4
POWER1
8
TB1
5
- TB2
+ TB3
Pr(SSR)-
- GF001
R2
MB42
1
Pr(MD) - 31
MD5
AC19V/4A
G ND
G ND
25V/0.23A
D RV
D RU
+15F
G ND
+15E
SCK
+5V
G ND
+15VD
3P Connector
1P Connector
-
SA1
BK911KD20
+
1
SCR1
G2
Pr(SCR)-GF001
+ (K)
G4
G
S1
G
S4
755
754
G ND
757
756
R2
G1
1
S1
G1
S5
G5
-12V
G2
G2
+12V
G1
5V
+12V
-12V
5V
G ND
S3
4
KCF-100-B
(2T)
9
PS33
MB50
1
G11
E11
G12
E12
754
756
1
1
EXIF
CN4
8
1
RC5
6
MB14
EC2
1
MB13
7
EC1
1
4
1
2
1
1
4
2
CT2
CT1
PS35
8
TX+
TXRX+
4
5
RX7
8
755
IGBT
} SH2
EAGL MOTOR
5
- 5 VA
GNDA
MIFB
+5VA
1
1
4
+15V 3
S 1U
S1V
1
2
MD4
MD2
RF3
EL135 x4
8
6
5
8
6
+12VZ
181
T2
T1
1
A
V
+- +-
}
}
OPTION
OP1
(AMS3102A 20-29S)
4
1
4
K5B RC 26x30x13-MG
(2T)
207B
202B
206
202
211
209
-5V
G ND
MIFB
+5V
1
SH3
KCF-100-B
(2T)
(3T)
KCF-100-B
+15VD
S 1U
S1V
12VD
MV
FAN
G ND
WI-FI
6
EL135
1
K5B RC 25x12x15-M
G ND
E1B
E1A
+5VA
313
314
757
CN1
2
CN2 1
S3
G3
S7
G7
RF4
MD3
2
2
1
RF2
MD5
TR1
22V/5A
3
TM1
3
1
PW_1
CN2
2
MD6
MD1
FAN SP
TR1
230V
Pr (MD) - 31
1
1
RF1
(5T)
{
EL119A
Pr (RF) - 31
R
4.7K,1/4W
1nF/3kV
317
(14SQ)
TB3
1
2
1
3
16
10
113
108
100
211
209
Pr(DI)-GF010
SH2
TB2
TB1
FG
207
202B
16
10
108
100
+5VA
FG1
E1A
G ND
E1B
S2
S1
T21
T22
C2
C1
R2
E
R1
E
319
(2061)
202
202B
202B
FG
SH3
}
FG4
E12
G12
E11
G11
237
R35
Interface For Robot
(Digital)
CO N8
238
(2061)
DCL3
Pr(CSC)-GF002
SW1
3 Output Terminal
2
1 Base Metal
CO N6
(AMS3102A 20-27)
For Push Motor
Pr(SN)-GF004
D2
D1
C
C
R36
CLR
320
(12AWG)
318
(206)
G1
314
5
-12V
+5V
G ND
S W4
S W3
S W2
S W1
TXD1
RXD1
S2
G2
S6
G6
S4
G4
S8
G8
{
{
{
{
+5VD
G ND
S W4
S W3
S W2
S W1
TXD1
RXD1
+12V
-12V
5V
G ND
G2
+12V
G1
5V
13-1
24V
G ND
THS3(DCL2)
0_CLAMP
THS2-1(IGBT) THS2-2(Rect)
{
{
{
{
ALM
ALMRST
S_ON
D A1
D A2
G ND
THS1-1(INV) THS1-2(R)
MTRQ
MCOM
531
529
202B
207B
209
211
G8
24V
G ND
0-CLAMP
ALM
ALMRST
S_ON
D A1
D A2
S8
+24V
G ND
G6
+24V
G ND
G7
18
S7
17
G5
209
211
207B
202B
529
531
M_TRQ
M_COM
S6
G
S5
G
}
TX+
TXRX+
4
5
RX7
8
FAN
HI
LO
FG
FG2
1
2
CN2
CN1
Pr(VR)-GF001-1
DCL2
1
3
202
PN
207
N
P

+12V
GNDA
13
202
313
CN1
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Connection System Diagram
13 Connection System Diagram
General view of connection system diagram
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206
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13
Enlarged view of connection system diagram (left part)
(8AWG)
302
305
(8AWG)
(8AWG)
301
304
(8AWG)
R2
+
SA1
BK911KD20
3P
+
Pr(FE)-GF008
TB1
Pr(SSR)-
1
- GF001
30305
(306)
Pr(GD)GF002A
TB4
Pr(GD)GF002D
Pr(GD)GF002C
Pr(DL)-GF008
- TB2
+ TB3
T
4
CT1
756
30305
(305)
FG
Pr(GD)GF002B
G7
311 (6AWG)
G8
TB1
CORE x 3
EL135
757
(8AWG)
754
306
G3
303
S3
NFB
(8AWG)
755
309
(6AWG)
+
G1
AC 480V
1
S5
G5
S7
S6
G6
S8
4
CT2
DCL1
- TB2
PW_2
5
AC/N
CN1
AC /L
1
1
CN2
6
1
8
CR-1
1
8
MB30
K5B RC 25x12x15-M
KCF-100-B
(2T)
1
2
MB4
1
1
IF32 5
(3T)
TX+
TXRX+
4
5
RX7
8
1
4
POWER2
G11
E11
G12
E12
755
754
G ND
757
756
+12V
-12V
5V
G ND
+5VD
G ND
S W4
S W3
S W2
S W1
TXD1
RXD1
+5V
G ND
S W4
S W3
S W2
S W1
TXD1
RXD1
-12V
G2
G2
+12V
G1
5V
TR1
200V
4
PS33
1
CN4
8
2
PS35
Pr (CR) - 031_6N0
313
314
1
4
531
THS1-1(INV) THS1-2(R)
THS2-1(IGBT) THS2-2(Rect)
THS3(DCL2)
256
257
2571
5311
531
256
257
258
531
258
G ND
+15VD
MB13
1
2
EC2
FG
1
5
CN3
1
CN4
7
CN1
CN5
6
1
Pr (MB) - 31
1
6
WI-FI
D RV
D RU
+15F
G ND
1
D RV
D RU
+15F
G ND
+15E
5
MB1
1
4
S8
G8
CN6
1
S6
G6
S5
G5
6
MCR
S4
G4
6
Pr(PT)-GF007
1
MB14
0.23A
19V
240V
G ND
IF31
AC19V/4A
0V
240V
5A
230V
200V-Conne ctor
0V
CON1
6P
CON3
4P
0.01uF/250Vac
5 1
AC/N
CN1
1
AC /L
C
MB50
1
9
1
EXIF
8
4
207B
202B
206
202
211
209
IGBT
} SH2
K5B RC 26x30x13-MG
(2T)
Pr(MD) - 31
MD6
-12V
0V
POWER1
1
Pr(MD) - 31
MD5
200V
305A
1
1
4A
22V
307A
6
RC5
MTRQ
MCOM
531
529
202B
207B
209
211
306B
PS29
1
3
ALM
ALMRST
S_ON
D A1
D A2
G ND
25V
F2
2
0_CLAMP
33051(305)
G
1
G ND
25V/0.23A
+12V
-12V
5V
G ND
TR1
24V
G ND
CON2
6P
33051(306)
-5V
G ND
MIFB
+5V
G2
+12V
G1
5V
F1
6
S7
G7
2P Connector
(33051)
S2
G2
S1
G1
1
S3
G3
{
{
{
{
2P Connector
(30305)
+
2
MB5
1
SCK
+5V
KCF-100-B
+15VD
S 1U
S1V
12VD
MV
FAN
G ND
7
MB42
FG3
531
SH3
1
4
1
3P Connector
2581
5311
KCF-100-B
(2T)
G ND
E1B
E1A
+5VA
EC1
1P Connector
{
{
{
{
CN2
6
PW_1
PW_2
CN1
FG
AC FAN 1
FAN
FAN SP
HI
LO
Pr(RF)-31
RF2-1
24V
G ND
0-CLAMP
ALM
ALMRST
S_ON
D A1
D A2
L1
L2
L3
PE
+ (K)
CN2
Pr(MB) -31
MB5+MCR
G3
G ND
5
S1
R2
G4
CN1
2
CN2 1
+15VD
+5V
1
SCR1
Pr(SCR)-GF001
S2
1
G
G
S4
Pr(VR)GF002-1
5
G2

CN1
Connection System Diagram
Pr(RF)-31
RF2-2,3
AC FAN 2
OP1
(AMS3102A 20-29S)
FAN SP
EAGL MOTOR
OPTION
13-2
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Connection System Diagram
Enlarged view of connection system diagram (right part)

Pr(DI)-GF010
320
(12AWG)
755
G1
1
T1
5
Pr(CSC)-GF002
TB1
CLR
6
8
1
5
DCL3
SH3
TB2
314
757
EL135
319
(2061)
R36
}
318
(206)
6
4
313
4
CT1
8
DCL2
T2
CT2
207
T21
EL135 x4
E
E11
G11
R1
206
G
C
T22
C
E
G
TB3
317
(14SQ)
R2
}
Pr(VR)-GF001-1
2
E12
G12
FG2
C1
D1
1
S1
237
K5B RC 25x12x15-M
D2
(3T)
1
4
N
202
FG
(5T)
E1A
G ND
E1B
KCF-100-B
+15VD
S 1U
S1V
12VD
MV
FAN
G ND
1
FG
FG4
1
3
Pr(SN)-GF004
SH2
SH3
EL119A
7
3
238
(2061)
R
4.7K,1/4W
KCF-100-B
(2T)
G ND
E1B
E1A
+5VA
1
PN
TX+
TXRX+
4
5
RX7
8
5
313
314
C2
R35
1
CN1
S2
211
209
{
1nF/3kV
2
CN2
P
CO N8
For Push Motor
Interface For Robot
(Digital)
FG1
3
RF1
+12VZ
181
2
113
108
100
1
RF3
Pr (RF) - 31
1
16
10
108
100
+5VA
207
202B
CO N6
(AMS3102A 20-27)
2
RF4
2
RF2
2
+24V
G ND
6
- 5 VA
GNDA
MIFB
+5VA
1
207B
202B
206
202
211
209
MD4
MD5
MD6
1
3
IGBT
TR1
22V/5A
} SH2
2
PW_1
CN2
SW1
3 Output Terminal
2
1 Base Metal
209
211
207B
202B
529
531
M_TRQ
M_COM
S_ON
D A1
D A2
EAGL MOTOR
+- +-
}
}
OPTION
1
202
202B
202B
K5B RC 26x30x13-MG
(2T)
20-29S)
16
10
Pr (MD) - 31
18
6
5
2
MD1
1
1
4
1
1
2
MD3
202
4
-5V
G ND
MIFB
+5V
1
MD2
+12V
GNDA
4
+15V 3
S 1U
S1V
17
1
FG
3
FAN SP
TR1
230V
+24V
G ND
WI-FI
1
FAN
HI
LO
1
1
A
TM1
V
13-3
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14
Welding power source Condition File of the Robot Controller
14 Welding power source Condition File of the Robot Controller
Welding condition files for the MOTOWELD-X500 are as follows.
