Motoweld SR350 Manual

YASKAWA
MOTOWELD-SR350
INSTRUCTIONS
TYPE: YWE-SR350-CE0
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
Part Number: 167300-1CD

Revision: 0
MANUAL NO.
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MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOWELD-SR350. Read
this manual carefully and understand the contents before handling the
MOTOWELD-SR350. For the wire feeder, the welding torch, and the gas
regulator, read each instruction manual carefully.
• General items related to safety are listed in the Safety Manual Section
1: Safety. To ensure correct and safe operation, carefully read the Setup
Manual before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA

representative to order a new copy. The representatives are listed on
the back cover. Be sure to tell the representative the manual number
listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your
product’s warranty.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
MOTOWELD-SR350.
In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”
“MANDATORY,” or “PROHIBITED.”
Indicates a potentially hazardous situation which, if not

WARNING avoided, could result in death or serious injury to personnel.
Indicates a potentially hazardous situation which, if not

CAUTION avoided, could result in minor or moderate injury to personnel
and damage to equipment. It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the items listed under this

MANDATORY heading.
PROHIBITED Must never be performed.
“Serious injury” described above indicates loss of eyesight, injuries, burns (both due to high/
low temperature), electric shock, fractures, poisoning, etc. which may cause personnel to
suffer aftereffects, hospitalization, or prolonged out-patient medical treatment.
“Moderate injury” indicates injuries, burns, or electric shock which does not require
hospitalization or prolonged out-patient medical treatment.
“Damage to equipment” indicates expanded damages relating to property or equipment.
Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING.”
For safe training concerning welding, utilize technical institutes held by the welding society or
association, or related societies or associations, technical courses held by the headquarters
or their branches, or qualifications examinations for welding technicians or engineers.
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WARNING
Be sure to observe the following warnings to avoid serious injury to personnel.
• Be sure to observe the precautions in this instruction manual although

this welder is designed and manufactured with sufficient consideration
given to safety.
Failure to observe this warning may result in death or serious injury to personnel.
• Observe the regulations and your own references for the construction of
the input power sources, selection of the installation site, handling of
high-pressure gases, storage and piping, storage of manufactured
products after welding, disposal of wastes, etc.
• Do not let personnel to approach the welder or welding sites

unnecessarily.
• Any person using a pacemaker must not approach the welder or welding
site under operation unless permitted by doctor.
The welder generates a magnetic field around it during current conduction, resulting in
bad influence on the pacemaker.
• Clean the cooling-water path once a month when using a water-cooled

torch and the cooling water circulator.
Failure to observe this warning may result in explosion or burns due to the choked path.
• In order to secure safe operations, only a trained or qualified person

who has understood the welder must perform installation, maintenance
and inspection, or repair of the welder.
• In order to secure safe operations, only a person that has understood

this instruction manual and has knowledge and techniques to handle
the welder safely must operate the welder.
• Do not use the welder for any applications other than welding.
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WARNING
Be sure to observe the following warnings to avoid an electric shock.
• Never touch the charged parts.
Touching the charged parts may result in critical electric shock or burns.
• Only a qualified person in electric construction should perform

grounding construction for the welder case and base metals (to be
welded) or jigs that are electrically connected to the base metals as
specified in the electric facility technical reference.
• Be sure to perform installation or maintenance and inspection five

minutes after all the input power supplies are turned OFF by using
switches in the switch box.
Even if the input power supply is turned OFF, the capacitor may still be charged. Be sure
to confirm that charged voltage is gone before starting operations.
• Do not use any cable of insufficient capacity or damaged or with its

conductor exposed.
• Tighten the cable connecting sections firmly and insulate them.
• Do not use the welder with its case or cover removed.
• Do not use worn, damaged or wet gloves. Always use dry insulated
gloves.
• Use lifelines when working at hights.
• Perform maintenance and inspection periodically. Repair damaged

parts immediately.
• Turn OFF all equipment input power supplies when not being used.
• When performing AC arc welding in a small space or at hights, be sure

to use equipment to prevent critical electric shock as specified by labor
safety and sanitary regulations.
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WARNING
Be sure to observe the following warnings and use protectors to protect
yourself or other people from the fumes or gases generated at welding and
short of the oxygen.
• In order to prevent gas poisoning or suffocation, be

sure to ventilate sufficiently or use an inhaler, etc.
when welding at a place specified by regulations such
as labor safety and sanitary regulations or hypoxia
preventive regulations.
• In order to prevent dust trouble or gas poisoning due to the fumes or

gases, use a local air exhaust facility specified by regulations such as
labor safety and sanitary regulations or dust trouble preventive
regulations or use effective protectors for breathing.
Fumes or gases generated at welding may harm your health.
• When welding within such areas as a tank, a boiler, or a ship’s hold, be

sure to ventilate sufficiently or use an inhaler, etc. in order to prevent or
offset any actual or potential oxygen shortage.
Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom.
• When welding in a small space, be sure to ventilate the site sufficiently

or use an inhaler. At the same time, operations must be done under
trained supervisor.
Welding operations at a small space may result in short of the air, causing a person to be
suffocated.
• Do not perform welding near degreasing, cleaning, or spraying

operations.
Failure to observe this warning may generate extremely noxious gases.
• Before welding coated steel plates, be sure to ventilate sufficiently or

use protectors for breathing.
Welding such coated steel plates generates noxious fumes or gases.
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WARNING
Observe the following cautions to prevent fire, explosion, or rupture.
• Remove inflammables so that they will not get spattered.

If they cannot be removed, use the inflammables with
nonflammable covers.
Spatters or hot base metal immediately after welding may result in fire.
• Do not weld near flammable gases.
If arc is generated in a container (for inflammables) in which gasoline or the like is put, the
container may explode.
• Do not make hot base metals immediately after welding close to

inflammables.
• Remove inflammables at the hidden side when welding ceiling, floor, or

wall.
Failure to observe this caution may result in fire.
• Tighten and insulate the cable connections.
Imperfect cable connections or imperfect contacting section of the current path at the
base metal such as iron framework may result in fire due to heat generation by current
conduction.
• Connect the cable at the base metal as close to the welding part as
possible.
• Do not weld a gas tube having gas inside or an enclosed tank or pipe.
Welding an enclosed tank or pipe may result in rupture.
• Locate fire extinguishers near the welding site.
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CAUTION
Be sure to observe the following cautions and use protectors to protect yourself
or other people from arc beams, spatters, slugs or noise generated from weld-
ing.
• Wear welding mask or shaded glasses appropriate for

welding.
• Wear protective glasses to protect your eyes from

spatters or slags.
Scattered spatters or slags may damage eyes or burn the skin.
• Use such protectors as leather gloves, clothes with long sleeves, leg
covers, or leather aprons for welding.
• Install protective curtains around the welding site to protect your eyes
from arc beams.
Arc beams may irritate eyes or burn skins.
• Use noise protector when there is excessive noise.
Noise may damage hearing.
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CAUTION
Be sure to observe the following cautions to prevent a gas cylinder from fall-
ing or a gas regulator from rupturing.
• Observe the regulations and your own references for

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

welder must remove the welder case for maintenance and
inspection or repair. Take preventive measures not to let
other personnel approach the welder or welding sites unnecessarily by
putting up a guard fence or the like.
• Do not contact the rotating cooling fan or feeding roll of the wire feeder
with hands, fingers, hair, or clothes.
Failure to observe this caution may cause someone to be caught in the machine resulting
in personal injury.
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CAUTION
Observe the following cautions to prevent personal injury by the end tip of the weld-
ing wire.
• Do not peep through the chip hole to confirm that the wire
is being fed.
If the wire is projected from the end tip of the welding torch, it may poke
you in the eyes or face.
• Do not bring the welding torch end close to eyes, face, or body to
perform inching or pulling the torch switch.
If the wire is projected from the end tip of the welding torch, it may poke you in the eyes,
face, or body.
• When hanging the wire feeder, remove the anti-fall fastening

from the spool shaft and tighten.
Failure to observe this caution may cause the wire to

be removed from the spool shaft, resulting in personal injury.
Observe the following cautions to prevent burns due to the plasma arc.
If body parts such as hands and fingers directly touch the plasma arc,
burns will result.
• Do not put your hands and fingers near the chip and
the electrodes of the torch end during cutting operation.
• Do not grasp near the base metal during cutting operation.
• Turn OFF the power supply before replacing the chip or the electrodes
of the torch.
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CAUTION
Observe the following cautions to prevent a fire accident caused by deterioration of
welder insulation.
• Perform all welding and grinding away from welder to

protect welder from spattering and metal powder.
Spatter and metal powder inside the welder may cause a deterioration of
insulation resulting in accidental fire.
• Be sure to perform maintenance and inspection periodically to prevent

deterioration of insulation caused by accumulation of dust and dirt.
• If spatter or metal powder enters the inside of the welder, remove it by

forced air spray after turning OFF the welder and switch in the switch
box.
Spatter and metal powder inside the welder may cause a deterioration of insulation result-
ing in accidental fire.
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Table of Contents
1 Basic Specifications
2 Installation and Connection

2.1 Installation Site and Welding Source Environment . 2-1
2.2 Precautions on Grounding . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Power Supply Installed Capacity and Connection
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Combination with Earth Leakage Breaker . . . . . . . . . . 2- 3
2.5 Connection of Electrical System . . . . . . . . . . . . . . . . . . . 2-4
2.6 Connection of Shielding Gas System . . . . . . . . . . . . . . 2-7
2.6.1 For Mixed Gas or Carbon Dioxide Gas Welding . . . . . . . . . . . .2-7
2.6.2 Installation Site and Gas Cylinder Environment . . . . . . . . . . . .2-7
2.7 Ambient Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8 Precautions on Transporting . . . . . . . . . . . . . . . . . . . . . . 2-11
3 Welding Preparation
3.1 Name of Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Welding Preparation Procedure . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Welding Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4 Operations on Panel
4.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Operation of Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.1 Changing F Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.2.2 Selecting Feeding Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.2.3 Saving Welding Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.2.4 Checking the Flow Amount of Shielding Gas . . . . . . . . . . . . . .4-9
4.2.5 Wire inching(Operation On Panel). . . . . . . . . . . . . . . . . . . . . . .4-9
4.2.6 User Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.2.7 Changing current increasing speed at short-circuit . . . . . . . . .4-12
4.2.8 Changing current decreasing speed at arc . . . . . . . . . . . . . . .4-12
4.2.9 Changing U Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
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4.2.10 Lock Of Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.3 List of U Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.4 List of F Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
5 Welding Operation
5.1 Checking the Welding Conditions . . . . . . . . . . . . . . . . . . 5-1
5.2 Wire Stickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Direction of Welding and Torch Angle . . . . . . . . . . . . . . 5-1
5.4 Precautions on Using Extension Cable . . . . . . . . . . . . . 5-2
6 Precautions on Welding
6.1 Error Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Tripped Power Supply Switch . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Precautions on Welding Operation . . . . . . . . . . . . . . . . . 6-4
7 Maintenance and Inspection

7.1 Daily Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Bimonthly to Semiannual Inspection Items. . . . . . . . . . 7-2
7.3 Annual Overhaul and Repair . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Guideline for Service Lifetime and Replacement of
Components Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.5 Cleaning of Dust Protective Filter . . . . . . . . . . . . . . . . . . . 7-3
7.6 Recover Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
8 Failure Analyses
8.1 Confirming Setting conditions . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Cause and Remedy of Welding Section Failure . . . . . 8-3
9 Robot Interface Signals

