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Daihen OTC WB-M400 User Manual

Daihen OTC WB-M400
141 pages
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E n s u r e t o r e a d t h i s
i n s t r u c t i o n m a n u a l
thoroughly for safe and
proper use of the product.
October, 2013
Manual No. : 1P30134-1
Model: WB-M400
Welbee Inverter
M400
OWNER'S MANUAL
CO
/MAG
Welding power source
2
DAIHEN Corporation

Table of Contents

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Daihen OTC WB-M400 Specifications

General IconGeneral
BrandDaihen
ModelOTC WB-M400
CategoryInverter
LanguageEnglish

Summary

Forward

Important Information

Provides essential instructions for safe operation and handling of the product.

Service and Support

Information on how to contact dealers for service and required information.

Chapter 1 Safety Information

Warning Symbols

Explains the meaning and usage of safety warning symbols in the manual.

Safety Precaution

Details general safety precautions for operating the welding power source.

Principal Safety Standards

Lists relevant safety standards and regulations for arc welding equipment.

Chapter 2 Product Specification and Configuration

Product Specification

Details the specifications and external dimensions of the welding power source.

Applicable Welding Method

Explains applicable welding methods, gas types, and wire diameters.

External Dimensions

Shows the external dimensions of the welding power source with diagrams.

Rated Duty Cycle

Explains the rated duty cycle of the welding power source and its implications.

Product Configuration

Explains the standard and optional composition of the welding power source.

Standard Composition

Details the standard components included with the welding power source for different welding types.

Accessory (Supplied)

Explains the accessories supplied with the welding power source.

Accessory (Not Supplied)

Lists accessories that need to be prepared by the customer.

Optional Accessories

Lists optional accessories available for the welding power source.

Details on Extension Cables and Hoses

Provides details on optional extension cables and hoses for extending working radius.

Part Names

Explains the names of the parts on the front and rear panels of the welding power source.

Front Panel

Identifies and describes the components on the front panel.

Rear Panel

Identifies and describes the components on the rear panel.

Chapter 3 Transportation and Installation

Required Equipment

Details necessary power supply equipment and protective devices for installation.

Welding Power Source Equipment

Specifies the required supply voltage and installed capacity for the welding power source.

Use of the Engine Generator and Auxiliary Power

Provides precautions when using engine generators or auxiliary power.

Ventilation Equipment/Partial Exhaust Facility

Explains the need for ventilation and partial exhaust facilities in welding work areas.

Ventilation Equipment

Details requirements for ventilation equipment to ensure oxygen concentration.

Partial Exhaust Facility

Explains the use of partial exhaust facilities to prevent health damage from fumes.

Installation Environment

Explains the required environmental conditions for installing the welding power source.

Installation Environment

Details safe installation locations considering factors like combustibles, chemicals, and ambient conditions.

Electromagnetic Interference

Discusses potential electromagnetic interference and methods to reduce it.

Transportation Procedure

Outlines the procedures and precautions for transporting the welding power source.

Transportation with Lifting Lug

Explains the procedure for safely transporting the welding power source using lifting lugs.

Chapter 4 Connection

Precautions for Connection Procedure and Grounding

Provides essential safety precautions for connecting and grounding the welding power source.

Connecting the Welding Power Source

Details the step-by-step procedure for connecting the welding power source.

Connection of Cable at Output Side

Explains how to connect the power cables to the output terminals.

Connection of Wire Feeder

Details the procedure for connecting the wire feeder.

Connection of Welding Torch

Explains how to connect the welding torch.

Connection at TIG Welding

Describes the specific connection procedure for TIG welding.

Connection at DC STICK Welding

Describes the specific connection procedure for DC STICK welding.

Connection of Shielding Gas

Explains the procedure for connecting the shielding gas system.

Grounding and Connection of Input Power Supply

Details the grounding work and input power supply connection procedures.

Confirmation of Connection

Explains the final checks required after completing all connections.

