YASKAWA MOTOWELD-E500-6N3 User manual

1
YASKAWA
MOTOWELD-E500-6N3
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read this instruction thoroughly, and
retain for future reference.
MANUAL NO.HW0482309
180368-1CD
0

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MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOWELD-E500III.
The welding type and some parameter meanings in MOTOWELD E500
III differ from the MOTOWELD-E350II. Therefore, even those who have
used the MOTOWELD-E350II must read this manual carefully and
understand the contents before handling the MOTOWELD-E500III.
For the wire feeder, the welding torch, and the gas regulator, read
each instruction manual carefully.
• General items related to safety are listed in the Safety Manual Section
1: Safety. To ensure correct and safe operation, carefully read the
Setup Manual before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples
and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due
to product improvements, modifications, or changes in specifications.
If such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA rep-
resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number
listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.

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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of the
MOTOWELD-E500III.
In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”
“MANDATORY,” or “PROHIBITED.”
WARNING Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury to personnel.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury to personnel and
damage to equipment. It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the items listed under this
heading.
PROHIBITED Must never be performed.
"Serious injury" described above indicates loss of eyesight, injuries, burns (both due to
high/low temperature), electric shock, fractures, poisoning, etc. which may cause personnel to
suffer aftereffects, hospitalization, or prolonged out-patient medical treatment.
"Moderate injury" indicates injuries, burns, or electric shock which does not require
hospitalization or prolonged out-patient medical treatment.
"Damage to equipment" indicates expanded damages relating to property or equipment.
Even items described as CAUTION may result in a serious accident in some situations.
At any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to follow all instructions,
even if not designated as "CAUTION" and "WARNING."
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.

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WARNING
Be sure to observe the following warnings to avoid serious injury to personnel.
• Be sure to observe the precautions in this instruction manual although
this welder is designed and manufactured with sufficient
consideration given to safety.
Failure to observe this warning may result in death or serious injury to personnel.
• Observe the regulations and your own references for the construction
of the input power sources, selection of the installation site, handling of
high-pressure gases, storage and piping, storage of manufactured
products after welding, disposal of wastes, etc.
• Do not let personnel to approach the welder or welding sites
unnecessarily.
• Any person using a pacemaker must not approach the welder or
welding site under operation unless permitted by doctor.
The welder generates a magnetic field around it during current conduction, resulting in
bad influence on the pacemaker.
• Clean the cooling-water path once a month when using a water-cooled
torch and the cooling water circular.
Failure to observe this warning may result in explosion or burns due to the choked path.
• In order to secure safe operations, only a trained or qualified person
who has understood the welder must perform installation, maintenance
and inspection, or repair of the welder.
• In order to secure safe operations, only a person that has understood
this instruction manual and has knowledge and techniques to handle
the welder safely must operate the welder.
• Do not use the welder for any applications other than welding.

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WARNING
Be sure to observe the following warnings and use protectors
to protect yourself or other people from the fumes or gases
generated at welding and short of the oxygen.
• In order to prevent gas poisoning or suffocation,
be sure to ventilate sufficiently or use an inhaler,
etc. when welding at a place specified by
regulations such as labor safety and sanitary
regulations or hypoxia preventive regulations.
• In order to prevent dust trouble or gas poisoning due to the fumes or
gases, use a local air exhaust facility specified by regulations such as
labor safety and sanitary regulations or dust trouble preventive
regulations or use effective protectors for breathing.
Fumes or gases generated at welding may harm your health.
• When welding within such areas as a tank, a boiler, or a ship's hold, be
sure to ventilate sufficiently or use an inhaler, etc. in order to prevent
or offset any actual or potential oxygen shortage.
Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom.
• When welding in a small space, be sure to ventilate the site sufficiently
or use an inhaler. At the same time, operations must be done under
trained supervisor.
Welding operations at a small space may result in short of the air, causing a person to
be suffocated.
• Do not perform welding near degreasing, cleaning, or spraying
operations.
Failure to observe this warning may generate extremely noxious gases.
• Before welding coated steel plates, be sure to ventilate sufficiently or
use protectors for breathing.
Welding such coated steel plates generates noxious fumes or gases.

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WARNING
Be sure to observe the following warnings to avoid an electric shock.
• Never touch the charged parts.
Touching the charged parts may result in critical electric shock or
burns.
• Only a qualified person in electric construction should perform
grounding construction for the welder case and base metals (to be
welded) or jigs that are electrically connected to the base metals as
specified in the electric facility technical reference.
• Be sure to perform installation or maintenance and inspection five
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 use any cable of insufficient capacity or damaged or with its
conductor exposed.
• Tighten the cable connecting sections firmly and insulate them.
• Do not use the welder with its case or cover removed.
• Do not use worn, damaged or wet gloves. Always use dry insulated
gloves.
• Use lifelines when working at hights.
• Perform maintenance and inspection periodically. Repair damaged
parts immediately.
• Turn OFF all equipment input power supplies when not being used.
• When performing AC arc welding in a small space or at hights, be sure
to use equipment to prevent critical electric shock as specified by
labor safety and sanitary regulations.

