No. 1L22440-E-7

AX series
INSTRUCTION MANUALWELDING INTERFACE(DIGITAL)■ Read and follow these instructions and all safety blocks carefully.
■ Have only trained and qualified persons install, operate, or service this unit.

■ Give this manual to the operator.
■ For help, call your distributor.

Be Sure to Read Instruction Manuals Before UseThank you for selecting DAIHEN arc welding robot Almega series.
Almega series are the robots with high performance and various functions developed by making full use of thelatest technology. Since the knowledge of welding peculiar to a welding machine maker is applied to both
hardware and software, we are sure that each user can be fully satisfied.
In order to use the superior performance and the abundant functions safely and fully, be sure to read thefollowing instruction manuals including this manual and other attached documents, and understand theknowledge of the machines, safety information, and notes thoroughly.
Instruction manuals related to the manipulator, and the robot control unit are as follows.
■AX series Standard Manuals
Instruction Manual Type

Instruction
Manual No.

Main Contents

INSTALLATION

Safety precautions, installing & connecting method,
starting up, periodical inspection, solution at the timeof failure
Specifications of controller, explanation of each partsand maintenance, parts list, etc.

1L8800A
CONTROLLER MAINTENANCE/STANDARD CONFIGURATIONSMANIPULATOR（AX-MV4AP/ MV6/ MV6L/ MV16/ MG3/ MH3/ MS3）
MANIPULATOR (AX-MV50)
MANIPULATOR (AX-MV133, MV166)
MANIPULATOR (AX-MV160)
BASIC OPERATIONS

1L8800B

Specifications or maintenance of manipulator, parts
list, etc.

1L7700A
1L7721A
1L7722A
1L7723A

Explanation of manual operation, teaching, automatic
operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
Basic operations, terms, explanations ofConstants/Service menus, Details of functioncommand, list of short-cut code, parts replacing
procedure, trouble shooting, etc.
※ This manual is not provided as the paper manual,
but is built in the robot as Help tutorial function.
Interfacing method with external control device, list of
I/O signals, start/halt the automatic operation, andusage of software PLC, etc.
Measures for safety, transportation, installation, andconnection
Controller's specification, maintenance for each parts,
part list and others

1L8800C
REFERENCE (Built-in Tutorial)
1L8800D

EXTERNAL INPUT/OUTPUT
1L8800H
CONTROLLER MAINTENANCE
ADDENDUM(for AXCLN1/ AXCLL1)

1L9440B■AX series Application Manuals
Instruction Manual TypeAPPLICATION MANUAL(ARC WELDING)APPLICATION MANUAL(HANDLING)
APPLICATION MANUAL(SPOT WELDING)

Instruction
Manual No.

Main Contents
Basic settings, functions for arc welding, teaching
technic, etc.
Basic settings, functions for handling, teaching
technic, etc.
Basic settings, functions for spot welding, teaching
technic, etc.

1L8800F
1L8800G
1L8800E-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 actualones.
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 otherattached 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.

DANGERWARNINGCAUTION

Cases where a mistake made in handling is likely to cause the user to be exposed tothe 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 thescale (including high-level danger).

Cases where a mistake made in handling is likely to cause the user to be exposed tothe danger of death or serious injury.

Cases where a mistake made in handling is likely to cause the user to be exposed tothe danger of minor injuries or of property damage only.

The following symbol is also used for particularly important checkpoints:

This is a particularly important checkpoint.

IMPORTANT

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.

-3-

Table of Contents

Table of Contents

Chapter 1 Introduction
1.1 Welding Interface (Digital)......................................................................................................................... 1-1
1.2 Main specifications.................................................................................................................................... 1-2
1.2.1 Hardware specifications ................................................................................................................. 1-2
1.2.2 Connectable robot controllers ........................................................................................................ 1-2
1.2.3 Connectable welding power sources ............................................................................................. 1-2
1.2.4 Available functions.......................................................................................................................... 1-4
1.2.5 “Welding Interface (Digital) Setup” tool .......................................................................................... 1-5
1.2.6 External view .................................................................................................................................. 1-6
1.3 Standard configuration .............................................................................................................................. 1-7
1.3.1 Components of Robot controller/Welding power source Peripherals ............................................ 1-7
1.4 Welding mode lists .................................................................................................................................... 1-9
1.4.1 Welding mode list of Welbee Inverter M350L ................................................................................ 1-9
1.4.2 Welding mode list of Welbee Inverter M350 ................................................................................ 1-10
1.4.3 Welding mode list of Welbee Inverter M500 ................................................................................ 1-12
1.4.4 Welding mode list of Welbee Inverter P350 ................................................................................. 1-13
1.4.5 Welding mode list of Welbee Inverter P500L ............................................................................... 1-16

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
3.2 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

Table of Contents

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
4.2 List of Welding Interface (Digital) error codes........................................................................................... 4-2
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
This chapter provides a general description of Welding Interface (Digital).
1.1 Welding Interface (Digital)...........................................................................1-1
1.2 Main specifications .....................................................................................1-2
1.2.1 Hardware specifications ........................................................................1-2
1.2.2 Connectable robot controllers ...............................................................1-2
1.2.3 Connectable welding power sources ....................................................1-2
1.2.4 Available functions ................................................................................1-4
1.2.5 “Welding Interface (Digital) Setup” tool .................................................1-5
1.2.6 External view.........................................................................................1-6
1.3 Standard configuration ................................................................................1-7
1.3.1 Components of Robot controller/Welding power source Peripherals ....1-7
1.4 Welding mode lists......................................................................................1-9
1.4.1 Welding mode list of Welbee Inverter M350L........................................1-9
1.4.2 Welding mode list of Welbee Inverter M350........................................1-10
1.4.3 Welding mode list of Welbee Inverter M500........................................1-12
1.4.4 Welding mode list of Welbee Inverter P350 ........................................1-13
1.4.5 Welding mode list of Welbee Inverter P500L ......................................1-16

1.1 Welding Interface (Digital)

1.1 Welding Interface (Digital)
When "Welding Interface (Digital)" is used, the latest Welbee Inverter series welding power source can beconnected to an AXC controller using digital communication. Compared to Welding Interface (AXWF-10**) that isconnected using analog signals, many more welding parameters that are available in the Welbee Inverter series
welding power source can be controlled by the robot controller. Also, various useful functions are available, suchas the real-time monitoring of the welding current and voltage during welding.
When the interface is used, D series welding power sources shown in Table 1.2.3 that are connected to the AXC
controller can be easily replaced with Welbee Inverter series welding power sources. In this case, you only needto adjust the welding conditions. You can continue using the existing programs and welding condition file.

Replace

Digital communication

D series
Welding
Interface(Digital)

AXC

Welbee Inverter series

Connect the Welbee Inverter series welding
power source to the AXC controller
Figure 1.1.1

Overview of Welding Interface (Digital)

1-1

1.2 Main specifications

1.2 Main specifications
The interface is installed inside the AXC controller. The main specifications are as follows.

1.2.1 Hardware specifications
Item
Product name
Part number
Input power supply (rated
voltage)
Permissible operating
temperature range
Permissible storage
temperature range
Communication interface

Table 1.2.1 Hardware specifications
Specification
Welding Interface (Digital)
L22440A00

USB port

DC24V ± 10%
0 to 60℃, 20 to 80% RH (no condensation)-30 to 70℃, 10 to 90% RH (no condensation)
CAN, 2ch
1 portFor USB memory (settings, maintenance)* Operation is not guaranteed to work with a commerciallyavailable USB memory.
Use the USB memory (parts number L21700U00)
recommended by OTC.

1.2.2 Connectable robot controllers
The interface can be connected to an AXC controller. It cannot be used with robot controllers
other than AXC robot controllers.

1.2.3 Connectable welding power sources
When the interface is used, the Welbee Inverter series welding power sources shown in Table
1.2.2 can be connected to the AXC controller. Up to 4 Welbee Inverter series welding powersources can be connected to the interface. These welding power sources are used by registering
them in f5 <Arc Constant> - [1 Registration of welder] on the AXC controller as the welding powersources shown in "Configuration on the robot controller" in Table 1.2.2.


IMPORTANT





1-2

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
panel.
For details, see the instruction manual of your welding power source.
D series welding power sources and Welbee Inverter series welding powersources cannot be used at the same time.

1.2 Main specifications
Table 1.2.2 Connectable welding power sources
Configuration on the robot
Connectable welding power sources
controller
W.P.S.
Area
Welbee Inverter M350L (specifications for Japan)
DL *1
Japan
Welbee Inverter M350L (specifications for CCC)
Welbee Inverter M350L (specifications for Asia)
Welbee Inverter M350 (specifications for Japan)
DR *2
Japan
Welbee Inverter M350 (specifications for CCC)
Welbee Inverter M350 (specifications for Asia)
Welbee Inverter M500 (specifications for Japan)
DM *3
Japan
Welbee Inverter M500 (specifications for Asia)
Welbee Inverter P350 (specifications for Japan)
DP *4
Japan
Welbee Inverter P500L (specifications for Japan)
DPR *5Japan*1 You can also use when set to DL or DL (S-2).
*2 Only when replacing an existing DM or DM(S-2) with the Welbee Inverter series, continue
using DM or DM(S-2)*3 You can also use when set to DM or DM(S-2).
*4 Apply the welding characteristic data for a rated current 350A when WB-P350 is inconnection.
*5 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.

POINT

Welbee Inverter series welding power sources connected using the interface arehandled 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
Welbee Inverter M350
DM350(S-2)
Japan
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
DP400RJapan
Welbee Inverter P500L
Japan
DP500
Japan

1-3

1.2 Main specifications

1.2.4 Available functions
Table 1.2.4 shows the functions related to welding that are available when a Welbee Inverter
series welding power source is connected to the AXC controller using the interface.
Table 1.2.4 Available welding related functions

Standardfunctions

Optionalfunctions

Item

Availability

Welding condition setting○*1

TP arc monitor○

Online changes○

Arc monitor signal output○

Arc retry○

Check welding○

User check function○

Welding condition database○

Welding section batch shift○

AS function with V variable specification(ASV, ASMV)
Welding characteristic data automatic
adjustment
Arc restart×

PC arc monitor○

Twin synchro welding○

Arc sensor○

Multi-pass welding○

Welding mode option

×Synchro MIG/FC-MIG

×

Servo torch

×

RS control

×

Robot RS control

×

Stitch pulse welding×

Gas Saver GFC

×○×○: Available
×: Not available*1: The items that can be set as welding conditions vary depending on the combination of
the Welbee Inverter welding power sources to be connected and the welding powersources registered in the robot controller. For details, see "Chapter 3 Configurations".


IMPORTANT

1-4



Even when a function is shown as available in the table above, it cannot be
used if the function is not supported by the connected Welbee Inverter
welding power source.
Functions not shown in the table above cannot be used.

1.2 Main specifications

1.2.5 “Welding Interface (Digital) Setup” tool
To use Welding Interface (Digital), you must configure the interface settings on your computer
using the "Welding Interface (Digital) Setup" tool. For details, see "Chapter 3 Configurations".
To use this software, your system environment must comply with Table 1.2.5.
Table 1.2.5 System Requirements
Item
Operating System

Personal
ComputerSpecifications(Note 1)

Windows XP, Windows 7(32bit)

Model

IBM PC/AT compatible PC

CPU

Pentium III or higher processor (Pentium III 1 GHz or higher
is recommended)

Memory256 MB or more

Hard disk

More than 5 MB of available hard-disk space

Disc unit

CD-ROM drive is mounted.

USB port(Note 2)

One or more
1024  768 dots or more

Display

USB memory(Note 2)Required

64 MB or more

Recommended

USB memory (1GB) for external storage:
L21700U00

CF card(Required for obtaining the backup data)

Required

64 MB or more

Recommended

External storage CF (256 MB) for AXC:
L9742U00

CF card reader

One or more (required for reading the backup data)(Note 1)

(Note 2)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.
For this interface, USB memory is required when writing the setup data onto the Welding Interface(Digital) board.

1-5

1.2 Main specifications

1.2.6 External view
Install the Welding Interface (Digital) board (Figure 1.2.1) inside the robot controller. For details on
the installation method, see "Chapter 2 Connections".

Figure 1.2.1

1-6

Unit（mm）
External view of Welding Interface (Digital) board

1.3 Standard configuration

1.3 Standard configuration
This section describes the standard configuration for a system that performs robot welding using Welding
Interface (Digital). For details on the basic configuration for the AX series and the optional products, see the AX
series instruction manual "Controller Maintenance Manual".

1.3.1 Components of Robot controller/Welding power source Peripherals
Table 1.3.1 Configuration
Ref.
No.

Parts Name
Welding Interface (Digital)
Welding Interface(Digital) board
Fuse (F1)(1)

Model Type /Part number
L22440A00

Refer to Table 1.2.1

L22440C00

Installed inside the robot controller

2171.25MXP(Parts number:
100-1742)

Communication cable

L22440E00

Power cable

L22440J00(2)

Cable and hose

AXRB-4#**(3)

Control cable 5

A2RB-52**-

Voltage detecting cable(workpiece side)

L9509B00(5m)Specifications

Rated 250V - 1.25A, UL, CSA, CCC certified productbetween Storage board and Welding Interface (Digital)board
for power supply 24V#
1:
WB-M350
MV4AP, MV4LAP, MV6, MV6L, MV16, MG3
2:
WB-M350
MH3, MS3
4:
WB-M500/ WB-P500L※
MV4AP, MV4LAP, MV6, MV6L, MV16, MG35:
WB-M500 / WB-P500L※
MH3, MS3
6:
WB-M350L
MV4AP, MV4LAP, MV6, MV6L, MV16, MG3
7:
WB-M350L
MH3, MS3
WB-P500L
D：
MV4AP, MV4LAP, MV6, MV6L, MV16, MG3
WB-P500L
E：
MH3, MS3
Cable length
5m** 05 :
10 :Cable length
10m
15 :Cable length
15m
Cable length
5m
for Welbee Inverter** 05 :
10 :Cable length
10m for Welbee Inverter
15 :Cable length
15m for Welbee Inverter
L9509C00(10m), L9509D00(15m) for WB-M350L※: When used for aluminum welding.

1-71.3 Standard configuration

Control cable 5

Welding Interface (Digital)

Figure 1.3.1

1-8

AX-C

Components for Peripherals of Robot controller and Welding power source1.4 Welding mode lists

1.4 Welding mode lists
The welding modes shown below can be used with a Welbee Inverter series welding power source that isconnected to the robot controller using the interface.