Connection of External Equipment

Explains how to connect external equipment like robots and automatic machines.

Connection of Robot

Provides an example configuration for connecting the welding power source to robots.

Configuration Example for Connection

Illustrates a configuration example for connecting the welding power source with robots.

Connection of Automatic Machine

Explains how to connect the welding power source to automatic machines.

Wiring for Connecting Automatic Machine

Details wiring for connecting automatic machines using the external connection terminal block.

Connection of Terminal for External Connection

Explains the procedure for connecting to the external connection terminals.

Wiring of Voltage Detection Cable at Base Metal Side

Explains how to wire the voltage detection cable at the base metal side.

Wiring to Wire Feeder

Details connecting the voltage detection cable to the wire feeder.

Wiring to Welding Power Source

Explains wiring the voltage detection cable to the welding power source.

Wiring Example of Voltage Detection Cable

Shows wiring examples for voltage detection cables.

Wiring Examples for Plural Welding Stages

Illustrates wiring examples for multiple welding stages.

Wiring Example when Power is Supplied with a Power Feeding Brush to the Positioner

Shows a wiring example when power is supplied via a power feeding brush to a positioner.

Chapter 5 Welding Operation

Precaution at Welding Operation

Explains safety precautions to be taken during welding operations.

Precautions for Air Discharge and Use of Respiratory Protective Equipment

Details precautions for air discharge and respiratory protection during welding.

Precaution for Protective Equipment

Advises on protective equipment to guard against arc ray, spatter, and noise.

Precautions on Welding Place

Provides precautions for selecting a suitable welding place to avoid poor welding.

Check Before Welding

Lists checks to perform before welding to prevent problems.

Power ON and Gas Supply

Explains the procedures for supplying power and shield gas.

Wire Inching

Explains the wire feeding (inching) operation.

Check and Setting of Welding Condition

Details checking and setting welding conditions, including error prevention.

Reading Welding Condition

Explains how to read previously set welding conditions.

Preventing Erroneous Operation on Operation Panel

Describes how to prevent unintended operations on the control panel.

Activating Erroneous Operation Prevention Function

Details the procedure to activate the erroneous operation prevention function.

Deactivating Erroneous Operation Prevention Function

Explains how to deactivate the erroneous operation prevention function.

Performing Welding Operation

Explains the procedures for executing the welding operation from start to end.

Operation of Welding Start

Details the steps for starting the welding operation.

Operation During Welding

Explains how to adjust welding current and voltage during the welding process.

Operation at Welding End

Explains the procedure for stopping power and shield gas supply after welding.

Chapter 6 Welding Condition

List of Welding Conditions

Lists the parameters and functions settable in the welding power source.

Parameter (Welding Parameter)

Details the welding parameters, their ranges, initial values, and descriptions.

Function

Lists the available functions and their settings.

Internal Function

Provides details on internal functions and their settings.

Function on Operation Panel

Explains the functions of the displays and keys on the operation panel.

Welding Conditions

Explains basic welding conditions and useful functions.

Basic Welding Conditions

Outlines fundamental factors to consider for welding operations.

Useful Functions

Explains useful functions like memory and synergistic voltage adjustment.

Preparing Welding Conditions

Describes the process for preparing basic welding conditions.

Memory Function of Welding Conditions

Explains the function to register and recall welding conditions.

Memory Registration of Welding Conditions

Details how to register current welding conditions into memory.

Read Out of Welding Conditions

Explains how to read out previously registered welding conditions from memory.

Deletion of Memory Registration

Describes how to delete registered welding conditions from memory.

Setting Welding Conditions

Explains how to set welding conditions, including welding modes and parameters.

Welding Mode Setting

Details how to select available welding modes and combinations.

Setting Welding Parameter

Explains how to set welding parameters like gas discharge time and current/voltage.

Welding Sequence

Describes the welding sequence process including pre-flow, main condition, and post-flow.