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WARNING
Observe the following cautions to prevent fire, explosion,
or rupture.
• Remove inflammables so that they will not get
spattered.
If they cannot be removed, use the inflammables
with nonflammable covers.
Spatters or hot base metal immediately after welding may result in fire.
• Do not weld near flammable gases.
If arc is generated in a container (for inflammables) in which gasoline or the like is put,
the container may explode.
• Do not make hot base metals immediately after welding close to
inflammables.
• Remove inflammables at the hidden side when welding ceiling, floor,
or wall.
Failure to observe this caution may result in fire.
• Tighten and insulate the cable connections.
Imperfect cable connections or imperfect contacting section of the current path at the
base metal such as iron framework may result in fire due to heat generation by current
conduction.
• Connect the cable at the base metal as close to the welding part as
possible.
• Do not weld a gas tube having gas inside or an enclosed tank or pipe.
Welding an enclosed tank or pipe may result in rupture.
• Locate fire extinguishers near the welding site.

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CAUTION
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.
• Wear welding mask or shaded glasses appropriate
for welding.
• Wear protective glasses to protect your eyes from spatters or slags.
Scattered spatters or slags may damage eyes or burn the skin.
• Use such protectors as leather gloves, clothes with long sleeves, leg
covers, or leather aprons for welding.
• Install protective curtains around the welding site to protect your eyes
from arc beams.
Arc beams may irritate eyes or burn skins.
• Use noise protector when there is excessive noise.
Noise may damage hearing.

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CAUTION
Be sure to observe the following cautions to prevent a gas cylinder
from falling or a gas regulator from rupturing.
• Observe the regulations and your own references
for the handling of gas cylinders.
Since a gas cylinder is filled with high pressure gas, improper handling may cause high
pressure gas to blow up, resulting in personal injury.
• Use the attached gas regulator or our recommended one.
• Read carefully the instruction manual of the gas regulator and observe
the precautions before using it.
• Hold the gas cylinder in the exclusive-use gas cylinder stand.
A gas cylinder falling may result in personal injury.
• Do not expose the gas cylinder to high temperature.
• Do not bring your face close to the discharging opening when opening
the valve of the gas cylinder.
• Be sure to attach the protective cap when the gas cylinder is not used.
• Do not hang the welding torch over the gas cylinder or keep the
electrode away from the gas cylinder.

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CAUTION
Observe the following cautions to prevent personal injury due to improper handling.
• Do not use the welder with the case or cover
removed.
• Only a qualified person or a person who has
understood the welder must remove the welder case for
maintenanceand inspection or repair. Take preventive measures
not to let other personnel approach the welder or welding sites
unnecessarily by putting up a guard fence or the like.
• Do not contact the rotating cooling fan or feeding roll of the wire
feeder with hands, fingers, hair, or clothes.
Failure to observe this caution may cause someone to be caught in the machine
resulting in personal injury.

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CAUTION
Observe the following cautions to prevent personal injury by
the end tip of the welding wire.
• Do not peep through the chip hole to confirm that
the wire is being fed.
If the wire is projected from the end tip of the welding torch, it may poke you in the eyes
or face.
• Do not bring the welding torch end close to eyes, face, or body to
perform inching or pulling the torch switch.
If the wire is projected from the end tip of the welding torch, it may poke you in the
eyes, face, or body.
• When hanging the wire feeder, remove the anti-fall fastening from
the spool shaft and tighten.
Failure to observe this caution may cause the wire to be removed from the spool
shaft, resulting in personal injury.
Observe the following cautions to prevent burns due to the plasma arc.
If body parts such as hands and fingers directly touch the plasma arc, burns will
result.
• Do not put your hands and fingers near the chip and the electrodes
of the torch end during cutting operation.
• Do not grasp near the base metal during cutting operation.
• Turn OFF the power supply before replacing the chip or the
electrodes of the torch..

