1L22440 e 7 PDF
1L22440 e 7 PDF
1L22440 e 7 PDF
1L22440-E-7
AX series
INSTRUCTION MANUAL
WELDING INTERFACE
(DIGITAL)
■ Read and follow these instructions and all safety blocks carefully.
■ Have only trained and qualified persons install, operate, or service this unit.
-1-
Instruction manuals are available other than the above for each optional function that you have purchased.
[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. Optional hardware or software is necessary in order to use the function described as “Optional” in the manual.
3. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual
ones.
4. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do not take any
responsibility for damages resulting from neither direct nor indirect errors.
5. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.
6. No part of this manual may be reproduced without permission.
7. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.
The warranty does not cover any altered or remodeled products.
-2-
Notice
Notes on Safety
Before installation, operation, be sure to read "Chapter 1 Points on Safety" in INSTALLATION manual and other
attached documents thoroughly and acquire all the knowledge of machines, safety information, and precautions.
Furthermore, before maintenance, inspection, and trouble scene, be sure to read CONTROLLER
MAINTENANCE manual and MANIPULATOR manual and other attached documents thoroughly and acquire all
the knowledge of machines, safety information, and precautions.
If operating machines in a wrong way, the accident resulting in various ranks of injury or death, or damage may
occur.
In order to call attention to wrong handling, the following four ranks of safety notes (“DANGER”, “WARNING”,
“CAUTION”, and “IMPORTANT”) are provided.
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury and where the degree of the urgency
(imminence) of the warning given for the danger to occur is at the high end of the
DANGER scale (including high-level danger).
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury.
WARNING
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of minor injuries or of property damage only.
CAUTION
Note that even the matters which are described as CAUTION can result in serious accident depending on the conditions.
Be sure to keep the safety notes since they describe very important matters.
The meanings of “Serious injury”, “Minor injury”, and “Damage” described above are as follows.
Serious injury : Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.
Minor injury : Injury which does not require either hospitalization or long-term treatment as an outpatient,
a burn (high temperature, low temperature), and an electric shock.
Damage : Direct and indirect damage in connection with damage of property and equipment.
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Table of Contents
Table of Contents
Chapter 1 Introduction
1.1 Welding Interface (Digital)......................................................................................................................... 1-1
Chapter 2 Connections
2.1 Connect Welding Interface (Digital) .......................................................................................................... 2-1
2.1.1 Installation of the Welding Interface (Digital) Board ....................................................................... 2-1
2.1.2 Connection of Control cable 5 (Robot controller side) ................................................................... 2-3
2.1.3 Connection of Control cable 5 (Welding power source side)......................................................... 2-4
2.1.4 Connection of Control cable 4........................................................................................................ 2-5
2.1.5 Connection of Workpiece side welding cable / Torch side welding cable ...................................... 2-5
2.1.6 Connection of Gas hose................................................................................................................. 2-5
2.1.7 Connection of Voltage detecting cable (workpiece side) (for WB-M350L/WB-P500L).................. 2-6
2.2 Electrical connection diagram ................................................................................................................... 2-8
Chapter 3 Configurations
3.1 Workflow.................................................................................................................................................... 3-1
3.5.1 Writing the setup data onto the robot controller ........................................................................... 3-14
3.5.2 Writing the setup data onto Welding Interface (Digital)................................................................ 3-16
3.6 Check the configuration .......................................................................................................................... 3-17
3.7 Configuring the Welbee Inverter series welding power source .............................................................. 3-18
3.7.1 The welding power source operations when a robot is connected .............................................. 3-18
3.7.2 The welding power source internal functions when a robot is connected ................................... 3-19
3.8 Welding conditions of WB-M350L........................................................................................................... 3-20
3.8.1 About the welding condition parameters ...................................................................................... 3-20
3.8.2 Points for setting the conditions ................................................................................................... 3-21
3.8.3 How the spatter adjustment parameter (APCS cond.) is used .................................................... 3-22
3.8.4 About the welding constants......................................................................................................... 3-24
3.9 Welding conditions of WB-M350/500...................................................................................................... 3-25
3.9.1 About the welding condition parameters ...................................................................................... 3-25
3.9.2 Points for setting the conditions ................................................................................................... 3-26
3.9.3 About the welding constants......................................................................................................... 3-27
3.10 Welding conditions of WB-P350 ........................................................................................................... 3-28
3.10.1 About the welding condition parameters .................................................................................... 3-28
3.10.2 Points for setting the conditions ................................................................................................. 3-29
3.10.3 To adjust the pulse conditions .................................................................................................... 3-30
3.10.4 Waveform control with DC wave pulsed welding ....................................................................... 3-31
3.10.5 About the welding constants....................................................................................................... 3-32
3.10.6 Settgins on the Welding Power Source Side ............................................................................. 3-33
3.11 Welding conditions of WB-P500L.......................................................................................................... 3-35
3.11.1 About the welding condition parameters .................................................................................... 3-35
3.11.2 Points for setting the conditions.................................................................................................. 3-36
3.11.3 How the spatter adjustment parameter (APCS cond.) is used................................................... 3-38
3.11.4 To adjust the pulse conditions .................................................................................................... 3-39
3.11.5 Waveform control with DC wave pulsed welding ....................................................................... 3-41
3.11.6 About the welding constants....................................................................................................... 3-42
3.11.7 Settgins on the Welding Power Source Side.............................................................................. 3-43
Chapter 4 Maintenance
4.1 Displaying the Welding Interface (Digital) version .................................................................................... 4-1
4.3 Errors of Welbee Inverter series welding power source ........................................................................... 4-4
4.3.1 Error code list ................................................................................................................................. 4-4
4.3.2 How to reset an error indication ..................................................................................................... 4-6
4.4 Notes on Scope of Warranty and Liability................................................................................................. 4-7
4.4.1 The product for a warranty target ................................................................................................... 4-7
4.4.2 Warranty period .............................................................................................................................. 4-7
4.4.3 Disclaimer....................................................................................................................................... 4-7
4.4.4 Limitation of liability ........................................................................................................................ 4-7
4.4.5 Service in Warranty Period............................................................................................................. 4-8
Chapter 1 Introduction
Replace
Digital communication
D series
Welding
Interface
AXC (Digital) Welbee Inverter series
1-1
1.2 Main specifications
Control software that supports the interface must be installed on the Welbee
Inverter series welding power source that is connected to the interface. To
confirm whether your welding power source is supported by the interface,
check the software version of the welding power source, and then contact
OTC’s Service.