9.1 Specifications of Robot Interface Signals . . . . . . . . . . . 9-1
9.2 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
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10 Connection System Diagram
11 Diagnosis Function
11.1 Starting up Welding Source in Diagnosis Mode . . 11-1
11.2 Display of Software Version and
Error Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2
11.2.1 Confirmation of Software Version . . . . . . . . . . . . . . . . . . . . .11-2
11.2.2 Confirmation of the Number of Welding Source Errors. . . . .11-2
11.3 Mode of clear the setting conditions . . . . . . . . . . . . . 11-3
11.3.1 Initialize the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.3.2 Clear of Error Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4
11.3.3 Reset All Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4
12 Process Parameters
(Adjustment of Welding Characteristics)
12.1 Adjustable Welding Characteristics . . . . . . . . . . . . . . 12-1
12.2 Adjustment of Arc Start Characteristics . . . . . . . . . . 12-2
12.2.1 Adjustment of Start Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
12.3 Adjustment of Arc End Characteristics . . . . . . . . . . 12-3
12.4 Adjustment of Short-circuit
Welding Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.5 Adjustment of Current Output Characteristics . . . 12-5
13 Welding Source Condition File of the Robot

Controller
14 Setting of Arc Monitoring Function
15 Operation by External Remote Mode

15.1 Gas Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.2 Switch of User Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
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16 Dimensions
17 List of Service Parts
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Item Specifications
Model MOTOWELD-SR350
Type YWE-SR350-CE0
Number of Phases, Three-phase, 380/415V 10 %

Rated Input Voltage
Rated Frequency 50/60 Hz common
Rated Input 20 kVA
15 kW
Welding Current Adjust- 30 to 350A (depends on the wire diameter)

ment Range
Welding Voltage Adjust- 12 to 36V (depends on the wire diameter)

ment Range
Rated Operational Ratio 60% (for 10 minutes)
Welding Type CO2 short-circuit welding, MAG short-circuit welding
Welding Object Material Iron(Refer to the “Type” on the panel for details.)
Feeding Motor Types of feeding motors can be selected among;

0: Print servomotor
2: 4-roller servomotor (YWE-WF-340MELC) (default setting)
Wire Feeding speed 1.0 to 18 m/min
Gas Running-in Time Approx. 20 seconds (Can be adjusted by panel operation)
Gas Pre-flow Time Approx. 0.05 seconds (Can be adjusted by panel operation)
Gas After-flow Time Approx. 0.5 seconds (Can be adjusted by panel operation)
Wire-stick Prevention Approx. 0.2 seconds (Can be adjusted by panel operation)

Time
External Dimensions 250 x 450 x 630 (width x depth x height)

[mm] (excluding the projections such as screws or eyebolts)
Mass Approx. 45 kg
Welding Voltage Setting Can be switched by "Auto Adjustment/Individual" (Synergic/Indepen-

Method dent) button on the welding source panel.
User File Number of files: 4

"Panel" or "robot" can be switched by the parameter F13.
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Item Specifications
Adjustment of Voltage Can be changed by U parameters in the user file.

and Current Waveform
Control
Interface for Robot Refer to Chapter 9 "Robot Interface Signals".

Controller
Output Setting Analog 0 to 14V (The set voltage, current are displayed on the welding source
Input panel.)
Error Output Outputs the arc failure signal to the robot side. (Error contents are
indicated on the welding source panel.)
Output for Arc Outputs the signal corresponding to current or voltage to the robot side.
Monitoring The output terminal stand for analog indicator is also available.
Power Supply of the None

Heater for the Gas
Regulator
Standard Accessory None
Remarks Front panel: Written in both English and Japanese
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2.1 Installation Site and Welding Source Environment
CAUTION
• The welding source can be moved easily by using the caster. After
installation, use the stopper to fix the welding source before starting
operations.
For precautions on transporting, see Section 2.8 "Precautions on
Transporting".
The welding source can be used under the following environmental conditions:
• Dry, indoor and at least 30 cm from the wall or peripheral devices
• Free from direct sunlight, wind, and rain
• Ambient temperature of 0 to 40C
• Altitude less than 1000m
• Free from direct splash of welding spatter or metallic fine powder at grinding
2.2 Precautions on Grounding
CAUTION
• Be sure to turn OFF the main switch of the switchboard before
performing the grounding work.
1. Be sure to perform secure grounding work (ground resistance must be 100 or less)
on the welding source so as not to charge its case or lead to unstable operation.
2. In the case of input voltage 380/415V, Connect a grounding cable of 8 mm2 or thicker
to the terminal marked "GROUND" or "EARTH".
3. Be sure to ground the base metal (ground resistance must be 100 or less) as well
when or any other non-conductive material is placed under the base metal.
4. If there is a pool or pond between the grounding of the power supply switchboard and
the welding source, the leak current is concentrated in the pool or pond. In such a
case, connect the grounding with a cable to escape the leak current through the cable.
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2.3 Power Supply Installed Capacity and Connection

Cables
The following table Table 1 "Power Supply Installed Capacity and Cables" shows the power
supply installed capacity and connection cables which are required for using the welding
source.
The rated input voltage for the welding source is three-phase, 380V/415V. The welding
source supports a voltage compensation circuit so that the equipment can operate at a power
voltage within 10% fluctuations of the rated value. All the same, it is recommended to use a
power supply as stable as possible. If fluctuations in power supply voltage exceed 10%,
welding source conditions cannot be guaranteed and problems may occur.
Diameter of the input cable and the fuse capacity must be in compliance with the table Table 1
"Power Supply Installed Capacity and Cables". Install a non-fuse breaker (NFB) or a switch
with fuse for each welding source.
The non fuse breaker used should be the same capacity of the fuse indicated in Table 1
"Power Supply Installed Capacity and Cables", and the tripping time at 600% of the rated
current should be one second or longer (General motor breakers satisfy these requirements).
If breaker capacity is insufficient or primary voltage is too high, the breaker will be tripped
when the welding source is turned ON.
Table. 1 Power Supply Installed Capacity and Cables
Rated input voltage 380V/415V
Installed Capacity 22 kVA
Fuse Rated Current 40A (rated voltage: 380/415 V)
Input Cable 8 mm2 or more
Exclusive-use base metal cable 60 mm2 or more *1
Grounding Cable 8 mm2 or more
*1 Be sure to use cables for welding. Also, use cables with sufficient thickness for
NOTE pulse welding or current of 250A or more. Small gauge cables may result in poor
welding and cause abnormal heating in burn or fire.
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2.4 Combination with Earth Leakage Breaker
When the welding source is used in a construction site, in a place with high humidity, or on an
iron plate, iron framework, or surface plate with high conductivity, a leakage breaker should be
installed according to the proper regulations or laws. In such a case, connect a leakage
breaker of current sensitivity 30 mA for each welding source. The welding source may
malfunction because of the inverter operations depending on the model or current sensitivity
of the leakage breaker. Therefore, select a proper one for inverter drives.
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2.5 Connection of Electrical System
CAUTION
• Open the disconnect switch of the swtichgear before connecting wires
between welding machine and primary power supply.
Even one imperfect contact in the connections precludes proper welding. Be sure to
make perfect connection to the base metal by using jigs.
1. Connection on the Welding Source Side

See Fig. 1 "Connection Diagram of Welding Source at Rear Face" for proper
connections.
1) Input cable
2) Ground cable
2. Connection on the Welding Side

See Fig. 2 "Connection Diagram of Welding Source at Front Face" for proper
connections.
1) Welding cable
The welding cable connects between the welding torch and power output
terminal (+).
2) Exclusive-use base metal cable
The exclusive-use base metal cable connects between the base metal and
power output terminal (-).
3. Connection of Control Cable

Connect cables of every kind to connectors at rear face of the welding source. When
connecting the cables, securely tighten the plug until it stops rotating.
1) Connect the control cable of the robot controller to the connector "CON 1".
2) Connect the motor cable of the wire feeder to the connector "CON 2".
3) Connect the encoder cable of the wire feeder to the connector "CON 3".
4) Welding Voltage Detecting Line(In the case of using long Exclusive-use base
metal cable)
When the welding cable and the Exclusive-use base metal cable are longer than
20m and welding is unstable, Use the welding voltage detecting line.
Usually the welding voltage detecting line is not necesarry.
• How to use the welding voltage detecting line
i) The welding voltage detecting line connects between the base metal and
the terminal at rear face of the welding source.
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0) Set the voltage detection switch in the back of the welding power source to
the "WORK"side.
For each phase, use the cable of the specified size

shown in Table 2-1.
The input voltage which is outside the specified

range (rated input voltage 10%) must not be used.
Ground the To the robot control unit
machine 3 phase, AC380V - 415V 50/60Hz
with a
cable of
8mm 2 or
above. Provide one switch for every
Switch in the one power source of welding.
switchgear CON1
Ground For the fuse capacity, refer Robot interface connector
cable ON/OFF to Table 2-1. (MS3102A 28-12S)
Type D
grounding work CON2 push motor connector CON3
(MS3102A 20-17S) Push motor encoder connector
(RM12BBR-4S)
Carbon dioxide gas
Input cable pressure regulator
(also functions as a
flow meter)
(Example: FCR2505A)
Carbon dioxide gas
cylinder CO 2
Gas cylinder
For welding, or JIS-K1106,

third class
Avoid storing at a place of
a high temperature
(35 C or above)
To the wire feed unit
Gas hose
The cooling fan is of

sacking system.
Exhaust
Exhaust
Fig. 2-1 Connection Diagram of Welding Source at Rear Face
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To push motor back surface CON2

To encoder back surface CON3
Output terminal cover
Table 2-1 size Output

or above Welding cable terminal Open the cover, and
then connect.
After connecting, be
sure to close the cover.
Feed unit Torch

Base material Table 2-1
side cable size or above
Base material
Ground cable
Type D grounding work
Fig. 2-2 Connection Diagram of Welding Source at Front Face
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4. Grounding
Ground terminal is provided at the input cable (line yellow/green) of the welding source
for safe operation. Connect the grounding cable of 8 mm2 or more to the crimp
contact. Ground resistance must be 100 or less.
Be sure to ground the base metal at resistance of 100 or less individually as shown in
Fig. 2-2 "Connection Diagram of Welding Source at Front Face". If it is not grounded,
voltage may be generated in the base metal resulting in electric shock. Make sure that
the grounding is always done individually, separated from grounding for the
manipulator. Also, connect the welding source and the base metal with exclusive-use
base metal cable.
2.6 Connection of Shielding Gas System
2.6.1 For Mixed Gas or Carbon Dioxide Gas Welding

The 100 VAC power supply is required for a heater of carbon dioxide gas regulator. Connect
the gas cylinder as follows:
1. Remove dust from the gas cylinder connecting port. Install the MAG/carbon dioxide
common gas regulator. Check the quality of the gas and the type of the cylinder.
2. Insert one end to the supplied rubber gas hose into the output of the gas regulator, and
the other end into the gas terminal inlet of the wire feeder. Clamp both ends securely
with hose bands.
2.6.2 Installation Site and Gas Cylinder Environment

Handle the gas cylinder with special care because it contains high pressure gas. Refer to the
instruction manual attached to the gas cylinder.
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1. Installation SIte of Gas Cylinder