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CAUTION
Observe the following cautions to prevent a fire accident caused
by deterioration of welder insulation.
• Perform all welding and grinding away from welder to
protect welder from spattering and metal powder.
Spatter and metal powder inside the welder may cause a deterioration of insulation
resulting in accidental fire.
• Be sure to perform maintenance and inspection periodically to prevent
deterioration of insulation caused by accumulation of dust and dirt.
• If spatter or metal powder enters the inside of the welder, remove it by
forced air sprot after turning OFF the welder and switch in the switch
box.
Spatter and metal powder inside the welder may cause a deterioration of insulation
resulting in accidental fire.

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CONTENTS
1. Configuration and Specification・・・・・・・・・・・・ 16
2. Installation and Connection・・・・・・・・・・・・・・ 18
2.1 Place of Installation・・・・・・・・・・・・・・・・ 18
2.2 Precautions for Grounding・・・・・・・・・・・・・ 18
2.3 Required Power Supply Facility Capacity
and Connection Cables・・・・・・・・・・・・・・ 19
2.4 Combination with Earch Leakage Breaker
・・・・・・・
19
2.5 Connection of Electric System
・・・・・・・・・・・・
20
2.6 Connection of Shielding Gas System
・・・・・・・・・
23
2.7 Consolidation of Ambient Condition
・・・・・・・・・・
25
2.8 Transporting
・・・・・・・・・・・・・・・・・・・・
26
3. Welding Preparation Procedure
・・・・・・・・・・・・・・・・・
28
4. Operations on Panel・・・・・・・・・・・・・・・・・・ 30
4.1Explanation of Welder Panel・・・・・・・・・・・・ 30
4.2 Setting on Welder Panel・・・・・・・・・・・・・ 33
4.2.1Changing Welding Type・・・・・・・・・・・・ 33
4.2.2 User Files・・・・・・・・・・・・・・・・・・ 35
4.2.3 Changing P Parameters・・・・・・・・・・・・ 35
4.2.4 Changing Common(C) Parmeters・・・・・・・・ 36
4.2.5 Changing D Parmeters・・・・・・・・・・・・ 37
4.2.6 Saving welding Conditions・・・・・・・・・・・ 38
4.2.7 Local Mode・・・・・・・・・・・・・・・・・ 38
4.2.8 Checking the Flow Amount of Shielding Gas・・・ 39
4.2.9Selecting the Feeding Motor・・・・・・・・・・ 39
4.2.10 Display of Motor Current・・・・・・・・・・・・ 40
4.2.11 System Reset・・・・・・・・・・・・・・・・・ 40
4.3 List of Process Parameters・・・・・・・・・・・・ 42
4.4 List of Common Parameters・・・・・・・・・・・・ 44
4.5 List of D Parameters・・・・・・・・・・・・・・・ 46
5. Welding Operation・・・・・・・・・・・
・・・・・・・・・
48
5.1 Checking the Welding Conditions・・・・・・・・・・ 48
5.2 Wire Stickout
・・・・・・・・・・・・・・・・・・・・
48
5.3 Direction of Welding and Torch Angle・・・・・・・・ 48
5.4Notes for Using Extension Cable・・・・・・・・・・ 49
6. Precautions on Welding・・・・・・・・・・・・・・・
・・・・・・・・・
50
6.1 Error Detection
・・・・・・・・・・・・・・・・・・・
50
6.2 Tripped Power Supply Switch・・・・・・・・・・・・ 51

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6.3Precautions on Welding Operation・・・・・・・・・ 51
７．Built-in Functions・・・・・・・・・・・・・・・・・・ 53
7.1Terminals for ARCON Signal Input
for Maintenance Check・・・・・・・・・・・・・・ 53
7.2 Internal Selecting Switch・・・・・・・・・・・・・ 53
7.3 Location of Printed Boards・・・・・・・・・・・・ 55
7.4 How to Use the Selecting Switch・・・・・・・・・ 56
8. Maintenance and Inspections・・・・・・・・・・・・・ 57
9. Fault Analyses・・・・・・・・・・・・・・・・・・・ 59
9.1 Confirming Setting conditions・・・・・・・・・・・ 59
9.2 Cause and Remedy of Welding Section Faults・・・・ 61
9.3 Cause and Remedy of Electrical Circuit Section Faults
・・
64
10. Robot Interface Signals ・・・・・・・・・・・・・・・ 66
10.1 Specifications of Robot Interface Signals・・・・・・ 66
10.2 Meaning and Function of Pr(RC2) Terminal・・・・・ 68
10.3 Meaning and Function of Signal
for Starting Point Detecting Funcion・・・・・・・・ 70
11. Connection System Diagram
・・・・・・・・・・・・・・・・
71
12. Diagnosis Function・・・・・・・・・・・・・・・ 72
12.1 Starting up the Welder in the Diagnosis Mode・・・・ 72
12.2 Confirmation of the DIP Switch Set Status・・・・・ 74
12.3 Confirmation of the Software Version・・・・・・・・ 75
12.4 Confirmation of Welder Error Occurrence Status・・・ 76
12.5 Confirming the Number of Welder Error・・・・・・・ 78
12.6 Clear of Error Record・・・・・・・・・・・・・・・ 79
12.7 End of Diagnosis Mode・・・・・・・・・・・・・・ 79
13. Adjustment of Welding Characteristics
Using Process Parameters・・・・・・・・・・・・・・ 80
13.1Adjustable Welding Characteristics・・・・・・・・・ 80
13.2 Adjustment of Starting Characteristics・・・・・・・ 81
13.2.1 Adjustment of Starting Pulse・・・・・・・・・・ 81
13.2.2 Adjustment ofHot Conditions・・・・・・・・・・ 82
13.3 Adjustment of Ending Characteristics・・・・・・・・ 83
13.4 Adjustment of Short-circuit Welding Characteristics・85
13.5 Adjustment of Pulse Welding・・・・・・・・・・・ 86
13.5.1 Adjustment of MAG Pulse Welding・・・・・・・ 86
13.5.2 Adjustment of MIG Pulse Welding・・・・・・・ 87
13.6 Adjustment Of Other Characteristics・・・・・・・・・・
・・・・
88
13.7 Adjustment of Current Output Characteristics
・・・・・
89