Common for All Welding Types: "Synergic (automatic adjustment)" (A/%)
Wire-stick prevention processing time: 0.1 seconds
Arc failure confirming time: 0.6 seconds
Command Voltage (V)
Welding Current (A)
Command Voltage (V)
Welding Voltage (%)
0.00
30
0.00
50
1.35
77
7.20
99
2.70
124
7.50
100
10.80
406
7.80
101
12.15
453
14.00
150
13.50
500
0.00
0
0.00
0
0.00
0
0.00
0
0.00
0
Common for All Welding Type: "Independent (individual)" (A/
V)
Wire-stick prevention processing time: 0.1 seconds*1
Arc failure confirming time: 0.6 seconds
Command Voltage (V)
Welding Current (A)
Command Voltage (V)
Welding Voltage (V)
0.00
30
0.00
12.0
1.35
77
2.25
17.5
2.70
124
4.50
23.0
10.80
406
6.75
28.5
12.15
453
9.00
34.0
13.50
500
11.25
39.5
0.00
0
13.50
45.0
0.00
0
0.00
0.0
SUPPLE
-MENT
Since the MOTOWELD-X500 uses a mechanical servomotor for its standard model, the motor stops within 0.1 seconds. To reduce the manipulator’s cycle time, YASKAWA
recommends that the wire-stick monitoring time on the robot
side be set short.
14-1
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15
List of Service Parts
15 List of Service Parts
Table 15-1: List of YWE-X500-6N0 Service Parts (Front Face)
Item No. Parts Code No. Parts Name
Q’ty per
Code
Text
101
X5C101
Front panel unit
1
100-243-737
X5C101 MW-PARTS
FRONT-PANEL-UNIT
102
X5C102
Panel-mold-Pr(CR)-031X500 unit (*1)
1
100-243-738
X5C102 MW-PARTS
PR(CR)-031-X500:P-MOLD
105
X3C105
Terminal cover
1
100-212-396
X3C105 MW-PARTS
TERMINAL-COVER
301
X5C301
Side cover (right)
1
100-243-739
X5C301 MW-PARTS SIDECOVER(RIGHT)
401
X5C401
Side cover (left)
1
100-243-740
X5C401 MW-PARTS SIDECOVER(LEFT)
501
X5C501
Cover (top)
1
100-243-741
X5C501 MW-PARTS
COVER(TOP)
502
X5C502
Eye bolt M10
2
100-243-742
X5C502 MW-PARTS IRONF29C: EYEBOLT-M10
606
XAC606
PP wheel
4
100-212-465
XAC606 MW-PARTS PPWHEEL
(*1) Item No.102 is set parts.
Set parts: panel , board[Pr(CR)-031-X500]
15-1
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List of Service Parts
Table 15-2: List of YWE-X500-6N0 Service Parts (Base Section)
Item No. Parts Code No. Parts Name
Q’ty per
Code
Text
601
X5C601
Base unit
1
100-243-743
X5C601 MW-PARTS BASEUNIT
602
X5C602
Terminal seat (lower)
1
100-243-744
X5C602 MW-PARTS
TERMINAL-SEAT(LOWER)
603
X5C603
Terminal seat (upper)
1
100-243-745
X5C603 MW-PARTS
TERMINAL-SEAT(UPPER)
605
X5C605
Terminal seat(+)(-)
2
100-243-746
X5C605 MW-PARTS
TERMINAL-SEAT(PLUS)
609A
X5C609A
Control transformer (TR1)
1
100-253-223
X5C609A MW-PARTS
CONTROLTRANSFORMER(TR1)
15-2
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List of Service Parts
307
13
304
8
E11
9 10
CN1
Pr(SN)-GF004
R1
11
G11
C1
D1
S1
R2
D2
C2
C3
E12
7 8
C2
9 10
G12
S2
RoHS
512
309
C1
C4
C5
C6
C7
C8
Pr(DI)-GF010
Rev.A
FRED Snubber unit
C13
TB1
C14
C15
C16
C33
C12
C11
C34
R1
R2
C10
C9
C38
TB3
C42
R4
C41
R3
C40
C39
C23
C24
C37
C43
R5
C44
R7
R6
C17
C45
C36
C18
C46
R8
C19
C20
TB2
C35
C25
C26
C27
C28
310
C29
C30
C31
C21
C22
C32
308
Right Face
Table 15-3: List of YWE-X500-6N0 Service Parts (Right Face)
Item No. Parts Code No. Parts Name
Q’ty per
Code
Text
304
X5C304
Dust partition (right side)
1
100-243-749
X5C304 MW-PARTS
DUSTPARTITION-RIGHTSIDE
307
X5C307
Printed board set Pr(SN)GF004
1
100-243-750
X5C307 MW-PARTS PBOARD-SETPR(SN)GF004
308
X5C308
Printed board set Pr(DI)GF010
1
100-243-751
X5C308 MW-PARTS PBOARD-SET-PR(DI)GF010
309
X5C309
Connect busbar
1
100-243-752
X5C309 MW-PARTS
CONNECT-BUSBAR
310
X3C310
Printed board set Pr(VR)GF001-1
1
100-212-408
X3C310 MW-PARTS PBOARDSETPR(VR)GF001-1
512
X5C512
Printed board set Pr(CSC)- 1
GF002
100-243-753
X5C512 MW-PARTS PBOARDSET-PR(CSC)GF002
15-3
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List of Service Parts
Table 15-4: List of YWE-X500-6N0 Service Parts (Rect Unit)
Item No. Parts Code No. Parts Name
Q’ty per
Code
302
X5C302
Sec. IGBT busbar(left
side)
1
100-243-754 X5C302 MW-PARTS
SEC.IGBTBUSBAR-LEFT-SIDE
303
X5C303
Sec. IGBT busbar(right 1
side)
100-243-755 X5C303 MW-PARTS
SEC.IGBTBUSBAR-RIGHTSIDE
305
X5C305
Heat sink (IGBT. unit)
1
100-243-756 X5C305 MW-PARTS HEATSINK(RECT.UNIT)
306
X3C306
IGBT Module
(GIS800IMG060)
2
100-212-415 X3C306 MW-PARTS
IGBT(GIS800IMG060)
311
X5C311
Reset-diode busbar
1
100-243-757 X5C311 MW-PARTS RESETDIODE-BUSBAR
312
X5C312
Reset-diode busbar
1
100-243-758 X5C312 MW-PARTS RESETDIODE-BUSBAR
313
X5C313
Reset-diode busbar
4
100-243-759 X5C313 MW-PARTS RESETDIODE-BUSBAR
314
X5C314
Reset-diode busbar
1
100-243-760 X5C314 MW-PARTS RESETDIODE-BUSBAR
315
X5C315
Diode busbar
2
100-243-761 X5C315 MW-PARTS DIODEBUSBAR
316
X5C316
Main-diode busbar
4
100-243-762 X5C316 MW-PARTS MAINDIODE-BUSBAR
317A
X5C317A
Diode Module
11
100-253-224 X5C317A MW-PARTS DIODEMODULE
318
X5C318
Heat sink (Rect. unit)
1
100-243-764 X5C318 MW-PARTS HEATSINK(RECT.UNIT)
319
X5C319
Thermal guard (85℃)
1
100-243-765 X5C319 MW-PARTS THERMALGUARD(85)UP72-LG
320
X5C320
Thermal guard (85℃)
1
100-243-766 X5C320 MW-PARTS THERMALGUARD(85)UP72
15-4
Text
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List of Service Parts
407
417
R2
S
+
T
-
416
R
+
G
-
C1
R2
402
BUS1
G2
G6
TB2
BUS3
BUS4
6
8D
S8 G8
51R
TP14
S2 G2
1
6
CN5
S7 G7
BUS8
BUS6 C10
1
C9
G1
G7
C8
S1
G3
S3 G3
6
BUS5
G4
G8
Q3
34C
Q9
Q6
Q8
CN1
1
PT4
C42
11D
608
TP1
PT2
6D
TP9
41R
41D
TP8
5D
TP7
3TP6
1R
CN3
BUS7
TB3
51D
4D
TP13
21D
TP12
3D
TP11
1
TB4
Q10
21R
11R
TP10
S5 G5
403
R2
C7
Q4
61D
TP16
7D
TP15
S4 G4
6
C4
Pr(DL)-GF008
Rev.A
Capacitor DC Link
C6
607
TP17
61R
7
1
C5
C3
R21
Pr(PT)-GF007 Rev.B
Pulse PT(PPT)&Driver
BUS2
C2
S6 G6
C1
R5
R1
G5
G1
TB1
CN4 CN6
R1
404
413
R2
31D
C1
91R 0 2 R
PT3
1U
C40
Q5
TP401D
1D
TP3
9D
604
1BC
2D
TP5
01R
9R
TP2
L2
14C
3R
Q7
2U
2R
2BC
1R
4R
PT1
414
405
Left Face
Table 15-5: List of YWE-X500-6N0 Service Parts (Left Face)
Item No. Parts Code No. Parts Name
Q’ty per
Code
Text
404A
X5C404A
NFB unit
1
100-253-225
X5C404A MW-PARTS NFB-UNIT
405
X3C405
Printed board set
Pr(PT)-GF007
1
100-212-426
