YASKAWA MOTOWELD-T300D User manual

AC/DC TIG Welder Used Exclusively For MOTOMAN
MOTOWELD-T300D
INSTRUCTIONS
YWE-T30D (0)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MANUAL NO. HW0481095
YASKAWA
Part Number: 158413-1CD
Revision: 0

2
MANDATORY
• This instruction manual is intended to explain operating
instructions and maintenance procedures primarily for the MOTOWELD-T300D.
• 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 representative 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.

3
NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or inspection of the
YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury to personnel.
Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury to personnel and damage to equipment. It may also be
used to alert against unsafe practices.
Always be sure to follow explicitly the items listed under this heading.
Must never be performed.
"Serious injury" described above indicates loss of eyesight, injuries, burns (both due to
high/low temperature), electric shock, fractures, poisoninig, 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 operaiton 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.
CAUTION
PROHIBITED
MANDATORY
IMPORTANT
WARNING

4
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.
• 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.
Be sure to observe the following warnings and use protectors to
protect yourself or other people from the fumes or gases
generated at welding.
• In order to prevent gas poisoning or suffocation, 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 in a small space, be sure to ventilate the site sufficiently or use breathing
protectors. 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 such as galvanizing, lead, or cadmium steel plates, remove
the coating materials or wear protectors for breathing.
Welding such coated steel plates generates noxious fume.

5
WARNING
Be sure to observe the following warnings 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.
If any input power supply is turned ON, the input circuit and the itnerior of the welder are charged. When
the welder is ON, the electrodes, base metals, and metallic parts contacting them are charged. 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 input or output cable of insufficient capacity or damaged or with its conductor
exposed.
• Tighten the cable connecting sections firmly and insulate them.
• Connect the cable at the base metal as close to the welding part as possible.
• Do not use the welder with its case or cover removed.
• Be sure to use the welder after attaching the cover on the input or output terminal box.
• 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.
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 weling site to protect your eyes from arc beams.
Arc beams may irritate eyes or burn skins.
• Use noise protector when there is excessive noise.
Noise may damage hearing.

6
CAUTION
Observe the following cautions to prevent fire, explosion, or rupture.
• Remove inflammables so that they will not get spattered. If they
cannot be removed, use the inflammables with nonflammable covers.
Spatters or hot base metal immediately after welding may result in fire.
• Do not weld near flammable gases.
If arc is generated in a container (for inflammables) in which gasoline or the
like is put, the container may explode.
• Do not make hot base metals immeidately after welding close to
inflammables.
• Locate fire extinguishers near the welding site.
• 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.
Be sure to observe the following cautions to prevent a gas regulator from falling or a gas flow rate
adjuster from rupturing.
• Observe the regulations and your own references for the handling of gas
regulators.
Since a gas regulator is filled with high pressure gas, improper handling may cause
high pressure gas to blow up, resulting in personal injury.
• Use the attached gas flow rate adjuster or our recommended one.
• Read carefully the instruction manual of the gas flow rate adjuster and observe the precautions
before using it.
• Hold the gas regulator in the exclusive-use gas regulator stand.
A gas regulator falling may result in personal injury.
• Do not expose the gas regulator to high temperature.
• Do not bring your face close to the discharging opening when opening the valve of the gas
regulator.
• Be sure to attach the protective cap when the gas regulator is not used.
• Do not hang the welding torch over the gas regulator or keep the electrode away from the gas
regulator.

7
CAUTION
Observe the following cautions to prevent personal indury due to improper
handling.
• Do not use the welder with the case or cover removed.
• Only a trained or qualified person 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 upa 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.
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 weld wire guide, 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 weld wire guide, it may poke you in the eyes, face, or body.
When hanging the wire feeder, remove the anti-fall fastner downward 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 a fire accident caused by deterioration of welder
insulation.
• Perfom 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 inpsection periodically to prevent
deterioration of insulation caused by accumulation of dust and dirt.
• If spatter or metal powder enters the inside of the welder, remove it by forced air sprot after
turning OFF the welder and switch in the switch box.
Spatter and metal powder inside the welder may cause a deterioration of insulation resulting in accidental
fire.