1.4.1 Welding mode list of Welbee Inverter M350L
Table 1.4.1

Welbee Inverter M350L (specifications for Japan/CCC/Asia)

Welding mode
Welding
process

Gas

Wire material

WirediameterTravelspeed

Welding mode description

DC
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

CO2
〃
〃
〃
〃
〃
〃
〃
MAG
〃
〃
〃
MIG
〃
〃
〃

Mild steel solid〃〃〃
Mild steel cored〃
SUS cored〃
Mild steel solid
〃
〃
〃
SUS
〃
〃
〃

0.8
0.9
1.0
1.2
1.2
1.4
0.9
1.2
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2

Standard
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

350A Co2 DC φ0.8 (Low)
350A Co2 DC φ0.9 (Low)
350A Co2 DC φ1.0 (Low)
350A Co2 DC φ1.2 (Low)
350A Co2 DC φ1.2 (Cored) (Low)
350A Co2 DC φ1.4 (Cored) (Low)
350A Co2 DC φ0.9 SuS(Cored) (Low)
350A Co2 DC φ1.2 SuS(Cored) (Low)
350A Mag DC φ0.8 (Low)
350A Mag DC φ0.9 (Low)
350A Mag DC φ1.0 (Low)
350A Mag DC φ1.2 (Low)
350A Mig_4 DC φ0.8 SuS (Low)
350A Mig_4 DC φ0.9 SuS (Low)
350A Mig_4 DC φ1.0 SuS (Low)
350A Mig_4 DC φ1.2 SuS (Low)

Notes
Number of
weldingcharacteristic
data inAX21/FD11$WTBD1719$WTBD1720$WTBD1721$WTBD1722$WTBD1724$WTBD1725$WTBD1729$WTBD1730$WTBD1732$WTBD1733$WTBD1734$WTBD1735$WTBD1736$WTBD1737$WTBD1738$WTBD1739

1-9

1.4 Welding mode lists

1.4.2 Welding mode list of Welbee Inverter M350
Table 1.4.2

Welbee Inverter M350 (specifications for Japan/CCC/Asia)

Welding mode

1-10

Welding
process

Gas

DC

CO2

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
MAG
〃
〃
〃
MIG
〃
〃
〃

〃

CO2

〃
〃
〃

〃
〃
〃

〃

〃

〃
〃
〃

〃
〃
〃

〃

MAG

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
MIG
〃
〃
〃

〃

CO2

〃
〃
〃

〃
〃
〃

〃

〃

〃
〃
〃

〃
〃
〃

〃

MAG

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
MIG
〃
〃
〃

Wire
material
Mild steel
solid
〃
〃
〃
〃
〃
〃
〃
SUS
〃
〃
〃
Mild steel
solid
〃
〃
〃
Mild steel
Cored〃
SUS cored〃
Mild steel
solid
〃
〃
〃
SUS
〃
〃
〃
Mild steel
solid
〃
〃
〃
Mild steel
Cored〃
SUS cored〃
Mild steel
solid
〃
〃
〃
SUS
〃
〃
〃

Welding mode description

Notes
Number of welding
characteristic data in
AX21/FD11

Wire
diameterTravel
speed

0.8

High

350A Co2 DC φ0.8 (High)$WTBD2000

0.9
1.0
1.2
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

350A Co2 DC φ0.9 (High)
350A Co2 DC φ1.0 (High)
350A Co2 DC φ1.2 (High)
350A Mag DC φ0.8 (High)
350A Mag DC φ0.9 (High)
350A Mag DC φ1.0 (High)
350A Mag DC φ1.2 (High)
350A Mig_4 DC φ0.8 SuS (High)
350A Mig_4 DC φ0.9 SuS (High)
350A Mig_4 DC φ1.0 SuS (High)
350A Mig_4 DC φ1.2 SuS (High)$WTBD2001$WTBD2002$WTBD2003$WTBD2004$WTBD2005$WTBD2006$WTBD2007$WTBD2008$WTBD2009$WTBD2010$WTBD2011

0.8

Standard

350A Co2 DC φ0.8 (Low)$WTBD2012

0.9
1.0
1.2

〃
〃
〃

350A Co2 DC φ0.9 (Low)
350A Co2 DC φ1.0 (Low)
350A Co2 DC φ1.2 (Low)$WTBD2013$WTBD2014$WTBD2015

1.2〃

350A Co2 DC φ1.2 (Cored) (Low)$WTBD2016

1.4
0.9
1.2

〃
〃
〃

350A Co2 DC φ1.4 (Cored) (Low)
350A Co2 DC φ0.9 SuS(Cored) (Low)
350A Co2 DC φ1.2 SuS(Cored) (Low)$WTBD2017$WTBD2018$WTBD2019

0.8〃

350A Mag DC φ0.8 (Low)$WTBD2020

0.9
1.0
1.2
0.8
0.9
1.0
1.2

350A Mag DC φ0.9 (Low)
350A Mag DC φ1.0 (Low)
350A Mag DC φ1.2 (Low)
350A Mig_4 DC φ0.8 SuS (Low)
350A Mig_4 DC φ0.9 SuS (Low)
350A Mig_4 DC φ1.0 SuS (Low)
350A Mig_4 DC φ1.2 SuS (Low)$WTBD2021$WTBD2022$WTBD2023$WTBD2024$WTBD2025$WTBD2026$WTBD2027

350A Co2 DC φ0.8 (Low*)$WTBD2028

0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃
Extension
cable
〃
〃
〃

350A Co2 DC φ0.9 (Low*)
350A Co2 DC φ1.0 (Low*)
350A Co2 DC φ1.2 (Low*)$WTBD2029$WTBD2030$WTBD2031

1.2〃

350A Co2 DC φ1.2 (Cored) (Low*)$WTBD2032

1.4
0.9
1.2

〃
〃
〃

350A Co2 DC φ1.4 (Cored) (Low*)
350A Co2 DC φ0.9 SuS(Cored) (Low*)
350A Co2 DC φ1.2 SuS(Cored) (Low*)$WTBD2033$WTBD2034$WTBD2035

0.8〃350A Mag DC φ0.8 (Low*)$WTBD2036

0.9
1.0
1.2
0.8
0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃

350A Mag DC φ0.9 (Low*)
350A Mag DC φ1.0 (Low*)
350A Mag DC φ1.2 (Low*)
350A Mig_4 DC φ0.8 SuS (Low*)
350A Mig_4 DC φ0.9 SuS (Low*)
350A Mig_4 DC φ1.0 SuS (Low*)
350A Mig_4 DC φ1.2 SuS (Low*)$WTBD2037$WTBD2038$WTBD2039$WTBD2040$WTBD2041$WTBD2042$WTBD2043

0.8

1.4 Welding mode lists

POINT

Use welding characteristic data with a "High" Travel speed as the welding characteristic
data for Table 1.4.2. If the welding speed is low (generally, 50 cm/min or less) and thewelding is unstable, use welding characteristic data with a "Standard" Travel speed.
Welding performance may become unstable when using the extended power cabledepending on the layout condition of cables (when the total length exceeds 30m or thecable is coiled). In that case, voltage adjustment will normally bring about stablecondition. 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

1.4.3 Welding mode list of Welbee Inverter M500
Table 1.4.3

Welbee Inverter M500 (specifications for Japan)

Welding mode
Welding
process

Gas

DC

CO2

〃
〃
〃
〃
〃
〃
〃

〃
〃
MAG
〃
〃
MIG
〃

〃

CO2

〃
〃

〃
〃

〃

〃

〃
〃
〃
〃

〃
〃
〃
〃

〃

MAG

〃
〃
〃
〃

〃
〃
MIG
〃

〃

CO2

〃
〃

〃
〃

〃

〃

〃
〃
〃
〃

〃
〃
〃
〃

〃

MAG

〃
〃
〃
〃

〃
〃
MIG
〃

Wire
material
Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
Mild steel
solid
〃
〃
Mild steel
solid
〃
〃
SUS cored〃
Mild steel
solid
〃
〃
SUS
〃
Mild steel
solid
〃
〃
Mild steel
Cored
〃
〃
SUS cored〃
Mild steel
solid
〃
〃
SUS
〃

POINT

Welding mode description

Notes
Number of welding
characteristic data in
AX21/FD11

Wire
diameterTravel
speed

1.2

High

500A Co2 DC φ1.2 (High)$WTBD2103

1.4
1.6
1.2
1.4
1.6
1.2
1.6

〃
〃
〃
〃
〃
〃
〃

500A Co2 DC φ1.4 (High)
500A Co2 DC φ1.6 (High)
500A Mag DC φ1.2 (High)
500A Mag DC φ1.4 (High)
500A Mag DC φ1.6 (High)
500A Mig_4 DC φ1.2 SuS (High)
500A Mig_4 DC φ1.6 SuS (High)$WTBD2104$WTBD2105$WTBD2109$WTBD2110$WTBD2111$WTBD2115$WTBD2116

1.2Standard

500A Co2 DC φ1.2 (Low)$WTBD2120

1.4
1.6

〃
〃

500A Co2 DC φ1.4 (Low)
500A Co2 DC φ1.6 (Low)$WTBD2121$WTBD2122

1.2〃

500A Co2 DC φ1.2 (Cored) (Low)$WTBD2124

1.4
1.6
1.2
1.6

〃
〃
〃
〃
〃

500A Co2 DC φ1.4 (Cored) (Low)
500A Co2 DC φ1.6 (Cored) (Low)
500A Co2 DC φ1.2 SuS(Cored) (Low)
500A Co2 DC φ1.6 SuS(Cored) (Low)$WTBD2125$WTBD2126$WTBD2127$WTBD2128

500A Mag DC φ1.2 (Low)$WTBD2132

500A Mag DC φ1.4 (Low)
500A Mag DC φ1.6 (Low)
500A Mig_4 DC φ1.2 SuS (Low)
500A Mig_4 DC φ1.6 SuS (Low)$WTBD2133$WTBD2134$WTBD2138$WTBD2139

500A Co2 DC φ1.2 (Low*)$WTBD2140

500A Co2 DC φ1.4 (Low*)
500A Co2 DC φ1.6 (Low*)$WTBD2141$WTBD2142

1.2
1.4
1.6
1.2
1.6

1.4
1.6

〃
〃
〃
〃
Extension
cable
〃
〃

1.2

〃

500A Co2 DC φ1.2 (Cored) (Low*)$WTBD2143

1.4
1.6
1.2
1.6

〃
〃
〃
〃

500A Co2 DC φ1.4 (Cored) (Low*)
500A Co2 DC φ1.6 (Cored) (Low*)
500A Co2 DC φ1.2 SuS(Cored) (Low*)
500A Co2 DC φ1.6 SuS(Cored) (Low*)$WTBD2144$WTBD2145$WTBD2146$WTBD2147

1.2〃500A Mag DC φ1.2 (Low*)$WTBD2148

1.4
1.6
1.2
1.6

〃
〃
〃
〃

500A Mag DC φ1.4 (Low*)
500A Mag DC φ1.6 (Low*)
500A Mig_4 DC φ1.2 SuS (Low*)
500A Mig_4 DC φ1.6 SuS (Low*)$WTBD2149$WTBD2150$WTBD2151$WTBD2152

1.2

Use welding characteristic data with a "High" Travel speed as the welding characteristic
data for Table 1.4.3. If the welding speed is low (generally, 50 cm/min or less) and thewelding is unstable, use welding characteristic data with a "Standard" Travel speed.
Welding performance may become unstable when using the extended power cabledepending on the layout condition of cables (when the total length exceeds 30m or thecable is coiled). In that case, voltage adjustment will normally bring about stablecondition. 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

1.4.4 Welding mode list of Welbee Inverter P350
Table 1.4.4 Welbee Inverter P350 (specifications for Japan)
Welding mode
Welding
process

Gas

DC

CO2

〃
〃
〃

〃
〃
〃

〃

MAG

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
MIG*
〃
〃
〃

〃

〃

〃
〃

〃
〃

〃

〃

〃
DC
pulsed
〃
〃
〃
〃
〃

〃
MAG
〃
〃
MIG*
〃
〃

〃

〃

〃
〃

〃
〃

〃

〃

〃

〃

DC

CO2

〃
〃
〃

〃
〃
〃

〃

〃

〃
〃
〃

〃
〃
〃

〃

MAG

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
MIG*
〃
〃
〃

〃

〃

〃
〃

〃
〃

〃

〃

〃

〃

Wire
material
Mild steel
solid
〃
〃
〃
Mild steel
solid
〃
〃
〃
SUS
〃
〃
〃
Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
SUS
〃
〃
Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
〃
Mild steel
Cored〃
SUS Cored〃
Mild steel
solid
〃
〃
〃
SUS
〃
〃
〃
Hard
aluminum〃〃Soft
aluminum〃

Welding mode description

Notes
Number of welding
characteristic data in
AX21/FD11

Wire
diameterTravel
speed

0.8

High

350A Co2 DC φ0.8(High)$WTBD2400

0.9
1.0
1.2

〃
〃
〃

350A Co2 DC φ0.9(High)
350A Co2 DC φ1.0(High)
350A Co2 DC φ1.2(High)$WTBD2401$WTBD2402$WTBD2403

0.8〃350A Mag DC φ0.8(High)$WTBD2408

0.9
1.0
1.2
0.8
0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃

350A Mag DC φ0.9(High)
350A Mag DC φ1.0(High)
350A Mag DC φ1.2(High)
350A Mig_4 DC φφ0.8 SuS(High)
350A Mig_4 DC φ0.9 SuS(High)
350A Mig_4 DC φ1.0 SuS(High)
350A Mig_4 DC φ1.2 SuS(High)$WTBD2409$WTBD2410$WTBD2411$WTBD2412$WTBD2413$WTBD2414$WTBD2415

1.0〃

350A Mig DC φ1.0 Hard Al(High)$WTBD2416

1.2
1.6

〃
〃

350A Mig DC φ1.2 Hard Al(High)
350A Mig DC φ1.6 Hard Al(High)$WTBD2417$WTBD2418

1.2〃

350A Mig DC φ1.2 Soft Al(High)$WTBD2419

1.6〃

350A Mig DC φ1.6 Soft Al(High)$WTBD2420

0.9〃350A Mag DC-Pulse φ0.9(High)$WTBD2421

1.0
1.2
0.9
1.0
1.2

〃
〃
〃
〃
〃

350A Mag DC-Pulse φ1.0(High)
350A Mag DC-Pulse φ1.2(High)
350A Mig_4 DC-Pulse φ0.9 SuS(High)
350A Mig_4 DC-Pulse φ1.0 SuS(High)
350A Mig_4 DC-Pulse φ1.2 SuS(High)$WTBD2422$WTBD2423$WTBD2424$WTBD2425$WTBD2426

1.0〃

350A Mig DC-Pulse φ1.0 Hard Al(High)$WTBD2427

1.2
1.6

〃
〃

350A Mig DC-Pulse φ1.2 Hard Al(High)
350A Mig DC-Pulse φ1.6 Hard Al(High)$WTBD2428$WTBD2429

1.2〃

350A Mig DC-Pulse φ1.2 Soft Al(High)$WTBD2430

1.6〃350A Mig DC-Pulse φ1.6 Soft Al(High)$WTBD2431

0.8Standard

350A Co2 DC φ0.8(Low)$WTBD2432

0.9
1.0
1.2

〃
〃
〃

350A Co2 DC φ0.9(Low)
350A Co2 DC φ1.0(Low)
350A Co2 DC φ1.2(Low)$WTBD2433$WTBD2434$WTBD2435

1.0〃

350A Co2 DC φ1.0 (Cored) (Low)$WTBD2436

1.2
0.9
1.2

〃
〃
〃

350A Co2 DC φ1.2 (Cored) (Low)
350A Co2 DC φ0.9 SuS(Cored) (Low)
350A Co2 DC φ1.2 SuS(Cored) (Low)$WTBD2437$WTBD2438$WTBD2439

0.8〃350A Mag DC φ0.8(Low)$WTBD2440

0.9
1.0
1.2
0.8
0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃

350A Mag DC φ0.9(Low)
350A Mag DC φ1.0(Low)
350A Mag DC φ1.2(Low)
350A Mig_4 DC φ0.8 SuS(Low)
350A Mig_4 DC φ0.9 SuS(Low)
350A Mig_4 DC φ1.0 SuS(Low)
350A Mig_4 DC φ1.2 SuS(Low)$WTBD2441$WTBD2442$WTBD2443$WTBD2444$WTBD2445$WTBD2446$WTBD2447

1.0〃

350A Mig DC φ1.0 Hard Al(Low)$WTBD2448

1.2
1.6

〃
〃

350A Mig DC φ1.2 Hard Al(Low)
350A Mig DC φ1.6 Hard Al(Low)$WTBD2449$WTBD2450

1.2〃

350A Mig DC φ1.2 Soft Al(Low)$WTBD2451

1.6〃

350A Mig DC φ1.6 Soft Al(Low)$WTBD2452

1-13

1.4 Welding mode lists
Welding mode
Welding
processDC
pulsed
〃
〃
〃
〃
〃

1-14

Gas
MAG
〃
〃
MIG*
〃
〃

〃

〃

〃
〃

〃
〃

〃

〃

〃

〃

DC

CO2

〃
〃
〃

〃
〃
〃

〃

〃

〃
〃
〃

〃
〃
〃

〃

MAG

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
MIG*
〃
〃
〃

〃

〃

〃
〃

〃
〃

〃

〃

〃
DC
wave
pulsed
〃
〃
〃
〃
〃

〃
MAG
〃
〃
MIG*
〃
〃

〃

〃

〃

〃

〃

〃

〃

〃

〃

MAG

〃
〃
〃
〃
〃

〃
〃
MIG*
〃
〃

〃

〃

〃

〃

〃

〃

Wire
material
Mild steel
solid
〃
〃
SUS
〃
〃
Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
〃
Mild steel
Cored〃
SUS Cored〃
Mild steel
solid
〃
〃
〃
SUS
〃
〃
〃
Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
SUS
〃
〃
Hard
aluminum〃Soft
aluminum〃
Mild steel
solid
〃
〃
SUS
〃
〃
Hard
aluminum〃Soft
aluminum

Welding mode description

Notes
Number of welding
characteristic data in
AX21/FD11

Wire
diameterTravel
speed

0.9

〃

350A Mag DC-Pulse φ0.9(Low)$WTBD2453

1.0
1.2
0.9
1.0
1.2

〃
〃
〃
〃
〃

350A Mag DC-Pulse φ1.0(Low)
350A Mag DC-Pulse φ1.2(Low)
350A Mig_4 DC-Pulse φ0.9 SuS(Low)
350A Mig_4 DC-Pulse φ1.0 SuS(Low)
350A Mig_4 DC-Pulse φ1.2 SuS(Low)$WTBD2454$WTBD2455$WTBD2456$WTBD2457$WTBD2458

1.0〃

350A Mig DC-Pulse φ1.0 Hard Al(Low)$WTBD2459

1.2
1.6

〃
〃

350A Mig DC-Pulse φ1.2 Hard Al(Low)
350A Mig DC-Pulse φ1.6 Hard Al(Low)$WTBD2460$WTBD2461