You can check the software version of the welding power source on the front
IMPORTANT panel.
For details, see the instruction manual of your welding power source.
D series welding power sources and Welbee Inverter series welding power
sources cannot be used at the same time.
1-2
1.2 Main specifications
Welbee Inverter series welding power sources connected using the interface are
POINT handled by the AXC controller as the D series welding power sources shown in
"Configuration on the robot controller" in Table 1.2.2 for operations and teaching.
If you replace an existing D series welding power source connected to the AXC controller with a
Welbee Inverter series welding power source as shown in Table 1.2.3, you can continue to use
the existing programs and welding condition file (however, you need to adjust the welding
conditions).
To replace using Welding Interface (AXWF-10**), you need to re-teach the arc start/end functions
(AS/AE functions) (delete and re-teach the AS/AE functions), and re-create the welding condition
file.
Table 1.2.3 Replacing the D series with the Welbee Inverter series
Welding power source after
Welding power source before replacement
replacement
Welding power source Area Welding power source Area
DM350 Japan
Japan
DM350(S-2) Japan Welbee Inverter M350
DM350 Asia Asia
Japan Japan
DM500 Welbee Inverter M500
Asia Asia
DR350 Japan Welbee Inverter M350 Japan
DL350 Japan
Welbee Inverter M350L Japan
DL350 (S-2) Japan
DP350 Japan Welbee Inverter P350 Japan
DP400R Japan
Welbee Inverter P500L Japan
DP500 Japan
1-3
1.2 Main specifications
1-4
1.2 Main specifications
Required 64 MB or more
USB memory (Note 2) USB memory (1GB) for external storage:
Recommended
L21700U00
Required 64 MB or more
CF card
(Required for obtaining the backup data) External storage CF (256 MB) for AXC:
Recommended
L9742U00
CF card reader One or more (required for reading the backup data)
(Note 1) The product of our company develops and sells English version and Japanese version Windows as
operation guarantee target OS. Please acknowledge not guaranteeing operation on other language
versions Windows.
(Note 2) For this interface, USB memory is required when writing the setup data onto the Welding Interface
(Digital) board.
1-5
1.2 Main specifications
Unit(mm)
Figure 1.2.1 External view of Welding Interface (Digital) board
1-6
1.3 Standard configuration
1-7
1.3 Standard configuration
Control cable 5
AX-C
Welding Interface (Digital)
Figure 1.3.1 Components for Peripherals of Robot controller and Welding power source
1-8
1.4 Welding mode lists
1-9
1.4 Welding mode lists
1-10
1.4 Welding mode lists
Use welding characteristic data with a "High" Travel speed as the welding characteristic
POINT data for Table 1.4.2. If the welding speed is low (generally, 50 cm/min or less) and the
welding is unstable, use welding characteristic data with a "Standard" Travel speed.
Welding performance may become unstable when using the extended power cable
depending on the layout condition of cables (when the total length exceeds 30m or the
cable is coiled). In that case, voltage adjustment will normally bring about stable
condition. However, use the welding characteristic data dedicated to “Extension cable”
application if the welding performance is not yet stable.
1-11
1.4 Welding mode lists
Use welding characteristic data with a "High" Travel speed as the welding characteristic
POINT data for Table 1.4.3. If the welding speed is low (generally, 50 cm/min or less) and the
welding is unstable, use welding characteristic data with a "Standard" Travel speed.
Welding performance may become unstable when using the extended power cable
depending on the layout condition of cables (when the total length exceeds 30m or the
cable is coiled). In that case, voltage adjustment will normally bring about stable
condition. However, use the welding characteristic data dedicated to “Extension cable”
application if the welding performance is not yet stable.
1-12
1.4 Welding mode lists
1-13
1.4 Welding mode lists
1-14
1.4 Welding mode lists
Use welding characteristic data with a "High" Travel speed as the welding characteristic
POINT data for Table 1.4.4. If the welding speed is low (generally, 50 cm/min or less) and the
welding is unstable, use welding characteristic data with a " Standard " Travel speed.
Welding performance may become unstable when using the extended power cable
depending on the layout condition of cables (when the total length exceeds 30m or the
cable is coiled). In that case, voltage adjustment will normally bring about stable
condition. However, use the welding characteristic data dedicated to “Extension cable”
application if the welding performance is not yet stable.
1-15
1.4 Welding mode lists
1-16
1.4 Welding mode lists
1-17
1.4 Welding mode lists
1-18
1.4 Welding mode lists
Normally, use the welding characteristic data given in Table 1.4.5 dedicated to “High”
POINT application. The ones for “Standard” application must be used only when the welding
speed is low (50cm/min or lower in general), which causes unstable welding
performance.
Welding performance may become unstable when using the extended power cable
depending on the layout condition of cables (when the total length exceeds 30m or the
cable is coiled). In that case, voltage adjustment will normally bring about stable
condition. However, use the welding characteristic data dedicated to “Extension cable”
application if the welding performance is not yet stable.
The welding mode cannot be switched as follows during welding. Do not perform teaching
for the following.
From DC low spatter to DC/DC pulse/DC wave pulse
IMPORTANT From DC/DC pulse/DC wave pulse to DC low spatter
Switching the welding mode as above causes “A5021 Arc welding characteristic data
failure.” or “A5023 Failure of the welding power supply occurred.”.