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14. Calibration for External Resistance
・・・・・・・・・・・・・・・・
90
14.1Outline
・・・・・・・・・・・・・・・・・・・・・・
90
14.2Procedure of Calibration for External Resistance・・・ 91
14.2.1Connecting the Cable for Resistance Measurement 91
14.2.2Measurring the External Resistance Value・・・・ 93
14.2.3 Display of External Resistance Setting Parameter 95
14.2.4Setting theD Parameter for Calibration
of External Resistance to “Enabled”・・・・・・ 96
15. Calibration of Welding Current・・・・・・・・・・・・ 98
15.1 Overview of the Welding Current Calibration Function
・
98
15.2 Procedure of Welding Current Calibration・・・・・・ 99
15.3 Parameters for Welding Current Calibration Function・102
16. Welder Condition File Data of the Robot Controller・・ 103
16.1 Common for All Welding Type of “Synergic”(A/%)・・ 103
16.2 Common for All Welding Type of “Independent”(A/V)・103
17. Setting of Arc Monitoring Function・・・・・・・・・・・ 104
17.1 For the Robot Controller: NX・・・・・・・・・・・・ 104
17.2 For the Robot Controller: XRC・・・・・・・・・・・ 105
18. Operation by External Remote Mode
・・・・・・・・・・・
106
18.1 Gas Check
・・・・・・・・・・・・・・・・・・・・
106
18.2 Switch of User Files
・・・・・・・・・・・・・・・・
107
19. List of Service Parts・・・・・・・・・・・・・・・・・ 108

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1 Configuration and Specification
Table. 1 Rated Specifications
Model MOTOWELD-E500III
Type YWE−E500-6N3
Rated Input Voltage and
Number of Phases 480V ±10% , three-phase
Rated Frequency 50 / 60Hz
27.5kVA
Rated Input 24.3kW
Rated Output Current 500A
Rated Output Voltage 42V
Welding Current
Adjustment Range 30 to 500A (depends on the wire diameter)
Welding Voltage
Adjustment Range 12 to 45V (depends on the wire diameter)
Rated Operational Ratio 80%(for 10 minutes)
Wire Feeding Speed 1.5 to 18 m/min
Wire Feed Motor - Servomotor: Print servomoter (standard)
(common for two-axis drive and four-axis drive)
- Applicable to the minertia servomotor for servo torch
Encoder cable 5 m (standard), 7 m max.
Range of Analog Input
Voltage 0 to 14V (Indication of voltage, current, or wire feeding speed that are set to the panel)
Welding Type CO2short-circuit welding, MAG/MIG short-circuit welding, pulse welding
Welding Object Material Iron, stainless steel (Refer to the “Type” on the panel for details.)
Welding Voltage Setting Synergic or independent
Can be switched by D1 parameter 13
User File The number of files: 3
“Panel” or “robot” can be switched by D1 parameter 11.
Adjustment of Voltage
and Current Waveform
Control
Can be changed by P parameter in the user file.
Error Output Output with the arc failure signal on the robot side. (Error contents are
indicated on the panel.)
Arc Touch Start Function This function can be used by D2 parameter 2, 3, and 4.
Gas Running-in Time Approximately 20 seconds (can be switched by panel operation)
Gas Pre-flow Time Approximately 0.06 seconds
(can be switched by panel operation: 65 seconds max.)
Gas After-flow Time Approximately 0.5 seconds
(can be switched by panel operation: 65 seconds max.)
Wire-stick Prevention
Time Approximately 0.2 seconds (Adjustable range by panel operation: 0.02 to 0.4 seconds)
Wire Feeding Slow-down
Speed
Approximately 3m/min for CO2short-circuit welding
(Adjustable range by panel operation: 1.5 to 6 m/min)
Approximately 2 m/min for MAG/MIG short-circuit welding and pulse
welding(Adjustable range by panel operation: 1 to 4 m/min)