1.2〃

350A Mig DC-Pulse φ1.2 Soft Al(Low)$WTBD2462

1.6

350A Mig DC-Pulse φ1.6 Soft Al(Low)$WTBD2463

350A Co2 DC φ0.8(Low*)$WTBD2464

0.9
1.0
1.2

〃
Extension
cable
〃
〃
〃

350A Co2 DC φ0.9(Low*)
350A Co2 DC φ1.0(Low*)
350A Co2 DC φ1.2(Low*)$WTBD2465$WTBD2466$WTBD2467

1.0〃

350A Co2 DC φ1.0 (Cored) (Low*)$WTBD2468

1.2
0.9
1.2

〃
〃
〃

350A Co2 DC φ1.2 (Cored) (Low*)
350A Co2 DC φ0.9 SuS(Cored) (Low*)
350A Co2 DC φ1.2 SuS(Cored) (Low*)$WTBD2469$WTBD2470$WTBD2471

0.8

0.8

〃

350A Mag DC φ0.8(Low*)$WTBD2472

0.9
1.0
1.2
0.8
0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃

350A Mag DC φ0.9(Low*)
350A Mag DC φ1.0(Low*)
350A Mag DC φ1.2(Low*)
350A Mig_4 DC φ0.8 SuS(Low*)
350A Mig_4 DC φ0.9 SuS(Low*)
350A Mig_4 DC φ1.0 SuS(Low*)
350A Mig_4 DC φ1.2 SuS(Low*)$WTBD2473$WTBD2474$WTBD2475$WTBD2476$WTBD2477$WTBD2478$WTBD2479

1.0〃

350A Mig DC φ1.0 Hard Al(Low*)$WTBD2480

1.2
1.6

〃
〃

350A Mig DC φ1.2 Hard Al(Low*)
350A Mig DC φ1.6 Hard Al(Low*)$WTBD2481$WTBD2482

1.2〃

350A Mig DC φ1.2 Soft Al(Low*)$WTBD2483

1.6〃

350A Mig DC φ1.6 Soft Al(Low*)$WTBD2484

0.9

High

350A Mag DC-Wave φ0.9(High)$WTBD2485

1.0
1.2
0.9
1.0
1.2

〃
〃
〃
〃
〃

350A Mag DC-Wave φ1.0(High)
350A Mag DC-Wave φ1.2(High)
350A Mig_4 DC-Wave φ0.9 SuS(High)
350A Mig_4 DC-Wave φ1.0 SuS(High)
350A Mig_4 DC-Wave φ1.2 SuS(High)$WTBD2486$WTBD2487$WTBD2488$WTBD2489$WTBD2490

1.2〃

350A Mig DC-Wave φ1.2 Hard Al(High)$WTBD2491

1.6〃

350A Mig DC-Wave φ1.6 Hard Al(High)$WTBD2492

1.2〃

350A Mig DC-Wave φ1.2 Soft Al(High)$WTBD2493

1.6〃

350A Mig DC-Wave φ1.6 Soft Al(High)$WTBD2494

0.9Standard

350A Mag DC-Wave φ0.9(Low)$WTBD2495

1.0
1.2
0.9
1.0
1.2

〃
〃
〃
〃
〃

350A Mag DC-Wave φ1.0(Low)
350A Mag DC-Wave φ1.2(Low)
350A Mig_4 DC-Wave φ0.9 SuS(Low)
350A Mig_4 DC-Wave φ1.0 SuS(Low)
350A Mig_4 DC-Wave φ1.2 SuS(Low)$WTBD2496$WTBD2497$WTBD2498$WTBD2499$WTBD2500

1.2〃

350A Mig DC-Wave φ1.2 Hard Al(Low)$WTBD2501

1.6〃

350A Mig DC-Wave φ1.6 Hard Al(Low)$WTBD2502

1.2〃

350A Mig DC-Wave φ1.2 Soft Al(Low)$WTBD2503

1.4 Welding mode lists
Welding mode
Welding
process

Gas

Wirematerial

Wire
diameterTravelspeed

Welding mode description

〃

〃

〃

1.6

〃

350A Mig DC-Wave φ1.6 Soft Al(Low)

Notes
Number of welding
characteristic data in
AX21/FD11$WTBD2504*：MIG gas defers in its mixing ratio depending on the wire material as below. For more details, refer to the

instruction manial for welding power supply.
When the wire material is a SUS/Ferrite
When the wire material is a Hard/Soft aluminum

POINT：Argon (Ar) 98% / Oxygen (O2) 2%：Argon (Ar) 100%

Use welding characteristic data with a "High" Travel speed as the welding characteristic
data for Table 1.4.4. If the welding speed is low (generally, 50 cm/min or less) and thewelding is unstable, use welding characteristic data with a " Standard " Travel speed.
Welding performance may become unstable when using the extended power cabledepending on the layout condition of cables (when the total length exceeds 30m or thecable is coiled). In that case, voltage adjustment will normally bring about stablecondition. 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

1.4.5 Welding mode list of Welbee Inverter P500L
Table 1.4.5 Welbee Inverter P500L (specifications for Japan)
Welding mode
Welding
process

Gas

Wire material

CO2

〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃
〃

Mild steel
solid
〃
〃
〃
〃
〃
Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃
Ferrite〃〃〃Hardaluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃
Ferrite

〃

〃

〃

DC

1-16

Wire
diameterTravel
speed

0.8

High

0.9
1.0
1.2
1.4
1.6
0.8

Welding mode description

Notes
Number of welding
characteristic data in
AX21/FD11500A Co2 DCφ0.8(High)$WTBD2600

〃
〃
〃
〃
〃
〃

500A Co2 DC φ0.9(High)
500A Co2 DC φ1.0(High)
500A Co2 DC φ1.2(High)
500A Co2 DC φ1.4(High)
500A Co2 DC φ1.6(High)$WTBD2601$WTBD2602$WTBD2603$WTBD2604$WTBD2605

500A Mag DC φ0.8(High)$WTBD2613

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6
0.8
0.9
1.0
1.2
1.0

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC φ0.9(High)
500A Mag DC φ1.0(High)
500A Mag DC φ1.2(High)
500A Mag DC φ1.4(High)
500A Mag DC φ1.6(High)
500A Mig_4 DC φ0.8 SuS(High)
500A Mig_4 DCφ0.9 SuS(High)
500A Mig_4 DCφ1.0 SuS(High)
500A Mig_4 DC φ1.2 SuS(High)
500A Mig_4 DC φ1.6 SuS(High)
500A Mig_4DC φ0.8 Ferrite(High)
500A Mig_4DC φ0.9 Ferrite(High)
500A Mig_4DC φ1.0 Ferrite(High)
500A Mig_4DC φ1.2 Ferrite(High)$WTBD2614$WTBD2615$WTBD2616$WTBD2617$WTBD2618$WTBD2619$WTBD2620$WTBD2621$WTBD2622$WTBD2623$WTBD2624$WTBD2625$WTBD2626$WTBD2627

500A Mig DC φ1.0 Hard Al(High)$WTBD2628

1.2
1.6
1.2

〃
〃
〃

500A Mig DC φ1.2 Hard Al(High)
500A Mig DC φ1.6 Hard Al(High)$WTBD2629$WTBD2630

500A Mig DC φ1.2 Soft Al(High)$WTBD2631

1.6〃500A Mig DC φ1.6 Soft Al(High)$WTBD2632

0.8〃500A Mag DC-Pulse φ0.8(High)$WTBD2649

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6
0.8

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

$WTBD2650$WTBD2651$WTBD2652$WTBD2653$WTBD2654$WTBD2655$WTBD2656$WTBD2657$WTBD2658$WTBD2659

〃

0.9

〃

〃

〃

1.0

〃

〃

〃

〃

1.2

〃

500A Mag DC-Pulse φ0.9(High)
500A Mag DC-Pulse φ1.0(High)
500A Mag DC-Pulse φ1.2(High)
500A Mag DC-Pulse φ1.4(High)
500A Mag DC-Pulse φ1.6(High)
500A Mig_4 DC-Pulseφ0.8 SuS(High)
500A Mig_4 DC-Pulseφ0.9 SuS(High)
500A Mig_4 DC-Pulseφ1.0 SuS(High)
500A Mig_4 DC-Pulse φ1.2 SuS(High)
500A Mig_4 DC-Pulse φ1.6 SuS(High)
500A
Mig_4
DC-Pulse
φ0.8
Ferrite(High)
500A
Mig_4
DC-Pulse
φ0.9
Ferrite(High)
500A
Mig_4
DC-Pulse
φ1.0
Ferrite(High)
500A
Mig_4
DC-Pulse
φ1.2
Ferrite(High)

〃

〃

1.0

〃

500A Mig DC-Pulse φ1.0 Hard Al(High)$WTBD2664

〃
〃
〃

〃
〃
〃

1.2
1.6
1.2

〃
〃
〃

500A Mig DC-Pulse φ1.2 Hard Al(High)
500A Mig DC-Pulse φ1.6 Hard Al(High)$WTBD2665$WTBD2666

500A Mig DC-Pulse φ1.2 Soft Al(High)$WTBD2667

〃
DC

〃
CO2

1.6
0.8

〃
Standard

500A Mig DC-Pulse φ1.6 Soft Al(High)$WTBD2668

500A Co2 DC φ0.8(Low)$WTBD2671

〃
〃

〃
〃

Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃

0.9
1.0

〃
〃

500A Co2 DC φ0.9(Low)
500A Co2 DC φ1.0(Low)$WTBD2672$WTBD2673

〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
MAG

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃

〃
〃
〃

〃
DC
pulsed
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
MAG

$WTBD2660$WTBD2661$WTBD2662$WTBD2663

1.4 Welding mode lists

Wire
diameterTravel
speed

1.2
1.4
1.6
1.0

〃
〃
〃
〃

500A Co2 DC φ1.2(Low)
500A Co2 DC φ1.4(Low)
500A Co2 DC φ1.6(Low)

Notes
Number of welding
characteristic data in
AX21/FD11$WTBD2674$WTBD2675$WTBD2676

500A Co2 DC φ1.0 (Cored) (Low)$WTBD2677

1.2
1.4
1.6
0.9
1.2
1.6
0.8

〃
〃
〃
〃
〃
〃
〃

500A Co2 DC φ1.2 (Cored) (Low)
500A Co2 DC φ1.4 (Cored) (Low)
500A Co2 DC φ1.6 (Cored) (Low)
500A Co2 DC φ0.9 SuS(Cored) (Low)
500A Co2 DC φ1.2 SuS(Cored) (Low)
500A Co2 DC φ1.6 SuS(Cored) (Low)$WTBD2678$WTBD2679$WTBD2680$WTBD2681$WTBD2682$WTBD2683

500A Mag DC φ0.8(Low)$WTBD2684

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6
0.8
0.9
1.0
1.2
1.0

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC φ0.9(Low)
500A Mag DC φ1.0(Low)
500A Mag DC φ1.2(Low)
500A Mag DC φ1.4(Low)
500A Mag DC φ1.6(Low)
500A Mig_4 DC φ0.8 SuS(Low)
500A Mig_4 DCφ0.9 SuS(Low)
500A Mig_4 DCφ1.0 SuS(Low)
500A Mig_4 DC φ1.2 SuS(Low)
500A Mig_4 DC φ1.6 SuS(Low)
500A Mig_4DC φ0.8 Ferrite(Low)
500A Mig_4DC φ0.9 Ferrite(Low)
500A Mig_4DC φ1.0 Ferrite(Low)
500A Mig_4DC φ1.2 Ferrite(Low)$WTBD2685$WTBD2686$WTBD2687$WTBD2688$WTBD2689$WTBD2690$WTBD2691$WTBD2692$WTBD2693$WTBD2694$WTBD2695$WTBD2696$WTBD2697$WTBD2698

500A Mig DC φ1.0 Hard Al(Low)$WTBD2699

1.2
1.6
1.2

〃
〃
〃

500A Mig DC φ1.2 Hard Al(Low)
500A Mig DC φ1.6 Hard Al(Low)$WTBD2700$WTBD2701

500A Mig DC φ1.2 Soft Al(Low)$WTBD2702

1.6〃500A Mig DC φ1.6 Soft Al(Low)$WTBD2703

0.8〃500A Co2 DC φ0.8(Low#)$WTBD2704

0.9
1.0
1.2
0.8

〃
〃
〃
〃

500A Co2 DC φ0.9(Low#)
500A Co2 DC φ1.0(Low#)
500A Co2 DC φ1.2(Low#)$WTBD2705$WTBD2706$WTBD2707

500A Mag DC φ0.8(Low#)$WTBD2708

0.9
1.0
1.2
0.8
0.9
1.0
1.2
0.8
0.9
1.0
1.2

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC φ0.9(Low#)
500A Mag DC φ1.0(Low#)
500A Mag DC φ1.2(Low#)
500A Mig_4 DC φ0.8 SuS(Low#)
500A Mig_4 DCφ0.9 SuS(Low#)
500A Mig_4 DCφ1.0 SuS(Low#)
500A Mig_4 DC φ1.2 SuS(Low#)
500A Mig_4DC φ0.8 Ferrite(Low#)
500A Mig_4DC φ0.9 Ferrite(Low#)
500A Mig_4DC φ1.0 Ferrite(Low#)
500ª Mig_4DC φ1.2 Ferrite(Low#)$WTBD2709$WTBD2710$WTBD2711$WTBD2712$WTBD2713$WTBD2714$WTBD2715$WTBD2716$WTBD2717$WTBD2718$WTBD2719

0.8〃500A Mag DC-Pulse φ0.8(Low)$WTBD2720

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6
0.8

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC-Pulse φ0.9(Low)
500A Mag DC-Pulse φ1.0(Low)
500A Mag DC-Pulse φ1.2(Low)
500A Mag DC-Pulse φ1.4(Low)
500A Mag DC-Pulse φ1.6(Low)
500A Mig_4 DC-Pulseφ0.8 SuS(Low)
500A Mig_4 DC-Pulseφ0.9 SuS(Low)
500A Mig_4 DC-Pulseφ1.0 SuS(Low)
500A Mig_4 DC-Pulse φ1.2 SuS(Low)
500A Mig_4 DC-Pulse φ1.6 SuS(Low)
500A
Mig_4
DC-Pulse
φ0.8$WTBD2721$WTBD2722$WTBD2723$WTBD2724$WTBD2725$WTBD2726$WTBD2727$WTBD2728$WTBD2729$WTBD2730$WTBD2731

Welding mode
Welding
process

Gas

Wire material

〃
〃
〃
〃

〃
〃
〃
〃

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
〃
MAG

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃

〃
〃
〃

〃
DC
(APCS)
〃
〃
〃
〃

〃

〃
〃
〃
Mild steel
Cored
〃
〃
〃
SUS Cored〃〃
Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃
Ferrite〃〃〃Hardaluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
〃
Mild steel
solid
〃
〃
〃
SUS
〃
〃
〃
Ferrite〃〃〃Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃
Ferrite

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
DC
pulsed
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

CO2
〃
〃
〃
MAG
〃
〃
〃
MIG*
〃
〃
〃
〃
〃
〃
〃
MAG
〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃
〃

Welding mode description

1-17

1.4 Welding mode lists
Notes
Number of welding
characteristic data in
AX21/FD11

Welding mode

1-18

Welding
process

Gas

Wire material

WirediameterTravel
speed

〃

〃

〃

0.9

〃

〃

〃

〃

1.0

〃

〃

〃

〃

1.2

〃

〃

〃

1.0

〃

〃
〃
〃

〃
〃
〃

1.2
1.6
1.2

〃

〃

1.6

DC

CO2

〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
〃
MAG

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃

〃
〃
〃

〃
DC
wave
pulsed
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃

Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
〃
〃
〃
Mild steel
Cored
〃
〃
〃
SUS Cored〃〃
Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃
Ferrite〃〃〃Hardaluminum〃〃Soft
aluminum〃

Welding mode description
Ferrite(Low)
500A
Mig_4
Ferrite(Low)
500A
Mig_4
Ferrite(Low)
500A
Mig_4
Ferrite(Low)

DC-Pulse

φ0.9

DC-Pulse

φ1.0

DC-Pulse

φ1.2$WTBD2732$WTBD2733$WTBD2734

500A Mig DC-Pulse φ1.0 Hard Al(Low)$WTBD2735〃〃〃

500A Mig DC-Pulse φ1.2 Hard Al(Low)
500A Mig DC-Pulse φ1.6 Hard Al(Low)$WTBD2736$WTBD2737

500A Mig DC-Pulse φ1.2 Soft Al(Low)$WTBD2738

500A Mig DC-Pulse φ1.6 Soft Al(Low)$WTBD2739

0.9
1.0
1.2
1.4
1.6
1.0

〃
Extension
cable
〃
〃
〃
〃
〃
〃

1.2
1.4
1.6
0.9
1.2
1.6
0.8

500A Co2 DC φ0.8(Low*)$WTBD2740

500A Co2 DC φ0.9(Low*)
500A Co2 DC φ1.0(Low*)
500A Co2 DC φ1.2(Low*)
500A Co2 DC φ1.4(Low*)
500A Co2 DC φ1.6(Low*)$WTBD2741$WTBD2742$WTBD2743$WTBD2744$WTBD2745