X3C405 MW-PARTS P-BOARDSET-PR(PT)GF007
407
X5C407
Dust partition (left
side)
1
100-243-771
X5C407 MW-PARTS DUSTPARTITION-LEFT-SIDE
413
X5C413
Current detector
2
100-243-772
X5C413 MW-PARTS CURRENTDETECTOR
414
X5C414
Printed board set
Pr(DL)-GF008
1
100-243-773
X5C414 MW-PARTS P-BOARDSET-PR(DL)-GF008
416
X5C416
Printed board set
Pr(SCR)-GF001
1
100-243-774
X5C416 MW-PARTS PBOARDSET-PR(SCR)-GF001
417
X5C417
Printed board set
Pr(SSR)-GF001
1
100-243-775
X5C417 MW-PARTS PBOARDSET-PR(SSR)-GF001
604
X3C604
Terminal guard
1
100-212-409
X3C604 MW-PARTS TERMINALGUARD
607
X5C607
Shunt
1
100-243-776
X5C607 MW-PARTS SHUNT
608
X5C608
Extended busbar (N) 1
100-243-777
X5C608 MW-PARTS
EXTENDED-BUSBAR(N)
15-5
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List of Service Parts
T
-
15
+
409
G
R
R2
S
415
419A
419B
411
418
408
406
320
1
2
3
4
419D
5
7
6
419C
INV. Unit
Table 15-6: List of YWE-X500-6N0 Service Parts (Inverter unit)
Item No. Parts Code No. Parts Name
Q’ty per
Code
406
X5C406
Printed board set
Pr(FE)-GF008
1
100-243-778 X5C406 MW-PARTS P-BOARDSET-PR(FE)GF008
408
X3C408
IGBT(GIH150IMN060)
4
100-212-429 X3C408 MW-PARTS IGBT
(GIH150IMN060)
409
X5C409
Diode Bridge
1
100-243-779 X5C409 MW-PARTS
PGH200N16:DIODE
411
X5C411
Heat sink (INV. unit)
1
100-243-780 X5C411 MW-PARTS HEATSINK(INV.UNIT)
320
X5C320
Thermal guard (85℃)
1
100-243-766 X5C320 MW-PARTS THERMALGUARD(85)UP72
415
X5C415
Heat sink (BD. unit)
1
100-243-782 X5C415 MW-PARTS HEATSINK(BD.UNIT)
418
X5C418
Connect busbar
8
100-243-783 X5C418 MW-PARTS CONNECTBUSBAR
419A
X5C419A
Printed board set
Pr(GD)-GF002A
1
100-243-784 X5C419A MW-PARTS PBOARD-S-PR(GD)-GF002A
419B
X5C419B
Printed board set
Pr(GD)-GF002B
1
100-243-785 X5C419B MW-PARTS PBOARD-S-PR(GD)-GF002B
419C
X5C419C
Printed board set
Pr(GD)-GF002C
1
100-243-786 X5C419C MW-PARTS PBOARD-S-PR(GD)-GF002C
419D
X5C419D
Printed board set
Pr(GD)-GF002D
1
100-243-787 X5C419D MW-PARTS PBOARD-S-PR(GD)-GF002D
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List of Service Parts
Table 15-7: List of YWE-X500-6N0 Service Parts (Res. Unit)
Item No. Parts Code No. Parts Name
Q’ty per
Code
Text
511
X5C511
Metel steel (Res.)
1
100-243-788
X5C511 MW-PARTS
METEL-STEEL(RES.)
513
X5C513
Metel steel (PT/DCL2/
DCL1)
1
100-243-789
X5C513 MW-PARTS
METEL-STEEL/PT/DCL2/
DCL1
514
X5C514
DC reactor (DCL2)
1
100-243-790
X5C514 MW-PARTS DCREACTOR(DCL2)
515
X5C515
Resistor (500R/150W)
1
100-243-791
X5C515 MW-PARTS
RESISTOR(500R/150W)
516
X5C516
Resistor (2.5R/150W)
1
100-243-792
X5C516 MW-PARTS
RESISTOR(2.5R/150W)
610A
X5C610A
Transformer set
2
100-253-226
X5C610A MW-PARTS
TRANSFORMER-SET
611
X5C611
DC reactor (DCL1)
1
100-243-794
X5C611 MW-PARTS DCREACTOR(DCL1)
612
X5C612
Connect busbar (PT)
1
100-243-795
X5C612 MW-PARTS
CONNECT-BUSBAR(PT)
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List of Service Parts
Table 15-8: List of YWE-X500-6N0 Service Parts (Partition Board)
Item No. Parts Code No. Parts Name
Q’ty per
Code
204
X3C204
PE terminal
4
100-109-970 MT2U0F25001 MW-PARTS
504
X5C504
Printed board set
Pr(MB)-031-X500
1
100-243-796 X5C504 MW-PARTS PR(MB)031-X500:P-BOARD
505A
X3C505A
Printed board set
Pr(VR)-GF002-1
1
100-219-955 X3C505A MW-PARTS PBOARD-S-PR(VR)GF002-1
506
X3C506
AC/DC power
supply(LDC30F-1)
2
100-212-441 X3C506 MW-PARTS AC/DC-PSUPPLY(LDC30F-1)
507
X3C507
Printed board set
Pr(MD)-31
1
100-212-442 X3C507 MW-PARTS P-BOARDSET-PR(MD)31
508A
X3C508A
Fuse 1.0A/500V
2
100-217-317 X3C508A MW-PARTS FUSE1.0A(500V)
509
X3C509
Fuse holder (2P)
1
100-174-170 EF431 FUSE
PARTS:HOIDER(2P):FUKUMINE
510
X3C510
Printed board set
Pr(RF)-31
1
100-212-443 X3C510 MW-PARTS P-BOARDSET-PR(RF)31
517
X3C517
Fuse 10A/250V-ADA
2
100-296-057 X3C517 ARC-PARTS FUSE10A250V-ADA
518
X3C518
Rubber bush (GF-049)
( 32)
3
100-309-486 X3C518 MW-PARTS RUBBERBUSH:32
519
X3C519
Rubber bush (GF-124)
( 26)
1
100-309-487 X3C519 MW-PARTS RUBBERBUSH:26
520
X3C520
Rubber bush (GF-310)
( 42)
1
100-309-488 X3C520 MW-PARTS RUBBERBUSH:42
15-8
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List of Service Parts
Table 15-9: List of YWE-X500-6N0 Service Parts (Rear Face)
Item No. Parts Code No. Parts Name
Q’ty per
Code
201
X5C201
Rear cover plate
1
100-243-797 X5C201 MW-PARTS REARCOVER-PLATE
202
X5C202
Push Motor
connect(CON6)
1
100-243-798 X5C202 MW-PARTS PUSHMOTOR-CONNECT(CON6)
203
X3C203
Terminal(TM1)
1
100-212-446 X3C203 MW-PARTS
TERMINAL(TM1)
205
X5C205
LAN connect(CON8)
1
100-243-799 X5C205 MW-PARTS LANCONNECT
207
X3C207
OP cover
2
100-302-710 X3C207 MW-PARTS OP-COVER
208
X3C208
Input terminal
1
100-212-448 X3C208 MW-PARTS INPUTTERMINAL
209
X3C209
Cover
1
100-212-449 X3C209 MW-PARTS COVER
210
X5C210
Cable clamp
1
100-243-800 X5C210 MW-PARTS CABLECLAMP
211A
X5C211A
Switch cover
1
100-253-227 X5C211A MW-PARTS SWITCHCOVER
15-9
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List of Service Parts
R
l
ta
ee
l st
Me
Sc
rew
Co
n
oli
gF
r
ea
Co
ve
r
an
1
rd
ua
G
an
F
Sc
rew
2
216
215
Cooling Fan
214
Table 15-10: List of YWE-X500-6N0 Service Parts (Cooling Fan)
Item No. Parts Code No. Parts Name
Q’ty per
Code
Text
214
X5C214
Fan Guard
2
100-243-802
X5C214 MW-PARTS FANGUARD
215
X5C215
Metal steel
1
100-243-803
X5C215 MW-PARTS
METEL-STEEL
216
X5C216
Cooling Fan
2
100-243-804
X5C216 MW-PARTS
COOLING-FAN
15-10
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16
List of Parameters
16.1 List of Process Parameters
16 List of Parameters
16.1
List of Process Parameters
Parameters P are set in the robot control unit side.
By changing the set values of Parameter P, the welding characteristics
determined by the database in the welding power source can be adjusted
according to your environment and preferences. All the factory setting are
100 (%) (The operations follow the database characteristics). When an
adjustment for the welding characteristics is required, refer to chapter 6.3
“Customize Screen”
Display No.
Item
Display No.