Place the gas cylinder in a specified gas container
position that is not exposed to direct sunlight. If the gas
cylinder is unavoidable placed at the welding site, it must
Gas cylinder stand

be fixed to post or cylinder stand in an upright position to
Gas cylinder
prevent it from falling. Also, the gas cylinder must not be
heated by a welding arc or the like.
2. Type of Gas Cylinder

Carbon dioxide gas-filled cylinders can be classified into
two types: one is the general type that is not the siphon
type, and the other is the siphon type.
Never use siphon type gas cylinders. The provided Fix the gas cylinder to prevent
carbon dioxide gas regulator is not applicable to siphon it from falling.
type cylinder. If the regulator is connected to a siphon Fig. 2-3 Installation Site of
Gas Cylinder
type gas cylinder, the contents of the cylinder are not
gaseous and enter the regulator as remaining liquefied.
In such a case, the pressure reduction mechanism of
the regulator cannot be operated. The type of gas
cylinder can be distinguished by cylinder color according
to the cylinder’s manufacturer. Contact the gas
distributor for details.
The safety valve operates when the pressure goes
extremely high. When the valve operates, stop
operation immediately, confirm the reason, and take
appropriate corrective actions to prevent that the same
error occurs again.
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3. Quality of Gas for Welding

Moisture or impurity in the carbon dioxide gas or argon gas used to shield welding arcs
adversely influenced welding. High purity and low moisture gas must be used.
Use MAG gas containing 80% argon and 20% carbon dioxide gas for mixed gas. The
gas mixing ratio of MAG gas is content, which contributes to constant welding quality.
Especially for pulse welding, improper pulse welding will be resulted if the argon gas
ration is less than 80%.
Use carbon dioxide gas designated as "for welding" or what conforms to Class 3
specified in JIS-K1106 (moisture content 0.005% or less) or the equivalent. Avoid
using carbon dioxide gas containing moisture more than 0.005%, not only for the
adverse effect on welding, but also because it may cause clogging in the gas regulator
if the water content freezes.
4. Gas Regulator with Flow Meter

Use gas regulator with flow meter suitable for the gas to be used. The following table
show the examples of the gas regulator.
Table. 2 Gas Regulator with Flow Meter
No. Type Applicable Gas Remarks
1 FCR-2505A CO2, MAG Meter: Indicates secondary pressure

and flow amount
Heater: 100 VAC*1, 190W
2 FCR-225 CO2, MAG, Ar Meter: Indicates primary pressure and

float-type flow amount
Heater: 100 VAC*1, 190W
*1 The power supply for the heater is not provided with the welding source. Prepare a
100 VAC power supply for the heater of the gas regulator.
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2.7 Ambient Environment
1. Wind Prevention
Normally, the allowable wind limit for welding using shielding gas is approx. 1.5 m/s or
less. If the wind speed is higher than this limit, stop operation or take some
countermeasures such as putting up a screen.
Even for indoor operations, sufficient attention to the shield effect must be paid when
using air tools or fans around the welding.
2. Ventilation
The carbon dioxide gas used as the shielding gas is decomposed by arc heating, and a
small amount of carbon monoxide is generated.
For operations indoor or in a container or a tank, ventilation is needed. In this case, do
not use a fan to blow the air, but ventilate the accumulated gas by providing a
ventilation fan or exhaust duct.
Ventilating fan
Torch
Torch
Screen
Wind
Object to be welded
Fig. 2-4 Shielding Wind for Welding Fig. 2-5 Ventilation Example
3. Shading Measures
For shaded glasses of helmets or hand shields, use filter numbers 8 to 10 of JIS T8141
for welding of thin plates since it has a weak arc beam and the arc must be seen easily.
Use numbers 10 to 13 for welding of medium-hick plates since the arc is bright. For
MAG welding, for which stronger arc light is required compared to CO2 welding, use
greater filter numbers.
The welder brings in ultraviolet rays stronger than that caused by manual welding.
Periodically check protectors for eyes and the skin. Also, be sure to always wear these
protectors.
When the welding source is controlled by external control input signal or while
operating the manipulator, provided proper shade around the welding torch.
Accidental arc generation may damage eyes or burn the skin of those without proper
protection.
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Helmet
Handshield
Jacket must be
long-sleeved.
Welding gloves
Foot covers
Safety boots
Fig. 2-6 Protection Example
2.8 Precautions on Transporting
CAUTION
• Sling applications and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock while transporting.
The welding source consists of precision components. Failure to observe this caution
may affect its performance.
1. Transporting with Using Casters

When using the casters, move the welding source slowly so that it can be stopped
quickly at any time. Moving the welding source with casters quickly may result in an
accident due to inertia, and you cannot control the direction of movement.
Moreover, be sure to stop the welding source with casters at a step and move it slowly
to prevent any shock sudden. Do not move the welding source with casters up a slope,
stairs, etc.
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2. Transporting with Using a Crane

When using the crane, be sure to confirm the following points before transporting.
1) Confirme the mass of the welding source by referring to Chapter 1 "Basic
Specifications". Select the wire rope suitable for the mass and angle.
2) Use eyebolts for transporting and confirm that the eyebolts are tightened firmly
before transporting.
3) Lift the welding source using the crane after the above confirmation.
Wire rope
60 or
M8 eyebolt above
3. Transporting with Using a Forklift

Observe the following points to use the forklift for transporting.
1) Confirm availability of safe operations site, and transfer the welding source to the
installing site.
2) After determining the operation site, warnings must be placed on transport path
to prevent accidents.
3) Put the welding source on the transporting pallet and fix firmly to prevent falling
or shifting. Employ a stopper on the casters to fix the welding source.
Over-tightening the cover may cause it to deform.
4) Do not raise the lift excessively.
5) Avoid excessive shock or vibration while transporting since the system consists
of precision component.
6) Transport the welding source at yield speed when using the forklift.
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4. Others
1) Do not climb up on the welding source or place anything on it.
2) Do not pass a rope directly around the welding source case during transporting.
Failure to observe this caution may deform the shape of the case or cause mal-
function.
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3.1 Name of Part
 Front View
Control panel
Power switch
ON
OFF
Output terminal
section details
Output terminal (-)
Output terminal (+)
 Rear View
Panel / Remote Operation

section select switch Monitor signal
Voltage detection line output terminal
select switch
Circuit breaker
(115V, 2.5A) Robot control connector
Circuit breaker
Motor encoder connector
(24V, 10A)
Motor/Gas control
connector
Input cable
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3.2 Welding Preparation Procedure
The following table describes the preparation procedure to start actual welding.
Table. 1 Welding Preparation Procedure
Step Item Details
Setting welding wire Set a wire suitable to the welding method. Make sure
1 that the diameter of the roller of wire feeder matches
the wire diameter.
Checking torch Confirm that a contact tip suitable to the diameter of

2
the wire is installed on the torch.
Turning ON the switch in the Confirm that connections are correct, then turn ON the
3
switch gear switch of the switch gear of the welding source.
Turning ON switches for the Turn ON the power switch. The power indicator lamp
welding source lights and the built-in cooling fan starts. The fan stops
4
after fifteen minutes unless the arc starts. The fan
automatically restarts when the arc starts.
Setting feeding motor The feeding motor type can be set by the parameter
F04.
0: Print servomotor
2: 4-roller servomotor (YWE-WF340MELC) (default
setting)
Incorrect setting of the feeding motor precludes proper

welding because the wire cannot be fed at wire
5 feeding speed as directed by the set value.
When the parameter was changed, follow the
instructions as follows:
1. Keep on pressing the "Record" button for
more than three seconds to save changes.
Do not turn OFF the welding source while
saving.
For details, refer to Section 4.2.2 "Selecting Feeding
Motor".
Setting welding source voltage Set the welding source voltage control: either
control "Synergic (auto adjustment)" or "Independent
6
(individual)".
"Synergic (auto adjustment)" is set before shipping.
Setting at the robot side Set the welding source condition files (including
“Synergic (auto adjustment)” or “Independent
7 (individual)”).
For details, refer to Chapter 13 "Welding Source
Condition File of the Robot Controller".
Selecting welding type Before Setting; Select the welding type according to
8
the type of shielding gas and wire.
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Table. 1 Welding Preparation Procedure
Step Item Details
Wire inching Adjust the welding wire by wire inching so that it can
be used for welding as follows:
1. Output the inching command from the robot
9
controller.
2. Inch the wire until it comes out from the end of
the torch.
Adjusting gas flow Adjust the gas flow as follows:

1. Press the "Gas" button on the panel of
welding source. The LED indicator lights and
the gas flows for 20 seconds. The gas
automatically stops after the 20 seconds.
(The gas flow time can be set by the
parameter F03. Refer to Section 4.2.4
"Checking the Flow Amount of Shielding
10 Gas".)
2. Turn the valve of the gas cylinder
counterclockwise to open.
3. Turn the knob of the gas regulator to adjust
the flow according to welding conditions.
Proper gas flow rate is 10 to 25 liters per
minute. The flow rate must be increased in
proportion to the welding current (the higher
the current, the larger the flow rate).
Saving welding conditions Save the conditions before turning OFF the welding
source as follows:
1. Keep on pressing the "Record" button for
more than three seconds to save changes.
11 Do not turn OFF the welding source while
saving.
2. The 7-segment LED indicators light up again
at the completion of the saving. Confirm that
the 7-segment LED indicators light again.
12 End
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3.3 Welding Type
material Shielding gas Wire diameter
MAG(Ar 80% + CO2 20%) ɸ0.8 mm
ɸ0.9 mm
ɸ1.0 mm
ɸ1.2 mm
Iron steel
CO2 ɸ0.8 mm
ɸ0.9 mm
ɸ1.0 mm
ɸ1.2 mm
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 Before Operating Welding Power Source

Set panel/remote opretation switch in the back of the welding power source to the "ROBOT"side,
when you set the welding current instruction and the welding voltage instruction from the robot
controller.
Please confirm LED of “ROBOT" at the right of the control panel lights.
4.1 Control Panel
3
11
4
5 12
6
7
8 1
10
2 9
Fig. 4-1 Control Panel

The following table explains the display of the meters ①、② .
The content of the display differs according to the status as follows:
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 Display Of Welding Current, Welding Voltage
Status During standby
CASE: parameter During

Setting CASE:paramete
F14= OFF welding
F14=ON
（Displays Setting
（Displays Stanby）
Conditions）
⑧ Select Weliding current The Displays the set Displays 0A. Displays the
content of welding current welding
the value(A). current
display value(A) that is
fedback.
⑧ Select welding voltage The Displays the set Displyas 0.0V. Displays the
content of welding voltage welding
the value(V). voltage
display. value(V) that is
fedback.
 Display Of Wirefeeding speed