500A Co2 DC φ1.0 (Cored) (Low*)$WTBD2746

〃
〃
〃
〃
〃
〃
〃

500A Co2 DC φ1.2 (Cored) (Low*)
500A Co2 DC φ1.4 (Cored) (Low*)
500A Co2 DC φ1.6 (Cored) (Low*)
500A Co2 DC φ0.9 SuS(Cored) (Low*)
500A Co2 DC φ1.2 SuS(Cored) (Low*)
500A Co2 DC φ1.6 SuS(Cored) (Low*)$WTBD2747$WTBD2748$WTBD2749$WTBD2750$WTBD2751$WTBD2752

500A Mag DC φ0.8(Low*)$WTBD2753

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6
0.8
0.9
1.0
1.2
1.0

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC φ0.9(Low*)
500A Mag DC φ1.0(Low*)
500A Mag DC φ1.2(Low*)
500A Mag DC φ1.4(Low*)
500A Mag DC φ1.6(Low*)
500A Mig_4 DC φ0.8 SuS(Low*)
500A Mig_4 DCφ0.9 SuS(Low*)
500A Mig_4 DCφ1.0 SuS(Low*)
500A Mig_4 DC φ1.2 SuS(Low*)
500A Mig_4 DC φ1.6 SuS(Low*)
500A Mig_4DC φ0.8 Ferrite(Low*)
500A Mig_4DC φ0.9 Ferrite(Low*)
500A Mig_4DC φ1.0 Ferrite(Low*)
500A Mig_4DC φ1.2 Ferrite(Low*)$WTBD2754$WTBD2755$WTBD2756$WTBD2757$WTBD2758$WTBD2759$WTBD2760$WTBD2761$WTBD2762$WTBD2763$WTBD2764$WTBD2765$WTBD2766$WTBD2767

500A Mig DC φ1.0 Hard Al(Low*)$WTBD2768

1.2
1.6
1.2

〃
〃
〃

500A Mig DC φ1.2 Hard Al(Low*)
500A Mig DC φ1.6 Hard Al(Low*)$WTBD2769$WTBD2770

500A Mig DC φ1.2 Soft Al(Low*)$WTBD2771

1.6〃500A Mig DC φ1.6 Soft Al(Low*)$WTBD2772

0.8

MAG

Mild steel
solid

0.8

High

500A Mag DC-Wave φ0.8(High)$WTBD2773

〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃

〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC-Wave φ0.9(High)
500A Mag DC-Wave φ1.0(High)
500A Mag DC-Wave φ1.2(High)
500A Mag DC-Wave φ1.4(High)
500A Mag DC-Wave φ1.6(High)
500A Mig_4 DC-Waveφ0.8 SuS(High)
500A Mig_4 DC-Waveφ0.9 SuS(High)
500A Mig_4 DC-Waveφ1.0 SuS(High)
500A Mig_4 DC-Wave φ1.2 SuS(High)
500A Mig_4 DC-Wave φ1.6 SuS(High)$WTBD2774$WTBD2775$WTBD2776$WTBD2777$WTBD2778$WTBD2779$WTBD2780$WTBD2781$WTBD2782$WTBD2783

1.4 Welding mode lists
Welding mode
Welding
process

Gas

Wire material

WirediameterTravelspeed〃〃

Ferrite

0.8

〃

〃

〃

〃

0.9

〃

〃

〃

〃

1.0

〃

〃

〃

〃

1.2

〃

〃

〃

1.0

〃

〃
〃
〃

〃
〃
〃

1.2
1.6
1.2

〃
〃

〃
MAG

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃
〃
〃
MIG*
〃
〃
〃
〃
〃
〃
〃
〃
〃

〃
〃
〃

〃
〃
〃

〃

〃

Hard
aluminum〃〃Soft
aluminum〃
Mild steel
solid
〃
〃
〃
〃
〃
SUS
〃
〃
〃
〃
Ferrite〃〃〃Hardaluminum〃〃Soft
aluminum〃

Welding mode description
500A
Mig_4
Ferrite(High)
500A
Mig_4
Ferrite(High)
500A
Mig_4
Ferrite(High)
500A
Mig_4
Ferrite(High)DC-Waveφ0.8
DC-Waveφ0.9
DC-Waveφ1.0
DC-Waveφ1.2

Notes
Number of welding
characteristic data in
AX21/FD11$WTBD2784$WTBD2785$WTBD2786$WTBD2787

500A Mig DC-Wave φ1.0 Hard Al(High)$WTBD2788〃〃〃

500A Mig DC-Wave φ1.2 Hard Al(High)
500A Mig DC-Wave φ1.6 Hard Al(High)$WTBD2789$WTBD2790

500A Mig DC-Wave φ1.2 Soft Al(High)$WTBD2791

1.6
0.8

〃
Standard

500A Mig DC-Wave φ1.6 Soft Al(High)$WTBD2792

500A Mag DC-Wave φ0.8(Low)$WTBD2793

0.9
1.0
1.2
1.4
1.6
0.8
0.9
1.0
1.2
1.6
0.8
0.9
1.0
1.2
1.0

〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃
〃

500A Mag DC-Wave φ0.9(Low)
500A Mag DC-Wave φ1.0(Low)
500A Mag DC-Wave φ1.2(Low)
500A Mag DC-Wave φ1.4(Low)
500A Mag DC-Wave φ1.6(Low)
500A Mig_4 DC-Waveφ0.8 SuS(Low)
500A Mig_4 DC-Waveφ0.9 SuS(Low)
500A Mig_4 DC-Waveφ1.0 SuS(Low)
500A Mig_4 DC-Wave φ1.2 SuS(Low)
500A Mig_4 DC-Wave φ1.6 SuS(Low)
500A Mig_4 DC-Waveφ0.8 Ferrite(Low)
500A Mig_4 DC-Waveφ0.9 Ferrite(Low)
500A Mig_4 DC-Waveφ1.0 Ferrite(Low)
500A Mig_4 DC-Waveφ1.2 Ferrite(Low)$WTBD2794$WTBD2795$WTBD2796$WTBD2797$WTBD2798$WTBD2799$WTBD2800$WTBD2801$WTBD2802$WTBD2803$WTBD2804$WTBD2805$WTBD2806$WTBD2807

500A Mig DC-Wave φ1.0 Hard Al(Low)$WTBD2808

1.2
1.6
1.2

〃
〃
〃

500A Mig DC-Wave φ1.2 Hard Al(Low)
500A Mig DC-Wave φ1.6 Hard Al(Low)$WTBD2809$WTBD2810

500A Mig DC-Wave φ1.2 Soft Al(Low)$WTBD2809

1.6〃500A Mig DC-Wave φ1.6 Soft Al(Low)$WTBD2810*：MIG gas defers in its mixing ratio depending on the wire material as below. For more details, refer to the

instruction manial for welding power supply.
When the wire material is a SUS/Ferrite
When the wire material is a Hard/Soft aluminum

POINT：Argon (Ar) 98% / Oxygen (O2) 2%：Argon (Ar) 100%

Normally, use the welding characteristic data given in Table 1.4.5 dedicated to “High”
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 cabledepending on the layout condition of cables (when the total length exceeds 30m or thecable is coiled). In that case, voltage adjustment will normally bring about stablecondition. However, use the welding characteristic data dedicated to “Extension cable”
application if the welding performance is not yet stable.

IMPORTANTThe welding mode cannot be switched as follows during welding. Do not perform teachingfor the following.
 From DC low spatter to DC/DC pulse/DC wave pulse
 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
This chapter describes how to connect the Welding Interface (Digital).
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

2.1 Connect Welding Interface (Digital)

2.1 Connect Welding Interface (Digital)
2.1.1 Installation of the Welding Interface (Digital) Board
Described here are the connections for the Welding Interface (Digital) Board that is used with therobot controller.
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 therobot controller by the plate and the locking card spacer.

Figure 2.1.1 Installation Positions of the Welding Interface (Digital) Board

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.

Figure 2.1.2 Installation Positions of the Built-in Touch Sensor

2-1

2.1 Connect Welding Interface (Digital)

3

Wire the signal cable, and connect the Welding Interface (Digital) Board CNCAN1 andthe 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).

Figure 2.1.3

2-2

Cable wiring and connector connection

2.1 Connect Welding Interface (Digital)

2.1.2 Connection of Control cable 5 (Robot controller side)
1

Turn off the primary power supply and circuit breaker on the controller.

2

Pull the control cable 5 connector through the control cable 5 inlet on the right side of therobot controller as shown in Figure 2.1.4.

Figure 2.1.4
3

Connection of control cable 5 (Pull cable through)Fix the shield section of the cables to the shield fixing fixtures on the left side of theservice entrance as shown in Figure 2.1.5.
Shield fixing plate
Control cable 5

Shield groundFigure 2.1.5
4

Connection of control cable 5 (Fix the shielding ground)

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)

2.1.3 Connection of Control cable 5 (Welding power source side)
For WB-M350L / WB-M350 / WB-M500 / WB-P350 / WB-P500L
1

Turn off the primary power supply and circuit breaker on the welding power source.

2

Remove the back cover on the welding power source.

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 circuitboard 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.

Front (Upper)

Printed circuit board
PCB1

Socket for wire feeder

Control cable 5

Front (Lower)
CN17

Output terminal (-)

Output terminal (+)

To robot controller

Workpiece side welding cable

To wire feeder
Torch side welding cable
Control cable 4
Rear

Printed circuit board
PCB10

Connect grounding cable.

Remove "STOP" jumper
wire.
TM3

Figure 2.1.7

2-4

Connection of digital welding power source (WB-M350L/ WB-M350 / WB-M500)

2.1 Connect Welding Interface (Digital)

2.1.4 Connection of Control cable 4
Connect each connector of the control cable 4 to the socket ICN4 for wire feeder on the welding
power source and to the connector CN4 on the rear panel of the manipulator, respectively.

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.

Installation of the welding power source and welding cables

CAUTIONFix the welding power source on a firm and level surface, such as a concrete floor,
rendering it immovable.
Wire the welding cable with some margin, so that no unreasonable force is applied tothe connector of the welding cable.
If you bend the connector section forcedly for wiring, it may cause damage of theconnector.
(Good example)(Wrong example)

In case of installation on the floor:
Provide some margin in wiring so as to
avoid any force applied to the connector.

In case of forced wiring of the welding
cable:
If you bend the connector section
forcedly for wiring, force is applied to theconnector.

Welding cable
Welding
powersourceWelding
power source

Floor surface

In case of installation on a mount, etc:
Place it sufficiently away from the mountedge or take other measures, so that noforce is applied to the connector.
Wide margin

Floor surface

In case of installation near the mountedge:
The connector may be pulled under theweight of the welding cable andsubjected to force.
Welding
powersourceWelding
power source
Mount

Welding cable

Welding cable

Mount
Mount
edge

Welding cable

Floor surface
Floor surface

2.1.6 Connection of Gas hose
Connect the gas hose to the connector GAS on the rear side of the manipulator and to the gas
regulator, respectively.

2-5

2.1 Connect Welding Interface (Digital)

2.1.7 Connection of Voltage detecting cable (workpiece side)(for WB-M350L/WB-P500L)
To fully utilize the welding performance of WB-M350L / WB-P500L(When the wire material is otherthan a steel or SUS, such as an aluminum), it is difficult to wire the voltage detecting cable in sucha manner to ensure accurate feedback of the arc voltage.

INFO.

Connect the voltage detecting cable (torch side) to the connector of the upperarm. For installation procedure, please refer to the instruction manual “Welding
Torch for Robot” and “Coaxial Power Cable for Robot”.

Connection of Voltage detecting cable (workpiece side)(1) Connecting the voltage detecting cable (workpiece side) Connect voltage detection cable (workpiece side) to a place near to workpiece as possible.
 Wire the torch (voltage detecting wire) to along with the voltage detecting cable (workpieceside) as much as possible and lower the shaded area Figure 2.1.8.

Connect the voltage
detecting cable in sucha manner to minimize
the shaded area.
Figure 2.1.8

Routing of the Voltage Detecting Cable (workpiece side)(2) In case of plural welding stages
Connect the workpiece cable to each stage subsequently, and then connect the voltage detecting
cable (workpiece side) to the stage which was connected at last (so as to avoid detection ofvoltage drop occurring in the workpiece cable).

CN28

Figure 2.1.9

2-6

Routing of the Voltage Detecting Cable (Workpiece side)(In case of plural welding stages)

2.1 Connect Welding Interface (Digital)(3) In case of installing the workpiece on a rotary jig
Connect it in such a manner to minimize the voltage drop due to the resistance.

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 aworkpiece, a jig and a surface of the table of the positioner.

There exists an stableelectrical connection
among a workpiece, a jig
and a surface of the tableof the positioner.

Workpiece
Jig

Voltage detection cable(Workpiece side)

2PF series / 1PB series
Figure 2.1.10 Routing of the Voltage Detecting Cable (Workpiece side)(In case of use of 2PF / 1PB series 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 aworkpiece, a jig and a surface of the table of the positioner.

POINT

If the voltage detection cable (workpiece side) is connected the place
where the part has a different voltage level, the welding power source
may not give the best performance.

Workpiece
Jig
Voltage detection cable(Workpiece side)

There exists an stableelectrical connection
among a workpiece, a jig
and a surface of the tableof the positioner.

Figure 2.1.11 Routing of the Voltage Detecting Cable (Workpiece side)(In case that the positioner which has no voltage detection terminal is combined)2-7

2.2 Electrical connection diagram

2.2 Electrical connection diagram
WB-M350L/ WB-P500L*1
Robot controller
Control cable 5

Com.line
CN17/18
CON1

Manipulator
CN4
CN1 CN2
Control cable 4

Wire feeding unit
Wire
feedingmotor

Wire feeding
motor
+5V
Encoder A phase
Encoder B phase

Encoder line

GND
Gas
Gas valve
Voltage detection (Torch)
Voltage detection(Workpiece)

CN28

OutputVoltage detection cable(Workpiece)

Figure 2.2.1

Torch
Workpiece

Voltage detection
cable (Torch)

Electrical connection diagram of WB-M350L / WB-P500L*1

WB-M350 / WB-M500 / WB-P350 / WB-P500L*2
Robot controller
Control cable 5

Com.line
CN17/18
CON1

Manipulator
CN4
CN1 CN2
Control cable 4

Wire feeding unit
Wire
feedingmotor

Wire feeding
motor
+5V
Encoder A phase
Encoder B phase

Encoder line

GND
Gas
Gas valve
Voltage detection (Torch)
Voltage detection(Workpiece)
OutputTorchWorkpiece

Figure 2.2.2

Electrical connection diagram of WB-M350 / WB-M500 / WB-P350 / WB-P500L*2*1 When the wire material is other than a steel or SUS, such as an aluminum.
*2 When the wire material is a steel or SUS.

2-8

2.2 Electrical connection diagram

Robot controller

Figure 2.2.3

Electrical connection diagram of AXC

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.

3.11 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

3.1 Workflow

3.1 Workflow
Configure Welding Interface (Digital) on your computer using the "Welding Interface (Digital) Setup" tool.
The workflow is shown below.

Configuration
preparations
Page 3-3

1

Download the "Welding Interface (Digital) Setup" tool
Download the "Welding Interface (Digital) Setup" tool onto yourcomputer.

2

Configure the welding power source
Configure the Welbee Inverter series welding power source toenable communication with the interface. Configure the internalfunctions as shown in the table below by operating the front
panel of the welding power source. For details on the operation
methods, see the instruction manual of your welding powersource.

Configuring the Welbee
Inverter series welding
power source
Instruction manual
for the welding
power source

No.
F4

F43

3

FunctionnameAuto/Semi
auto mode

CANID

Setting
Set "3: OTC robot 1".
When connecting 1 welding powersource to the interface, set "1".
When connecting multiple welding
power sources to the interface, set thesame number as the registration
number in the next item, "Register thewelding power source".

Registering the welding power source
Register the welding power source to use for the robot
controller. In this step, register a D series welding power source
instead of the Welbee Inverter series welding power source.
When changing the welding power source from the D series tothe Welbee Inverter series as shown in Table 1.2.3 andcontinuing to use the existing programs, this step is not
required.

Configuring the robot
controller
Page 3-4

4

Register the welding mode
Register the welding mode to use for the robot controller.
When changing the welding power source from the D series tothe Welbee Inverter series as shown in Table 1.2.3 andcontinuing to use the existing programs, this step is not
required.

5

Creating a backup
Back up all the robot control data onto a CF card.

6
Creating the setup data
Page 3-9

Create the setup data
Create the setup data for configuring the robot controller andthe interface by using the "Welding Interface (Digital) Setup"
tool.