1-19
Chapter 2 Connections
1 Turn off the primary power supply and circuit breaker on the robot controller.
2 The Welding Interface (digital) board is fixed to the position shown in Figure 2.1.1 of the
robot controller by the plate and the locking card spacer.
INFO. If you use two Relay Units and the Built-in Touch Sensor at the same time, the Built-in
Touch Sensor and the Welding Interface (Digital) Board are fixed to the position shown in
Figure 2.1.2.
2-1
2.1 Connect Welding Interface (Digital)
3 Wire the signal cable, and connect the Welding Interface (Digital) Board CNCAN1 and
the Storage Board CNCAN.
4 Wire the 24V power supply cable, and connect the Welding interface (Digital) Board
CNP24V and the Sequence board TBEX3(P1), (M1). If the terminal block on the
Sequence Board is used for another purpose, connect the terminal to the Relay unit
TBIN1(24V), TBIN2(0V).
2-2
2.1 Connect Welding Interface (Digital)
2 Pull the control cable 5 connector through the control cable 5 inlet on the right side of the
robot controller as shown in Figure 2.1.4.
3 Fix the shield section of the cables to the shield fixing fixtures on the left side of the
service entrance as shown in Figure 2.1.5.
Shield fixing plate
Control cable 5
Shield ground
4 Wire the cables as shown in Figure 2.1.6, and connect the Welding Interface (Digital)
Board CNCAN2 and the Sequence Board CNWEL.
Figure 2.1.6 Connection of control cable 5 (Cable wiring and connector connection)
2-3
2.1 Connect Welding Interface (Digital)
3 Pull the connector of control cable 5 from the back of the welding power source and fix
the cable flange with the attached screws.
4 Connect the connector of control cable 5 to the connector CN17 on the printed circuit
board PCB1.
5 Connect the grounding cable to the grounding terminal.
6 Remove the “STOP” jumper wire connected to the terminal block TM3 on the printed
circuit board PCB10 in the welding power source.
7 Attach the back cover.
Control cable 5
Printed circuit board
Front (Upper) Socket for wire feeder PCB1
Front (Lower)
CN17
To wire feeder
Torch side welding cable
Control cable 4
Figure 2.1.7 Connection of digital welding power source (WB-M350L/ WB-M350 / WB-M500)
2-4
2.1 Connect Welding Interface (Digital)
2.1.5 Connection of Workpiece side welding cable / Torch side welding cable
Connect the cable respectively referring to “CONNECTION PROCEDURE AND GROUND FOR
SAFETY USE” in the instruction manual of each welding power source.
Welding cable
Welding Welding Welding cable
power power source
source
Floor surface
Floor surface
Floor surface
2-5
2.1 Connect Welding Interface (Digital)
INFO. Connect the voltage detecting cable (torch side) to the connector of the upper
arm. For installation procedure, please refer to the instruction manual “Welding
Torch for Robot” and “Coaxial Power Cable for Robot”.
CN28
2-6
2.1 Connect Welding Interface (Digital)
Example 1: In case that the positioner which has a voltage detection terminal is combined
Connect a voltage detection cable (workpiece side) to the voltage detection
terminal.
Be sure to confirm that there exists a stable electrical connection among a
workpiece, a jig and a surface of the table of the positioner.
Example 2: In case that the positioner which has no voltage detection terminal is combined
Connect it directly to the table. When connecting it, select such a position as not
to cause any obstruction during rotation (e.g. lower side of the table).
Be sure to confirm that there exists a stable electrical connection among a
workpiece, a jig and a surface of the table of the positioner.
2-7
2.2 Electrical connection diagram
WB-M350L/ WB-P500L*1
Robot controller
Control cable 5
Com.line
CN17/18
Manipulator Wire feeding unit
CON1 CN4
Control cable 4 CN1 CN2 Wire
Wire feeding
feeding
motor
motor
+5V
Encoder A phase
Encoder line
Encoder B phase
GND
Gas
Gas valve
Voltage detection (Torch)
Voltage detection
(Workpiece) CN28
Output Torch
Voltage detection cable
Voltage detection
(Workpiece)
Workpiece cable (Torch)
Robot controller
Control cable 5
Com.line
CN17/18
Manipulator Wire feeding unit
CON1 CN4
Control cable 4 CN1 CN2 Wire
Wire feeding
feeding
motor
motor
+5V
Encoder A phase
Encoder line
Encoder B phase
GND
Gas
Gas valve
Voltage detection (Torch)
Voltage detection
(Workpiece)
Output Torch
Workpiece
2-8
2.2 Electrical connection diagram
Robot controller
2-9
Chapter 3 Configurations
To use Welding Interface (Digital), you must create setup data using the "Welding
Interface (Digital) Setup" tool. This chapter describes the configuration method
after connecting the various devices, and the method for creating the setup data
and writing it onto the robot controller and the interface.