8
CONTENTS
1Receiving ･････････････････････････････････････････････ 10
2Transporting ･･･････････････････････････････････････････ 11
2.1 Using the Casters ･･･････････････････････････････････････････････ 11
2.2 Using the Crane ････････････････････････････････････････････････ 11
2.3 Using the Forklift ････････････････････････････････････････････････ 12
3Installation ････････････････････････････････････････････ 13
3.1 Installation Site and Welder Environment･･･････････････････････････ 13
3.2 Installation Site and Gas Regulator Environment ････････････････････ 13
4Wiring ････････････････････････････････････････････････ 15
4.1 Grounding ･････････････････････････････････････････････････････ 15
4.2 Required Power Supply Facility Capacity and Connection Cables ･････ 16
4.3 Combination with Leakage Breaker････････････････････････････････ 17
4.4 Connection of Electric System ････････････････････････････････････ 17
5Gas for Welding････････････････････････････････････････ 22
5.1 Quality of Gas for Welding ･･･････････････････････････････････････ 22
5.2 Gas Pressure Adjuster and Flow Meter ････････････････････････････ 22
6Shading Measures ･････････････････････････････････････ 23
7Precautions on Welding and Preparation Procedure ････････ 24
7.1 Precautions on Welding･･････････････････････････････････････････ 24
7.2 Welding Preparation Procedure ･･･････････････････････････････････ 27
8Basic Specifications ････････････････････････････････････ 30
8.1 Specifications of Both DC/AC TIG Welder ･･････････････････････････ 30
8.2 External Dimensions ････････････････････････････････････････････ 32
9Interface Signals ･･･････････････････････････････････････ 33
9.1 Connector CON2 for Manipulator (17 Pins) ･････････････････････････ 33
9.2 Connector CON3 for Manipulator (11 Pins) ･････････････････････････ 33
9.3 Connector CON1 for Wire Feeder (4 Pins)･･････････････････････････ 34
9.4 Analog Signals ･････････････････････････････････････････････････ 34
10 Built-in Functions･･･････････････････････････････････････ 37
10.1 Terminals for Automatic Machine･･････････････････････････････････ 37
10.2 Internal Adjusting Knob Functions ･････････････････････････････････ 38
10.3 Internal Selector switch Functions ･････････････････････････････････ 38
10.4 Internal Indicator Lamp ･･････････････････････････････････････････ 39
11 Maintenance and Inspection ･････････････････････････････ 41
12 Fault Analyses ･････････････････････････････････････････ 43

9
13 Welding Conditions ･････････････････････････････････････49
13.1 Selection of Welding Method ･････････････････････････････････････ 49
13.2 Electrode and Gas Flow Rate for Various Welding Current ･･･････････ 50
13.3 Welding Conditions of Stainless Steel (SUS 304) and Middle Pulse ･･･ 51
13.4 Conditions of Low-pulse Welding ･････････････････････････････････ 53
13.5 Welding Conditions of Aluminum ･････････････････････････････････ 55
14 Connection Diagrams ･･･････････････････････････････････56
14.1 Connection System Diagram ･････････････････････････････････････ 56
14.2 External Signal System Diagram･･････････････････････････････････ 58
15 Lists of Service Components ･････････････････････････････59

10
1 Receiving
Checking Package Contents
When the package arrives, check the contents for the following standard items (Any
additional options ordered should be checked as well):
• Welder
• Attachment at installation
• Hose for gas (φ6×3 m) ×1
• Hose for cooling water (φ8×5 m) ×2
• A set of hose bands (for gas and water)
• Fuses 3A, 8A, 10A (1 for each)
■ Equipments required for TIG welding
The following shows the configuration of TIG welding.
Welder Welding
torch
Argon
gas
pressure
adjuster
Cooling water
circulator
exclusive for
high-voltage
start
Argon
gas
++++
*1 *2 *3
*1. Do not connect any other cable other than the torch power cable to
the negative side output terminal of the welder (output terminal of
the torch side power cable). Failure to observe this caution may
cause the high DC voltage for arc to start to leak, resulting in poor
arc start performance.
*2. Selected attachment: Two-stage Regulator (with flow meter) (Set the
secondary pressure to 0.15 Mpa.)
*3. Tap water cannot be used as the cooling water source for water
cooled torch. Failure to observe this caution may cause a high DC
voltage for arc to start to leak, resulting in poor arc start performance.
Use a cooling water circulator of cooling-water path insulation type
exclusive for high DC voltage start method.
INFO

11
2 Transporting
CAUTION
• Sling applications and crane or forklift operations must be performed by authorized personnel
only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock while transporting.
The system consists of precision components, so failure to observe this caution may adversely affect
performance.
2.1 Using the Casters
CAUTION
• When using the casters, move the welder slowly so that it can be stopped quickly at any time.
Moving the welder with casters quickly may result in an accident due to inertia and you cannot control the
direction of movement.
• Be sure to stop the welder with casters at a step and move it slowly to prevent any shock
sudden.
• Do not move the welder with casters up a slope, stairs, etc.
2.2 Using the Crane
When using the crane, be sure to confirm the following points before transporting.
• The welder mass is approx. 60kg. Select the wire suitable for the mass and angle.
• Use the eyebolts for transporting and confirm that the eyebolts are tightened firmly
before transporting.
Lift the welder using crane after completion of the above confirmation.
Wire
60° or more
Eyebolt M8