3-1

3.1 Workflow

7
Writing the setup data
Page 3-14

Write the setup data onto Welding Interface (Digital) and therobot controller.
8

Check the configuration
Page 3-17
Adjusting the welding
characteristic data
WB-M350L
Page 3-20
WB-M350/500
Page 3-25
WB-P350
Page 3-28

Writing the setup data

Check the configuration
Check that the interface is configured correctly and the welding
power source can be used.

9

Adjust the welding conditions
Adjust the welding conditions to suit your welding power source.
For details on the welding conditions that can be used with theinterface, see the welding conditions for the various welding
power sources from the section 3.8 .
Also, for details on editing the welding conditions, see the
APPLICATION MANUAL (ARC WELDING) instruction manualfor your robot controller.

WB-P500L
Page 3-35

IMPORTANT

POINT

3-2

Be sure to check the welding conditions that can be used in step 9.
The welding condition editing screen of the robot controller includes the parameters for D
series welding power sources, which are not used by Welbee Inverter series welding powersources.
When you turn on a robot controller again, please also turn on a welding power source again .

To change the registration of the welding characteristic data in f5 <Arc Constant> - [4 Settingof 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 Configuration preparations

3.2 Configuration preparations
This section describes the preparation for the "Welding Interface (Digital) Setup" tool and the USB media.

3.2.1 "Welding Interface (Digital) Setup" tool preparations
Download the "Welding Interface (Digital) Setup" tool from the OTC website onto your computer.

Downloading the setup tool
1

Access the DAIHEN website, and then download the "Welding Interface (Digital)
Setup" tool.
Download page for the "Welding Interface (Digital) Setup" tool
(DAIHEN Welding and Mechatronics System Corporation > Downloads)
http://www.daihen.co.jp/yosetsu/other/download_e.html

2

Unzip the "Welding Interface (Digital) Setup" tool into any folder.
>> This completes the setup tool preparations.

3.2.2 USB memory preparations
Create a folder in the USB memory for saving the setup data.

IMPORTANT

Operation is not guaranteed to work with a commercially available USB memory.
Use the USB memory (parts number L21700U00) recommended by OTC.

USB memory preparations
1

Create an "UPDATE" folder and "BACKUP" folder in the USB memory.

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

3.3 Configuring the robot controller
This section describes the procedure for the configuration performed on the robot controller.

3.3.1 Registering the welding power source
When using the interface to connect a Welbee Inverter series welding power source, register
the welding power source as the corresponding D series welding power source shown in Table
3.3.1 in f5 <Arc Constant> - [1 Registration of welder] on the robot controller.
When changing from an existing D series welding power source to a Welbee Inverter series
welding power source as shown in Table 1.2.3 and continuing to use the existing programs, thisstep is not required.

IMPORTANTPOINT

D series welding power sources and Welbee Inverter series welding powersources cannot be used at the same time.

Register the Welbee Inverter series welding power source in the robot
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 registersource to be connectedin 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 replacedwith 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.
For details, see the "1.2.3 Connectable welding power sources".

INFO.

3-4

After registering the welding power source, configure the robot to which thewelding power source will be connected, and the connection type. For details on
the configuration method, see "Chapter 1 Basic settings" in the APPLICATIONMANUAL (ARC WELDING) instruction manual for the robot controller.

3.3 Configuring the robot controller

3.3.2 Register the welding mode
Register the welding mode you will use with the Welbee Inverter series welding power source in
f5 <Arc Constant> - [4 Setting of weld data] on the robot controller. For details on the welding
modes that can be used in the Welbee Inverter series welding power source, see "Chapter 1
Introduction" in this manual.
The robot controller handles the Welbee Inverter series welding power source as the D series
welding power source registered in "3.3.1 Registering the welding power source". For thisreason, as shown in the examples in Table 3.3.2 to Table 3.3.4, in the robot controller, register
the welding characteristic data of the D series welding power source that is most similar to thewelding mode used in the Welbee Inverter series welding power source. During robot playback
operation, welding is performed after the interface converts the welding mode registered in the
robot controller into the welding mode that will actually be used. Create the information required
for this conversion in "3.4 Creating the setup data" described later, and then install it onto theinterface.

IMPORTANTFor the welding characteristic data to be registered in the robot controller, selectdata 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 varydepending on the welding characteristic data to be registered in the robot
controller.

Table 3.3.2 Welding mode registration example (registering WB-M350L as DL(S-2))
Welding characteristic data registered in the
Welding mode used inrobot controller
WB-M350L
No.
File comment
Characteristic 1
350A Co2 DC φ1.2 (Low)$WTBD1410 350A Co2 DC φ1.2 (High)Characteristic 2
350A Mig_4 DC φ1.2 SuS (Low)$WTBD1439 350A Mig DC φ1.2 SuS (High)Description

 Register a welding mode where the welding process and wire material match.
 For "Travel speed: Low", register "Polarity: Electrode positive" of "Welding
speed: High/Low".
 For the "Mig_4" gas type, register the similar "MIG".

Table 3.3.3 Welding mode registration example (registering WB-M350 as DR)
Welding characteristic data registered in the
Welding mode used inrobot controller
WB-M350
No.
File comment
Characteristic 1
350A Co2 DC φ1.2 (High)$WTBD824
350A Co2 DC φ1.2 (High)Characteristic 2
350A Co2 DC φ1.2 (Low)$WTBD803
350A Co2 DC φ1.2
Characteristic 3
350A Mig_4 DC φ1.2 SuS (High) $WTBD832
350A Mig DC φ1.2 SuS (High)Characteristic 4
350A Mig_4 DC φ1.2 SuS (Low) $WTBD815
350A Mig DC φ1.2 SuS
Description

 Register a welding mode where the welding process and wire material match.
 For "Travel speed: High", register "Welding speed: High".
 For "Travel speed: High", register "Welding speed: High".
 For the "Mig_4" gas type, register the similar "MIG".

Table 3.3.4 Welding mode registration example (registering WB-M500 as DM)
Welding characteristic data registered in the
Welding mode used inrobot controller
WB-M500
No.
File comment
Characteristic 1
500A Co2 DC φ1.2 (High)$WTBD824
500A Co2 DC φ1.2
Characteristic 2
500A Co2 DC φ1.2 (Low)$WTBD815
500A Co2 DC φ1.4

Description

 Register a welding mode where the welding process and wire material match.
 Independent Standard and High welding speed modes are not available for the
DM series welding modes. Register as unused wire diameter welding
characteristic data where the welding process and wire material match(Characteristic 2).

3-5

3.3 Configuring the robot controller
Table 3.3.5 Welding mode registration example (registering WB-P350 as DP)
Welding mode used in
WB-P350
Characteristic 1
Characteristic 2
Characteristic 3

350A Co2 DC φ1.2(High)
350A Co2 DC φ1.2(Low)
350A Mig_4 DC-Pulse φ 1.2
SuS(High)

Welding characteristic data registered in the
robot controller
No.
File comment$WTBD603
350A Co2 DC φ1.2
$WTBD602
350A Co2 DC φ1.0
$WTBD635

350A Mig DC-Pulse φ1.2 Sus

 Register a welding mode where the welding process and wire material match.
 Apply the welding characteristic data for a rated current 350A when WB-P350 isin connection.
 Independent Standard and High welding speed modes are not available for the
DP-350. Register as unused wire diameter welding characteristic data where
the welding process and wire material match (Characteristic 2).
 For the "Mig_4" gas type, register the similar "MIG".

Description

Table 3.3.6 Welding mode registration example（registering WB-P500L as DPR）
Welding mode used in
WB-P500L
Characteristic 1
Characteristic 2
Characteristic 3
Characteristic 4
Characteristic 5

500A Co2 DC φ1.2 (High)
500A Co2 DC φ1.2 (Low)
500A Co2 DC φ1.2(Low#)
500A Mig_4 DC-Pulse φ 1.2
SuS(High)
500A Mig_4 DC-Wave φ 1.2
SuS(High)

Welding characteristic data registered in the
robot controller
No.
File comment$WTBD1503 400A Co2 DC φ1.2
$WTBD1502 400A Co2 DC φ1.0
$WTBD1501 400A Co2 DC φ0.9
$WTBD1528

400A Mig DC-Pulse φ1.2 Sus$WTBD1546

400A Mig DC-Wave φ1.2 Sus

 Register a welding mode where the welding process and wire material match.
 Independent Standard and High welding speed modes are not available for the
DP-400R. Register as unused wire diameter welding characteristic data where
the welding process and wire material match (Characteristic 2).
 DC low spatter welding mode is registered as DC welding mode of DP-400R(Characteristic 3).
 For the "Mig_4" gas type, register the similar "MIG".

Description

Table 3.3.7 Welding mode registration example (registering WB-P500L as DP)
Welding mode used in
WB-P500L
Characteristic 1
Characteristic 2
Characteristic 3
Characteristic 4
Characteristic 5

Description

3-6

500A Co2 DC φ1.2(High)
500A Co2 DC φ1.2(Low)
500A Co2 DC φ1.2(Low#)
500A Mig_4 DC-Pulse φ 1.2
SuS(High)
500A Mig_4 DC-Wave φ 1.2
SuS(High)

Welding characteristic data registered in the
robot controller
No.
File comment$WTBD703
500A Co2 DC φ1.2
$WTBD702
500A Co2 DC φ1.0
$WTBD701
500A Co2 DC φ0.9
$WTBD738

500A Mig DC-Pulse φ1.2 Sus$WTBD752

500A Mig DC-Wave φ1.2 Hard
Al Register a welding mode where the welding process and wire material match.
 Apply the welding characteristic data for a rated current 500A when WB-P500 isin connection.
 Independent Standard and High welding speed modes are not available for the
DP-500. Register as unused wire diameter welding characteristic data where
the welding process and wire material match (Characteristic 2).
 DC low spatter welding mode is registered as DC welding mode of DP-400R(Characteristic 3)
 For the "Mig_4" gas type, register the similar "MIG".
 Use these settings only when replacing from DP-500.

3.3 Configuring the robot controller

3.3.3 Creating a backup
Use the following procedure to create a backup on the CF card.

POINT

This section reproduces the backup operation procedure from the instruction
manual of the robot controller (only this procedure is reproduced). For details
on the backup function and the other file operation functions, see "6 Fileoperations" 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

Opening the backup screen
Enter

1

Select “10 File Backup” on the file operation menu, and press [Enter].
>> The [File Backup] screen is now opened.

2

Files are backed up on this screen.
To move through each field, use the left and right keys.
To select the items displayed in the fields, use the up and down keys.

3-7

3.3 Configuring the robot controller

Backing up the folders

Enter

3-8

1

In the device selection field, select “Card1” for instance.

2

Move to the folder selection field, select the backup destination folder, and press[Enter].

3

Press f12 <Execute>.
>> Backup now starts.

3.5 Writing the setup data

3.4 Creating the setup data
This section describes the procedure for creating the data required for connecting a Welbee Inverter series
welding power source to the interface and using the power source (this is called the "setup data").
The setup data consists of the following 2 data types.
 Data to be written onto the interface
This is the data for converting the welding mode registered in the robot controller (see 3.3.2 ) into thewelding mode that will actually be used in the Welbee Inverter series welding power source.
 Welding characteristic data file to be written onto the robot controller
This is the welding characteristic data file with the current and voltage output characteristics changed
to match the welding mode of the Welbee Inverter series welding power source that will be used.
The "Welding Interface (Digital) Setup" tool is used in the operations in this section.

3.4.1 Configuring the setup tool
Select the folder for saving the backup created in "3.3 Configuring the robot controller", and thefolder for saving the setup data of Welding Interface (Digital).

Selecting a backup folder
1

Connect the CF card that stores the backup data obtained in "3.3.3 Creating a
backup" to a computer.

2

Double-click "MakeConfigWIF.exe" in the "Welding Interface (Digital) Setup"folder.
>> The setup tool starts and the folder browse window opens.
Alternatively, after "Welding Interface (Digital) Setup" starts, select "SelectBackup folder" in the "Settings" menu.
>> The folder browse window opens.

3-9

3.4 Creating the setup data
3

Select the backup you created in "3.3.3 Creating a backup".

4

Select the backup folder.
>> The backup data of the robot controller is loaded from the selected backup folder,and "Welding Interface (Digital) Setup" starts.

The name of the backup folder is given automatically using the following format.

INFO.

NRA2001-2012-12-20-1200
Date

3-10

Time

3.5 Writing the setup data

Selecting the save folder for the setup data
1

Connect the USB memory you prepared in "3.2.2 USB memory preparations" tothe computer.

2

Select "Select Setup folder" in the "Settings" menu.

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 thewelding 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.

POINT

When the setup data is created, the welding characteristic data selected in"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 ofRC].

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 thewelding power source" and check the correspondence between the D series
welding power source and Welbee Inverter series welding power source. If there isno corresponding power source, perform the procedure again from "3.3.1
Registering the welding power source".

POINT

When the “Use welding char.” checkbox is displayed

Check this box when replacing an existing D series welding power source witha Welbee Inverter series welding power source. Checking this box changes thewelding 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.

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3.5 Writing the setup data

3

In the [Welding characteristic] item, select the welding mode to use with theWelbee Inverter series welding power source.
>> The welding mode displayed in [Welding mode in RC side] is associated with thewelding mode set in this step.

INFO.

For details on selecting the welding mode, also see "3.3.2 Register the weldingmode".

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 thewelding modes registered in the robot controller with the welding modes of theWelbee Inverter series welding power source.

5

Press the [Create Files] button.
>> The setup data is created. The setup data is saved on both the USB memory andthe CF card (that stores the robot controller backup) selected in "3.4.1
Configuring the setup tool".

3-13

3.5 Writing the setup data

3.5 Writing the setup data
This section describes the procedure for writing the setup data you created in "3.4 Creating the setup data" onto
Welding Interface (Digital) and the robot controller.

3.5.1 Writing the setup data onto the robot controller
Write the setup data you created in "3.4.2 Configuring the welding mode for the Welbee Inverter
series welding power source" onto the robot controller.

Writing the setup data onto the robot controller

Enter

Enter

3-14

1

While the power of the robot controller is OFF, insert the backup CF card thatyou created in "3.4.2 Configuring the welding mode for the Welbee Inverter
series welding power source" into the robot controller.

2

While the power of the robot controller is ON,
Select “1 File Copy” on the file operation menu, and press [Enter].
>> The [File Copy] screen is now opened.

3

Select "Card 1" in the Device (src) selection field.
To move through each field, use the [left or right] keys.
To select the items displayed in the fields, use the [up or down] keys.

4In "Card 1", select the folder that stores the backup, select "WORK" →"A_APPLICATION" → "WELD" in this order, and then press [Enter].
>> The "WELD" folder is selected.

3.6 Check the configuration

Enter

5

In the “Device (dest)” folder selection field, select the folders in the order of"Internal memory" → "WORK" → "A_APPLICATION", and then press [Enter].
>> The "A_APPLICATION" folder is selected.

POINT

6

In step 5, select "A_APPLICATION", not the "WELD" folder you selected instep 4.

Press f12 <Execute>.
>>The setup data is written onto the robot controller.

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3.5 Writing the setup data

3.5.2 Writing the setup data onto Welding Interface (Digital)
Write the setup data you created in "3.4.2 Configuring the welding mode for the Welbee Inverter
series welding power source" onto Welding Interface (Digital).

Writing the setup data onto Welding Interface (Digital)

IMPORTANT
1Make sure that the power of the robot controller is OFF before inserting the USB
memory or operating a DIP switch.

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.

3

Turn ON the power of the robot controller.
>> After 10 seconds, the writing of the setup data onto the interface starts automatically.
The setup data writing finishes after approximately 10 seconds.

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.

IMPORTANT
INFO.

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).

If 'E' → 'n' → 'd' is not displayed, see "Chapter 4 Maintenance".
When these steps are performed, the setup file already written in this board isbacked up automatically to a USB memory.
If step2 is changed “Both No.2 and No.3 of a DIP switch are turned ON”, thesetup file can be restored from backup.

3-16

3.6 Check the configuration

3.6 Check the configuration
Use the following procedure to check that the configuration up to section 3.5 was performed correctly.

Writing the setup data onto the robot controller
1Turn OFF the power of the robot controller and welding power source.

2

Turn ON the power of the welding power source.
>> Check that "000 000" blinks on the front panel of the welding power source.
If different from above, refer to "Chapter 2 Connections", and check that control
cable 5 is connected, and that the STOP (+) / STOP (-) jumper wire of terminal block
TM3 on the PCB10 printed circuit board of the Welbee Inverter series welding powersource is removed.

3

Turn ON the power of the robot controller.
>> On the teach pendant (TP) of the robot controller, check that the starting process
has completed and that the robot controller is ready for operation.
>> Next, check on the TP that no errors related to the welding power source haveoccurred, such as "A5013 Power of arc welding power source not ON."
If different from above, refer to "Chapter 2 Connections" and "Chapter 4
Maintenance", and check that the interface and the robot controller, and the interface
and the welding power source are connected correctly. Also, perform "3.5 Writing the
setup data" again.