3.1 Workflow .....................................................................................................3-1
3.2 Configuration preparations..........................................................................3-3
3.2.1 "Welding Interface (Digital) Setup" tool preparations ............................3-3
3.2.2 USB memory preparations....................................................................3-3
3.3 Configuring the robot controller...................................................................3-4
3.3.1 Registering the welding power source ..................................................3-4
3.3.2 Register the welding mode....................................................................3-5
3.3.3 Creating a backup.................................................................................3-7
3.4 Creating the setup data ..............................................................................3-9
3.4.1 Configuring the setup tool .....................................................................3-9
3.4.2 Configuring the welding mode for the Welbee Inverter series welding
power source ....................................................................................3-12
3.5 Writing the setup data ...............................................................................3-14
3.5.1 Writing the setup data onto the robot controller ..................................3-14
3.5.2 Writing the setup data onto Welding Interface (Digital) .......................3-16
3.6 Check the configuration ............................................................................3-17
3.7 Configuring the Welbee Inverter series welding power source .................3-18
3.7.1 The welding power source operations when a robot is connected......3-18
3.7.2 The welding power source internal functions when a robot is connected3-19
3.8 Welding conditions of WB-M350L.............................................................3-20
3.8.1 About the welding condition parameters .............................................3-20
3.8.2 Points for setting the conditions ..........................................................3-21
3.8.3 How the spatter adjustment parameter (APCS cond.) is used ............3-22
3.8.4 About the welding constants ...............................................................3-24
3.9 Welding conditions of WB-M350/500 ........................................................3-25
3.9.1 About the welding condition parameters .............................................3-25
3.9.2 Points for setting the conditions ..........................................................3-26
3.9.3 About the welding constants ...............................................................3-27
3.10 Welding conditions of WB-P350 .............................................................3-28
3.10.1 About the welding condition parameters ...........................................3-28
3.10.2 Points for setting the conditions ........................................................3-29
3.10.3 To adjust the pulse conditions ...........................................................3-30
3.10.4 Waveform control with DC wave pulsed welding ..............................3-31
3.10.5 About the welding constants .............................................................3-32
3.10.6 Settgins on the Welding Power Source Side.....................................3-33
This is a dummy page. DO NOT ERASE.
3.1 Workflow
Configure Welding Interface (Digital) on your computer using the "Welding Interface (Digital) Setup" tool.
The workflow is shown below.
5 Creating a backup
3-1
3.1 Workflow
WB-M350L Adjust the welding conditions to suit your welding power source.
Page 3-20 For details on the welding conditions that can be used with the
interface, see the welding conditions for the various welding
WB-M350/500 power sources from the section 3.8 .
Page 3-25 Also, for details on editing the welding conditions, see the
APPLICATION MANUAL (ARC WELDING) instruction manual
WB-P350 for your robot controller.
Page 3-28
WB-P500L
Page 3-35
POINT To change the registration of the welding characteristic data in f5 <Arc Constant> - [4 Setting
of weld data] on the robot controller in order to change the welding mode that is used, repeat
steps 4 to 7 in this procedure.
3-2
3.2 Configuration preparations
2 Unzip the "Welding Interface (Digital) Setup" tool into any folder.
>> This completes the setup tool preparations.
Create the "UPDATE" folder and "BACKUP" folder in the top level of the USB
memory hierarchy, as shown in the figure.
IMPORTANT
Figure 3.2.1 USB memory preparations
3-3
3.3 Configuring the robot controller
D series welding power sources and Welbee Inverter series welding power
sources cannot be used at the same time.
IMPORTANT
Register the Welbee Inverter series welding power source in the robot
POINT controller as the corresponding D series welding power source shown below.
Table 3.3.1 Recommended settings
D series welding power source
WB series welding power
to register
source to be connected
in the robot controller
WB-M350 DR *1
WB-M500 DM
WB-M350L DL(S-2)
WB-P350 DP *2
WB-P500L DPR *3
*1 Only when replacing an existing DM or DM(S-2) with the Welbee
Inverter series, continue using DM or DM(S-2).
*2 Apply the welding characteristic data for a rated current 350A when
WB-P350 is in connection.
*3 Continue using DP as is only when the existing DP-500 is replaced
with WB-P500L. Also, when using WB-P500L, a rated current 500A
for WB-P500L is available at the maximum even if it is registered as
DPR in the robot controller.
INFO. After registering the welding power source, configure the robot to which the
welding power source will be connected, and the connection type. For details on
the configuration method, see "Chapter 1 Basic settings" in the APPLICATION
MANUAL (ARC WELDING) instruction manual for the robot controller.
3-4
3.3 Configuring the robot controller
For the welding characteristic data to be registered in the robot controller, select
data that matches as much as possible the welding mode used in the Welbee
Inverter series welding power source in terms of welding process, wire material
and polarity. The welding start/end condition setting items that can be edited vary
IMPORTANT depending on the welding characteristic data to be registered in the robot
controller.
3-5
3.3 Configuring the robot controller
3-6
3.3 Configuring the robot controller
This section reproduces the backup operation procedure from the instruction
POINT manual of the robot controller (only this procedure is reproduced). For details
on the backup function and the other file operation functions, see "6 File
operations" in the BASIC OPERATIONS instruction manual of the robot
controller.
The name of the backup folder is given automatically using the following format.
INFO. NRA2001-2012-12-20-1200
Date Time
3-7
3.3 Configuring the robot controller
2 Move to the folder selection field, select the backup destination folder, and press
Enter [Enter].
3-8
3.5 Writing the setup data
The "Welding Interface (Digital) Setup" tool is used in the operations in this section.
3-9
3.4 Creating the setup data
The name of the backup folder is given automatically using the following format.
INFO. NRA2001-2012-12-20-1200
Date Time
3-10
3.5 Writing the setup data
3 Select the "UPDATE" folder that you created in the USB memory.
INFO. If you have not yet created the "UPDATE" folder, you can create it with the
"Create new folder" button. For details on the "UPDATE" folder location, see
"3.2.2 USB memory preparations".
3-11
3.4 Creating the setup data
3.4.2 Configuring the welding mode for the Welbee Inverter series welding
power source
Associate the welding mode used in the Welbee Inverter series welding power source with the
welding mode registered in the robot controller, and save this information in the setup data. For
details on the welding modes that can be used, see "Chapter 1 Introduction" in this manual.
When the setup data is created, the welding characteristic data selected in
POINT "3.3.2 Register the welding mode" is replaced with the data for Welbee Inverter
welding power source.
The welding characteristic data saved in the backup data specified in "3.4.1
Configuring the setup tool" is replaced.
Associating the welding modes of the robot controller and Welbee Inverter welding
power source
1 In [WPS No], select the welding power source registered in the robot controller.
>> The type of the registered welding power source is displayed in [Registered WPS of
RC].