Item
P00
C
Wire slow down speed
P31
P
MAG/MIG pulse current increasing speed
P01
C
Wire speed at start
P32
-
System reservation
(Do not change this item)
P02
C
Start pulse peak current
P33
S
P
Welding current decreasing speed
MAG/MIG pulse current decreasing speed
P03
-
System reservation
(Do not change this item)
P34
-
System reservation
(Do not change this item)
P04
C
Start pulse peak time
P35
A
Increasing rate of aluminum MIG pulse
current
P05
C
Hot average current value
P36
A
Decreasing rate of aluminum MIG pulse
current
P06
C
Hot average voltage value
P37
S
Short current increase speed 1
P07
-
System reservation
(Do not change this item)
P38
S
Short current increase speed 2
P08
P
Pulse current
P39
-
System reservation
(Do not change this item)
P09
P
Base current
P40
-
System reservation
(Do not change this item)
P10
P
Pulse time
P41
-
System reservation
(Do not change this item)
P11
C
End average current
P42
-
System reservation
(Do not change this item)
P12
C
End average voltage
P43
C
Hot slope time
P13
C
End time
P44
C
End slope time
P14
C
Flaming average current value
P45
-
System reservation
(Do not change this item)
P15
C
Flaming average voltage value
P46
-
System reservation
(Do not change this item)
P16
C
Flaming time
P47
S
Short current target value 1
P17
C
Drop pulse peak current
P48
-
System reservation
(Do not change this item)
P18
C
Drop pulse peak time
P49
S
Arc control 1
P19
-
System reservation
(Do not change this item)
P50
S
System reservation
(Do not change this item)
P20
C
Adhesion prevention time
P51
S
System reservation
(Do not change this item)
P21
P30
-
System reservation
(Do not change this item)
P52
P54
S
System reservation
(Do not change this item)
16-1
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16
List of Parameters
16.2 List of Common Parameters
Display No.
Display
Item
Display No.
Item
P55
A
Low pulse frequency ratio
(welding type 91 for aluminum)
Changes the frequency on the basis of the
parameter C-C03.
Example: If C03=100 and P55=50%, the
frequency is 5.0 Hz.
P56
A
Low pulse wire feed speed ratio
(welding type 91 for aluminum)
Changes the amplitude on the basis of the
parameter C-C04.
Example: If C04=10 and P55=200%, C04 x
200% = 20%.
P57
P59
-
System reservation
(Do not change this item)
Item
Content
No.
P60
-
System reservation
(Do not change this item)
P61
P
Arc length control gain
P62
C
Current output characteristics 1
Correction rate 1 of the wire feed speed (Unit: %)
P63
C
Current output characteristics 2
Correction rate 2 of the wire feed speed (Unit: %)
P64
S
Offset voltage
Voltage correction factor (Unit: %)
-1.0V in case of 90%
+1.0V in case of 110%
P65
P67
-
System reservation
(Do not change this item.)
*1
P: For pulse welding (including aluminum pulse)
A: For aluminum welding
S: For short-circuit welding
C: Common for all the welding types
Unit: %
16.2
List of Common Parameters
These parameters determine the operation of the welding power source.
Set them according to your environment. For parameters C50 to C59,
setting can be made only in the welding power source side. For the other
parameters, setting is made in the robot control unit side.
Note: Factory settings may vary by version.
Display
Item
No.
Factory
Contents
setting
C00
Gas adjustment time
20
Gas check time, Unit: sec
C01
Gas pre-flow time
0
Gas time before starting the welding output (Min.
time 56 ms), Unit: 0.1s
C02
Gas after-flow time
5
Gas time after delivering the welding output,
Unit: 0.1s
16-2
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16
List of Parameters
16.2 List of Common Parameters
Display
Item
No.
Factory
Contents
setting
C03
Low pulse frequency
(welding type 91 for aluminum)
100
Low pulse frequency, Unit: 0.1 Hz
C04
Low pulse amplitude
(welding type 91 for aluminum)
20
Low pulse wire feed speed amplitude,
Unit: A
C05
Low pulse acceleration
(welding type 91 for aluminum)
120
Current at low pulse acceleration,
Unit: %
C06
Low pulse deceleration
(welding type 91 for aluminum)
100
Current at low pulse deceleration,
Unit: %
C07
Digital meter display speed
4
Average time of display shift between current
and voltage,
Unit: (0.1s)
C08
External resistor set value
505
Electric resistance value of the welding current
path (power cable, jib base, etc.) connected to
the welding power source
Unit: (x 10-5 )
C09
Motor setting
2
Motor selection
0: Print servo
2: Mechanical servo (YWE-WFR42DX2,YWEWFX40TELC, YWE-WF340MELC, YWEWF340TELC) (Factory setting)
8: EAGLX torch
9: EAGL7 torch
10: EAGL motor
C10
System reservation
50
Do not change this item.
C11
System reservation
150
Do not change this item.
C12
System reservation
250
Do not change this item.
C13
System reservation
150
Do not change this item.
C14
System reservation
250
Do not change this item.
C15
System reservation
150
Do not change this item.
C16
System reservation
250
Do not change this item.
C17
System reservation
150
Do not change this item.
C18
System reservation
250
Do not change this item.
C19
System reservation
0
Do not change this item.
C20
System reservation
0
Do not change this item.
C21
System reservation
0
Do not change this item.
C22
System reservation
0
Do not change this item.
C23
System reset
0
When C23 is set to "204, " the system is reset,
returning to the factory setting.
Before executing the system reset, be sure to
memorize the changed parameters. After
executing the system reset, turn OFF the power
and then turn it ON again.
When the power is turned OFF, C23 is returned
to "0."
C24
System reservation
0
Do not change this item.
C25
Motor power alarm criterion value
70
Criterion value for delivering an alarm for an
overcurrent in the feed motor.
Unit: (% for the rated current of the motor)
C26
System reservation
48
Do not change this item.
C27
System reservation
600
Do not change this item.
16-3
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16
List of Parameters
16.2 List of Common Parameters
Display
Item
No.
Factory
Contents
setting
C28
Output current range abnormality
2
0: When the output current is out of the range,
the error (Err790, Err791) is delivered.
1: When the output current is out of the range,
the error (Err790, Err791) is delivered during
welding, terminating welding.
2: When the output is out of the range, no error
message is delivered.
C29
Setting range for output current
range abnormality
70
The abnormality range of the output current
(Err790, Err791) is set.
When the current is in the range of the welding
current command ± C29, no error message is
delivered. If the current exceeds the range, the
error (Err790, Err791) is delivered.
Unit: A
C30
System reservation
80
Do not change this item.
C31
Operation time after welding the
cooing fan
15
The operation time of the cooling fan after
completion of welding is set.
When the upper limit is set to 60, the cooling fan
operates all the time.
Unit: min
C32
Meter section display during standby 0
Used to select the meter section display during
standby.
0: Command value display
1: Standby (0.0 V, 0 A, 0 n/min) display
C33
System reservation
0
Do not change this item.
C34
System reservation
8
Do not change this item.
C35
System reservation
38
Do not change this item.
C36
System reservation
0
Do not change this item.
C37
System reservation
1
Do not change this item.
C38
System reservation
0
Do not change this item.
C39
System reservation
100
Do not change this item.
C40
System reservation
20
Do not change this item.
C41
System reservation
100
Do not change this item.
C42
System reservation
1
Do not change this item.
C43
Adjustment range of Heat And Wave
Form Control
20
Adjustment range of Heat And Wave Form
Control
C44
System reservation
0
Do not change this item.
C45
System reservation
10
Do not change this item.
C46
System reservation
200
Do not change this item.
C47
System reservation
150
Do not change this item.
C48
System reservation
600
Do not change this item.
C49
System reservation
50
Do not change this item.
C50
welding power source side IP
address
0
Set the forth digit of the welding power source
side IP address. (Addition value to the reference
value 210)
When the set value is 0: 192.168.255.210
When the set value is 1: 192.168.255.211
C51
System reservation
0
Do not change this item.
C52
System reservation
200
Do not change this item.
C53
System reservation
0
Do not change this item.
16-4
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16
List of Parameters
16.2 List of Common Parameters
Display
Item
Factory
Contents
setting
No.
C54
System reservation
192
IP address subnet.
Do not change this item.
C55
System reservation
168
IP address subnet.
Do not change this item.
C56
System reservation
255
IP address subnet.
Do not change this item.
C57
System reservation
210
IP address subnet.
Do not change this item.
C58
System reservation
200
Do not change this item.
C59
System reservation
0
Do not change this item.
C60
Average time for the current range
over
0
（ms）Average time of the current range over
C61
Mode for the range over error of the
short-circuit times
2
0: When the short-circuit times is out of the
range, the error(Err795) is delivered.
1: When the short- circuit times is out of the
range, the error(Err795) is delivered during
welding, terminating welding.
2: When the short- circuit times is out of the
range, no error message is delivered.
C62
The detecting value for the range
over of the short-circuit times
50
(%) Setting range of the short-circuit range over
error.
C63
・
・
・
C71
System Reservation
0
Do not change this item.
C72
Average calculation time
10
Average time of the voltage range over
When setting value is 0: 1000 ms
Unit: 100 ms
C73
Setting range for output voltage outof-range error
50
The range for output voltage out-of-range error
(Err780, Err781) is set.
When the voltage is in the range of the welding
voltage command ±C73, no error message is
delivered. If the voltage exceeds the range, the
error (Err780, Err781) is delivered.
Unit: 0.1 V
C74
Output voltage out-of-range error
2
0: When the output voltage is out of the range,
the error (Err780, Err781) is delivered.
1: When the output voltage is out of the range,
the error (Err780, Err781) is delivered during
welding, terminating welding.
2: When the output voltage is out of the range, no
error message is delivered.
C75
Setting range of forced stop for
output voltage out-of-range error
100
The setting range of forced stop for output
voltage out-of-range error (Err782, Err783) is set.
When the voltage is in the range of the welding
voltage command ±C75, no error message is
delivered. If the voltage exceeds the range, the
error (Err782, Err783) is delivered.
Unit: 0.1 V
C76
・
・
・
C99
System Reservation
0
Do not change this item.
16-5
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16
List of Parameters
16.3 List of D Parameters
16.3
List of D Parameters
These parameters determine the operating conditions of the welding
power source. Set them according to your environment.
Parameters D are set in the robot control unit side.
Note: Factory settings may vary by version.
Pan
el
R/C *1
Display
Item
ON
0
D-1-1
System reservation
Do not change this item.