Welding Parameter Setting

Details how to set welding parameters according to the welding sequence.

Crater Setting

Explains details of crater treatment and torch switch operation modes.

Arc Spot Time

Explains details of arc spot welding and torch switch operation.

Welding Voltage Adjustment

Explains how to adjust welding voltage using SYNERGIC or INDIVIDUAL modes.

Arc Characteristics Adjustment

Explains how to adjust arc characteristics for soft or hard arc conditions.

Penetration Control Adjustment

Details how to adjust penetration control for consistent welding current.

Setting Internal Functions

Explains how to set and customize internal functions for convenient use.

Setting Procedure

Details the step-by-step procedure for setting internal functions.

Detailed Information on Internal Functions

Provides detailed information on various internal functions.

F1: Standard/Extended Cable Mode

Sets welding control status for extended cables in STANDARD mode.

F4: Auto/Semi-auto Mode

Sets I/O interface for robots or automatic machines based on application.

F5: Maximum External Command Voltage

Sets the maximum value of external command voltage input for auto/semi-auto modes.

F6: Upslope Time

Adjusts time for changing from initial to welding current to prevent wire burn-up.

F7: Downslope Time

Adjusts time for changing from welding to crater current to prevent wire plunging.

F8: Welding Result Display Time

Sets the duration for displaying welding results after completion.

F9: Analog Remote Control Scale

Changes the scale plate setting for the analog remote control.

F10: Motor Overcurrent Detection Level

Sets the overcurrent detection level for the wire feed motor.

F11: Fine Adjustment of Welding Conditions Memory

Allows fine adjustment of stored welding current/voltage using analog remote control.

F12: Operation Time of Water-Cooled Pump

Sets the operation time for the water-cooled pump after welding ends.

F13: Turbo Start

Enables turbo start function for smoother welding start using capacitor discharge.

F14/F15: Start Control (Time/Current) Adjustment

Adjusts time and current for start control to ensure proper wire burning.

F16: Slowdown Speed Adjustment

Adjusts the wire feed slowdown speed for optimal starting performance.

F17/F18: Anti-Stick Time/Voltage Adjustment

Sets anti-stick time/voltage to prevent wire adhesion and ensure stable starts.

F19: Switching Alarm Setting

Controls whether alarms stop the welding power source output.

F20: Low Input Voltage Detection Level

Sets the low input voltage detection level to display an error code.

F21: Maximum Cooling Fan Operation

Controls cooling fan operation modes for power saving or maximum cooling.

F22: Operation Sound Switching

Sets whether to emit operation sound when keys are pressed.

F23: Sleep Mode Switching Time

Sets the time until the welding power source enters sleep mode.

F24: Wire Feeding Speed Setting

Automatically sets welding current based on wire feed speed.

F25 to F28: External Output Terminal Setting (Reserved)

External output terminals reserved for automatic machines.

F29 to F32: External Input Terminal Setting

Sets functions for external input terminals used with robots or automatic machines.

F38: Arc Voltage Direct Detection Switching

Sets status for voltage direct detection terminals for improved spatter control.

F39/F40: Current Display Adjustment (Gain/Offset)

Adjusts current display values when they differ from the actual current.

F41/F42: Voltage Display Adjustment (Gain/Offset)

Adjusts voltage display values when they differ from the actual voltage.

F43: CAN ID

Sets ID for CAN when multiple power sources are connected to a PC monitoring system.

F44: Reading Welding Conditions with Remote Control

Sets whether to read stored welding conditions via analog remote control.

F45/F46/F47: Special Crater Sequence (Effective/Initial Standard Time Setting/Crater Standard Time Setting)

Incorporates initial and crater conditions into the "No crater" sequence.

F48: Adjusting Current with Torch Switch

Adjusts welding current via torch switch operation (single/double-click).

F49: Current Increase and Decrease by Single-Clicking

Sets current change volume for single-clicking the torch switch.