2 In [Actual WPS], select the Welbee Inverter series welding power source to be used.
>> If you cannot select the power source you want, refer to "3.3.1 Registering the
welding power source" and check the correspondence between the D series
welding power source and Welbee Inverter series welding power source. If there is
no corresponding power source, perform the procedure again from "3.3.1
Registering the welding power source".
Check this box when replacing an existing D series welding power source with
a Welbee Inverter series welding power source. Checking this box changes the
welding characteristic data file to current and voltage output characteristics
silimar to those of the D series welding power source.
Unchecking the box changes the welding characteristic data file to the original
current and voltage output characteristics for the Welbee Inverter series
welding power source.
3-12
3.5 Writing the setup data
3 In the [Welding characteristic] item, select the welding mode to use with the
Welbee Inverter series welding power source.
>> The welding mode displayed in [Welding mode in RC side] is associated with the
welding mode set in this step.
INFO. For details on selecting the welding mode, also see "3.3.2 Register the welding
mode".
4 If multiple welding modes are registered in the robot controller, select the next
[Register] tab and repeat the operation from step 3. In this way, associate all the
welding modes registered in the robot controller with the welding modes of the
Welbee Inverter series welding power source.
3-13
3.5 Writing the setup data
4 In "Card 1", select the folder that stores the backup, select "WORK" →
Enter
"A_APPLICATION" → "WELD" in this order, and then press [Enter].
>> The "WELD" folder is selected.
3-14
3.6 Check the configuration
5 In the “Device (dest)” folder selection field, select the folders in the order of
Enter
"Internal memory" → "WORK" → "A_APPLICATION", and then press [Enter].
>> The "A_APPLICATION" folder is selected.
POINT In step 5, select "A_APPLICATION", not the "WELD" folder you selected in
step 4.
3-15
3.5 Writing the setup data
Make sure that the power of the robot controller is OFF before inserting the USB
memory or operating a DIP switch.
IMPORTANT
1 While the power of the robot controller is OFF, connect the USB memory to the
Welding Interface (Digital) board.
USB port
7 segment LED
DIP switch
2 While the power of the robot controller is OFF, turn ON the No. 3 DIP switch on
the Welding Interface (Digital) board. Turn OFF the other DIP switches.
4 When the 7-segment LED displays 'E' → 'n' → 'd' in order, check on the robot
controller teach pendant that the robot controller has started, turn OFF the robot
controller power, and then turn OFF all the DIP switches. Take off the USB
memory.
>> This completes the configuration of the Welding Interface (Digital) board.
After turning ON the power of the robot controller, do not turn OFF the power until
the starting process has completed (do not turn OFF during startup).
IMPORTANT
When these steps are performed, the setup file already written in this board is
backed up automatically to a USB memory.
If step2 is changed “Both No.2 and No.3 of a DIP switch are turned ON”, the
setup file can be restored from backup.
3-16
3.6 Check the configuration
4 Check that the emergency stop is not being input to the robot controller, and
check whether errors other than those described above have occurred.
If the emergency stop is being input, cancel it.
If an error has occurred, troubleshoot by referring to the instruction manual of the
robot controller.
5 Check that the front panel display of the welding power source is as follows.
(1) The "000 000" blinking has gone off.
(2) The dots to the bottom right of the left and right digital meters are
blinking.
(3) The display indicating the welding mode (wire diameter, material and gas)
is the last welding mode (mode with the highest registration number) that
was registered in "3.4.2 Configuring the welding mode for the Welbee
Inverter series welding power source".
If different from (1) above, refer to "Chapter 2 Connections" and check that the
interface is connected correctly.
If different from (2) or (3) above, refer to "Chapter 4 Maintenance" and check that no
errors have occurred for the interface. Also, perform "3.3 Configuring the robot
controller" to "3.5 Writing the setup data" again.
6 Operate the TP of the robot controller to check that the gas check and the
inching/retracting of the welding wire was executed correctly.
If different from above, check that "3.3 Configuring the robot controller" was
performed correctly.
>> The setup operations were completed correctly.
3-17
3.7 Configuring the Welbee Inverter series welding power source
Figure 3.7.1 Welbee Inverter series welding power source Front Panel
Table 3.7.1 Keys that can be used when the welding power source is connected to a robot
Key name Description of function
Used when saving a simple data log to a USB memory. For details, see the
LOAD
instruction manual for the welding power source.
This key cannot work alone. Press [ENTER] key for a while (Approx. 3 sec.) to
ENTER switch the key lock ON/OFF.
When the key lock is ON, LED for [ENTER] key flashes.
When the key is pressed once, gas is discharged (for up to 2 minutes), and
GAS CHECK the LED lights. When it is pressed again, the gas discharge stops, and the
LED goes off.
When the key lock is disabled, the functions (status settings) become
available by holding down this key for a few seconds. But the settings of the
F functions are ignored when Welbee Inverter series is configured for a robot.
If holding down the [F] key when turning ON the power, the software version is
displayed.
INFO. When set for the robot dedicated application, all LEDs in TRAVEL SPEED key are
OFF.
3-18
3.7 Configuring the Welbee Inverter series welding power source
3.7.2 The welding power source internal functions when a robot is connected
When a Welbee Inverter series welding power source is connected to the robot, internal functions
that can be used with the welding power source are displayed in Table 3.7.2. Any other functions
related to the welding control and welding performance itself are configured by the welding
constants.
Table 3.7.2 Internal functions that can be used when the Welbee Inverter series welding power
source is connected to a robot
Function
Function name Function
number
Switches the I/O settings for the welding power
source.
0 : Semi-automatic machine
4 Auto/Semi auto mode 1 : Automatic 1
2 : Automatic 2
3 : OTC robot 1 (500Kbps mode)
4 : OTC robot 2 (1Mbps mode)
Setting of Result Display See the instruction manual for the welding power
8
Holding Time source.