1
D-1-2
System reservation
Do not change this item.
ON
2
D-1-3
System reservation
Do not change this item.
ON
3
D-1-4
System reservation
Do not change this item.
4
D-1-5
Feed speed/Motor
current display
Feed speed display
5
D-1-6
System reservation
Do not change this item.
6
D-1-7
System reservation
Do not change this item.
ON
7
D-1-8
System reservation
Do not change this item.
ON
8
D-1-9
System reservation
Do not change this item.
ON
9
D-1-10
System reservation
Do not change this item.
OFF
OFF
Factory
setting
OFF
ON
Motor current display
ON
OFF
10
D-1-11
System reservation
Do not change this item.
OFF
11
D-1-12
System reservation
Do not change this item.
OFF
12
D-1-13
System reservation
Do not change this item.
OFF
13
D-1-14
System reservation
Do not change this item.
ON
14
D-1-15
System reservation
Do not change this item.
15
D-1-16
System reservation
Do not change this item.
16
D-2-1
System reservation
Do not change this item.
OFF
17
D-2-2
System reservation
Do not change this item.
OFF
18
D-2-3
System reservation
Do not change this item.
OFF
19
D-2-4
System reservation
Do not change this item.
OFF
20
D-2-5
System reservation
Do not change this item.
ON
21
D-2-6
System reservation
Do not change this item.
ON
22
D-2-7
System reservation
Do not change this item.
ON
23
D-2-8
System reservation
Do not change this item.
ON
24
D-2-9
System reservation
Do not change this item.
OFF
25
D-2-10
System reservation
Do not change this item.
OFF
26
D-2-11
System reservation
Do not change this item.
OFF
27
D-2-12
System reservation
Do not change this item.
OFF
28
D-2-13
System reservation
Do not change this item.
ON
29
D-2-14
System reservation
Do not change this item.
ON
30
D-2-15
System reservation
Do not change this item.
OFF
31
D-2-16
System reservation
Do not change this item.
OFF
32
D-3-1
System reservation
Do not change this item.
OFF
33
D-3-2
System reservation
Do not change this item.
OFF
34
D-3-3
System reservation
Do not change this item.
OFF
35
D-3-4
System reservation
Do not change this item.
OFF
36
D-3-5
System reservation
Do not change this item.
OFF
16-6
OFF
ON
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16
List of Parameters
16.3 List of D Parameters
Pan
el
R/C *1
Display
Item
ON
37
D-3-6
System reservation
Do not change this item.
OFF
38
D-3-7
System reservation
Do not change this item.
OFF
39
D-3-8
System reservation
Do not change this item.
OFF
40
D-3-9
System reservation
Do not change this item.
OFF
41
D-3-10
System reservation
Do not change this item.
OFF
42
D-3-11
System reservation
Do not change this item.
OFF
43
D-3-12
How to set the outside
Settings for each user file
voltage setting error (Err780 (individual settings)
& Err781)
44
D-3-13
System reservation
Do not change this item.
OFF
45
D-3-14
System reservation
Do not change this item.
OFF
46
D-3-15
System reservation
Do not change this item.
OFF
47
D-3-16
System reservation
Do not change this item.
OFF
48
D-4-1
System reservation
Do not change this item.
ON
49
D-4-2
System reservation
Do not change this item.
ON
50
D-4-3
System reservation
Do not change this item.
ON
51
D-4-4
System reservation
Do not change this item.
ON
52
D-4-5
System reservation
Do not change this item.
ON
53
D-4-6
System reservation
Do not change this item.
ON
54
D-4-7
System reservation
Do not change this item.
ON
55
D-4-8
System reservation
Do not change this item.
ON
56
D-4-9
System reservation
Do not change this item.
ON
57
D-4-10
System reservation
Do not change this item.
ON
58
D-4-11
System reservation
Do not change this item.
ON
59
D-4-12
System reservation
Do not change this item.
ON
60
D-4-13
System reservation
Do not change this item.
ON
61
D-4-14
System reservation
Do not change this item.
ON
62
D-4-15
System reservation
Do not change this item.
ON
63
D-4-16
System reservation
Do not change this item.
ON
OFF
Factory
setting
Collective setting
OFF
*1 R/C Robot controller
• Auto adjustment voltage: The voltage that we assumed to be proper
is regarded as 100%.
When the voltage is changed by 10% from 100%, the voltage is
changed by approx. 1 V.
(Example: When 100% is 20 V, 90% is 19 V and 110% is 21 V.)
The adjustment range is 50% - 150% (± 5 V). The auto adjustment
voltage set in the robot control unit is displayed on the welding unit.
• In the CO2 short arc welding method, the touch start is not used, but
the normal start is used.
• In case of the aluminum welding, because the crater processing is
automatically executed, it is recommended to set the end event to
ON(valid). It takes about 2 seconds to finish the crater processing
after arc off. Therefore add a timer instruction to stop the manipulator for 2 seconds at the welding end. Or set the wire-stick prevention
processing time of the welding condition file to 2 seconds before
using it.
• When select aluminum for the welding type, the welding starts by the
touch start.
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List of Parameters
16.4 List of A Parameters
16.4
List of A Parameters
These parameters determine the operation of the welding power source. A
parameters is set for each user file. Set them according to your
environment.
For A parameters, setting is made in the robot control unit side.
Note: Factory settings may vary by version.
Display No. Item
Factory
setting
Contents
A00
Peak current correction amount
0
Unit: A
A01
Base current correction amount
0
Unit: A
A02
Pulse time correction amount
0
Unit: 0.1 ms
A03
Offset voltage
0
Unit: 0.1 V
A04
Setting range for output current out-ofrange error
(set for each user file)
0
A05
Detecting value for the range
over of the short-circuit times
(set for each user file)
0
A06
Setting range for output voltage out-ofrange error
(set for each user file)
0
Unit: 0.1 V
Used when D-3-12=ON
(Ver1.20-055-F later)
A07
System reservation
0
Do not change this item.
A08
System reservation
0
Do not change this item.
A09
System reservation
0
Do not change this item.
A10
LOW side current value when using low
pulse 2
30
Unit: A
(Ver1.20-073-F later)
A11
EAGL current value when using EAGL+
Pulse
100
Unit: A
(Ver1.20-080-F later)
A12
・
・
・
A31
System reservation
0
Do not change this item.
16-8
Unit: A
Used when D-3-12=ON
Unit: %
Used when D-3-12=ON
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List of Parameters
16.5 List of BIT Parameters
16.5
List of BIT Parameters
These parameters determine the operation of the welding power source.
BIT parameters is set for each user file. Set them according to your
environment.
For BIT parameters, setting is made in the robot control unit side.
Note: Factory settings may vary by version.
Display No. Item
ON
OFF
Factory
setting
BIT-1-1
Touch start function
Enabled
Disabled
BIT-1-2
End event
Enabled
Disabled
ON
BIT-1-3
Pulse arc length control
Enabled
Disabled
ON
BIT-1-4
Heat and wave form
control (HAWC) function
Enabled
Disabled
OFF
BIT-1-5
System reservation
Do not change this item.
OFF
BIT-1-6
System reservation
Do not change this item.
OFF
BIT-1-7
Voltage auto correction
(X350)
Enabled
OFF Short-circuit welding only
BIT-1-8
System reservation
Do not change this item.
BIT-2-1
System reservation
Do not change this item.
ON
BIT-2-2
System reservation
Do not change this item.
ON
BIT-2-3
System reservation
Do not change this item.
ON
BIT-2-4
Voltage auto correction
(X500)
Enabled
Disabled
ON
BIT-2-5
System reservation
Do not change this item.
ON
BIT-2-6
System reservation
Do not change this item.
ON
BIT-2-7
System reservation
Do not change this item.
ON
BIT-2-8
System reservation
Do not change this item.
ON
BIT-3-1
EAGL+ Pulse function
Enabled
BIT-3-2
System reservation
Do not change this item.
OFF
BIT-3-3
System reservation
Do not change this item.
OFF
BIT-3-4
System reservation
Do not change this item.
OFF
BIT-3-5
System reservation
Do not change this item.
OFF
BIT-3-6
System reservation
Do not change this item.
OFF
BIT-3-7
System reservation
Do not change this item.
OFF
BIT-3-8
System reservation
Do not change this item.
OFF
BIT-4-1
System reservation
Do not change this item.
OFF
BIT-4-2
System reservation
Do not change this item.
OFF
BIT-4-3
System reservation
Do not change this item.
OFF
BIT-4-4
System reservation
Do not change this item.
OFF
BIT-4-5
System reservation
Do not change this item.
OFF
BIT-4-6
System reservation
Do not change this item.
OFF
BIT-4-7
System reservation
Do not change this item.
OFF
BIT-4-8
System reservation
Do not change this item.
OFF
OFF
Disabled
Disabled
16-9
Remarks
OFF
Short-circuit welding only
OFF (Ver1.20-080-F later)
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List of Welding Types
17 List of Welding Types
The welding type available for the software version 1.00-001-E (CPU) are
listed below.
Refer to chapter 5.4 “Welding Method Setup” for details on changing of
the welding type.
Using improper welding type will result in unstable welding, which causes
excessive spatters or imperfect bead appearance. Before starting
welding, confirm that the welding type has been correctly selected.
Note: Conventional EAGL/EAGL7/EAGL7H welding methods cannot be
used with the EAGLX servo torch.
Shielding Gas
Wire
Pulse or
Short-circuit
Wire
Weld
Diamete Type
r
No.