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Output for Arc Monitoring Outputs the signal corresponding to current or voltage to the robot side.
And also, outputs to the output terminal block for analog display.
Interface for
Robot Controller Refer to “Robot Interface Signals”.
Voltage for Starting Point
Detecting Function
(optional) Peak value: 280V ±10% (full-wave rectification)
Dimensions
（W×D×H）360mm(W) x 670mm(D) x 601mm(H)
(excluding the protrusion such as screws or eyebolts)
Mass Approximately 70kg
Power Supply of the
Heater for the Gas
Regulator None
Standard accessories
Fuse contained in glass tube of 5A (1 fuse)
Remarks
Front face panel: written in English

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2 Installation and Connection
2.1 Place of Installation
This equipment is designed to be operated under the following conditions:
(1) In a dry indoor location spaced at least 30cm away from walls and from other
surrounding articles.
(2) At a place that is not exposed direct sunlight or rain.
(3) At ambient temperatures from 0℃to +40℃.
(4) At altitude not exceeding 1000 m.
(5) Not in the presence of gases or dust exceeding the amount that can be caused by
normal arc welding.
CAUTION
• The welder can be moved easily by using the caster. After installation,
use the stopper to fix the welder before starting operations.
2.2 Precautions for Grounding
(1) Be sure to carry out secure grounding work on the welder for safety. If the unit is not
properly grounded , its case may be charged and operation of the unit may become
unstable.
(2) Connect a grounding cable of 14mm2or thicker to the terminal marked “GROUND” or
“EARTH”. CAUTION
• Be sure turn off the main switch on the distribution panel before
performing the grounding work.
(3) Be sure to ground the base metal as well when or any other non-conductive material
is place under the base metal.
(4) If there is a pool or pond between the grounding of the power distribution panel and
the welding machine, 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.

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2.3 Required Power Supply Facility Capacity and
Connection Cables
"Table 2-1 Power Supply Capacity and Power Cables" shows the required power supply
facility capacity and connection cables.
The rated input voltage for the welder is three-phase, 480V.
The welder 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 source as stable as possible. If fluctuations in power supply voltage exceed
10％of the rated value , power welding conditions cannot be guaranteed and problems may
occur.
Diameter of the input power cable and the fuse capacity must be in compliance with Table 2-1.
Install a non-fuse breaker (NFB) or a switch with fuse for each welder.
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 at power on.
Table. 2-1 Power Supply Capacity and Power Cables
Power Supply Capacity 30 kVA
Fuse Rated Current 75 A (rated voltage: 480V)
Input Cable 14 mm2or more
Exclusive-use base metal
cable 60 ㎜2or more (cable length: 5 m or less)
80 ㎜2or more (cable length: 5 m or more) *1
Ground Cable 14 ㎜2or more
*1: Be sure to use cables for welding. Also, use cables with sufficient thickness for
pulse welding or current of 250A or more.
Excessively small gauge cables may result in poor welding and cause abnormal
heating resulting in burn or fire.
2.4 Combination with Earth Leakage Breaker
When the welder is used in a construction site, in a place with high humidity, or on an iron
plate, iron framework, or surface plate with high conductivity, a leakage breaker should be
installed according to the proper regulations or laws. In such a case, connect a leakage
breaker of current sensitivity 30 mA for each welder. The welder 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 Connection of Electric System
CAUTION
• Open the disconnect switch of the switchgear before connecting wires
between welding machine and 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.
Fig.2-1 Connection of Power Supply
(1) Connection of Power Supply
Refer to Fig. 2-1,Fig.2-2 for proper connections.
(2) Connection on the Welding Side
Refer Fig. 2-3 for proper connections.
For carbon dioxide gas or MAG gas arc welding, connect the base metal to the minus
cable and connect the torch (wire) to the plus cable. (This is called reverse polarity or
electrode positive.)
(3) Connection of Control Cable
Connect the connector at rear face of the welder and the wire feeder, and the robot
interface connector at rear face of the welder and the control cable (with plug) from
the robot controller. Securely tighten the plug until it stops rotating.