Cooling fan maximum See the instruction manual for the welding power
21
operation source.
Keypad tone ON/OFF See the instruction manual for the welding power
22
Selection source.
This is used to set the numbers (1 to 4) of the
welding power sources.
43 Welders ID (CANID) Select <Arc Constant> – [1 Registration of welder],
and select the numbers corresponding to the
welding power sources to be registered.
Do not change any other internal functions other than the above.
If changes are made, the welding power source may not operate properly. However, it
may be necessary to configure the settings separately for the function when the
registered welding power source is DP. For details, see “3.11.7 Settgins on the
IMPORTANT Welding Power Source Side” or “3.11.7 Settgins on the Welding Power Source Side”.
As for the function number 4 [Auto/Semi-auto mode], set it to “3: OTC robot 1
(500Kbps)”.
In the initial factory settings, the setting for function number 4 "Auto/Semi auto mode" is
INFO. set to "0: Semi-automatic machine".
If the welding power source is communicating normally with the robot controller, the
lowest dots in the left/right digital meters are blinked.
3-19
3.8 Welding conditions of WB-M350L
3-20
3.8 Welding conditions of WB-M350L
In the case where the arc characteristic is set in “+” side, the further minimizing spatter may
INFO. be found in the current area where the angular-advance spatter-reducing effect can be
produced. However, if the value is set too high, the welding easily becomes unstable and the
electrical tolerance of the condition will drop to a lower value. A “–” figure setting yields a
stronger immunity to the fluctuations in the protruding wire and an improved stability of the
posture welding. Note that if the high value is set in the respective sides “+” and “–”, the
welding may become unstable.
Normally, set the same values to Arc char.1 (Short) and Arc char.2 (Arc).
When the crater time has been set at 0, the “Welding method” for the arc end
condition shall be set to the same one for the main welding.
IMPORTANT
3-21
3.8 Welding conditions of WB-M350L
Short-circuit current
inclination period Short-circuit current
fixation period
0A
Neck
The sensitivity for detecting necking is set in advance for each welding method and wire diameter.
However, this sensitivity is affected by such factors as the welding environment (lengths and
routing of secondary cables) and the actual welding conditions (welding conditions such as the
posture, lap welding and fillet welding, and the protrusion length of the wire). For this reason, the
preset necking detection sensitivity is not necessarily optimal, and the generation of spatter may
not be reduced satisfactorily.
WB-M350L has a function for automatically adjusting the necking detection sensitivity in the face
function. It is called the automatic necking sensitivity adjustment function.
Whether the necking is being detected properly can be determined by the “reduction rate” on the
arc monitor.
3-22
3.8 Welding conditions of WB-M350L
The automatic adjustment results are displayed on the arc monitor upon completion of welding
(after the AE command has been executed). If, however, welding is suspended due to a
temporary stop or other action, the adjustment results immediately prior to the action will be
displayed.
3-23
3.8 Welding conditions of WB-M350L
POINT In the case where the automatic necking sensitivity adjustment is not
performed
In the case of corresponding to the welding conditions shown in Table 3.8.3,
automatic adjustment isn’t applied. The fixed adequate conditions in the
welding power source are applied.
Table 3.8.3 Field where automatic necking sensitivity adjustment is not performed
Welding mode
Current setting value
Wire material Gas Wire diameter
CO2 0.8, 0.9, 1.0, 1.2
Mild steel solid 300A or over
MAG 0.8, 0.9, 1.0, 1.2
3-24
3.9 Welding conditions of WB-M350/500
3-25
3.9 Welding conditions of WB-M350/500
When the crater time has been set at 0, the “Welding method” for the arc end condition
shall be set to the same one for the main welding.
IMPORTANT
3-26
3.9 Welding conditions of WB-M350/500
3-27
3.9 Welding conditions of WB-M350/500
Arc character. ○ ― ―
Wave frequency ― ― ○
Burnback adj. T. ― ○ ○
○: Can be used
―: Cannot be used.
※: The welding mode displayed on the robot controller may be different from the welding mode
of the Welbee Inverter welding power source. For details, see "3.4.2 Configuring the welding
mode for the Welbee Inverter series welding power source".
3-28
3.9 Welding conditions of WB-M350/500
When the crater time has been set at 0, the “Welding method” for the arc end condition
shall be set to the same one for the main welding.
IMPORTANT
3-29
3.9 Welding conditions of WB-M350/500
• Arc characteristic ... For hardening or softening the condition of the arc.
• Wave frequency ... For adjusting the ripple pitch of the beads shaped like fish scales.
Fig 3.10.1 Adjustment of beads shaped like fish scales using wave frequency
In some cases, ripple patterns of the welded beads may not be precisely
INFO. visible depending on the type of material used, welding speed and the heat
input during welding. Especially, the patterns of welding materials such as
the SUS, a mild steel that takes time to harden, cannot be seen unlike the
welded beads of aluminum alloy welding.
There is a major relationship between the reduction of blowholes and the
measure of the melted metal’s vibration. The bigger the extent of the molten
pool, the bigger the vibrations as well; reducing more blowholes. On the
contrary, if the molten pool is small, then fewer blowholes will be eliminated.
If thicker beads are used for welding, the effects are bigger. However,
blowholes should not be taken away from all of the welding materials such
as extremely thick coated or oil-based steel products and cast materials.
If short-circuit occurs frequently while welding using soft aluminum, the
overview of the bead could appear black.
3-30
3.9 Welding conditions of WB-M350/500
Waveform control (arc start - welding underway - crater treatment) is conducted as follows.