CO2
Soft steel Fe
Short-circuit
φ0.8
42
φ0.9
32
φ1.0
22
φ1.2
12
φ1.4
192
(Ver1.20-030-F later)
(Ver1.20-071-F later)
MAG
(Ar 80%,
CO2 20%)
Soft steel Fe
Short-circuit
φ1.6
197
φ0.8
40
φ0.9
30
φ1.0
20
φ1.2
10
φ1.4
190
(Ver1.20-071-F later)
φ1.6
195
(Ver1.20-071-F later)
For zinc-plated steel plate
Super
sunarc242
Soft steel Fe
Short-circuit
φ1.2
19
MAG
(Ar 80%,
CO2 20%)
Soft steel Fe
Pulse
φ0.8
41
φ0.9
31
φ1.0
21
MIG
(Ar 92%,
CO2 8%)
Soft steel Fe
Pulse
Remarks
φ1.2
13
Middle-peak pulse
φ1.2
11
High-peak pulse
(For zinc-plated steel plate
and wire for CO2)
φ1.2
47
Low-peak pulse
(For zinc-plated steel plate)
(Ver1.20-010-F later)
φ1.2
100
For low viscosity wire
(Ver1.20-071-F later)
φ1.4
191
(Ver1.20-071-F later)
φ1.6
196
(Ver1.20-071-F later)
φ0.9
33
For zinc-plated steel plate
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List of Welding Types
Shielding Gas
Wire
Pulse or
Short-circuit
Wire
Weld
Diamete Type
r
No.
Remarks
Super
sunarc242
Soft steel Fe
Pulse
φ1.2
14
For zinc-plated steel plate
MAG
(Ar 80%,
CO2 20%)
Stainless
steel
SUS
Pulse
MIG
(Ar 98%,
O2 2%)
MIG
(Ar 98%,
O2 2%)
Stainless
steel
SUS
Stainless
steel
SUS
Short-circuit
Pulse
φ0.8
82
φ0.9
72
φ1.0
62
φ1.2
52
φ0.8
80
φ0.9
70
φ1.0
60
φ1.2
50
φ0.8
81
φ0.9
71
φ1.0
61
φ1.2
51
High-peak pulse
Middle-peak pulse
φ1.2
54
MIG
(Ar 98%,
O2 2%)
Stainless
steel
SUS
Pulse
φ1.2
53
Ar
5000 series
aluminum
Pulse
φ1.2
90
Servo torch recommended
Low pulse
φ1.2
91
Servo torch required
Low pulse 2
φ1.2
188
Servo torch required
(Ver1.20-073-F later)
EAGL
φ1.2
95
(Ver1.20-010-F later)
EAGL7
φ1.2
96
(Ver1.20-010-F later)
Pulse
φ1.2
92
Servo torch required
Low pulse
φ1.2
93
Servo torch required
Pulse 2
φ1.2
94
Servo torch required
(Ver1.20-080-F later)
Pulse 2
φ1.6
198
Servo torch required
(Ver1.20-080-F later)
Low pulse 2
φ1.2
189
Servo torch required
(Ver1.20-073-F later)
EAGL7H
φ1.2
97
(Ver1.20-060-F later)
EAGLX
φ1.2
99
EAGLX servo torch required
(Ver1.20-080-F later)
Ar
4000 series
aluminum
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List of Welding Types
Shielding Gas
Wire
Pulse or
Short-circuit
Wire
Weld
Diamete Type
No.
r
CO2
Soft steel Fe
EAGL
φ1.0
26
φ1.0
27
MAG
(Ar 80%,
CO2 20%)
MIG
(Ar 98%,
O2 2%)
Soft steel Fe
Stainless
steel
SUS
Remarks
EAGL Arc small/anti blow
φ1.2
16
EAGL Soft Arc(lap joint)
φ1.2
17
EAGL Normal Arc(Steel, Zn)
φ1.2
29
EAGL Arc small/anti blow
EAGL7
φ1.2
116
(Ver1.20-010-F later)
EAGL7H
φ0.8
146
(Ver1.20-020-F or later)
φ0.9
136
(Ver1.20-022-F later)
φ1.0
126
(Ver1.20-040-F later)
φ1.2
117
(Ver1.20-024-F later)
EAGLX
φ1.2
120
EAGLX servo torch required
(Ver1.20-080-F later)
EAGL
φ1.0
25
φ1.0
28
EAGL Arc small/anti blow
φ1.2
15
φ1.2
18
EAGL Arc small/anti blow
EAGL7
φ1.2
115
(Ver1.20-010-F later)
EAGL7H
φ0.8
148
(Ver1.20-030-F later)
φ0.9
138
(Ver1.20-040-F later)
φ1.0
128
(Ver1.20-030-F later)
φ1.2
118
(Ver1.20-022-F later)
EAGLX
φ1.2
119
EAGLX servo torch required
(Ver1.20-080-F later)
EAGL
φ1.0
67
EAGL Arc small/anti blow
φ1.2
55
EAGL7
φ1.2
155
(Ver1.20-010-F later)
EAGL7H
φ1.0
166
(Ver1.20-060-F later)
φ1.2
156
(Ver1.20-030-F later)
φ1.2
157
Ferrite type
(Ver1.20-055-F later)
φ1.2
158
EAGLX servo torch required
(Ver1.20-080-F later)
EAGLX
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List of Errors
18 List of Errors
Error detection is performed for the following items, and the welding power
source is automatically stopped when an error is detected.
If an error occurs, the error number is displayed in the digital meter on the
panel face for 10 seconds. For the contents of errors, refer to the
following table.
◆ 4242: MOTOWELD Input over current [Error No. in the welding power source side Err107]
An overcurrent flows through the primary side control circuit.
Sub
Code
107
Meaning
Sub Code: Error number that
occurred in the welder
Cause
Remedy
Arc welding power
source error
(1) Check for any short-circuit or grounding of
the output cable.
(2) In order to reset this error, turn OFF the
welding power source and turn ON it again. If
turning ON again, be sure to check that 30
seconds have elapsed after turning OFF.
(3) The power circuit may be broken.
Contact your YASKAWA representative.
◆ 4243: MOTOWELD Output over current [Error No. in the welding power source side Err701]
An overcurrent flows through the secondary side control circuit.
Sub
Code
701
Meaning
Cause
Remedy
Arc welding power
source error
Check the following items:
(1) Check to confirm that the wire extrusion
length is not shortened.
(2) Check to confirm that the torch cable, torch
clamp and the power cable are not shorted to
the ground.
(3) Check to confirm that the contact chip and
the welding work are not in contact. Cancel the
contact if any, and weld them.
(4) Check the wire feeder cable for any
damage.
(5) If the wire feeder cable is broken or the
connector is loose, the wire feed speed will
become abnormally fast, which may cause an
output overcurrent.
Check the feeder cable and connector.
Replace the feeder cable or tighten the
connector.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
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List of Errors
◆ 4244: MOTOWELD Input over voltage [Error No. in the welding power source side Err001]
An input voltage which is greater than the rated input voltage +15% is applied for 2 sec.
Sub
Code
―
Meaning
Cause
Remedy
Arc welding power
source error
Check the input voltage.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
―
◆ 4245: MOTOWELD Temperature abnormality
[Error No. in the welding power source side Err102, Err103, Err105]
The temperature of the welding power source has exceeded the default value.
Sub
Code
102
103
Meaning
The temperature in the
primary control circuit
exceeds the specified value of
the welding source.
The temperature in the
secondary control circuit
exceeds the specified value of
the welding source.
Cause
Remedy
Arc welding power
source error
(1) Check the ambient temperature (45C or
below) and the usage rate (60%).
(2) Check the fan guard for dirt and clogging,
and clean or replace it.
(3) Check the cooling fan is working properly,
and clean or replace it.
(4) Check that the primary side thermal guard
(X500: Item No. 320) has not failed. (A
conductive state is normal.)
(5) Check that the thermal guard of the
Pr(SSR) board (X500: Item No. 417) has not
failed. (A conductive state is normal.)
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Arc welding power
source error
(1) Check the ambient temperature (45C or
below) and the usage rate (60%).
(2) Check the fan guard for dirt and clogging,
and clean or replace it.
(3) Check the cooling fan is working properly,
and clean or replace it.
(4) Check that the secondary side thermal
guard (X500: Item No. 319, 320) has not failed.
(A conductive state is normal.)
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
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Sub
Code
105
Meaning
The temperature in the DC
reactor exceeds the specified
value of the welding source.
List of Errors
Cause
Remedy
Arc welding power
source error
(1) Check the ambient temperature (45C or
below) and the usage rate (60%).
(2) Check the fan guard for dirt and clogging,
and clean or replace it.
(3) Check the cooling fan is working properly,
and clean or replace it.
(4) Check that the thermal guard of the DC
reactor (X500: Item No. 514) has not failed. (A
conductive state is normal.)
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
◆ 4246: MOTOWELD Input insufficient voltage
[Error No. in the welding power source side Err002]
An input voltage which is smaller than the rated input voltage -15% is applied for 2sec.
Sub
Code
-
Meaning
Cause
Remedy
Arc welding power
source error
Check the input voltage.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
-
◆ 4248: MOTOWELD Communication abnormality between the welding power source and the
robot control unit [Error No. in the welding power source side Err401]
A communication error occurs between the welding power source and the robot control unit.
Sub
Code
401
Meaning
Sub Code: Error number that
occurred in the welder
Cause
Remedy
Arc welding power
source error
Check the following items.
(1) Check to confirm that the communication
cable is securely connected.
(2) Check if the IP address setting on the
welding power source side is correct. (C
parameter of welding power source)
(3) Check that the robot controller is turned on.
(4) Check the robot controller Ethernet settings
(Ethernet function enabled, IP address setting
(RS parameter, AxP parameter)).
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List of Errors
◆ 4251: MOTOWELD User file number abnormality
[Error No. in the welding power source side Err404]
A non-existing user file is set.
Sub
Code
404
Meaning
Sub Code: Error number that
occurred in the welder
Cause
Remedy
Arc welding power
source error
Set the user file number in the range of 1 - 16.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
◆ 4258: MOTOWELD Feed unit abnormality [Error No. in the welding power source side Err501]
The welding wire is not fed according to the feed amount command.
Sub
Code
501
Meaning
Cause
Remedy
Arc welding power
source error
Check the following items.
(1) Check the wire feeder cable for any
damage.