4

Check that the emergency stop is not being input to the robot controller, andcheck 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 therobot 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 areblinking.
(3) The display indicating the welding mode (wire diameter, material and gas)is the last welding mode (mode with the highest registration number) thatwas 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 theinterface is connected correctly.
If different from (2) or (3) above, refer to "Chapter 4 Maintenance" and check that noerrors 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 theinching/retracting of the welding wire was executed correctly.
If different from above, check that "3.3 Configuring the robot controller" wasperformed correctly.
>> The setup operations were completed correctly.

3-17

3.7 Configuring the Welbee Inverter series welding power source

3.7 Configuring the Welbee Inverter series welding powersourceThis section describes the front panel operations and internal functions of the welding power source when a
Welbee Inverter series welding power source is to be connected with the robot.

3.7.1 The welding power source operations when a robot is connected
When Welbee Inverter Series welding characteristics is connected to the robot, operable keys are
displayed in Table 3.7.1. The keys, other than the ones indicated, cannot be used.
All basic settings such as selecting the welding modes and setting the welding conditions are
performed by commands from the robots.
Concerning the operation of the welding power source
For details on how to operate the welding power source, refer to its instruction
manual.

INFO.

Figure 3.7.1
Table 3.7.1

Keys that can be used when the welding power source is connected to a robot

Key name

Description of function

LOAD

Used when saving a simple data log to a USB memory. For details, see theinstruction manual for the welding power source.

ENTER

This key cannot work alone. Press [ENTER] key for a while (Approx. 3 sec.) toswitch the key lock ON/OFF.
When the key lock is ON, LED for [ENTER] key flashes.

GAS CHECKWhen the key is pressed once, gas is discharged (for up to 2 minutes), andthe LED lights. When it is pressed again, the gas discharge stops, and the
LED goes off.

F

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 thefunctions 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 isdisplayed.

INFO.

3-18

Welbee Inverter series welding power source Front Panel

When set for the robot dedicated application, all LEDs in TRAVEL SPEED key areOFF.

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
Function
numberINFO.

Function name

Function

4

Auto/Semi auto mode

8

Setting of Result Display
Holding Time

Switches the I/O settings for the welding powersource.
0 : Semi-automatic machine
1 : Automatic 1
2 : Automatic 2
3 : OTC robot 1 (500Kbps mode)
4 : OTC robot 2 (1Mbps mode)
See the instruction manual for the welding powersource.

21

Cooling fan maximum
operation

See the instruction manual for the welding powersource.

22

Keypad tone ON/OFF
Selection

See the instruction manual for the welding powersource.

Welders ID (CANID)

This is used to set the numbers (1 to 4) of thewelding power sources.
Select <Arc Constant> – [1 Registration of welder],and select the numbers corresponding to thewelding power sources to be registered.

43

IMPORTANTInternal functions that can be used when the Welbee Inverter series welding powersource is connected to a robot

 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 theregistered welding power source is DP. For details, see “3.11.7 Settgins on the
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" isset to "0: Semi-automatic machine".
If the welding power source is communicating normally with the robot controller, thelowest dots in the left/right digital meters are blinked.

3-19

3.8 Welding conditions of WB-M350L

3.8 Welding conditions of WB-M350L
This section describes the welding conditions that can be set when WB-M350L is connected.

3.8.1 About the welding condition parameters
The welding conditions that can be set when WB-M350L is connected using the interface areshown in Table 3.8.1. Some welding conditions vary depending on the type of welding powersource registered in the robot controller. Welding condition parameters not included in this tablecannot be used.
Table 3.8.1 Welding conditions of WB-M350L
Welding power source
registered in robot
Welding conditions
controller
DL
DL(S-2)
Welding process
○ *1
○ *1
Current cond.
○○AS

Welding current / Wire speed○○

Welding voltage / Arc length tun.

○○

Welding speed○○

Arc char.1(Short)○○

Arc char.2(Arc)○○APCS cond.

○

○

*2

○

○

APCS parameter 2 / APCS parameter 2 EP *2○○

Slope time / Slope distance○○

Initial current / Ini. wire speed○○

Initial voltage / Ini. arc length○○

Start adjust time×○

Start voltage adj

×

APCS parameter 1 / APCS parameter 1 EP

AE

○
*1

○ *1
○
○

Welding process
Current cond.
Welding current / Wire speed○○○

Welding voltage / Arc length tun.

○○

Crater time○○

Post flow time○○

Arc char.1(Short)○○

Arc char.2(Arc)○○APCS cond.

× *3

× *3

APCS parameter 1 / APCS parameter 1 EP *2○○

APCS parameter 2 / APCS parameter 2 EP *2○○

Slope time / Slope distance○○

Burnback pulse○○

Burnback pulse value○○○: Can be used
×: Cannot be used (operates with the initial value of the welding power source)*1: The welding mode displayed on the robot controller may be different from the welding modeof the Welbee Inverter welding power source. For details, see "3.4.2 Configuring the welding
mode for the Welbee Inverter series welding power source".
*2: The parameter names may be different depending on the welding power source, but thefunctions are not different. For details on the functions, see "3.8.3 How the spatter
adjustment parameter (APCS cond.) is used" described later.
*3: Always set to "AUTO".

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3.8 Welding conditions of WB-M350L

3.8.2 Points for setting the conditions
The points to be observed when setting the welding conditions are set forth below.
Concerning the welding current and wire feed speed
The welding current (or wire feed speed) which is input as a welding condition becomes theaverage current (or average wire feed speed) during welding. The welding waveform control
parameter optimally suited for the welding current (or wire feed speed) which has been set is
calculated automatically on the basis of the welding current (or wire feed speed) which has been
input.
Concerning the arc length tuning
The WB-M350L has two modes: synergic adjustments and individual adjustments.
When it is used in the synergic adjustment, the optimum voltage for the current which has been
set is output automatically. The “arc length tun.” is an adjustment value for increasing or reducing
the voltage which is output automatically. For instance, if a setting of +5 is used, the output
voltage will be raised by about 0.5 V as a theoretical value.
Concerning the input of the wire feed speed
The wire feed speeds which are actually valid as welding conditions differ according to the welder
and welding mode used. If the standard software has been installed in the welder, the minimum
speed is approximately 130 cm/min. and the maximum speed is approximately 1800 cm/min. as a
general rule. However, depending on the welding mode, the maximum and minimum wire feed
speed may be more restricted than the ranges given.
Concerning the setting range of the welding speed
Although any speed from 1 to 999 cm/min. can be set as the welding speed, the maximum speed
is actually 600 cm/min. or so. Since this is also the maximum operable speed and not a speed
which can be used for actual welding, it must be adjusted to ensure optimum welding.
Concerning the Arc char.1 (Short)
The arc characteristic is expressed in the form of a numerical value which enables the arc
hardness or softness to be set.
A “+” figure yields a soft arc with minimized short-circuit current peaks.
A “–” figure yields a hard arc yielded by a high short-circuit current.
Concerning the Arc char.2 (Arc)As with the Arc char.1 setting, the values for this condition enable hard or soft to be set for
the arcs.
A “+” figure yields a soft arc with minimized current change in the arc discharge.
A “–” figure yields a hard arc with the large current change in the arc discharge.

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 beproduced. However, if the value is set too high, the welding easily becomes unstable and theelectrical tolerance of the condition will drop to a lower value. A “–” figure setting yields astronger 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 “–”, thewelding may become unstable.
Normally, set the same values to Arc char.1 (Short) and Arc char.2 (Arc).
What is the slowdown speed?
The slowdown speed denotes the speed at which the wire is fed until the arc is started at the arc
start point.
When crater treatment is not performed
When crater treatment is not going to be performed, set the crater time to “0.” However, in thiscase, set the same conditions as for regular welding as the crater current or wire feed speed
setting value. Unless the same conditions are set, the appropriate burnback voltage level may not
be displayed properly at the teaching stage.

IMPORTANT

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.

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3.8 Welding conditions of WB-M350L
Concerning the burnback pulse control
Teaching of this parameter is available only when the wire material is SUS. This should benormally set to “ON”.
Meanwhile, the burnback pulse output value should be normally set to “0”.
This shall be set to “OFF” only when a meltdown occurs on the thin plate during burnback.

3.8.3 How the spatter adjustment parameter (APCS cond.) is used
In short arc welding where short-circuits and arcs are repeated, most of the spatter is generated
when short-circuiting occurs and immediately before arc generation. A phenomenon referred to as“necking” occurs in the wires immediately before arc generation of the latter category, as shown in
the figure below. By detecting this necking and sharply reducing the current at that instant, themelted metal is not blown about by the arc force and the generation of spatter can be significantly
reduced. To achieve this, it is most essential to detect the necking. Unless the necking is detected
at the appropriate timing, it will lead to the generation of spatter. The sensitivity with which necking
is detected can be adjusted using the APCS parameters.

Arc

Short-circuit current
inclination period

Short

Arc

Short-circuit current
fixation period

0A

Neck

Fig. 3.8.1 Principle behind reducing spatter by detecting necking

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 androuting of secondary cables) and the actual welding conditions (welding conditions such as theposture, lap welding and fillet welding, and the protrusion length of the wire). For this reason, thepreset 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 thearc monitor.

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3.8 Welding conditions of WB-M350L
Table 3.8.2 Reduction rate
Reduction
rate (%)

Denotation

100 to 90“Necking” detection has been performed properly.

90 to 70

“Necking” detection has been performed basically.
The reduction rate may be improved by reviewing the working environment.

Under 70

Review the working environment in accordance with “working environment
checklist” described in the instruction manual for the welding power source.
In addition, if the welding is unstable, review the welding conditions.

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 atemporary stop or other action, the adjustment results immediately prior to the action will be
displayed.

POINT

INFO.

How to reduce the spatter and keep the condition
In order to reduce spatter, it is necessary for necking to be detected properly.
To this end, the arc voltage must be fed back accurately. If the voltage cannot
be obtained properly because the arc voltage feed back is affected by noise,
the necking will not be detected properly, and this will give rise to spatter.
Furthermore, the automatic necking sensitivity adjustment function will notwork properly either. If the welding is unstable and large amount of spatterare generated, review the routing of the voltage detection cable inaccordance with the “working environment checklist” described in the
instruction manual for the welding power source.
How to automatically adjust APCS parameter specifying the initial value
It is possible to set the initial value to APCS parameter. To set it, first, select“TEACH” for the spatter adjustment method and input the values in “APCS
parameter 1 EP/EN” or “APCS parameter 2 EP/EN”.
Then, select “AUTO” for the spatter adjustment method and store the data.
How to reflect the results of the automatic necking sensitivity adjustmentin the AS command
When the automatic necking sensitivity adjustment function is enabled (AUTO
is selected as the APCS cond. setting), the background of “Spatter” on the arcmonitor turns yellow.
At this point, press [Edit] on the arc monitor to establish a status whichenables on-line changes to be made. When f12 <Complete> or [Edit] ispressed, the APCS parameters set at the time are stored in the memory as
the conditions of the AS command.
As with on-line changes, these parameters can also be stored in the memory
automatically upon completion of welding.

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3.8 Welding conditions of WB-M350L

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 thewelding power source are applied.

POINT

Table 3.8.3 Field where automatic necking sensitivity adjustment is not performed
Welding mode
Wire material
Mild steel solid

Gas
CO2
MAG

Wire diameter
0.8, 0.9, 1.0, 1.2
0.8, 0.9, 1.0, 1.2

Current setting value
300A or over3.8.4 About the welding constants
The welding constants that can be set when WB-M350L is connected using the interface areshown in Table 3.8.4. Welding constants not included in this table cannot be used.
Table 3.8.4 Welding constants of WB-M350L
Welding power source
registration
Item
DL(S1)
DL(S2)
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○○

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.

○○Turbo start

○

○

○

○

Arc outage detect. time (Arc End)○: Can be used.

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3.9 Welding conditions of WB-M350/500

3.9 Welding conditions of WB-M350/500
This section describes the welding conditions that can be set when WB-M350/500 is connected.

3.9.1 About the welding condition parameters
For the WB-M350/500 welding power source, the welding conditions shown in Table 3.9.1 can be
set. Some welding conditions vary depending on the type of welding power source registered in
the robot controller. Welding conditions not included in this table cannot be used with theinterface.
Table 3.9.1 Welding conditions of WB-M350/500
Welding power source
registered
Welding condition
on robot controller
DM
DM(S-2)DR

AS

AE

Welding process

○ *1

○*1

○*1

Current cond.

○

○

○

Penetration adjustment

×

×

×

Welding current / Wire speed

○

○

○

Welding voltage / Arc length tun.

○

○

○

Welding speed

○

○

○

Arc character.

○

○

○

Slope time / Slope distance

×

○

○

Initial current / Ini. wire speed

×

○

○

Initial voltage / Ini. arc length

×

○

○

○

○*1

○

○

○

Welding current / Wire speed

○

○

○

Welding voltage / Arc length tun.

○

○

○

Crater time

○

○

○

Post flow time

○

○

○

Arc character.

○

○

○

Slope time / Slope distance

×

○

○

Welding process○

Current cond.

*1*1○: Can be used
×: Cannot be used (operates with the initial value of the welding power source)*1: 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".

3-25

3.9 Welding conditions of WB-M350/500

3.9.2 Points for setting the conditions
The points to be observed when setting the welding conditions are set forth below.
Concerning the welding current and wire feed speed
The welding current (or wire feed speed) which is input as a welding condition becomes theaverage current (or average wire feed speed) during welding. The welding waveform control
parameter optimally suited for the welding current (or wire feed speed) which has been set is
calculated automatically on the basis of the welding current (or wire feed speed) which has been
input.
Concerning the arc length tuning
The WB-M350/500 has two modes: synergic adjustments and individual adjustments.
When it is used in the synergic adjustment, the optimum voltage for the current which has been
set is output automatically. The “arc length tun.” is an adjustment value for increasing or reducing
the voltage which is output automatically. For instance, if a setting of +5 is used, the output
voltage will be raised by about 0.5 V as a theoretical value.
Concerning the input of the wire feed speed
The wire feed speeds which are actually valid as welding conditions differ according to the welder
and welding mode used. If the standard software has been installed in the welder, the minimum
speed is approximately 130 cm/min. and the maximum speed is approximately 1800 cm/min. as a
general rule. However, depending on the welding mode, the maximum and minimum wire feed
speed may be more restricted than the ranges given.
Concerning the setting range of the welding speed
Although any speed from 1 to 999 cm/min. can be set as the welding speed, the maximum speed
is actually 600 cm/min. or so. Since this is also the maximum operable speed and not a speed
which can be used for actual welding, it must be adjusted to ensure optimum welding.
Concerning the arc characteristic
The arc characteristic is the value that enables to set hard/soft of the arc. Intensive and hard arcs
are generated by increasing this value to the (–) side, while extensive and soft arcs to the (+) side.
When crater treatment is not performed
When crater treatment is not going to be performed, set the crater time to “0.” However, in thiscase, set the same conditions as for regular welding as the crater current or wire feed speed
setting value. Unless the same conditions are set, the appropriate burnback voltage level may not
be displayed properly at the teaching stage.

IMPORTANT

3-26

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.

3.9 Welding conditions of WB-M350/500

3.9.3 About the welding constants
The welding constants that can be set when WB-M350/500 is connected using the interface areshown in Table 3.9.2. Some of the welding constants available for setting vary depending on thetype of welding power source registered in the robot controller. Welding condition parameters notincluded in this table cannot be used.
Table 3.9.2 Welding constants of WB-M350/500
Item

Welding power source registration
DM(S1)

DM(S2)

DR

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

○

○

○

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.

○Turbo start

○*

○*

○

Penetration adjustment

－

○

－

Arc outage detect. time (Arc End)

－

○

○

○
1

○
1

○: Can be used.
×: Cannot be used. (Operates with the initial value of the welding power source.）*1: Operates with the "Auto" setting set to "ON".

3-27

3.9 Welding conditions of WB-M350/500

3.10 Welding conditions of WB-P350
This section describes the welding conditions that can be set when WB-P350 is connected.

3.10.1 About the welding condition parameters
The welding conditions that can be set when WB-P350 is connected using the interface areshown in Table 3.10.1. Some welding conditions vary depending on the type of welding powersource registered in the robot controller. Welding condition parameters not included in this tablecannot be used.
Table 3.10.1

Welding conditions of WB-P350
Welding method

Condition

AS

AE

DC

DC pulsed

DC wavepulsedWelding process

○※

○※

○※

Current cond.

○

○

○

Welding current / Wire speed

○

○

○

Welding voltage / Arc length tun.

○

○

○

Welding speed

○

○

○

Pulse arc characteristic

―

○

○

Arc character.

○

―

―

Slope time / Slope distance

○

○

○

Initial current / Ini. wire speed

○

○

○

Initial voltage / Ini. arc length

○

○

○

Wave frequency

―

―

○

○

○※

○

○

○

○

○

○

Welding voltage / Arc length tun.