Wire speed
Welding current
Fig 3.10.2 Waveform control with the DC wave pulsed welding method
(arc start – welding underway – crater treatment)
3-31
3.9 Welding conditions of WB-M350/500
Enable
Item
/Disable
Inching/Retract speed ○
Inching/Retract Key operation ○
Gas check operation ○
Preflow time ○
Arc outage detect time ○
Online modification cycle ○
Auto. storing for online mod. ○
Arc start failure detect time ○
Arc start timing adjust time ○
Arc start retry number ○
Wire retract time ○
Scratch start ○
Waiting time after welding starts ○
Arc end timing adjustment time ○
Wire stick check ○
Wire stick release time ○
Torch △
WIF timeout check △
Restart retract distance ○
Arc monitor display cycle ○
Arc monitor sample data num ○
Welding curr./volt. fail. act. ○
Welding current failure limit ○
Welding voltage failure limit ○
Wire feed load fail action ○
Wire feed load fail rate ○
Stop welder at END ○
WIF timeout check adjust. ○
Arc outage detect. time (Arc End) ○
Processing when fan error △
Processing when volt shortage △
Direct arc voltage detection △
○: Can be used.
△: Perform settings on the front panel of welding
power source. For details, see “3.10.6
Settgins on the Welding Power Source Side”.
The settings made on the screen of welding
constants cannot be reflected.
3-32
3.9 Welding conditions of WB-M350/500
・Torch
・Penetration adjustment function
・Arc voltage direct detection
・Process in the fan failure
・Process in the shortage of input voltage
4 Move the kob on the front panel to align the digital indication on the left side to “A1”.
Press F key.
The digital indication on the right side blinks. Move the kob on the front panel under the
condition to set ON.
5 Configure the settings for each function. For the setting manner, see Table 3.10.3.
3-33
3.9 Welding conditions of WB-M350/500
ON :Available
OFF:Not available
It selects the torch cooling
maner.
3-34
3.11 Welding conditions of WB-P500L
3-35
3.11 Welding conditions of WB-P500L
INFO. In the case where the arc characteristic is set in “+” side, the further minimizing spatter may
be found in the current area where the angular-advance spatter-reducing effect can be
produced. However, if the value is set too high, the welding easily becomes unstable and the
electrical tolerance of the condition will drop to a lower value. A “–” figure setting yields a
stronger immunity to the fluctuations in the protruding wire and an improved stability of the
posture welding. Note that if the high value is set in the respective sides “+” and “–”, the
welding may become unstable.
When the crater time has been set at 0, the “Welding method” for the arc end condition
shall be set to the same one for the main welding.
IMPORTANT
3-36
3.11 Welding conditions of WB-P500L
POINT When the registered welding power source is DP, it is not available to set the
retract adjustment time. Retracting is executed for the time specified in the
Table 3.11.2 as the adjustment time of 0.
3-37
3.11 Welding conditions of WB-P500L
Short-circuit current
inclination period Short-circuit current
fixation period
0A
Neck
The sensitivity for detecting necking is set in advance for each welding method and wire diameter.
However, this sensitivity is affected by such factors as the welding environment (lengths and
routing of secondary cables) and the actual welding conditions (welding conditions such as the
posture, lap welding and fillet welding, and the protrusion length of the wire). For this reason, the
preset necking detection sensitivity is not necessarily optimal, and the generation of spatter may
not be reduced satisfactorily.
WB-P500L function for automatically adjusting the necking detection sensitivity in the face
function. It is called the automatic necking sensitivity adjustment function.
POINT In the case where the automatic necking sensitivity adjustment is not
performed
In the case of corresponding to the welding conditions shown in Table 3.11.3,
automatic adjustment isn’t applied. The fixed adequate conditions in the
welding power supply are applied.
3-38
3.11 Welding conditions of WB-P500L
Table 3.11.3 Field where automatic necking sensitivity adjustment is not performed
Welding mode
Current setting value
Wire material Gas Wire diameter
CO2 0.8, 0.9, 1.0, 1.2
Mild steel solid
MAG 0.8, 0.9, 1.0, 1.2 300A or over
SUS solid MIG 0.8, 0.9, 1.0, 1.2
• Arc characteristic ... For hardening or softening the condition of the arc.
• Wave frequency ... For adjusting the ripple pitch of the beads shaped like fish scales.
Fig. 3.11.2 Adjustment of beads shaped like fish scales using wave frequency
3-39
3.11 Welding conditions of WB-P500L
In some cases, ripple patterns of the welded beads may not be precisely
INFO. visible depending on the type of material used, welding speed and the heat
input during welding. Especially, the patterns of welding materials such as
the SUS, a mild steel that takes time to harden, cannot be seen unlike the
welded beads of aluminum alloy welding.
There is a major relationship between the reduction of blowholes and the
measure of the melted metal’s vibration. The bigger the extent of the molten
pool, the bigger the vibrations as well; reducing more blowholes. On the
contrary, if the molten pool is small, then fewer blowholes will be eliminated.
If thicker beads are used for welding, the effects are bigger. However,
blowholes should not be taken away from all of the welding materials such
as extremely thick coated or oil-based steel products and cast materials.
If short-circuit occurs frequently while welding using soft aluminum, the
overview of the bead could appear black.
3-40
3.11 Welding conditions of WB-P500L
Waveform control (arc start - welding underway - crater treatment) is conducted as follows.
Wire speed
Welding current
Fig. 3.11.3 Waveform control with the DC wave pulsed welding method
(arc start – welding underway – crater treatment)
INFO.
Even if “100% (Maximum)” is set for the mild and stainless steels, the melted
metal will flow before it hardens. Therefore, there are cases where the bead’s
ripple does not exceed the ripples that are created at “50% (Standard).”
POINT
When the registered welding power source is DP, it is not available to set the
amplitude rate.
3-41
3.11 Welding conditions of WB-P500L
3-42
3.11 Welding conditions of WB-P500L
・Torch
・Penetration adjustment function
・Arc voltage direct detection
・Process in the fan failure
・Process in the shortage of input voltage
INFO. The setting of these items can be managed on the screen of welding constants
when DPR is registered.
4 Move the kob on the front panel to align the digital indication on the left side to “A1”.
Press F key.