(2) Check that the connector on the wire
feeder cable is not loosen. Disconnection of
the wire feeder cable or looseness of the
connector may cause an abnormally high wire
feed speed or an abnormal feed rate. Replace
the wire feeder cable and tighten the
connector.
(3) Check that the wire load has not become
larger. Avoid extreme bending of torch and
conduit cables.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
◆ 4259: MOTOWELD Motor overcurrent [Error No. in the welding power source side Err502]
An overcurrent exceeding the rated current level flows through the motor.
Sub
Code
502
Meaning
Cause
Remedy
Arc welding power
source error
Check that the wire load is not too great.
Be careful that the torch cable and the conduit
cable are not bent excessively.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
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List of Errors
◆ 4269: MOTOWELD Start signal abnormality
[Error No. in the welding power source side Err601]
An arc start signal is inputted before booting the main power of the welding unit.
Sub
Code
601
Meaning
Cause
Remedy
Arc welding power
source error
Check the operation timing and connection of
the signal cable.
A same error may occur in the case of an
instantaneous service interruption.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
◆ 4270: MOTOWELD No welding type
[Error No. in the welding power source side Err602]
A welding type is not set in a user file. The selected welding type does not exist.
Sub
Code
602
Meaning
Cause
Remedy
Arc welding power
source error
(1) Set a welding type in the user file.
(2) Install the latest software on the welding
power source.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
◆ 4271: MOTOWELD Voltage sensing cable abnormality
[Error No. in the welding power source side Err702]
The welding voltage is not detected.
Sub
Code
702
Meaning
Cause
Remedy
Arc welding power
source error
(1) Check to confirm that the welding voltage
sensing cable select switch is set to "Base
Metal".
(2) Check to confirm that the contact chip and
the welding work are not in contact. Cancel the
contact if any, and weld again.
(3) An instantaneous serviceinterruption may
have occurred. Please restart.
(4) When the welding voltage sensing cable is
used, check to confirm that the base metalside welding voltage sensing cable connects
between the base metal and the welding
power source via wire feeder cable.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
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List of Errors
◆ 4274: MOTOWELD Voltage sensing unit abnormality
[Error No. in the welding power source side Err110]
The welding voltage is not detected.
Sub
Code
110
Meaning
Cause
Remedy
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Contact your YASKAWA representative about
occurrence status (operating procedure).
In order to reset this error, turn OFF the
welding power source and turn ON it again.
◆ 4275: MOTOWELD Aux. circuit overcurrent
[Error No. in the welding power source side Err111]
Overcurrent flows in the auxiliary circuit.
Sub
Code
111
Meaning
Cause
Remedy
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Contact your YASKAWA representative about
occurrence status (operating procedure).
◆ 4276: MOTOWELD DSP ADC error
[Error No. in the welding power source side Err119]
The main board broken.
Sub
Code
119
Meaning
Cause
Remedy
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Replace the main control board for the welding
power source.
◆ 4277: MOTOWELD Output current set range over (Exceeding the upper limit)
[Error No. in the welding power source side Err790]
An actual welding current exceeds the welding current command value too much. (Exceeding the
upper limit)
Sub
Code
790
Meaning
Cause
Remedy
Arc welding power
source error
(1) Check to confirm that the motor selection is
proper and the set contents of parameter C09
is proper.
(2) Check to confirm that the welding wire does
not slip and that it is fed according to the feed
command.
(3) Check to confirm that the wire extrusion
length is proper.
(4) Check to confirm that the set range of C29
is enough.
(5) Check to confirm that the settings of the
wire, the shield gas, the welding method, and
grounding are properly made.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
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List of Errors
◆ 4278: MOTOWELD Output current set range over (Exceeding the lower limit)
[Error No. in the welding power source side Err791]
An actual welding current exceeds the welding current command value too much. (Exceeding the
lower limit)
Sub
Code
791
Meaning
Cause
Remedy
Arc welding power
source error
(1) Check to confirm that the motor selection is
proper and the set contents of parameter C09
is proper.
(2) Check to confirm that the welding wire does
not slip and that it is fed according to the feed
command.
(3) Check to confirm that the wire extrusion
length is proper.
(4) Check to confirm that the set range of C29
is enough.
(5) Check to confirm that the settings of the
wire, the shield gas, the welding method, and
grounding are properly made.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
◆ 4279: MOTOWELD Output instantaneous over current
[Error No. in the welding power source side Err108]
An instantaneous over current flows through the secondary side control circuit.
Sub
Code
108
Meaning
Sub Code: Error number that
occurred in the welder
Cause
Remedy
Arc welding power
source error
(1) Check for any short-circuit or grounding of
the output cable.
(2) The power circuit may be broken. Contact
your YASKAWA representative.
(3) In order to reset this error, turn OFF the
welding power source and turn ON it again.
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List of Errors
◆ 4283: MOTOWELD Welding method number abnormality
[Error No. in the welding power source side Err406, Err407]
There is an error in the welding method in the user file.
Sub
Code
406
407
Meaning
A wrong welding process is
set in the welding user file.
Cause
Remedy
Arc welding power
source error
Set the proper welding method number.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Arc welding power
source error
Set a welding type to user file of MOTOWELD.
The user file can setup in the editor screen for
ARC START CONDITION FILE or ARC END
CONDITION FILE.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
A welding type is not set in a
user file of the MOTOWELD.
◆ 4284: MOTOWELD Software malfunction
[Error No. in the welding power source side Err310, Err311, Err312, Err316, Err317, Err318,
Err400]
An error occurred in the software in the welding power source.
Sub
Code
310
311
312
316
Meaning
Cause
Remedy
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Load the version of the database that is
compatible with the CPU version.
The version of the data base
is not suitable for the software
of the welding power source.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Replace the main board (Pr(MB) -031) if this
error recurs.
The version information of the
PLD on the main board
Pr(MB) is wrong.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Replace the front panel for the welding power
source.
The version of the firmware of
front panel is not suitable for
the software of the main board
Pr(MB).
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
Arc welding power
source error
Replace the main board (Pr(MB) -031) if this
error recurs.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
The check sum of the PLD on
the main board Pr(MB) is
wrong.
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List of Errors
◆ 4284: MOTOWELD Software malfunction (Continued)
Sub
Code
Meaning
Sub Code: Error number that
occurred in the welder
Cause
Remedy
Arc welding power
source error
Software or database loading over the
Ethernet has been successfully completed.
Please restart.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Arc welding power
source error
Load data error occurred while loading
software or database over the Ethernet.
(1) Perform loading over the Ethernet again
without turning off the welding power source.
(2) If the welding power source was turned off,
restart, and after startup is successful, perform
loading again.
(3) If the welding power source was turned off,
restart, and if startup fails, load the software
using the dedicated loading tool.
(4) If restarting cannot be performed and the
dedicated loading tool is not available, replace
the main control board Pr(MB) of the welding
power source.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Arc welding power
source error
A PLD operation error occurred, and the
welding power source was restarted. Replace
the main control board Pr(MB) for the welding
power source.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
317
The program or data base
was load by the ethernet.
Sub Code: Error number that
occurred in the welder
318
The check sum error of
loading data.
400
Sub Code: Error number that
occurred in the welder
Watch dog error of the PLD.
◆ 4285: MOTOWELD Machine setting error
[Error No. in the welding power source side Err320]
The machine type is wrong.
Sub
Code
320
Meaning
Sub Code: Error number that
occurred in the welding power
source
Cause
Remedy
Arc welding power
source error
(1) Check the connection between front panel
and main board Pr(MB).
(2) Check the status of dip switch (SW301) on
the front panel.
(3) Replace the front panel.
(4) Replace the main board Pr(MB).
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
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List of Errors
◆ 4286: MOTOWELD Current class (350/500) error
[Error No. in the welding power source side Err330]
The current class 350A / 500A setting is wrong.
Sub
Code
330
Meaning
Sub Code: Error number that
occurred in the welding power
source
Cause
Remedy
Arc welding power
source error
(1) The current capacity supported by the
software loaded on the main control board Pr
(MB) does not match the current capacity
selected by the current capacity setting switch
(SW3) on the main control board Pr (MB).
Change the setting of the software or current
capacity setting switch (SW3), or check the
connection of the MB1 connector on the main
control board Pr (MB).
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
◆ 4287: MOTOWELD Range over error of the short-circuit times (perforated detection)
[Error No. in the welding power source side Err795]
Short-circuit count is equal to or less than the set value.
Sub
Code
795
Meaning
Cause
Remedy
Arc welding power
source error
(1) Make sure that the welding current
command is not high.
(2) Please make sure no large setting range
C62.
(3) Make sure that the protruding length has
not been shortened.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub Code: Error number that
occurred in the welder
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List of Errors
◆ 4289: MOTOWELD Servo pack alarm
[Error No. in the welding power source side Err530]
An error occurred in the SERVOPACK.
Sub
Code
Meaning
Cause
Remedy
(1) A.720: Overload (maximum continuous)
• Check to make sure that wire is not sticking
out and contacting the workpiece or other
object.
• Check to whether the feed resistance is not
excessive.
• There is a possibility of servo pack failure.
Please replace the servo pack.
(2) A.C90: Encoder communication error
• There is a bad connection possibility of wire
feeder cable. Check the connection of each
connector.
• There is a possibility of disconnection of the
wire feeder cable. Please replace the wire
feeder cable.
530
Sub Code: SERVO PACK
ALARM (EAGL).
• There is a possibility of servo pack failure.
Please replace the servo pack.
SERVO PACK ALARM
(EAGL).
(3) A.b33: Current detection abnormality
• There is a bad connection possibility of the
servo motor main circuit cable. Check the
connection of each connector.
• There is a possibility of disconnection of the
servo motor main circuit cable. Please
replace the servo motor main circuit cable.
• There is a possibility of servo pack failure.
Please replace the servo pack.
(4) A.101: Overcurrent detection
• There is a bad connection possibility of the
servo motor main circuit cable. Please
replace the servo motor main circuit cable.