The current display is switched to the wire feeding speed display by pushing the rotary switch ⑩ .
During standby
During
CASE: parameter
Setting CASE:paramete welding
F14= OFF
F14=ON
（Displays Setting
Conditions）
⑧ Select Weliding current The Displays the set Displays 0A. Displays the
display. value(A) that is
fedback.
The Displays the set Displays 0. Displays the

content of wire feeding speed wire feeding
the value(m/min) speed(m/min)
display. that is fedback.
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 Display of Welding Voltage percentage at the synergic (auto

adjustment) setting.
The welding voltage setting display is switched to voltage setting percent display by pushing the rotary
switch ⑩ at the synergic(auto adjustment) setting.
During standby
During
CASE: parameter
Setting CASE:paramete welding
F14= OFF
F14=ON
（Displays Setting
Conditions）
⑧ Select welding voltage The Displays the set Displays 0 Displays the
the value(V). voltage
fedback.
The Displays the set Displays 0 Displays the

the percentage(%). voltage
fedback.
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 Setting Buttons
3
11
4
5 12
6
7
8
10
No Content Explanation
③ Selecting of Gas type CO2 and MAG gas can be selected by pressing button during
standby.
④ Selecting of wire diameter Wire diameter(0.8 mm / 0.9 mm / 1.0 mm / 1.2 mm) can be
selected by pressing button during standby. Each time the
button is pressed, LED of the wire diameter is changed.
⑤ Selecting of the User File Selects the file to save the contents of the changed settings.Each time
the "User File Select" button is pressed, the LED indicator lamp for
the file number is changed.(FILE No.0 → FILE No.1 → FILE No.2
→ FILE No.3)
⑥ Record Uses to save the setting. The LED indicator lamp blinks when
the setting is changed.
To save the changed setting, keep pressing the "Save
condition" button for three seconds or more. If the welding
source is turned OFF when the 7-segment LED indicators go
out, the changed setting cannot be saved successfully.
Turn the welding source OFF and back ON without pressing
this button so as not to save the changed settings.
⑦ Selecting of Parameter U parameter setting is displayed at the 7-segment LED during
standby. Display of Meter ① is U parameter Item, Display of ② is U
Parameter setting value.F parameter setting is displayed when
pressing button again.
Furthermore when the button is pressed, the parameter setting display
is released.
⑧ Changing of setting Selects current increasing speed at the short-circuit, current
decreasing speed at arc.(In the case of control by panel
operation, selects welding current, welding voltage
furthermore.)
Each time the button is pressed, LED of setting item is
changed.
⑨ Auto Adjustment(synergic)/ Switches the control type of welding voltage.
Individual switch -Auto adjustment: Output voltage is set at % from the robot
controller.
-Individual: Output voltage is set by welding voltage command
from the robot controller.
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No Content Explanation
⑩ rotary volume adjusts value of welding current ,welding voltage, parameter

switch
button selects parameter .
⑪ Checking gas Checks the gas. The LED indicator lamp lights when pressing
the "Gas" button, and the gas flows for 20 seconds. (The
default setting for the gas flow time is 20 seconds. This time
can be changed by F03 parameter.) When this button is
pressed again during the gas check, the gas stops flowing.
⑫ wire inching The wire is fed while the button is being pushed during standby.
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4.2 Operation of Control Panel
4.2.1 Changing F Parameters

The F parameter is the common parameters for the welding source.For the details on the F
parameter, refer to Section 4.4 "List of F Parameters".
6 13
1
10
2
Follow the instructions to change F parameter value as follows:

(1) Press the button ⑦ "Selecting of Parameter" twice during standby status. The 7-segment
LED indicator  displays "F.01" blinking, and the 7-segment LED indicator ②
displays the parameter value lighting.
(2) Turning the rotary switch ⑩ , the display number of F parameter that wants to be set
is selected.
(3) A set value of the voltage meter ② changes into the blinking display when the
push-button of the rotary switch ⑩ is pressed.
(4) The set value is changed by turning the rotary switch ⑩ .
(5) For changing the parameter number, press the rotary switch ⑩ again.The blinking
digits move as shown below with each pressing of the rotary switch ⑩ .
(6) After changing the value, press the button ⑦ to return to the standby display.
Press the button ⑥ "Record" for three seconds or more to save the changed values
(conditions). Do not turn OFF the welding source during saving conditions. When
the LED ⑬ is turned off, the saving of conditions is completed.The setting unit of the
F parameter can be distinguished by LED.
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sec light
msec blink
A light
m/min blink
4.2.2 Selecting Feeding Motor
6 13
The feeding motor can be selected by change in the numerical value of F parameter F04.
F04: 0 Print servo
F04: 2 4-roller servo (YWE-WF340MELC)(Default setting)
Press the button ⑥ "Record" button for 3 seconds or more to save the changed value.
NOTE Do not turn OFF the breaker until the LED⑬ indicator is turned off when the “Record”
button was pressed.
CAUTION
• Welding performance will be unsatisfactory, since the wire cannot be
fed at the wire feeding speed as instructed by the command value
unless the feeding motor is set correctly.
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4.2.3 Saving Welding Conditions
6 13
When the parameter set value is changed by the operations on the welding source panel, the
LED indicator lamp ⑬ blinks.
The following describe how to save the settings.

(1) Referring to Section 4.2.6 "User Files", specify the user file
number(File0,File1,File2,File3) where the data are to be saved.
(2) Press the button ⑥ "Record" for 3 seconds or more, and the LED indicator lamp ⑬
is turned off.
(3) When the saving is completed, the 7-segment LED indicators returns to the status
where the conditions were saved.
If the power supply is turned OFF while saving the welding conditions, the data
cannot be successfully saved. Confirm that the LED indicator lamp ⑬ is turned off
before turning OFF the power supply.
CAUTION
• For U parameters, the changed data are validated at the same time the
change is made. However, when the welding type is changed or the
power supply switch of the welding source is turned OFF, the changed
data will be lost.
The changed data are overwritten on the data of the file where the data
are to be stored.
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4.2.4 Checking the Flow Amount of Shielding Gas
11
6 13
The shielding gas flow amount can be checked.

Press the button ⑪ "Gas" button. The LED indicator lamp near "GAS" button lights and the
gas flows for 20 seconds.
Press the button again during gas checking to stop the gas flow.
The checking time of the gas flow amount can be adjusted by change in the numerical value
of F parameter F03, while, the default setting is 20 seconds (unit: second).
Press the button ⑥ "Record" for 3 seconds or more to save the changed value.
NOTE Do not turn OFF the breaker until the LED⑬ indicator is turned off when the “Record”
button was pressed.
4.2.5 Wire inching(Operation On Panel)
12
1
10
The wire can be fed while pressing wireinching button ⑫ on the control panel.
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Wire feeding speed command value is given by the robot controller when wire inching on control panel.
When the rotary switch ⑩ is pressed, 7-segment LED ① is switched to the display of the wire feeding
speed.
During standby
CASE: parameter During

Setting CASE:paramete
F14= OFF welding
F14=ON
（Displays Setting
Conditions）
⑧ Select Weliding current The Displays the set Displays 0. Displays the
display. value(A) that is
fedback.
The Displays the set Displays 0. Displays the

content of wire feeding speed wire feeding
the value(m/min) speed(m/min)
display. that is fedback.
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4.2.6 User Files

.
5 13
66
The conditions changed by the U parameter concerning any welding type are saved in the
user files: File No.0, File No. 1, File No. 2, and File No. 3.
In the case of file No.0, LED indicators of file No. is turned off.
Also, the user file can be called up from the robot controller to perform welding.
(1) When the content of U parameter is to be changed, confirm that the user file can be
changed by the panel operation (Fparameter F13=OFF), then select the user file:
file No. 0, 1, 2, or 3. The file No. is changed each pressing of “User File Select”
button ⑤ , and the LED indicator lamp of selected file lights. The file No. is changed
as: File No.0File No.1File No.2File No.3.
(2) Set the gas type, the wire diameter, the parameter
(3) Press the button ⑥ "Record" for 3 seconds or more to save the changed value.
When conditions are changed, the LED indicator lamp ⑬ for "Record" blinks.
SUPPLE
-MENT
Keep pressing the button ⑥ "Record" for three seconds or more to save the changed
content. Do not turn OFF the welding source while pressing this button. The saving of
conditions is completed when the LED indicator lamp ⑬ is turned off.
CAUTION
• When the welding type which is set in the user file is changed, the U
parameters are initialized and everything becomes the initial value.
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4.2.7 Changing current increasing speed at short-circuit
6 13
14
10
8 2
The reference value of current increasing speed at short-circuit is 100%.

The following describe how to change current increasing speed at short-circuit.
(1) Press the "changing of setting" button ⑧ to light LED⑭ of current increasing speed .
Confirm that 7-segment LED ② blinks and LED of [%] lights.
(2) Change the value to turn the rotary switch ⑩ .
(3) LED ⑬ of blinks when the setting is changed.Press the button ⑥ "Record" for 3
seconds or more to save the changed value.
SUPPLE
-MENT
conditions is completed when the LED indicator lamp⑬ is turned off.
4.2.8 Changing current decreasing speed at arc
6 13
15 10
8 2
The reference value of current decreasing speed at arc is 100%.

The following describe how to change current decreasing speed at arc.
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(1) Press the "changing of setting" button ⑧ to light LED⑮ of current decreasing speed
.Confirm that 7-segment LED ② blinks and LED of [%] lights.
(2) Change the value to turn the rotary switch ⑩ .
(3) LED ⑬ of blinks when the setting is changed.Press the button ⑥ "Record" for 3
seconds or more to save the changed value.
SUPPLE
-MENT
conditions is completed when the LED indicator lamp ⑬ is turned off.
4.2.9 Changing U Parameters

The U parameters are used for welding adjustment. The U parameters are changed the
internal set data of the selected welding type. For details on the U parameter, refer to Section
4.3 "List of U Parameters".
6 13
1
10
2
Follow the instructions to change U parameter value as follows:

(1) Press the button ⑦ "Selecting of Parameter" during standby status. The 7-segment LED
indicator  displays "U.01" blinking, and the 7-segment LED indicator ② displays
the parameter value lighting.
(2) Turning the rotary switch⑩ , the display number of U parameter that wants to be set
is selected.
(3) A set value of the voltage meter ② changes into the blinking display when the push-
button of the rotary switch ⑩ is pressed.
(4) The set value is changed by turning the rotary switch ⑩ .
(5) For changing the parameter number, press the rotary switch ⑩ again.The blinking
digits move as shown below with each pressing of the rotary switch ⑩ .
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(6) After changing the value, press the button ⑦ twice to return to the standby display.
Press the button ⑥ "Record" for three seconds or more to save the changed values
(conditions). Do not turn OFF the welding source during saving conditions. When
the LED ⑬ is turned off, the saving of conditions is completed.The setting unit of the
U parameter can be distinguished by LED.
msec blink
A light
% light
V light
4.2.10 Lock Of Panel Operation

"Lock of panel operation" is a function to invalidate the button operation so as not to operate
the button of a front panel of the welding power supply by mistake. The button that can be
operated with the panel operation locked is only a gas check button and a wire inching button.
 Method of setting "lock of panel operation"

Keep Pressing the button ⑧ and the button ⑦ at the same time.
The welding power source becomes "Lock of panel operation" state when it beeps.
In the state of "lock of panel operation", only the gas check button and the wire inching button
can be operated.
"LOC "is displayed when buttons other than the gas check button and the wire inching button
are pus
hed, and the button operation is not accepted.
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 Method of releasing "lock of panel operation"

