YASKAWA MOTOWELD-E500-6N3 User manual

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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.