○

○

○

Crater time

○

○

○

Post flow time

○

○

○

Pulse arc characteristic

―

○

○

Arc character.

○

―

―

Slope time / Slope distance

○

○

○

Wave frequency

―

―

○

Burnback adj. T.

―

○

○

Welding process○

Current cond.
Welding current / Wire speed※※○: Can be used―: Cannot be used.
※: The welding mode displayed on the robot controller may be different from the welding modeof 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

3.10.2 Points for setting the conditions
The points to be observed when setting the welding conditions are set forth below.
Concerning the welding current and wire feed speed
The welding current (or wire feed speed) which is input as a welding condition becomes theaverage current (or average wire feed speed) during welding. The welding waveform control
parameter optimally suited for the welding current (or wire feed speed) which has been set is
calculated automatically on the basis of the welding current (or wire feed speed) which has
been input.
Concerning the arc length tuning
The WB-P350 has two modes: synergic adjustments and individual adjustments.
When it is used in the synergic adjustment, the optimum voltage for the current which has
been set is output automatically. The “arc length tun.” is an adjustment value for increasing or
reducing the voltage which is output automatically. For instance, if a setting of +5 is used, theoutput voltage will be raised by about 0.5 V as a theoretical value.
Concerning the input of the wire feed speed
The wire feed speeds which are actually valid as welding conditions differ according to thewelder and welding mode used. If the standard software has been installed in the welder, theminimum speed is approximately 130 cm/min. and the maximum speed is approximately 1800
cm/min. as a general rule. However, depending on the welding mode, the maximum andminimum wire feed speed may be more restricted than the ranges given.
Concerning the setting range of the welding speed
Although any speed from 1 to 999 cm/min. can be set as the welding speed, the maximum
speed is actually 600 cm/min. or so. Since this is also the maximum operable speed and not a
speed which can be used for actual welding, it must be adjusted to ensure optimum welding.
Concerning the arc characteristic
The arc characteristic is the value that enables to set hard/soft of the arc. Intensive and hardarcs are generated by increasing this value to the (–) side, while extensive and soft arcs to the(+) side.
When crater treatment is not performed
When crater treatment is not going to be performed, set the crater time to “0.” However, in thiscase, set the same conditions as for regular welding as the crater current or wire feed speed
setting value. Unless the same conditions are set, the appropriate burnback voltage level may
not be displayed properly at the teaching stage.

IMPORTANT

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.

Concerning the pulse conditions
To adjust the pulse conditions, proceed by changing “arc characteristic” and “pulse frequency”,
described in 3.10.1 . And refer to “3.10.2 Points for setting the conditions”

3-29

3.9 Welding conditions of WB-M350/500

3.10.3 To adjust the pulse conditions
Generally, to adjust the pulse conditions, the following two parameters are the only ones that need
to be changed.
• 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.
What are the arc characteristic?
The arc characteristic is a parameter used for internally, adjusting the pulse rise time andpulse fall time. When its value is increased, an expansive soft arc is obtained; conversely,
when it is reduced, a concentrated hard arc is obtained.
What is the wave frequency?
For the wave pulsed welding method periodical changes of the wire feed speed and the unit
pulse condition can be made in low frequencies. Furthermore, synchronizing this periodic
cycle, then the deposition rate can be increased / decreased and the vibrations of the molten
pool can be made.
For aluminum alloy welding, beads shaped like fish scales can be formed. This welding
improves the ability to counter gaps that may exist in the welded areas. Furthermore, grain
size can be minimized by the stirring effect, caused by the molten pool vibration, and toleranceof welding cracks will also be improved.
For steel and stainless welding, the melted metal takes time to solidify. Therefore, in thiswelding, there are cases where clear beads, shaped like fish scales, cannot be formulated,because the metal flows before it can solidify. However, the blowhole can be reduced by thestirring effect caused by the molten pool vibrations.
The wave pulsed welding method will change the wire feed speed, unit pulse conditions, etc.
However, for changes of the wire feed speed, if the wire feed motor’s response characteristic
comes close to a limiting value, the feed amplitude will automatically be reduced. If the wave
frequency is over 3 Hz, the speed of the wire feed will gradually be reduced. If it exceeds over
5 Hz the amplitude will run out. In this case, the wire feed speed with stabilize and only the unit
pulse condition will change.
For aluminum alloy welding where the beads can be formed in shapes of fish scales, it ispossible to adjust the ripple pitches freely, depending on the combinations between thewelding speed and wave frequency.
The width of the pitches will become narrow if the wave frequencies are expanded withoutchanging the welding speed. Vise versa, if the frequencies are made smaller with the welding
speed unchanged, the pitches will widen.

Bead
DetailThe ripple pitch

The beads shaped like fish scales canbe adjusted using the wave frequency.
During automatic operation a fixedinterval is maintained, but the ripple pitchinterval may be disrupted by temporarystop and restart thereafter.

Fig 3.10.1 Adjustment of beads shaped like fish scales using wave frequency

INFO.

 In some cases, ripple patterns of the welded beads may not be precisely
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 thewelded beads of aluminum alloy welding.
 There is a major relationship between the reduction of blowholes and themeasure of the melted metal’s vibration. The bigger the extent of the molten
pool, the bigger the vibrations as well; reducing more blowholes. On thecontrary, 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 suchas extremely thick coated or oil-based steel products and cast materials.
 If short-circuit occurs frequently while welding using soft aluminum, theoverview of the bead could appear black.

3-30

3.9 Welding conditions of WB-M350/500

3.10.4 Waveform control with DC wave pulsed welding
DC wave pulsed welding is essentially pulsed welding, where a wave frequency period consists ofa low pulse section and high pulse section. The number of pulses in a low pulse section and highpulse section in each period depends on the wave frequency and pulse conditions.

Welding current

Wire speed

Waveform control (arc start - welding underway - crater treatment) is conducted as follows.

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

3.10.5 About the welding constants
The welding conditions that can be set when WB-P350 is connected using the interface areshown in Table 3.10.2. Some welding conditions vary depending on the type of welding powersource registered in the robot controller. Welding condition parameters not included in this tablecannot be used.
Table 3.10.2

Welding conditions of WB-P350

Item

Enable/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

3.10.6 Settgins on the Welding Power Source Side
In order to use the welding constants given below when WB-P500L is connected using thisdevice, it is necessary to configure the settings on the welding power source side.
・Torch・Penetration adjustment function
・Arc voltage direct detection
・Process in the fan failure
・Process in the shortage of input voltage

１Turn on the power of welding power source.

２

By holding down Execute key, switch the keylock ON/OFF.

３

Change the function type from Normal to Almega.
The setting manner is as follows.
① Hold down F key.
② The front panel indicates “F＊” blinking on its left side.
③ Hold down Execute key, switch the digital indication to “A＊”.

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 thecondition to set ON.

５

Configure the settings for each function. For the setting manner, see Table 3.10.3.

INFO.

The function type can be switched by pressging Execute key.
It is available to change the number and settings by moving the knob on thefront panel.

INFO.

How to operate the welding power source:
For the details of operation manner for the welding power source, see theinstruction manual for welding poiwer supply.

3-33

3.9 Welding conditions of WB-M350/500

Function name

WIF-Digital function
ON/OFF

Penetration
adjustment function

Table 3.10.3

Setting manner for each function

Function
type

Function
numberFunction

Initialvalue

It switches ON/OFF for thefunction in this table.
A

A

1

2

ON ：Available
OFF：Not available
It switches ON/OFF for the
penetration adjustment functionof the welding power source.

OFF

OFF

ON ：Available
OFF：Not available

Process in the fan
failure / Process inthe shortage of input
voltage

Arc voltage direct
detection

F

19

It designates the process on the
robot side when the welding
power source detects the fan
alarm or the shortage alarm of
input voltage.

OFF

ON ： Indicates the error by“Alarm”.
OFF：Not detecting the error.

F

38

Set this function ON whenconnecting the voltage detection
cable for directly detecting thearc voltage (－) to the welding
power source.

OFF

ON ：Available
OFF：Not available
It selects the torch coolingmaner.

Torch

―

―

Press the Torch key on the front
panel. By pressing this key, LED
indicated as “Water cooled” on
the Torch key puts the light on
and off.
“Water cooled” LED ON：
Using the water-cooled torch.
“Water cooled” LED OFF：
Using the air-cooled torch.

3-34

OFF

3.11 Welding conditions of WB-P500L

3.11 Welding conditions of WB-P500L
This section describes the welding conditions that can be set when WB-P500L is connected.

3.11.1 About the welding condition parameters
The welding conditions that can be set when WB-P500L is connected using the interface areshown in Table 3.11.1. Some welding conditions vary depending on the type of welding powersource registered in the robot controller. Welding condition parameters not included in this tablecannot be used.
Table 3.11.1

Welding conditions of WB-P500L
Welding methodDC/
DC(APCS)DC
pulsedWelding process

○※1

○※1

DC
wave
pulsed○※1

Current cond.

○

○

○

Welding current / Wire speed

○

○

○

Welding voltage / Arc length tun.
Welding speed
Pulse arc characteristic

○
○
―

○
○
○

○
○
○

Arc character.

○

―

―

Slope time / Slope distance

○

○

○

Initial current / Ini. wire speed

○

○

○

Initial voltage / Ini. arc length○○

Welding condition

AS

AE

※２

○
※２

Start adjust time

○

○

○※２

Wave frequency

―

―

○

Amplitude rate

―

―

○※２

Welding process

○※1

○※1

○※1

Current cond.

○

○

○

Welding current / Wire speed

○

○

○

Welding voltage / Arc length tun.

○

○

○

Crater time

○

○

○

Post flow time

○

○

○

Pulse arc characteristic

―

○

○

Arc character.

○

―

―

Slope time / Slope distance

○

○

○

※2

Robot stop time

○

○

○※2

Wave frequency

―

―

○※2

Amplitude rate

―

―

○

Burnback adj. V.

―

○

○

※2

※2

※2

Burnback adj. T.

○

○

○※2

Burnback delay T

―

○※2

○※2

Retract adj. T

○※２

○※２

○※２

○: Can be used―: Cannot be used.
*1: The welding mode displayed on the robot controller may be different from the welding modeof the Welbee Inverter welding power source. For details, see "3.4.2 Configuring the welding
mode for the Welbee Inverter series welding power source".
*2:Cannot be used if the registered welding power source is DP.

3-35

3.11 Welding conditions of WB-P500L

3.11.2 Points for setting the conditions
The points to be observed when setting the welding conditions are set forth below.
Concerning the welding current and wire feed speed
The welding current (or wire feed speed) which is input as a welding condition becomes theaverage current (or average wire feed speed) during welding. The welding waveform control
parameter optimally suited for the welding current (or wire feed speed) which has been set is
calculated automatically on the basis of the welding current (or wire feed speed) which has
been input.
Concerning the arc length tuning
For instance, if a setting of +5 is used, the output voltage will be raised by about 0.5 V as atheoretical value.
The WB-P500L has two modes: synergic adjustments and individual adjustments.
When it is used in the synergic adjustment, the optimum voltage for the current which has
been set is output automatically.
Concerning the input of the wire feed speed
The wire feed speeds which are actually valid as welding conditions differ according to thewelder and welding mode used. If the standard software has been installed in the welder, theminimum speed is approximately 130 cm/min. and the maximum speed is approximately 1800
cm/min. as a general rule. However, depending on the welding mode, the maximum andminimum wire feed speed may be more restricted than the ranges given.
Concerning the setting range of the welding speed
Although any speed from 1 to 999 cm/min. can be set as the welding speed, the maximum
speed is actually 600 cm/min. or so. Since this is also the maximum operable speed and not a
speed which can be used for actual welding, it must be adjusted to ensure optimum welding.
Concerning the arc characteristic
The arc characteristic is the value that enables to set hard/soft of the arc. Intensive and hardarcs are generated by increasing this value to the (–) side, while extensive and soft arcs to the(+) side.

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 beproduced. However, if the value is set too high, the welding easily becomes unstable and theelectrical tolerance of the condition will drop to a lower value. A “–” figure setting yields astronger 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 “–”, thewelding may become unstable.
What is the slowdown speed?
The slowdown speed denotes the speed at which the wire is fed until the arc is started at thearc start point.
When crater treatment is not performed
When crater treatment is not going to be performed, set the crater time to “0.” However, in thiscase, set the same conditions as for regular welding as the crater current or wire feed speed
setting value. Unless the same conditions are set, the appropriate burnback voltage level may
not be displayed properly at the teaching stage.

IMPORTANT

3-36

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.

3.11 Welding conditions of WB-P500L
Concerning the pulse conditions
To adjust the pulse conditions, proceed by changing “arc characteristic” and “pulse frequency”,
described inTable 3.11.1 And refer to “3.11.4 To adjust the pulse conditions”
Concerning the retract adjustment time
The wire is automatically retracted in order to adjust its protrusion length after processing thearc end. By setting the retract adjustment time, it enables to adjust the amount of wire
retracting after the arc end.
The retract time before adjustment depends on the type of wire feeding unit as given in Table
3.11.2. Even if setting the retract time to a negative value, the retract time becomes 0, in which
the wire cannot be inched.

Table 3.11.2 Retract time before adjustment

POINT

Wire feeding unit

Retract time (msec)

Standard wire feeding unit

200

Servo wire feeding unit

100

When the registered welding power source is DP, it is not available to set theretract 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

3.11.3 How the spatter adjustment parameter (APCS cond.) is used
In short arc welding where short-circuits and arcs are repeated, most of the spatter is generated
when short-circuiting occurs and immediately before arc generation. A phenomenon referred to as“necking” occurs in the wires immediately before arc generation of the latter category, as shown in
the figure below. By detecting this necking and sharply reducing the current at that instant, themelted metal is not blown about by the arc force and the generation of spatter can be significantly
reduced. To achieve this, it is most essential to detect the necking. Unless the necking is detected
at the appropriate timing, it will lead to the generation of spatter.

Arc

Short-circuit current
inclination period

Short

Arc

Short-circuit current
fixation period

0A

Neck

Fig. 3.11.1 Principle behind reducing spatter by detecting necking

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 androuting of secondary cables) and the actual welding conditions (welding conditions such as theposture, lap welding and fillet welding, and the protrusion length of the wire). For this reason, thepreset 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

POINT

3-38

How to reduce the spatter and keep the condition
In order to reduce spatter, it is necessary for necking to be detected properly.
To this end, the arc voltage must be fed back accurately. If the voltage
cannot be obtained properly because the arc voltage feed back is affected bynoise, the necking will not be detected properly, and this will give rise to
spatter. Furthermore, the automatic necking sensitivity adjustment function
will not work properly either. If the welding is unstable and large amount of
spatter are generated, review the routing of the voltage detection cable inaccordance with the “working environment checklist” described in the
instruction manual for the welding power supply.

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 thewelding power supply are applied.

3.11 Welding conditions of WB-P500L
Table 3.11.3

Field where automatic necking sensitivity adjustment is not performed
Welding mode

Wire material
Mild steel solid
SUS solid

Gas
CO2
MAG
MIG

Wire diameter
0.8, 0.9, 1.0, 1.2
0.8, 0.9, 1.0, 1.2
0.8, 0.9, 1.0, 1.2

Current setting value

300A or over

3.11.4 To adjust the pulse conditions
Generally, to adjust the pulse conditions, the following two parameters are the only ones that need
to be changed.
• 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.
What are the arc characteristic?
The arc characteristic is a parameter used for internally, adjusting the pulse rise time andpulse fall time. When its value is increased, an expansive soft arc is obtained; conversely,
when it is reduced, a concentrated hard arc is obtained.
What is the wave frequency?
For the wave pulsed welding method periodical changes of the wire feed speed and the unit
pulse condition can be made in low frequencies. Furthermore, synchronizing this periodic
cycle, then the deposition rate can be increased / decreased and the vibrations of the molten
pool can be made.
For aluminum alloy welding, beads shaped like fish scales can be formed. This welding
improves the ability to counter gaps that may exist in the welded areas. Furthermore, grain
size can be minimized by the stirring effect, caused by the molten pool vibration, and toleranceof welding cracks will also be improved.
For steel and stainless welding, the melted metal takes time to solidify. Therefore, in thiswelding, there are cases where clear beads, shaped like fish scales, cannot be formulated,because the metal flows before it can solidify. However, the blowhole can be reduced by thestirring effect caused by the molten pool vibrations.
The wave pulsed welding method will change the wire feed speed, unit pulse conditions, etc.
However, for changes of the wire feed speed, if the wire feed motor’s response characteristic
comes close to a limiting value, the feed amplitude will automatically be reduced. If the wave
frequency is over 3 Hz, the speed of the wire feed will gradually be reduced. If it exceeds over
5 Hz the amplitude will run out. In this case, the wire feed speed with stabilize and only the unit
pulse condition will change.
For aluminum alloy welding where the beads can be formed in shapes of fish scales, it ispossible to adjust the ripple pitches freely, depending on the combinations between thewelding speed and wave frequency.
The width of the pitches will become narrow if the wave frequencies are expanded withoutchanging the welding speed. Vise versa, if the frequencies are made smaller with the welding
speed unchanged, the pitches will widen.