F50: Current Increase and Decrease by Double-Clicking

Sets current change volume for double-clicking the torch switch.

F51: Special Crater Repeat

Allows repeated switching between welding and crater treatment via torch switch.

F52: Data Type of Data Log Function

Selects data types to be saved for the data log function.

F53: Sampling Speed of Data Log Function

Selects the data sampling interval for the data log function.

F54 Tack Start Process

Enables tack welding start with normal feeding speed for less transition time.

F55 to F58: Reserved

Functions reserved for automatic machines from other manufacturers.

F67: Setting Change of Current Value (Initial Condition, Crater Condition)

Sets initial and crater condition current as percentage of welding condition.

F68: Setting of Current Value (Initial Condition)

Sets initial condition current as percentage of welding condition.

F69: Setting of Current Value (Crater Condition)

Sets crater condition current as percentage of welding condition.

Operation of Analog Remote Control (Optional)

Explains functions and operations of the optional analog remote controller.

Chapter 7 Administrator Functions

Protection of Welding Conditions

Explains the password function for protecting welding conditions and preventing erroneous operations.

Setting/Changing Password

Details how to set and change the password for welding condition protection.

Disabling Erroneous Operation Prevention

Explains how to disable the password-protected erroneous operation prevention function.

Welding Result Control Function

Enables management of welding results, including monitoring parameters.

Setting Welding Result Control Function

Details how to set the welding result control function.

Details of Welding Control Items

Explains the details of various welding control items like welding points and wire consumption.

Number of Welding Point

Controls the number of welding points based on set ranges and operations.

Wire Consumption

Controls and measures wire consumption during welding.

Total Welding Time

Controls total welding time based on set ranges and operations.

Welding Monitor

Monitors average current/voltage and alerts on out-of-range values.

Data Backup (Utilization of Data)

Explains backing up and importing data like welding conditions via USB.

Setting of Welding Conditions/Internal Functions

Details contents of backup files, including welding conditions and internal functions.

Simplified Data Log Function

Samples and checks welding status via computer by backing up data to USB.

Failure Log Function

Records the latest ten error codes encountered during operation.

Backup Operation

Explains the procedure for backing up data to a USB flash drive.

Importing Backup Data

Explains how to import backup data from a USB flash drive into the welding power source.

Initializing Welding Conditions and Internal Functions

Initializes welding conditions and internal functions to their default settings.

Checking Software Version

Explains how to check the software version installed in the welding power source.

Chapter 8 Maintenance and Inspection

Precautions for Maintenance and Inspection

Provides safety precautions for performing maintenance and inspection work.

Daily Inspection

Explains the daily inspection procedures for the welding power source.

Periodical Inspection

Details the periodic inspection items for the welding power source every three to six months.

Periodical Replacement Parts

Lists parts that require periodic replacement, such as PCBs and fans.

Insulation Resistance Measurement and Withstand Voltage Test

Explains the procedure for insulation resistance and withstand voltage tests.

Chapter 9 Troubleshooting

Action in Case of Error

Describes how to cope with abnormalities indicated by warning LEDs and error codes.

Troubleshooting

Explains common problems, their causes, and corrective actions.

Chapter 10 Reference Materials

Parts List

Lists the part numbers and specifications for the welding power source components.

Reference Drawing

Contains the schematic diagram and parts layout drawing of the welding power source.

Schematic Diagram

Provides the electrical schematic diagram of the welding power source.

Parts Layout Drawing

Shows the physical layout of components within the welding power source.

Materials for Setting Welding Conditions

Provides reference information for setting welding conditions.

Guide for Changing Welding Conditions

Gives examples of problems caused by improper welding conditions.

Samples of Welding Condition Settings

Provides sample welding condition settings for common scenarios.

Example of CO2 Welding Conditions

Shows example welding conditions for CO2 welding of horizontal fillet.

Example of MAG Short Arc Welding

Shows example welding conditions for MAG short arc welding of butt joints.

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