In the state of "lock of panel operation",Keep Pressing the button ⑧ and the button ⑦ at the
same time.The welding power source is released "Lock of panel operation" state when it
beeps.All the button operations of a front panel become possible.
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4.3 List of U Parameters
The welding characteristics (start/main conditions/end) that are specified by database in the
welding source can be adjusted according to your environmental conditions by changing the
set values of the process parameters (U parameters).
All the values are set to "100% = Operating as the characteristics in the database" before
shipping.
If the adjustment of welding characteristics is required, refer to Chapter 12 "Process
Parameters (Adjustment of Welding Characteristics)"
Display
Items Unit
No.*1
U01 Starting pulse peak current A
U02 Starting pulse peak time msec
U03 Starting pulse decrease time msec
U04 Reserved for system
U06 Average voltage value at burning V
U07 Burning time msec
U08 Wire stick prevent time msec
U14 Offset Voltage V
U15 Current output characteristic 1 %
U16 Current output characteristic 2 %
U17〜U28 Reserved for system
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4.4 List of F Parameters
Common parameters (F parameters) specify the operations of the welding source. Set the
parameters according to the operation conditions.
Save the changed common parameters to enable common parameters.
Display Default
Contents Unit Description
No. Setting
Gas pre-flow time Gas flowing time before welding
F01 s 0.05
output starts (minimum: 50 ms)
Gas after-flow time Gas flowing time after welding
F02 s 0.5
output completes
F03 Gas check time s 20 
Motor setting Motor selection
0: Print-type servomotor
F04 - 2
2: 4-roller servomotor (YWE-
WF340MELC) (default setting)
F05 Reserved for system 50
F07 Reserved for system 0.5
F09 Wire slowdown speed m/min 1
F10 Wire retract speed m/min 1
F11 Reserved for system 100 Do not change.
User file switching OFF/ OFF:Switched on panel
F13 OFF ON:Switched at robot side
ON
Digital Meter Display during OFF:Displays setting conditions
OFF/
F14 stanby ON ON:Displays stanby status
ON
(0.0V,0A).
Prohibit changing F parameter OFF: Permit changeing F
OFF/ parameter.
F15 OFF
ON ON: Prohibit changing F
parameter.
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Display Default
Contents Unit Description
No. Setting
Reserved for system OFF/ Do not change.
F27 OFF
ON
The parameters between F22 and F25 are different values in each wirefeeding motor by the parameter
F04 setting of motor type.
Case F04=0 Case F04=2

F22=180 F22=50
F23=40 F23=20
F24=100 F24=10
F25=6 F25=6
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5 Welding Operation
5 Welding Operation
5.1 Checking the Welding Conditions
Before starting actual welding operation, perform the test welding for welding conditions to
check if the welding performance is satisfactory. Remove oil, rust, oil paint, water, and foreign
matter generated by gas-cutting to prevent the surface pore and blowhole.
5.2 Wire Stickout
The wire length from the torch tip to the arc point is called wire stickout. Keep this length
constant during welding.
The following table shows the length ( ) of wire stickout as standard.
Wire Diameter (1.2 mm) Wire Diameter (0.9 mm)
Length ( ) of wire stickout 15 mm 10 to 15 mm
5.3 Direction of Welding and Torch Angle
There are two welding types: backhand welding (same as manual welding), in which the torch
is tilted by 0 to 10 in the direction of welding, and forward welding, in which welding is
carried out in the same state but in the opposite direction. The forward welding is more
popular in robot welding because it results in better gas shielding and the welding can be
performed viewing the welding line.
0° 10°
Torch
out
stick
Wire
Nozzle
Forward Backhand
welding welding
Gas
Base metal
Forward welding is preferred in CO2/MAG welding.

Fig. 5-1 Direction of Welding and Torch Angle
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5 Welding Operation
5.4 Precautions on Using Extension Cable
When an extension cable is used, actual output between the torch and the base metal
decreases because of voltage drop in the cable. To prevent this, set the command value of
welding voltage adjustment higher than the target voltage value to compensate for the output
voltage drop. Fig. 5-2 "Reference for Voltage Drop along Extension Cable" shows a reference
for the voltage drop along an extension cable.
Use the one-class thicker extension cable to keep stable welding voltage.
4 This graph indicates the relationship

Extension cable length
(one way)
between voltage drop and welding
25m current when an extension cable of
Voltage 20m 60 mm2 is used. If extension cables
drop (V) 2
15m
10m are used for both ways, the voltage
drop becomes twice as much as the
0 value indicated in this graph.
100 200 300 500
Welding current (A)
4 This graph indicates the relationship

Extension cable length
(one way) between voltage drop and welding
25m current when an extension cable of
Voltage 20m
drop (V) 2 80 mm2 is used. If extension cables are
15m
10m used for both ways, the voltage drop is
twice as much as the value indicated in
0
100 200 300 500
this graph.
Welding current (A)
Fig. 5-2 Reference for Voltage Drop

along Extension Cable
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6.1 Error Detection Function
Error detection is performed for the following items, and the welding source is automatically
stopped when an error is detected.
If an error occurs, the welding power source beeps and the error number is displayed in the
digital meter on the panel face. For the contents of errors, refer to the following table.
At error detection, an arc failure signal is output at the robot side.
Table 6-1 List of Error Display Contents
Error No. Item Contents Remedy
Err001 Input Primary input voltage exceeding Check the input voltage.
overvoltage the rated input voltage +15% is
applied continuously for two
seconds.
Err002 Input Primary input voltage is lower Check the input voltage.
undervoltage than the rated input voltage -15%
continuously for two seconds.
Err004- other input The input setting and the input Check the input voltage.
009 voltage error voltage are different.
Err102 Excessive The temperature in the primary • Check the ambient temperature
temperature control circuit exceeds the (40C or less) and operational
in the primary specified value of the welding ratio (60%).
circuit source. • Check if there are dust, dirt, and
clogging on the dust protective
filter. Clean or replace the dust
protective filter if necessary.
Err103 Excessive The temperature in the • Check the ambient temperature

temperature secondary control circuit exceeds (40C or less) and operational
in the the specified value of the welding ratio (60%).
secondary source. • Check if there are dust, dirt, and
circuit clogging on the dust protective
filter. Clean or replace the dust
protective filter if necessary.
Err104 Thermal The temperature is not • Contact your Yaskawa

detector error detected. representative.
Err107 Input/output Overcurrent flows in the primary • Check if the output cable is
overcurrent control circuit. short-circuited or grounded.
• The power circuit may be
broken. Contact your Yaskawa
representative.
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Err201- System error An error occurs in the data in the The data may not have been
202 welding source internal memory correctly saved when the welding
or system error conditions are recorded because
of a power failure, etc. Reset the
system after saving the changed
parameters.
If the error occurs again, the
board may be broken. Contact
your Yaskawa representative.
Err203 - CPU error A communications error between The board may be broken.
205 the CPU1 and the CPU2 occurs Contact your Yaskawa
representative.
Err501 Improper The welding wire was not fed as Check the following.
feeding instructed by the feeding amount • Check that the encoder cable is
amount command value. not damaged.
There is a certain difference • Check if the screws of the
between the feeding amount connector terminal block are
command value and the securely fastened. If the
feedback from the encoder. encoder cable is disconnected
or the screws are loosened, the
wire feeding speed becomes
excessively fast and an error
occurs in the wire feeding
amount. Replace the encoder
cable or fasten the screws of
the connector terminal block.
• Check if the wire load becomes
heavy. Make sure that the torch
cable and conduit cable are not
bent excessively.
Err502 Motor Overcurrent above the rated Check if the wire load becomes
overcurrent current flows in the motor circuit. heavy. Make sure that the torch
cable and conduit cable are not
bent excessively.
Err601 Starting Arc starting signal is input before Check again the operation timing
signal error the welding source’s main power or signal cable connections. The
supply starts up. same error may occur at
momentary power failure.
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Err701 Output Overcurrent flows in the Confirm the following.

overcurrent secondary control circuit. • Check that the torch cable or
power cable is not grounded.
• Check that the contact tip does
not contact the workpiece to be
welded. Set the contact tip so
as not to contact the workpiece,
then perform welding.
• Check that the encoder cable is
not damaged.
• Check if the screws of the
connector terminal block are
securely fastened. If the
encoder cable is disconnected
or the screws are loosened, the
wire feeding speed becomes
excessively fast and an error
occurs in the wire feeding
amount. Replace the encoder
cable or fasten the screws of
the connector terminal block.
Err702 Voltage The welding voltage is not • Check the switch of voltage
detection wire detected. detection.
error • Check if the voltage detection
wire is connected. Check if the
voltage detection line is
connected to the terminal for
voltage detection.
• Check that the contact tip does
not contact the workpiece to be
welded. Set the contact tip so
as not to contact the workpiece.
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6.2 Tripped Power Supply Switch
If the power supply switch is tripped, do not turn it ON again. Contact your Yaskawa
representative. If the power is turned ON again with the power supply switch tripped, the
problem may be compounded and may affect the welding.
6.3 Precautions on Welding Operation
Check the following precautions before starting welding.
1. The welding wire is electrically charged during welding. Be careful that the welding
voltage still remains for two seconds after the welding ends due to the two-second
delay set for the welding source.
2. If a conduit cable is extremely bent, the welding wire cannot be smoothly fed, and thus
the set welding conditions may be altered. To prevent this, place conduit as straight as
possible.
3. If welding is performed at a current exceeding the rated output current, internal parts of
the welding source may be burnt. Allowable operational ratio for a current under the
rated value is calculated as follows:
Rated current
Allowable operational ratio = Rated operational ratio  Operating current ]2%
Table 6-2 Allowable Operational Ratio of the Welding Source of 350 Ampere
(with Rated Operational Ratio of 60%)
Welding Allowable
Allowable Continuous
Current Operational Ratio Welding Pause Time
Welding Time
(A) (%)
350 60 6 minutes or less 4 minutes or more
270 100 Continuous welding possible -
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4. Power switch operation

The inverter welding source is the forced air-suction cooling type. Do not turn OFF the
power supply switch until the cooling fan completely stops after completion of the
operation. To prevent electric shock, never disconnect or connect the cables for the
welding source, the wire feeder, the welding torch, etc. while the power is ON. Make
sure that the power supply switch of the welding source is turned OFF after the
operation.
5. Cooling fan
The cooling fan starts rotating as soon as the power supply is turned ON.
6. Stretch a protective curtain around the welding operation space for workers and others
to protect from arc light, spatter, and slag.
7. Installation Environment
Do not weld on a wet earth floor or metallic floor to avoid electric shock. Also avoid
welding where there are inflammables to prevent fire due to scattering of heated
spatter or slag.
8. The welding source cannot be used for gouging other than CO2/MAG welding.
9. Radio disturbance
Noise may be generated over the radio during welding.
When listening to the radio, keep the radio as far as possible from the welding source.
When a radio is not on battery but on a 100 VAC power supply, do not bring the
welding torch close to the 100 VAC cable.
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WARNING
• Before maintenance or inspection, or wiring, be sure to turn OFF the
switch in the switchgear on the input side and put up a warning sign.
(ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in electric shock or injury.
• For internal inspection immediately after using the welding source, the
capacitor in the welding source may be charged. Wait for approx. five
minutes and remove the cover for inspection.
CAUTION
• Maintenance and inspection must be performed by specified personnel.
Failure to observe this caution may result in electric shock or injury.
Perform periodical maintenance and inspection for safe and efficient operations of the welding
source.
7.1 Daily Inspection Items
Check the following:

(1) The switches operate without fail.
(2) The cooling fan rotates smoothly by turning ON/OFF the power supply switch and
draws the air in from the rear face.
(3) There is no abnormal vibration, beat, or odor.
(4) There is no leakage of gas.
(5) The cable connecting section is not excessively heated.
(6) The welding cable and its connecting section is not excessively heated.
(7) There is no damage on the connection cable such as a cable on the input side or on
the base metal side, resulting in imperfect insulation.
(8) Each connecting section is tightened securely.
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7.2 Bimonthly to Semiannual Inspection Items
Perform the following:

(1) Cleaning of dust protective filter
Remove the dust protective filter on the side face of the welding source, then
remove the dust and dirt on the air filter.
(2) Removal of dust and dirt

Remove dust and dirt by spraying dry compressed air. Carefully clean spaces
between the transformer and reactor windings, and semiconductors.
To clean circuit boards, use the exclusive-use dust remover device.
(3) Inspection of electric connecting sections

Check that the bolts are firmly tightened and rust or the like does not deteriorate the
contacts in the connecting sections with the external wiring such as input/output
terminals or with the internal wiring. Retighten the bolts if necessary or use a file to
remove rust, if any, so that the metallic faces contact with each other.
(4) Inspection of ground line

Confirm that the case is grounded properly.
7.3 Annual Overhaul and Repair
Carry out the integrated repair such as replacement of defective components, case repair, and
reinforcement of insulation deteriorated parts. Insulation resistance must be 1 M or more
between the control unit circuit and the case; if it is less than 1 M, the insulation of the
deteriorated part must be repaired.
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7.4 Guideline for Service Lifetime and Replacement of

Components Used
The welding source is composed of many components. Unless all these components operate
normally, the welding source cannot utilize its essential functions. Therefore, it is absolutely
necessary to find any sign leading to a failure of a component or device as early as possible
according to the periodical inspection and take proper corrective action.
These components cannot be used continuously for ever. Even under normal operation
status, they are apt to have variation of the characteristics or malfunction after the life elapses.
Therefore, it is recommended that the components be replaced periodically so that the welder
can operate at optimum performance.
Normally, refer to the following guideline of the component replacement when the welding
source is used in the rated specifications (8 hours a day, 250 days a year).
• Electrolytic capacitor: Approx. 5 years

• Cooling fan: Approx. 5 years
• Breakers, relays: Depends on how often they are used. It is recommended that they be
replaced approx. every 5 years.
7.5 Cleaning of Dust Protective Filter
Dust protective filter prevents spatters, etc from entering into the welding source and reduces
damage on components due to dust and dirt. The air suction power into the welding source,
however, gets weakened as the welding source operates and the filter gets contaminated. As
a result of this, the temperature in the welding source may increase and the component life
may be shortened.
It is recommended to clean the filter once every two months periodically in order to maximize
the product life.
The dust protective filter is installed in the side face of the welding source as illustrated in Fig.
7-1 "Cleaning of Filter". Clean the filter by following procedures below.
(1) Loosen and remove the bolts (4 places).

(2) Remove the filter cover.
(3) Clean the filter.
Tap at the filter with a rod, etc. to remove dust and dirt.
(4) Install the filter cover on the side face of the welding source.
(5) Fasten the bolts (4 places).
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Filter
Hand screw
Filter
Fig. 7-1 Cleaning of Filter
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7.6 Recover Fuse
If any fault shown below occurs,Check fuse.If Fuse blown again after recover fuse,Contact
your Yaskawa representative.
Table 7-1 Fuse
Item Fault
Fuse 10A blown • Although the start signal is ON or the wire inching signal is
ON,Motor does not operate.
Fuse 2.5A blown • Although power switch is ON or gas check button is

pressed, the gas doesn’t flow.
When the fuse operates, the fuse knob

extends out. To reset the fuse, push
the fuse knob in.
Fuse (2.5A)
Fuse (10A)
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8 Failure Analyses
8 Failure Analyses
WARNING
• Before maintenance, inspection, or wiring, be sure to turn OFF the
switch in the primary side switch gear and put up a warning sign. (ex.
DO NOT TURN THE POWER ON.)
CAUTION
• To connect a nylon connector, insert the connector after matching the
connector number and confirm that it is locked. Do not apply excessive
force to the printed board when inserting the connector. Never change
the positions of the internal wiring or modify the connections.
Failure to observe this caution may result in device problems.
Confirm that the junctions between the metal receptacle and the cable, and the connectors on
the printed boards are connected securely. Then, take corrective action by referring to Table 7
"Check Items", Table 8 "Failure Analyses for Welding Section". If the equipment does not
function properly even after the corrective action, contact your Yaskawa representative to
investigate the cause and to repair as soon as possible.
8.1 Confirming Setting conditions
If any fault occurs, check the following items in Table 7 "Check Items". Afterwards, take
proper corrective actions in Table 8 "Failure Analyses for Welding Section"."
Table 8-1 Check Items
Item Contents
Welding type Check if the welding type suitable for material and the wire diameter or shielding
gas has been selected.
Parameter Check that changing of parameters does not lead to the error in welding operation.
After recording the changed parameters, return the data to the initial values and
check how welding is performed.
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8 Failure Analyses
Table 8-1 Check Items
Item Contents
Synergic/ Check if synergic/independent (auto adjustment/individual) selection of the welding

Independent source is the same as that on the robot side. Synergic/Independent of the welding
selection source can be set by the panel button ⑨ "Auto Adjustment/Individual" on the
welding source panel. If the setting is different from that on the robot side, incorrect
welding voltage value is displayed on the panel. Furthermore, if the welding source
condition files of the robot are not correctly set, the robot command values are not
correctly displayed on the welding source panel.
Motor Confirm the set value of F parameter F04 to check if the motor is correctly selected.
selection (0: Print servo, 2: 4-roller servo (YWE-WF340MELC))
If the motor is not correctly selected, the wire is not fed as instructed by the
command value and welding performance becomes unsatisfactory.
User files F parameter F13 is used to specify whether the user file is selected from the panel
cannot be or the robot. (F13 OFF: from panel, ON: from robot)
selected.
Record of After selecting the welding type or changing the parameter, save conditions before
conditions turning OFF the welder power supply. Before recording conditions, be sure not to
select other welding type while the user file is being adjusted because the changed
data on U parameters are deleted.
Encoder When the encoder cable is disconnected, or when the phases A and B are
cable connected inversely, the wire feeding becomes excessively fast or the motor runs
inversely. In addition, the 7-segment LED indicator for wire feeding speed displays
0 and the error Err501 "Improper feeding amount" is issued. Check the connection
of encoder cable.
Shielding gas Check if the shielding gas suitable for the welding type is selected.
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8 Failure Analyses
8.2 Cause and Remedy of Welding Section Failure

Table 8-2 Failure Analyses for Welding Section
Fault Cause Remedy
Blowholes Excessive oil, rust, or paint Carefully remove the adherent substances to
and pits adheres to the base metal. clean the base metal.
occur.
Oil adheres to the welding wire. Carefully store and handle the welding wire.
Or rust occurs. Remove the oil or rust from the feeding roller or
conduit.
Sufficient shielding gas does Check for gas leakage. Also check that the gas
not flow. regulator has been correctly adjusted and the gas
cylinder is not empty.
Gas shielding in the welding When the wind blows hard, stop the operation or
section does not properly work use a screen, etc. to help block the wind.
due to wind, etc.
Spatters adhere to the nozzle Often remove the spatters from the nozzle and
and the gas does not flow out apply spatter preventive agent to the interior of the
smoothly. nozzle.
The quality of the shielding gas Replace the shielding gas with one of better
is poor. quality.
The nozzle is too far from the Keep the proper length of the wire stickout (10 mm
arc point. to 25 mm) to perform welding. Increase the gas
flow amount.
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8 Failure Analyses
Fault Cause Remedy
Arc is Power supply voltage Use a different power supply from that of other
unstable. excessively fluctuates. machines that cause power supply voltage
fluctuation. Or increase the power supply
transformer capacity.
Chip hole diameter becomes Replace the chip. (Use a genuine chip.)
larger and worn.
Welding wire is not fed Remove the dust or iron powder choking up the
smoothly. feeding roller section or conduit.
Check that the conduit is not excessively bent and
that the liner, contact tip, and feeding roller match
the wire diameter.
Voltage between phases of the Use a different power supply from that of other
3-phase power supply is not machines that cause the imbalance. Or increase
balanced. the power supply transformer capacity.
The welding conditions are not Use the test arc to increase or decrease the
correct. settings of the welding current value and voltage
value.
Unstable arc tends to occur Use gas mixed with carbon dioxide gas and argon
when thin-plate or small-current gas to improve the arc behavior.
welding is performed only with
carbon dioxide gas.
The connecting section is Check each terminal connection and the

loose. connections with the base metal. Securely re-
tighten if necessary.
Voltage drop is excessive with Shorten the extension cable’s length.

the extension cable. Use a thicker cable. Use the extension cable
without bending it.
The polarities of the secondary Correct the connection of + and -.

terminal are inverted.
Jig current conduction is poor. Correct the contact between the jig and the base
metal.
Excessive The welding conditions are not Increase or decrease the settings of the welding
spatters correct. voltage and current values to adjust the welding
conditions.
Welding wire is not suitable for Check if a welding wire suitable for the welding
the shielding gas. type is used.
The status of the base metal is Check the groove forms or dirt of the base metal.
poor. Replace them with one of higher accuracy.
The welding section is Check each terminal connection and the

distorted. connections with base metal. Polish the
contacting face and tighten them securely.
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8 Failure Analyses
Fault Cause Remedy
Bead form Manipulation of electrode is not Change the welding torch angle a little. Employ
is bad and correct. the forward welding method and practice so that
the welding torch can constantly aim at a target. Or
appearance change the welding speed.
is poor.
The shielding gas has a Since the gas flow amount is not sufficient, let the
problem. gas flow 10 to 25 litters per minute, and mix argon
gas if necessary. Or use a gas of better quality.
The welding conditions are not Increase or decrease the settings of the welding
correct. voltage or current value a little.
Arc-start is Welding current conduction is Check the connections and the current conduction
poor. not perfect. contacting section of the base metal to confirm the
current conduction.
The connection cable is too Replace the cables at the 3-phase input side and
thin. base metal side with those of sufficient thickness.
The welding conditions are not Check that the welding voltage set value is not too
correct. small or that the wire feeding speed set value is
not too large.
The status of the base metal is Check that dirt or insulating material does not
poor. adhere to the base metal or slugs do not remain
on it.
The welding torch operations The wire stickout of the welding wire is too long.
are not correct. Shorten it a little. Change the welding torch angle.
Or slow down the welding speed.
The power cable is wired with Wire the power cable as straight as possible.
the cable being winded.
Burnback The welding torch operations The wire stickout of the welding wire is too short.
occurs. are not correct. Extend it a little. Change the welding torch angle.
(The
welding The welding conditions are not Check that the welding voltage set value is not too
wire sticks correct. large or that the wire feeding set value is not too
to the end small.
of the
contact tip.) Contact tips are defective. Check that the contact tip hole is worn and its inner
diameter has become too big. Also check for
defect on the tip inner side.
Welding current conduction is Check the connections and the current conduction
not perfect. contacting section of the base metal to confirm the
current conduction.
The welding wire almost Pull the welding wire from the inside of the conduit
buckles. and pass the welding wire again through the
conduit.
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9.1 Specifications of Robot Interface Signals
The following table shows the correspondence of the pin number and the signal of connector
CON3 (26 pins).
For signal systems, refer to Chapter 10 "Connection System Diagram"
Pin No.
Correspon Signal Direct Signal
No. Function *1
ding to Meaning ion Form
Connector
A-B Arc voltage Gives the compensation value of the arc R Analog
(0V side) adjustment voltage when set to "Synergic." W voltage
1
instruction (When set to "independent," the arc input of
voltage is sent directly.) 0V to 14V
C-D Welding Gives the set value of the output current R Analog
(0V side) current (wire feeding amount) for the welding W voltage
2
instruction source. input of
0V to 14V
F-G Wire inching Performs the wire inching. R Contact

instruction W input
3
(Valid at
closed)
H-J Wire retract Withdraws the wire. R Contact

instruction W input
4
(Valid at
closed)
K-L ARCON/ Instructions to start/stop the welding. R Contact