• There is a possibility of life of the servo motor.
Please replace the servo motor.
• There is a possibility of servo pack failure.
Please replace the servo pack.
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Other
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List of Errors
◆ 6052: MOTOWELD ERROR
[Error No. in the welding power source side Err780, Err781, Err782, Err783]
Detected an error in the MOTOWELD welding power source.
Sub
Code
Meaning
Error 780: OUTSIDE OF
VOLTAGE SETTING (High)
Cause
Remedy
Arc welding power
source error
The weld voltage command value and the weld
voltage output value are different. Please
check the following.
(1) Check if the weld voltage command is not
too low or too high.
(2) Check if the selection of motor is correct, or
confirm the settings of C parameter C09.
(3) Check if the wire, shield gas, weld type,
grounding are correctly set.
(4) Check if the welding wire does not slip, or
the wire is fed as instructed by the feeding
command.
(5) Check if the wire stick out is not excessively
short or long.
(6) Check if the range set in C parameter
C72(Average calculation time used for
OUTSIDE OF VOLTAGE SETTING(Unit:0.1s))
of the MOTOWELD is not too narrow.
(7) When D-3-12 parameter of the
MOTOWELD is set to "OFF", Check if the
range set in C parameter C73(Judgment range
for OUTSIDE OF VOLTAGE
SETTING(Unit:0.1V)) of the MOTOWELD is
not too narrow.
(8) When D-3-12 parameter of the
MOTOWELD is set to "ON", Check if the range
set in A parameter A6(Judgment range for
OUTSIDE OF VOLTAGE SETTING(Unit:0.1V))
of the MOTOWELD is not too narrow.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
X780
Sub code: X780
(X: welder 1 to welder 8)
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List of Errors
◆ 6052: MOTOWELD ERROR (Continued)
Sub
Code
Meaning
Error 781: OUTSIDE OF
VOLTAGE SETTING (Low)
Cause
Remedy
Arc welding power
source error
The weld voltage command value and the weld
voltage output value are different. Please
check the following.
(1) Check if the weld voltage command is not
too low or too high.
(2) Check if the selection of motor is correct, or
confirm the settings of C parameter C09.
(3) Check if the wire, shield gas, weld type,
grounding are correctly set.
(4) Check if the welding wire does not slip, or
the wire is fed as instructed by the feeding
command.
(5) Check if the wire stick out is not excessively
short or long.
(6) Check if the range set in C parameter
C72(Average calculation time used for
OUTSIDE OF VOLTAGE SETTING(Unit:0.1s))
of the MOTOWELD is not too narrow.
(7) When D-3-12 parameter of the
MOTOWELD is set to "OFF", check if the
range set in C parameter C73(Judgment range
for OUTSIDE OF VOLTAGE
SETTING(Unit:0.1V)) of the MOTOWELD is
not too narrow.
(8) When D-3-12 parameter of the
MOTOWELD is set to "ON", check if the range
set in A parameter A6(Judgment range for
OUTSIDE OF VOLTAGE SETTING(Unit:0.1V))
of the MOTOWELD is not too narrow.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
X781
Sub code: X781
(X: welder 1 to welder 8)
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List of Errors
◆ 6052: MOTOWELD ERROR (Continued)
Sub
Code
X782
Meaning
Error 782: OUTSIDE OF
VOLTAGE SETTING
FORCED STOP (High)
Cause
Remedy
Arc welding power
source error
The weld voltage command value and the weld
voltage output value are different. Please
check the following.
(1) Check if the weld voltage command is not
too low or too high.
(2) Check if the selection of motor is correct, or
confirm the settings of C parameter C09.
(3) Check if the wire, shield gas, weld type,
grounding are correctly set.
(4) Check if the welding wire does not slip, or
the wire is fed as instructed by the feeding
command.
(5) Check if the wire stick out is not excessively
short or long.
(6) Check if the range set in C parameter
C72(Average calculation time used for
OUTSIDE OF VOLTAGE.SETTING FORCED
STOP(Unit:0.1s)) of the MOTOWELD is not
too narrow.
(7) Check if the range set in C parameter
C75(Judgment range for OUTSIDE OF
VOLTAGE.SETTING FORCED
STOP(Uint:0.1V)) of the MOTOWELD is not
too narrow.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Arc welding power
source error
The weld voltage command value and the weld
voltage output value are different. Please
check the following.
(1) Check if the weld voltage command is not
too low or too high.
(2) Check if the selection of motor is correct, or
confirm the settings of C parameter C09.
(3) Check if the wire, shield gas, weld type,
grounding are correctly set.
(4) Check if the welding wire does not slip, or
the wire is fed as instructed by the feeding
command.
(5) Check if the wire stick out is not excessively
short or long.
(6) Check if the range set in C parameter
C72(Average calculation time used for
OUTSIDE OF VOLTAGE.SETTING FORCED
STOP(Unit:0.1s)) of the MOTOWELD is not
too narrow.
(7) Check if the range set in C parameter
C75(Judgment range for OUTSIDE OF
VOLTAGE.SETTING FORCED
STOP(Uint:0.1V)) of the MOTOWELD is not
too narrow.
Other
If the alarm occurs again, save the CMOS.BIN,
and then contact your YASKAWA
representative about occurrence status
(operating procedure).
Sub code: X782
(X: welder 1 to welder 8)
X783
Error 783: OUTSIDE OF
VOLTAGE SETTING
FORCED STOP (Low)
Sub code: X782
(X: welder 1 to welder 8)
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List of Errors
◆ [Error number that occurred in the welder Err800]
The communication error of the main board {Pr(MB)-031} and the panel board {Pr(CR)-031} occurred.
Meaning
Remedy
The communication error of
the main board {Pr(MB)-031}
and the panel board {Pr(CR)031} occurred.
(1) Please confirm whether the connection of Connector MB30 of
the main board {Pr(MB)-031} and Connector CN301of the panel
board {Pr(CR)-031} does not have a problem. After confirmation,
please turn on a power supply again.
(2) Please change the panel board {Pr(CR)-031}.
(3) Please change the main board {Pr(MB)-031}.
* during the loading of the software will be displayed "Err800".
* For digital data on the panel "888 888"
Item
Contents
Remedy
Communication error
of main board {Pr(MB)031} and panel board
{Pr(CR)-031} or The
DSP abnormality
Communication error
The communication error of
the main board {Pr(MB)-031}
and the panel board {Pr(CR)031} occurred.
(1) Please confirm whether the connection of
Connector MB30 of the main board {Pr(MB)-031}
and Connector CN301 of the panel board {Pr(CR)031} does not have a problem. After confirmation,
please turn on a power supply again.
(2) Please change the panel board {Pr(CR)-031}.
(3) Please change the main board {Pr(MB)-031}.
DSP abnormality
The main board {Pr(MB)-031}
does not work normally.
Please change the main board {Pr(MB)-031}.
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MOTOWELD-X500
INSTRUCTIONS
TYPE:YWE-X500-6N0
For inquiries or after-sales service on this product, contact
your local YASKAWA representative as shown below.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu, 806-0004, Japan
Phone: +81-93-645-7703 Fax: +81-93-645-7802
www.yaskawa.co.jp
YASKAWA AMERICA, INC. (MOTOMAN ROBOTICS DIVISION)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone: +1-937-847-6200 Fax: +1-937-847-6277
www.motoman.com
YASKAWA EUROPE GmbH (ROBOTICS DIVISION)
Yaskawastrasse 1, 85391, Allershausen, Germany
Phone: +49-8166-90-0 Fax: +49-8166-90-103
www.yaskawa.eu.com
YASKAWA NORDIC AB
Verkstadsgatan 2, Box 504, SE-385 25 Torsas, Sweden
Phone: +46-480-417-800 Fax: +46-486-414-10
www.yaskawa.se
YASKAWA ELECTRIC (CHINA) CO., LTD.
22F, One Corporate Avenue, No.222 Hubin Road, Huangpu District, Shanghai 200021, China
Phone: +86-21-5385-2200 Fax: +86-21-5385-3299
www.yaskawa.com.cn
YASKAWA SHOUGANG ROBOT CO., LTD.
No.2 Building, No.6 Rongchang East Street, Beijing E&T Development Area, Beijing 100176, China
Phone: +86-10-6788-2858 Fax: +86-10-6788-2878
www.ysr-motoman.cn
YASKAWA ELECTRIC KOREA CORPORATION
6F, 112, LS-ro, Dongan-gu, Anyang-si, Gyeonggi-do, 14118, Korea
Phone: +82-31-8015-4224 Fax: +82-31-8015-5034
www.yaskawa.co.kr
YASKAWA ELECTRIC TAIWAN CORPORATION
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone: +886-2-8913-1333 Fax: +886-2-8913-1513
www.yaskawa.com.tw
YASKAWA ASIA PACIFIC PTE. LTD.
30A Kallang Place, #06-01, 339213, Singapore
Phone: +65-6282-3003 Fax: +65-6289-3003
www.yaskawa.com.sg
YASKAWA ELECTRIC (THAILAND) CO., LTD.
59, 1st-5th Floor, Flourish Building, Soi Ratchadapisek 18, Ratchadapisek Road, Huaykwang,
Bangkok 10310, Thailand
Phone: +66-2-017-0099 Fax: +66-2-017-0199
www.yaskawa.co.th
PT. YASKAWA ELECTRIC INDONESIA
Secure Building-Gedung B Lantai Dasar & Lantai 1 Jl. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone: +62-21-2982-6470 Fax: +62-21-2982-6471
www.yaskawa.co.id
YASKAWA INDIA PRIVATE LIMITED (ROBOTICS DIVISION)
No.136, Sector-8, Industrial Estate, IMT Manesar, Gurugram, Haryana 122050, India
Phone: +91-124-475-8500
www.yaskawaindia.in
C 2019 YASKAWA ELECTRIC CORPORATION
Published by YASKAWA
October 2024 19-06
MANUAL NO.
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