12
2.3 Using the Forklift
Observe the following points to use the forklift for transporting.
• Confirm availability of safe operations site, and transfer the welder to the installing
site.
• After determinig the operation site, warnings must be placed on transport path to
prevent accidents.
• Put the welder on the transporting pallet and fix firmly to prevent falling or shifting.
Employ a stopper on the casters to fix the welder.
Over-tightening the cover may cause it to deform.
• Do not raise the lift excessively.
• Transport the welder at yield speed when using the folklift.

13
3 Installation
CAUTION
• The welder can be moved easily by using the caster. After installation, use the stopper to fix the
welder before starting operations.
3.1 Installation Site and Welder Environment
The welder can be used under the following environmental conditions:
• Dry, indoor and at least 30 cm from the the wall or peripheral devices
• Free from direct sunlight, wind, and rain
• Ambient temperature of -10 to 40℃
• Altitude less than 1000 m
• Free from direct splash of welding spatter or metalic fine powder at grinding
• Humidity up to 90% at 20℃, up to 50% at 40℃with no condensing
■ Wind Prevention and Ventilation
When the welder is used outside and the wind blows, or when a fan is used, put up a screen
to prevent the arc section from being exposed directly to the wind. Normally, the
allowable wind limit for welding using shielding gas is approx. 1.5 m/s or less. If the
wind speed is higher than this limit, stop operation or take some countermeasures such as
putting up a screen.
At operations indoor or in a container, ventilation is needed. In this case, do not use a fan
to blow the air, but ventilate the accumulated gas by providing a ventilating fan or exhaust
duct. A continuous supply of fresh air is required to prevent suffocation of the workers.
Even for indoor operations, sufficient attention to the shield effect must be paid when using
air tools or fans around the welder.
3.2 Installation Site and Gas Regulator Environment
Handle the gas regulator with special care since it contains high pressure gas. Refer to the
instruction manual attached to the gas regulator.
Use the gas regulator in the specified site free from direct sunlight. If you cannot help
installing at the welding site, fix it vertically to the column or gas regulator stand to prevent
it from falling. Avoid heating by welding arc or the like.

14
Fix the gas regulator to prevent it from falling.
Gas regulator
Gas regulator stand

15
4 Wiring
WARNING
• Ground resistance must be 100Ωor less.
The regulation specifies that the ground resistance must be 100Ωor less when the welder is used with
power supply voltage 200 V.
Failure to observe this warning may result in charging the case or unstable operations when the welder is
not installed.
• Before wiring, be sure to turn the primary power supply OFF, and put up a warning sign. (ex.
DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
4.1 Grounding
Ground terminal (crimp terminal) is provided at the lower part of the rear face of the
welder for safe operation.
Follow the local regulations for ground line size.
Connect the ground wire of 14 mm2or more to the terminal which is specified as ground
terminal. (Refer to “Fig. 4.1 Connection at the Rear Face.”)
If there is a pool or pond between the power supply switch gear ground and the welder
ground so that the leak current is concentrated into the pool or pond, not only ground them
but also connect both grounds with cable to make any leak current flow in the cable.
■ Grounding of Base Metal
Be sure to ground the base metal at resistance of 100Ωor less, even when a base such as
lumber is floated.
As shown in “Fig. 4.2 Connection at Front Face,” be sure to connect the base metal to the
positive side output terminal of the welder and ground base metal at resistance of 100Ωor
less individually. If it is not grounded, voltage may be generated in the base metal
resulting in electric shock.
Connect the welder and the base metal with exclusive-use base metal cable.

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4.2 Required Power Supply Facility Capacity and Connection Cables
CAUTION
• Be sure to use cables for welding with sufficient thickness.
Excessively thin cables may cause abnormal heating resulting in burn or fire.
• If the output cable is extended, do not use the cable while it is still wound. Otherwise, an output
resistance increase will interrupt assurance of start performance. Be sure to straighten it up to
20 m as standard.
Failure to observe this caution may result in malfunction.
“Table 4.1 Power Supply Facility Capacity and Connection Cables” shows the required
power supply facility capacity and connection cables.
Since a voltage compensation circuit is provided for the welder, welding is possible
without any problems even if power supply voltage is fluctuated within ±10% from rated
power supply voltage. However, use as stable a power supply as possible for proper
welding. If voltage varies more than 10% from rated power supply voltage, proper
welding conditions cannot be established, resulting in device problems.
For safe operations, be sure to attach a no-fuse breaker or a switching device with fuse for
each welder.
When a no-fuse breaker is used, it must satisfy rated current in Table 4.1 and trip at 600%
current of rated current for one minute or more (generally, it will be a breaker for motor).
If the breaker has too small a rating or power supply voltage is too high, the breaker may
trip when the welder is turned ON.
Table 4.1 Power Supply Facility Capacity and Connection Cables
Model YWE-T30D (0)
Rated output current TIG 300D
(Three-phase 200/220 V)
Power supply facility capacity Three-phase 14 kVA or more
Fuse capacity 50 A
Input cable 8 mm2or more
Output cable 38 mm2or more
Ground cable 14 mm2or more