ARCOF W input
5
instruction (Valid at
closed)
M-N Wire stick Sends the output terminal voltage of the W Welding
("-" side) detection welding source. R source
The wire stick detection voltage output
6
(approx.15V) is input from the robot side. voltage
(Analog
value)
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Pin No.
No. Function
ding to Meaning ion*1 Form
Connector
P-E Arc 1. The signal is output when the current W Contact

(COM) occurrence is detected continuously for 16 ms R output
detection after the gas pre-flow upon receiving (Valid at
the arc start signal. closed)
2. If the current is not detected for 48 ms
or more continuously after the signal is
7
output, the signal stops being output.
3. (1) and (2) are repeated.
The signal stops being output at the same

time as the wire stick prevention voltage
ends.
R-E Arc failure 1. The signal is output when the arc start W Contact
(COM) detection is not detected for 1.5 seconds after R output
the gas pre-flow upon receiving the (Valid at
arc start signal. closed)
2. After the arc occurrence is detected
within 1.5 seconds, the signal is output
when the arc occurrence is not
8 detected for 0.6 seconds or more
continuously.
3. After the arc failure is detected, the
states described in (1) and (2) are self-
maintained until the start command of
welding source is released.
4. The signal is output also when an
error occurs in the welder.
S-E Reserved W Contact

(COM) R output
9
(Valid at
closed)
T-E Reserved W Contact

(COM) R output
10
(Valid at
closed)
E (536) Common Common for detection line W Return

R line of
11
contact
output
W-X Monitoring Sends the monitoring signal of the output W Analog

output for current. R voltage
output 3.0V/600A
12 current Note: When using the arc monitoring
function, refer to Chapter 14
"Setting of Arc Monitoring
Function".
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Pin No.
No. Function
ding to Meaning ion*1 Form
Connector
U-V Monitoring Sends the monitoring signal of the output W Analog

output for voltage. R voltage
output 3V/60V(66V for 66V or more)
13
voltage Note: When using the arc monitoring
function, refer to Chapter 14
"Setting of Arc Monitoring Function"
b-Z User file Externally switches the user file selection R +24V
14 selection by connecting each signal to common (Z). W 10%,
OP1 Note: Connected to the pin terminals: current
"OP1" and "OP2" of the standard capacity
Y-Z User file welding instruction cable. of 50mA
15 selection To externally switch the user file, set or more
OP2 F parameter F13 to "ON".
a-Z Gas check Turns ON/OFF the gas solenoid valve by R +24V
GAS connecting to common (Z). W 10%,
Note: Connected to "GAS" pin terminal of current
16
the standard welding instruction capacity
cable. of 50 mA
or more
Z (531) Common Common of OP1, OP2, and GAS signals R Return

COM Note: Connected to "COM" pin terminal of W line of
17
the standard welding instruction contact
cable. input
*1 "R" indicates the robot side while "W" indicates the welding source side.
The voltage for wire stick detection which is output from the robot side does not appear on the
welding source panel.
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9.2 Terminal
The following describe the cable number of the connection terminal block and corresponding
signals.
Signal Directi
No. Function
Meaning on*1
1
Ammeter Outputs 400A,
WR
terminal 60mV.
2
3 Directly outputs
Voltmeter
the output WR
terminal
4 voltage.
5
Wire
wire is fed. R W
inching
6
detects the
Voltage
7 voltage of the Input
sensing
workpiece.
*1 "R" indicates the robot side while "W" indicates

the welding source side.
The external meters connected to the terminal are analog meters of ammeter
NOTE (400A / 60 mV) and voltmeter (75V). Values of the ten's volts for wire stick or ground
detection at the robot controller side may be displayed in the analog voltmeter, which is
not a failure of the device.
9-4
HW0485574 73/101
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167300-1CD
HW0485574
75/101
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MOTOWELD-SR350 has a Diagnosis mode to confirm the software version, the number of
occurrence of welding source error.
11.1 Starting up Welding Source in Diagnosis Mode
To start up the welding source in the Diagnosis mode, Keep Pressing the button ① and the
rotary switch ② at the same time when the power is ON.
The diagnosis information is displayed in the 7-segment LED indicators on the welding source
front panel once the Diagnosis mode is launched.The information of the software version is
displayed when the Diagnosis mode is launched.
Diagnostic mode
Software version
error display
Press 3
1
Setting clear mode
2
3 Press 3
Normal mode
Fig. 11-1 Panel at Launch of MOTOEWELD-SR350 Diagnosis Mode
The information which is displayed in the 7-segment LED indicator can be changed with using
the rotary switch ② on the MOTOWELD-SR350 front panel.
To return the normal mode, Press the button ③ (Mode of Initialize parameter) , and press the
button ③ once more.
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11.2 Display of Software Version and Error Information
11.2.1 Confirmation of Software Version

By referring to the information: "S-1", "S-2", and "S-3" which is displayed in the Diagnosis
mode, the software version which is loaded in the welding source can be confirmed.
• S-1: Main CPU 1 Software Version

• S-2: Main CPU 1 Software Version
• S-3: Sub CPU 2 Software Version
The software version is displayed as shown below.
Turn the rotary switch.
Selected
number
Software
version
Fig. 11-2 Display of Software Version
11.2.2 Confirmation of the Number of Welding Source Errors

By referring to the information: "Err.001" to "Err.702" which is displayed in the Diagnosis
mode, the number of errors which occurred in the welding source can be confirmed.
NOTE The number of welding source errors is automatically saved.
The number of welding source errors which has been recorded is displayed in the Diagnosis
mode as shown below.
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Turn the rotary switch.
Displayed
alternatively
Fig. 11-3 Display of the Number of Welding Source Errors

Turn the rotary switch to display the number of each error.
The 7-segment LED indicator shows the number of welding source errors. The number of
welding source errors is counted from when the welding source is delivered to when the
welding source is started up in the Diagnosis mode. Once an error has occurred, the 7-
segment LED indicator displays "1" for the error. From then onward, every time the error
occurs, one is added to the number of errors.
In case of the figure Fig. 11-3 "Display of the Number of Welding Source Errors", the 7-
segment LED indicator shows that the error Err001 (Input overcurrent) has occurred once.
For details on errors, see Table 6-1 "List of Error Display Contents".
11.3 Mode of clear the setting conditions
11.3.1 Initialize the parameters

Follow the instruction to initialize the parameter.
(1) In the Diagnosis mode, press the button ① to set the welding source ready for
initializing parameter ("SEt rSt " is displayed).
(2) Keep pressing "RECORD" button ② with "SEt rSt " displayed for 3 seconds or more
to initialize the parameter. To cancel the operation for initializing the parameter,
press the button ① again.
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11.3.2 Clear of Error Record

To delete the number of welding source errors, perform the clear operation of the error record.
The following explain how to clear the error record.
Rotate the
3 rotary switch
one turn.
2
1
Fig. 11-4 Error Record Clear Mode
(1) In the Diagnosis mode, press the button ① and turn the rotary switch ② to set the
welding source ready for clearing of error record ("Err CLr " is displayed).
(2) Keep pressing "RECORD" button ④ with "Err CLr " displayed for 3 seconds or more
to clear the error record. To cancel the operation for clearing the error record, press
the button ① again.When the Clear of error is completed, the diagnosis mode is
finished.
11.3.3 Reset All Setting

Follow the instruction to Initialize the parameter and clear the number of error at the same
time.
Rotate the
3 rotary switch
two turns.
2
1
(1) In the Diagnosis mode, press the button ① and turn the rotary switch ② to set the
welding source ready for resetting all setting ("ALL rSt " is displayed).
(2) Keep pressing "RECORD" button ④ with "ALL rSt " displayed for 3 seconds or more
to reset all setting. To cancel the operation for resetting all setting, press the button
① again.When the reset of all setting is completed, the diagnosis mode is finished.
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In the diagnosis mode, welding operation cannot be performed.After the diagnosis

NOTE mode,Set the normal mode.
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12 Process Parameters (Adjustment of Welding Characteristics)
12 Process Parameters
(Adjustment of Welding Characteristics)
Welding characteristics of the welding source: MOTOWELD-SR350 are specified by database

in the welding source. The values of welding characteristics, however, can be changed with
using process parameters (U parameters).
The characteristics values specified by database can be usually used without change. If the
database values need to be changed in accordance with ambient environment and your
convenience, change the characteristics values referring to the following description.
All the values are set to "100 (%) = Operating as specified by the characteristics in the
database" before shipping.
12.1 Adjustable Welding Characteristics
The welding characteristics that can be adjusted by U parameters are as follows:
• Arc start characteristics: Characteristics from when ARCON signal is

output until the main welding condition becomes
stable
• Arc end characteristics: Characteristics from when ARCOF signal is
output until arc disappears
• Short-circuit welding Characteristics while the main welding is
characteristics: performed at short-circuit welding (short arc)
• Other characteristics: Characteristics of current output
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12.2 Adjustment of Arc Start Characteristics
12.2.1 Adjustment of Start Pulse

The following parameters change the characteristics related to the first arc start at ARCON
signal.
Parameter
Meaning Guideline of Adjustment
No.
Wire speed until the wire contacts -When scrap of the wire tip end remains;
the base metal Decrease the value.
F09
-When arc does not start;
Increase the value.
Peak value of pulsed current that -For arc burning at arc start;
U01
flows for arc start Decrease the value.
-For excessive repelling at arc start;
Peak time of pulsed current that Increase the value.
U02
flows for arc start
Peak decreasing time of pulsed

U03
current that flows for arc start
F09
U03
U01
U02
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12.3 Adjustment of Arc End Characteristics
The following parameters change the characteristics from when ARCOF signal is input until
arc disappears.
Parameter
Meaning Guideline of Adjustment
No.
U06 Average voltage to adjust the burning after welding -When wire sticks to the
base metal;
Arc time to adjust the burning after welding Increase the value.
-When wire sticks to the
U07 contact tip;
Decrease the value.
Time to prevent the wire from sticking to the base metal -When wire sticks to the
after welding base metal;
Increase the value.
U08 -When arc comes out to
the part other than the
welded spot at air-cut;
Decrease the value.
U08
U06 U07
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12.4 Adjustment of Short-circuit Welding

Characteristics
The following parameters change the short-circuit welding characteristics under the main
welding characteristics.
Parameter Meaning Guideline of Adjustment

Current increasing speed at short-circuit -For unstable arc; Increase the value.
-For excessive spatters; Decrease the value.
Current decreasing speed at arc To make beads flat: Decrease the value
To reduce the input heat: Increase the value
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12.5 Adjustment of Current Output Characteristics
Parameter Meaning Guideline of Adjustment

No.
Welding current output characteristic 1 - When real welding current value is
(150A) higher than the welding current
Changes the wire feeding amount so command: Decrease the value.
U15
that the real welding current value - When real welding current value is lower
corresponds to the welding current than the welding current command:
command. Increase the value.
Welding current output characteristic 2 - When real welding current value is
(250A) higher than the welding current
Changes the wire feeding amount so command: Decrease the value.
U16
that the real welding current value - When real welding current value is lower
corresponds to the welding current than the welding current command:
command. Increase the value.
The welding current output can be adjusted by setting parameters U15 and U16. The change
in the welding current output includes checking the welding current command against the
welding current that is fed back.
p Co pe sa o by
the parameter U15 calibration points 1 and 2 the parameter U16 Wire feeding amoutn
after the compensation
U16
speed command
Wire feeding
Wire feeding amount

before the compensation
U15
Calibration current 1 Calibration current 2 Welding current command

150 A 250 A (Panel display current)
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13 Welding Source Condition File of the Robot Controller
13 Welding Source Condition File of the

Robot Controller
Welding condition files for the MOTOWELD-SR350 are as follows.