Bead
DetailThe ripple pitch

The beads shaped like fish scales canbe adjusted using the wave frequency.
During automatic operation a fixedinterval is maintained, but the ripple pitchinterval may be disrupted by temporarystop and restart thereafter.

Fig. 3.11.2 Adjustment of beads shaped like fish scales using wave frequency

3-39

3.11 Welding conditions of WB-P500L

INFO.

 In some cases, ripple patterns of the welded beads may not be precisely
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 thewelded beads of aluminum alloy welding.
 There is a major relationship between the reduction of blowholes and themeasure of the melted metal’s vibration. The bigger the extent of the molten
pool, the bigger the vibrations as well; reducing more blowholes. On thecontrary, 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 suchas extremely thick coated or oil-based steel products and cast materials.
 If short-circuit occurs frequently while welding using soft aluminum, theoverview of the bead could appear black.

3-40

3.11 Welding conditions of WB-P500L

3.11.5 Waveform control with DC wave pulsed welding
DC wave pulsed welding is essentially pulsed welding, where a wave frequency period consists ofa low pulse section and high pulse section. The number of pulses in a low pulse section and highpulse section in each period depends on the wave frequency and pulse conditions.

Welding current

Wire speed

Waveform control (arc start - welding underway - crater treatment) is conducted as follows.

Fig. 3.11.3 Waveform control with the DC wave pulsed welding method(arc start – welding underway – crater treatment)
What is the Amplitude Rate?
When the wave frequency is below 5 Hz, the wire feed speed is changed in wave pulsed
welding. By slightly adjusting the amplitude of this feed speed, welding results intended for
different purposes can be achieved.
The amplitude rate is meant for adjusting the shift value of the wire feed. Having 50% as its
standard measurement, adjustments can be made within the range from 0 to 100%. The
minimum adjustment unit is “1”.
The relationship between the settings of the amplitude rate and the welding results are shownin the table below. Adjust the amplitude rate accordingly to its intended purpose.
Table 3.11.4 Relationship between Amplitude Rate and Welding Results
Amplitude rate
Shift value of wire feed
Shift value of arc length
Ripple bead
Blowhole reduction
Welding speed
Gap tolerance

INFO.

POINT

0%
(Minimum)
None（Stabilized）
Small
Smooth, small
SmallHigh to Low speed
Small

50%
(Standard)

100%(Maximum)Twice the % ofStandard
Big
Clear, big
Big
Low speed
Large

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).”When the registered welding power source is DP, it is not available to set theamplitude rate.

3-41

3.11 Welding conditions of WB-P500L

3.11.6 About the welding constants
The welding conditions that can be set when WB-P500L is connected using the interface areshown in Table 3.11.5. Some welding conditions vary depending on the type of welding powersource registered in the robot controller. Welding condition parameters not included in this tablecannot be used.
Table 3.11.5 Welding conditions of WB-P500L
Item

Welding power source registration
DP
DPR

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

○

△

Penetration adjustment○△

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 “3.11.7
Settings on Welding Power Source Side”.
The settings made on the screen of welding
constants cannot be reflected.

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3.11 Welding conditions of WB-P500L

3.11.7 Settgins on the Welding Power Source Side
In order to use the welding constants given below when WB-P500L is connected using thisdevice, it is necessary to configure the settings on the welding power source side.
・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.

１Turn on the power of welding power source.

２

By holding down Execute key, switch the keylock ON/OFF.

３

Change the function type from Normal to Almega.
The setting manner is as follows.
① Hold down F key.
② The front panel indicates “F＊” blinking on its left side.
③ Hold down Execute key, switch the digital indication to “A＊”.

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 thecondition to set ON.

５

Configure the settings for each function. For the setting manner, see Table 3.11.6.

INFO.

The function type can be switched by pressging Execute key.
It is available to change the number and settings by moving the knob on thefront panel.

INFO.

How to operate the welding power source:
For the details of operation manner for the welding power source, see theinstruction manual for welding poiwer supply.

3-43

3.11 Welding conditions of WB-P500L

Function name

WIF-Digital function
ON/OFF

Penetration
adjustment function

Table 3.11.6

Setting manner for each function

Function
type

Function
numberFunction

Initialvalue

It switches ON/OFF for thefunction in this table.
A

A

1

2

ON ：Available
OFF：Not available
It switches ON/OFF for the
penetration adjustment functionof the welding power source.

OFF

OFF

ON ：Available
OFF：Not available

Process in the fan
failure / Process inthe shortage of input
voltage

Arc voltage direct
detection

F

19

It designates the process on the
robot side when the welding
power source detects the fan
alarm or the shortage alarm of
input voltage.

OFF

ON ： Indicates the error by“Alarm”.
OFF：Not detecting the error.

F

38

Set this function ON whenconnecting the voltage detection
cable for directly detecting thearc voltage (－) to the welding
power source.

OFF

ON ：Available
OFF：Not available
It selects the torch coolingmaner.

Torch

―

―

Press the Torch key on the front
panel. By pressing this key, LED
indicated as “Water cooled” on
the Torch key puts the light on
and off.
“Water cooled” LED ON：
Using the water-cooled torch.
“Water cooled” LED OFF：
Using the air-cooled torch.

3-44

OFF

Chapter 4 MaintenanceThis chapter describes the maintenance function and warranty of the interface.
4.1 Displaying the Welding Interface (Digital) version.......................................4-1
4.2 List of Welding Interface (Digital) error codes .............................................4-2
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

This is a dummy page. DO NOT ERASE.

4.1 Displaying the Welding Interface (Digital) version

4.1 Displaying the Welding Interface (Digital) version
The version of the internal firmware of Welding Interface (Digital) can be checked with the following procedure.

Display the firmware version
1

Turn ON the power of the robot controller and the welding power source
connected to the interface.

2

Switch the operator qualification to EXPERT.

IMPORTANT
RESET

R

OFF

2

Enter

8

6

Display the firmware version while the power of the welding power source
connected to the interface is ON.

3

In the top screen of the teach or playback mode, press [Reset/R].
>> The [Shortcut R code Entry] screen is displayed.

4

Press [2], [8], [6], [Enter] in this order.
Press F10(next page).
>> The system environment is displayed as follows.

The version displayed for the "Arc WPS1" item is the interface firmware version.

POINT

About the welding power source version display
The software version of the Welbee Inverter series welding power source cannot
be checked from the robot controller. Check the software version of the welding
power source on the front panel. For details, see the instruction manual of yourwelding power source.

4-1

4.2 List of Welding Interface (Digital) error codes

4.2 List of Welding Interface (Digital) error codes
When an error occurs in the interface, the error code is displayed 1 digit at a time on the 7-segment LED on
Welding Interface (Digital)board. For example, if E-900 occurs, the error code is displayed as 'E' -> '-' -> '9' -> '0'-> '0'. Check the error code, and take the measures described in Table 4.2.1.

IMPORTANT

When an error occurs in the interface, one of the following errors is displayed on the teachpendant (TP) of the robot controller.
 “A5023 Failure of the welding power supply occurred.” “E4000 Communication timeout occurred between the controller and the welding power
supply.”Table 4.2.1 Error code list of Welding Interface (Digital)

Failure
code

E-001

Error generaldescription

Contents of failure

MeasureCommunication timeout

The interface cannot
communicate with the robot
controller or welding powersource.

 Check that the power cable that connects theinterface to the sequence board (or relayunit) of the robot controller is connected
correctly (see Chapter 2).
 Check that the communication cable thatconnects the interface to the storage boardof the robot controller is connected correctly(see Chapter 2).
 Check that control cable 5 (on the welding
power source side, interface side) thatconnects the interface to the welding powersource is connected correctly (see Chapter2).
 Check that the power of the welding powersource is ON.
 Check that the following settings are correct
for the welding power source connected tothe interface.
For Welbee Inverter series- Auto/Semi auto mode (F4)- CAN ID(F43)

Communication control
errorThis is an interface internal
error.

Contact us.

Setup incomplete

The setup data has notbeen written onto theinterface.

Write the setup data onto the interface (seeChapter 3).

E-002
E-003
E-004
E-005
E-006
E-100

E-101
Setup data error
E-102

4-2

A robot controller notsupported by the interface
has been specified in the
setup data written onto theinterface.
A welding power source notsupported by the interface
has been specified in the
setup data written onto theinterface.

 Create the setup data again and write it onto
the interface (see Chapter 3).
 Check that the interface firmware supports
your robot controller or welding powersource. For details, contact us.

4.2 List of Welding Interface (Digital) error codes
Failure
code

E-103

E-104

Error generaldescription

USB memory
connection error

Setup file open error

Contents of failure

MeasureThe USB memory cannot
be recognized.

 Check that the USB memory has been
inserted correctly into the interface.
The interface does not support the hot
plugging of USB memory. Before inserting or
removing the USB memory, turn OFF thepower of the robot controller (including theinterface).
 Use the USB memory recommended by us.

The setup file stored on the
USB memory cannot be
opened.

 Check that the USB memory has beenformatted with "FAT (FAT16)".
 Check that the setup data has been createdin an UPDATE folder that is in the root folderof the USB memory (see Chapter 3).
 Check that there are no errors in the USB
memory.*1
 Use the USB memory recommended by us.

E-105

Setup file reading error

The setup file stored on the
USB memory cannot be
read.

 Check that the USB memory has beenformatted with "FAT (FAT16)".
 Check that there are no errors in the USB
1memory.* Use the USB memory recommended by us.
 Create the setup data again and write it onto
the interface (see Chapter 3).

E-106

Setup file data error

The setup file stored on the
USB memory contains anerror.

Create the setup data again and write it onto
the interface (see Chapter 3).
 Check the free space on the USB memory.
 Use the USB memory recommended by us.
 Check that the USB memory has beenformatted with "FAT (FAT16)".
 Check that there are no errors in the USB
1memory.* Check whether the USB memory is
write-protected.

E-107

Setup file backup error

A backup file cannot becreated in the USB
memory.

E-200

Setup file delete error

The setup file stored on theinterface could not bedeleted.

E-201

Setup file write error

The setup file could not be
written onto the interface.

E-300
E-301

Insufficient memory forcontrolThis is an interface internal
error.

Contact us.

E-999

Firmware error

The firmware is notinstalled on the interface.

Contact us.

INFO.

Perform "Writing the setup data" again for theinterface (see Chapter 3).
If this error persists, the interface may be
malfunctioning. Contact us.

You can perform a USB memory error check (*1 in the previous table) on a Windows computerby 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

4.3 Errors of Welbee Inverter series welding power sourceThis section describes the errors detected by the Welbee Inverter series welding power source.

4.3.1 Error code list
When using a Welbee Inverter series welding power source to connect to a robot, refer to table
Table 4.3.1 that shows the error codes in the front panel and on the teach pendant of the robot.

Table 4.3.1 Error code list of Welbee Inverter series welding power source
Error code of
supporting
robots *4

Error
displayreleasemethod *3

Panel communication error

A5023

(3)

Control power supply error

A5039

(3)

Digital meter
Left

4-4

Right

Contents of error

E-

41

E-

100

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)

E-

215

Error in the arc voltage detection(RS Control)

A5097

(1)

E-

220

Primary side main circuit error

A5023

(3)

E-

230

Primary driver error

A5023

(3)

E-

240

Secondary current detection
error

A5040

(3)

E-

250

Secondary side main circuit error

A5023

(3)

E-

260

Error in the output voltage
detection circuit

A5039

(3)

E-

300

E-

301

E-

302

Thermal overload

A5026

(3)

E-

303

E-

310

E-

311

Cooling fan error

A5023

(3)

E-

312

(2)

E-

500

Lack of water pressure

For
DM/DM(S-2)/DR/DP/DPR
A5023
For DL/DL(S-2)
A5036

E-

615

Memory backup error

-

(1)

E-

700

Secondary side output overcurrent error

A5025

(1)

E-

710

Lack of phase error

A5028

(3)

E-

800

E-

801

Encoder in the wire feeder error

A5032

(1)

E-

810

Thermal overload in the governor
circuit

A5042

(1)

4.3 Errors of Welbee Inverter series welding power source
Table 4.3.1 Error code list of Welbee Inverter series welding power source
Contents of error

Error code of
supporting
robots *4

Error
displayreleasemethod *3

For
DM/DM(S-2)/DR/DP/DPR
A5023
For DL/DL(S-2)
A5095

(1)

Digital meter
Left

Right

E-

830

Motor over current error

E-

850

E-

860

Control power supply error in thegovernor circuit

A5039

(3)

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 yourrobot controller.

About welding power source registration
The error codes displayed on the robot controller may differ depending on theregistered welding power source.
When A5023 occurs
If "A5023 Failure of the welding power supply occurred." occurs, check thefront panel of the welding power source for details of the error.

IMPORTANT

When a number is displayed in this code, refer to the contents of the error in
the table below.
If no number is displayed, check the error code displayed on the front panel of
the welding power source.
Code
5021

Contents of error
The arc characteristic can't be changed while arc welding.
Please modify the task program.

When an error not included in the table occurs
If a welding power source error not included in Table 4.3.1 is displayed, referto the instruction manual of the welding power source.

4-5

4.3 Errors of Welbee Inverter series welding power source

4.3.2 How to reset an error indication
If an error code is displayed on the front panel of the Welbee Inverter Series welding power source
connected to the robot, the error code display cannot be reset with the "f12 <Failure Reset>” keyon the teach pendent or "External reset" signal from the basic input signals.
The error codes displayed on the front panel are released automatically when any of theoperations described below are performed. However, the displays of some error codes are notreleased even with the following operations.










When pre-flow has started during automatic operation
When pre-flow has started during a check operation in which check welding is effective
When the ICH command or RTC command has been executed with welding ON automatic
operation
When inching is performed using f10 <Inching> on the teach pendant *When retracting is performed using f11 <Retract> on the teach pendant *When gas check is performed using f12 <Gas> on the teach pendant
When inching has been performed using the “inching ON/OFF” dedicated arc input signal *When retract has been performed using the “retract ON/OFF” dedicated arc input signal *When gas output has been performed using the “gas ON/OFF” dedicated arc input signal*

This includes cases where the inching or retract speed is either high or low.

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.
Table 4.3.2 Error display release methods

4-6

ReleasemethodDescription(1)

When any of the above operations is performed, the error display isreleased automatically.

(2)

When the cause of the error is eliminated, the error display is released
automatically.

(3)

If the cause of the error had been eliminated when any of the above
operations was performed, the error display is released automatically.
However, since these are errors which originate in the hardware, turn thewelding power source off, and take the appropriate action described in
the operating manual of the welding power source.

(4)

The welding power source must be turned off and then turned back on inorder to release the error display.

4.4 Notes on Scope of Warranty and Liability

4.4 Notes on Scope of Warranty and Liability
4.4.1 The product for a warranty target
It is only as follows the composition of a ”Table 1.3.1 Configuration”.
- Welding Interface (Digital) board （Model type : L22440C）
Fuse, Communication cable, Power cable of Ref No.(1) in Table 1.3.1 is outside for a warranty.

4.4.2 Warranty period
Warranty period and its information vary according to region.
For details, contact your nearest sales distributor.

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 notdescribed 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 otherthan 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 bythird 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 causedby the failure of our company is not excluded from the range of assurance.

4.4.4 Limitation of liability(1) We do not accept any responsibility on the opportunity loss, special loss, indirect loss causedby this equipment, or accident compensation, damage other than out product.
(2) For the programmable this equipment, we do not accept any responsibility on the
programming implemented by person other than our company and the result caused by that
programming.
(3) We do not accept any responsibility on the processing quality when this equipment is used.
(4) If this equipment is repaired or the parts and/or the software are replaced, it is sometimes
necessary to repair or adjust the existing teaching program or parameter.
Note that we do not accept any responsibility on those works and processing quality for theuse of this robot system.
(5) This assurance is applied only when this equipment is installed within the country where theequipment is purchased. For the transaction and use in the foreign country, please contact
us.

4-7

4.4 Notes on Scope of Warranty and Liability

4.4.5 Service in Warranty Period(1) In case any failure occurs or for information on regular inspection, contact us (or our
appointed service providers).
(2) Service expense payment principle is as follows:(A) In case of affected product failure is attributed to manufacturing:
If we deem it necessary to repair the equipment on-site (domestic location only) within
above warranty period, we will dispatch engineer for repair work without charge.
(B) In case of failure is not in affected product itself:
Costs for analyzing the cause will be charged separately.
(C) In case of failure cannot be identified:If failure part cannot be identified despite certain analysis work, or if the failure cannot be
reproduced, we shall consult with customer.

4-8