The digital indication on the right side blinks. Move the kob on the front panel under the
condition to set ON.
5 Configure the settings for each function. For the setting manner, see Table 3.11.6.
3-43
3.11 Welding conditions of WB-P500L
ON :Available
OFF:Not available
It selects the torch cooling
maner.
3-44
Chapter 4 Maintenance
This chapter describes the maintenance function and warranty of the interface.
Display the firmware version while the power of the welding power source
connected to the interface is ON.
IMPORTANT
RESET 3 In the top screen of the teach or playback mode, press [Reset/R].
R >> The [Shortcut R code Entry] screen is displayed.
The version displayed for the "Arc WPS1" item is the interface firmware version.
4-1
4.2 List of Welding Interface (Digital) error codes
When an error occurs in the interface, one of the following errors is displayed on the teach
pendant (TP) of the robot controller.
“A5023 Failure of the welding power supply occurred.”
IMPORTANT “E4000 Communication timeout occurred between the controller and the welding power
supply.”
4-2
4.2 List of Welding Interface (Digital) error codes
INFO. You can perform a USB memory error check (*1 in the previous table) on a Windows computer
by right-clicking the drive of the USB memory, and then executing the check in "Properties" →
"Tools" tab → "Error checking".
4-3
4.3 Errors of Welbee Inverter series welding power source
Table 4.3.1 Error code list of Welbee Inverter series welding power source
Digital meter Error code of Error
Contents of error supporting display
Left Right robots *4 release
method *3
E- 41 Panel communication error A5023 (3)
E- 100
Control power supply error A5039 (3)
E- 110
E- 150 Input over voltage A5023 (3)
E- 160 Shortage of input voltage A5023 (3)
E- 200 Primary current detection error A5040 (3)
E- 210 Error in the arc voltage detection A5030 (1)
Error in the arc voltage detection
E- 215 A5097 (1)
(RS Control)
E- 220 Primary side main circuit error A5023 (3)
E- 230 Primary driver error A5023 (3)
Secondary current detection
E- 240 A5040 (3)
error
E- 250 Secondary side main circuit error A5023 (3)
Error in the output voltage
E- 260 A5039 (3)
detection circuit
E- 300
E- 301
Thermal overload A5026 (3)
E- 302
E- 303
E- 310
E- 311 Cooling fan error A5023 (3)
E- 312
For
DM/DM(S-2)/DR
/DP/DPR
E- 500 Lack of water pressure (2)
A5023
For DL/DL(S-2)
A5036
E- 615 Memory backup error - (1)
Secondary side output over
E- 700 A5025 (1)
current error
E- 710 Lack of phase error A5028 (3)
E- 800
Encoder in the wire feeder error A5032 (1)
E- 801
Thermal overload in the governor
E- 810 A5042 (1)
circuit
4-4
4.3 Errors of Welbee Inverter series welding power source
Table 4.3.1 Error code list of Welbee Inverter series welding power source
Digital meter Error code of Error
Contents of error supporting display
Left Right robots *4 release
method *3
For
DM/DM(S-2)/DR
/DP/DPR
E- 830 Motor over current error (1)
A5023
For DL/DL(S-2)
A5095
E- 850 Control power supply error in the
A5039 (3)
E- 860 governor circuit
E- 950 CAN Bus off error A5023 (4)
E- 957 CAN Timeout error A5023 (4)
E- 980 Characteristic data error A5023 (4)
000 000 *1 Operation Stop None *2 (2)
*1: Both right and left displays flash on and off. This display appears when the robot
controller is in the following conditions.
An emergency stop was input by an emergency stop button or external
emergency stop signal
An error has occurred
If this display appears when the robot controller is in a condition other than the above,
check the connection of control cable 5.
*2: A5096 is displayed when operating Welding power sources during non-operation.
*3: For details, refer to Table 4.3.2.
*4: May be displayed as a different error code, depending on the software version of your
robot controller.
When a number is displayed in this code, refer to the contents of the error in
IMPORTANT the table below.
If no number is displayed, check the error code displayed on the front panel of
the welding power source.
Code Contents of error
The arc characteristic can't be changed while arc welding.
5021
Please modify the task program.
4-5
4.3 Errors of Welbee Inverter series welding power source
The method for clearing error displays on the “Table 4.3.1 Error code list of Welbee Inverter
series welding power source” are as shown below.
4-6
4.4 Notes on Scope of Warranty and Liability
Fuse, Communication cable, Power cable of Ref No.(1) in Table 1.3.1 is outside for a warranty.
4.4.3 Disclaimer
The following cases are out of the scope of warranty within the warranty period.
(1) Failure caused by improper condition environment, handling and usage that are not
described in the instruction manual and catalog
(2) When the cause of failure is due to the reason other than our product
(3) Failure due to the reason other than our product such as customer's equipment or software
(4) Failure caused by the modification and repair implemented by party other than our company
(including the specified service shop)
(5) When the failure is caused by improper maintenance or replacement of consumable parts
described in the instruction manual and catalog (failure etc. caused by the use of goods other
than genuine parts and parts / lubrication oil specified by our company)
(6) When the failure cannot be forecasted by the science / technology level as of purchase
(7) Damage caused by natural disaster such as earthquake, fire, flood disaster or offence by
third party and the failure that has a roots in that damage
(8) Failure caused by movement after delivery and defective storage
(9) Sound, vibration, bleeding of oil, color degradation of coated surface, rust and slight dent on
appearance that have no problem in performance
(10) Failure caused by transportation and construction work out of range of our construction
(11) In case of reselling, assignment and lend-lease (including the rental equipment)
(12) Other case that conforms to above and consumable parts / service parts
However, the assurance here means the assurance of our product single unit, so the loss caused
by the failure of our company is not excluded from the range of assurance.
4-7
4.4 Notes on Scope of Warranty and Liability
4-8