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4.3 Combination with Leakage Breaker
When the welder is used in a construction site, in a place with high humidity, or on an iron
plate, iron framework, or surface plate with high conductivity, a leakage breaker should be
installed according to the law. In such a case, connect a leakage breaker of current
sensitivity 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.
4.4 Connection of Electric System
Even one imperfect contact in the connections precludes proper welding. Be sure to
make a perfect connection to the base metal by using jigs.

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■ Precautions on Wiring of High DC Voltage Start Method
The followng shows a case where the water cooled torch is used.
Never connect the negative (-) side of the weld wire sticking
detection cable to the negative (-) side of the welder output
terminal (at the torch side).
∗ Pay attention to the insulation of the cable at the torch side since high voltage may leak if the
cable directly contacts to the concrete floor, etc.
If the resistance between the electrode and the base metal is 20 MΩor less when measured
with a 500-V insulation tester, the operation is hard to start. Ensure proper insulation. Pay
attention to the polarity of the measuring device so that the base metal side is always
connected to the positive side.
Note: The occurrence of discharge between the electrode and the base metal confirms the proper
application of high DC voltage (approx. 10 mm, under the argon shielding gas
environment).
Welder
Cooling water circulator:
Use the circulator for high
DC voltage. Insulate from
the floor or other faces by
using an insulation cover
even if the circulator is
provided with rubber legs.
Cooling water path: Insulate
from the other devices since it
becomes the same electrical
potential as that of the electrode
in the torch.
Weld wire
Base metal
Ｐ
Insulation
cover
Insulation resistance:
Requires 20 MΩor
more. (positive side
at base metal)
Cable at base metal:
Be sure to connect to the
positive side output terminal and
ground at the base metal side.
Torch side cable path and torch
fixed section:
Insulate from the other devices.*
Insulation
cover
Weld wire feeder and wire path:
Insulate from the other devices by using an
insulation cover.
High pressure
power supply
Case grounding:
Be sure to ground the case
for safe operations.
- Weldwire
+ sticking detection circuit

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■ Connection of Power Supply
Refer to “Fig. 4.1 Connections at Rear Face” to make proper connections. The 200/220-V
selector switch is provided at the rear face.
1 見出し 2（見出し 1は欠番）
本文 2
1.1 見出し 3
本文 3
■ 見出し 4
本文 4
見出し 5
本文 5
1. 見出し 6
Can be switched by rated input
200/220-V selector switch.
A
ttach one switch for
each welder.
Refer to Table 2.1 for fuse capacities.
Three-phase 200 VAC
at 50/60 Hz
Input terminal
Phase
W
Switch
in the
switch
gear
CON2 (for manipulator)
CON3 (for manipulator)
200/220-V
selector switch Input terminal
cover
Use a cable of 8 mm2or
more for each phase.
Remove the input terminal cove
r
and connect the three cables.
A
fter connection, be sure to
reattach the input terminal
cover.
Input cable
argon gas
pressure adjuster
Use welding
argon gas (JIS
K1105). Do
not put this gas
cylinder where
the ambient
temperature
exceeds 35℃.
A
rgon gas
Cooling water
circulator for high
DC voltage start:
Insulated from base
metal grounding
Insulation
Cooling water
hose
Make wiring after turning
OFF the switch in the
switch gear.
Ground cable
Gas hose
Use a cable of 14 mm
2
or more for grounding.
Fig. 4.1 Connections at Rear Face
Phase
V
Phase
U
N
ote: Piping related to the cooling water is not needed when air cooling torch is used.

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■ Connections at Welding Side
Refer to “Fig. 4.2 Connections at Front Face” for proper connections.
The welder is a high DC voltage start type which applies DC voltage between the electrode
and the base metal. If insulation is not made between the electrode and the base metal,
the welder is hard to start. Confirm that the welding torch, the cables at the welding side,
the cooling water path including the cooling water circulator and the weld wire are
insulated from the base metal grounding.