The settings for MOTOWELD-SR350 are common with the MOTOWELD-EL350 .
Common for All Welding Types: "Synergic (automatic adjustment)" (A/%)

Wire-stick prevention processing time: 0.1 seconds
Arc failure confirming time: 0.6 seconds
Command Voltage (V) Welding Current (A) Command Voltage (V) Welding Voltage (%)
0.00 30 0.00 50
1.35 62 7.20 99
2.70 94 7.50 100
10.80 286 7.80 101
12.15 318 14.00 150
13.50 350 0.00 0
0.00 0 0.00 0
0.00 0 0.00 0
Common for All Welding Type: "Independent (individual)" (A/V)

Wire-stick prevention processing time: 0.1 seconds*1
Arc failure confirming time: 0.6 seconds
Command Voltage (V) Welding Current (A) Command Voltage (V) Welding Voltage (V)
0.00 30 0.00 12.0
1.35 62 2.25 16.0
2.70 94 4.50 20.0
10.80 286 6.75 24.0
12.15 318 9.00 28.0
13.50 350 11.25 32.0
0.00 0 13.50 36.0
0.00 0 0.00 0.0
Since the MOTOWELD-SR350 uses a print-type servomotor for its standard model, the
SUPPLE motor stops within 0.1 seconds. To reduce the manipulator’s cycle time, Yaskawa
-MENT
recommends that the wire-stick monitoring time on the robot side be set short.
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For using the arc monitoring function on the robot side, the setting of parameters for the robot
controller as shown below is required.
NOTE Parameters to be set are different according to the type of robot controller.
For the Robot Controller: NX
Parameter No. Item Set Value Remarks
S2C355 Arc monitoring function: Magnification of current 200 For welder 1

conversion
S2C356 Arc monitoring function: Current offset 0 For welder 1
S2C357 Arc monitoring function: Magnification of voltage 200 For welder 1

conversion
S2C358 Arc monitoring function: Voltage offset 0 For welder 1

conversion

conversion

conversion

conversion

conversion

conversion
For details on the arc monitoring function, see "NX100 OPTIONS INSTRUCTIONS FOR
SUPPLE
-MENT ARC MONITORING FUNCTION".
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For the Robot Controller: XRC
Parameter No. Item Set Value Remarks

conversion

conversion

conversion

conversion

conversion

conversion
SUPPLE
For details on the arc monitoring function, see "YASNAC XRC INSTRUCTIONS FOR ARC
-MENT MONITORING FUNCTION".
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The external remote operations are available for MOTOWELD-SR350 as follows:

1. Gas check
2. Switch of user files
For external remote operations, connect contacts (dry contacts) to the pin terminals which
emerge from adjacent to the connector on the robot controller side of welding command
cable.
Pin terminal for gas check (GAS)

Pin terminals for user files switching (OP1, OP2)
Pin terminal COM
Welding command cable
15.1 Gas Check
Connect contacts to the pin terminals "GAS" and "COM", which emerge from adjacent to the
connector of the welding command cable.
• Contact ON (closed): The shielding gas flows with the gas magnet valve ON.
• Contact OFF (open): The shielding gas stops with the gas magnet valve OFF.
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15.2 Switch of User Files
Perform the settings as follows to select a user file by external command.

1. Set the F parameter F13 to "ON". Then save conditions by referring to Section 4.2.3
"Saving Welding Conditions".
2. Connect the contacts to the pin terminals "OP1", "OP2", and "COM", which emerge
from adjacent to the connector of the welding command cable.
The user files can be selected by combinations of contacts ON/OFF as follows:
Selection of User File Contact OP1 Contact OP2
No user files OFF OFF
User file No.1 ON OFF
User file No.2 OFF ON
User file No.3 ON ON
The user files cannot be selected externally when the F parameter F13 is set to "OFF".
NOTE Additionally, the switch of user files is only enabled either by the external command or the
welding source panel.
With the F parameter F13, change the user file selection method: by the external
command or by the welding source panel.
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16 Dimensions
16 Dimensions
270 450
250
630
8-M8
(including the
opposite side)
2-M10
Rating label
35
20
45 325
FRONT FACE SIDE FACE REAR FACE
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 Front Face
6
3
2
7 8 9
4
MOTOWELD
SR350
10
List of YWE-SR350-CE0 Service Parts (Front Face)
Q’ty per
No. Parts Code No. Parts Name Welding
Source
1 J5B470401 Front panel installation metal fittings 1 pair

2 U1A111700 Control Panel ASSY
E0C346000 Control Panel Cover 1
N1B185200 Control Panel Sheet 1
3 JDA891201 Control panel cover metal fittings 1
4 JFA947401 Control panel metal fittings 1
5 JCA476901 Output Terminal Cover 1
6 J4B752400 Cover(top) 1
7 50990000300 Encoder cap 1
8 50990001600 Encoder switch 1
9 P0A552801 WK-5528 U01 Encoder PCB 1
10 U1A111800 Front Panel Cover Assy
J5B470303 Front Panel Cover 1
N5A440400 N5A440400 Pet Name Label 1
Software ver. Label 1
N5A456800 Error Code Label 1
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 Front Face
23
13
12
54
17 11
15 56
19
21
20 18
57
55 22
16
14
24
Q’ty per
Source
11 25315002400 Input Breaker 1
12 35015025500 Power Supply For Gas Valve 1
13 35021007300 Power Supply For Interface 1
14 EFA032200 Output Terminal 2
15 450A30160 DFA100BA160 R Diode 1
16 50801118814 Pin For Output Terminal Cover 2
17 P0A617000 Print board(power serje absorption) 1
18 P0A611600 CPU Print board 1
19 P0A611700 Sub CPU Print board 1
20 P0A481912 Input voltage detection PCB 1
21 P0A554808 Control power supply PCB 1
22 P0A559705 1
23 P0A552729 Print board (LED Display) 1
24 U1A111900 Output terminal fixation ASSY
EFA032600 Output terminal fixation board 1
Output Terminal Label 1
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Q’ty per
Source
54 47953014500 Reactor (L8) 1

55 63200006500 Reactor (L6) 1
56 63200009600 Reactor (L7) 1
57 47953014500 Reactor (L5) 1
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 Rear Face
29 35 30
27
31
36
32 28
33
34
25
26
List of YWE-SR350-CE0 Service Parts (Rear Face)
Q’ty per
Source
25 J5B470501 Rear Cover Plate 1

26 JFA244401 Rear Cover 1
27 EFA286400 Clear Cover For Monitoring terminal 1
28 53613001500 Input cable clamping 1
29 JHA268000 Input cable fixation board 1
30 24704531400 Slide Switch 2
31 25720001000 Fuse For Gas Valve 1
32 25720001100 Fuse For Wirefeeder Motor 1
33 26343147900 4-pin receptacle (Encoder) 1
34 26351003300 6-pin receptacle(Motor) 1
35 26351003400 26-pin receptacle(Robot I/F) 1
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Q’ty per
Source
36 26031248700 8-pin terminal(For monitoring) 1
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 Rear Face
58
59
41 38
40
39
Q’ty per
Source
38 P0A597500 Print board(Interface) 1

39 P0A616000 Print board(Motor Control) 1
40 P0A616100 Print board(Detect Voltage) 1
41 P0A597600 Print board(Motor Control CPU) 1
58 63200009600 Reactor (L2) 3
59 63200012800 Reactor (L4) 1
17-6
HW0485574 97/101
167300-1CD
 Side Face
47
45
44
60
43
46
List of YWE-SR350-CE0 Service Parts (Side Face)
Q’ty per
Source
43 J5B638501 Side Cover 2

44 J5B642600 Filter 2
45 89000334100 Filter installation screw 4
46 50602003400 Caster 2
47 E0C299200 Cover For Control Panel 1
60 U1A112300 Input cable Assy 1
17-7
HW0485574 98/101
167300-1CD
 Side Face
50
61 49
51
52
48
53
Q’ty per
Source
48 U1A112100 IGBT Assy

43490003400 IGBT TO-3P 12
EDA227700 Insulation rubber seat 2
E1B850100 Metal fittings for fixation of IGBT 4
P0A585802 Print board(Gate) 2
EEA247400 Protection bag 1
E2B173300 Packing box 1
54999546100 Static electricity prevention bag 1
49 U1A112200 Cooling FAN Assy
33311130300 Cooling FAN 1
333111140 Finger Guard 1
53001026301 M4 x 65 screw 2
26303420500 Housing 02P-MWPV-SSR 1
26303420200 Pin contacting BSM-21T-P1.4 2
50 F3A279501 Transformer For Wirefeeder 1
51 P0A613100 Print board(Diode) 1
52 4583A0060 Diode 6
17-8
HW0485574 99/101
167300-1CD
Q’ty per
Source
53 11401113300 Shunt 400A 60mV 1

61 63200009500 Reactor (L3) 1
17-9
HW0485574 100/101
MOTOWELD-SR350
INSTRUCTIONS
TYPE: YWE-SR350-CE0
Specifications are subject to change without notice

for ongoing product modifications and improvements.
MANUAL NO.
HW0485574 0 101/101

Motoweld SR350 Manual

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Motoweld SR350 Manual

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YASKAWA

Part Number: 167300-1CD

• The drawings and photos in this manual are representative examples

• If your copy of the manual is damaged or lost, contact a YASKAWA

• YASKAWA is not responsible for incidents arising from unauthorized

Notes for Safe Operation

Indicates a potentially hazardous situation which, if not

Indicates a potentially hazardous situation which, if not

Always be sure to follow explicitly the items listed under this

PROHIBITED Must never be performed.

• Be sure to observe the precautions in this instruction manual although

• Do not let personnel to approach the welder or welding sites

• Clean the cooling-water path once a month when using a water-cooled

• In order to secure safe operations, only a trained or qualified person

• In order to secure safe operations, only a person that has understood

• Never touch the charged parts.

• Only a qualified person in electric construction should perform

• Be sure to perform installation or maintenance and inspection five

• Do not use any cable of insufficient capacity or damaged or with its

• Tighten the cable connecting sections firmly and insulate them.

• Do not use the welder with its case or cover removed.

• Use lifelines when working at hights.

• Perform maintenance and inspection periodically. Repair damaged

• When performing AC arc welding in a small space or at hights, be sure

• In order to prevent gas poisoning or suffocation, be

• In order to prevent dust trouble or gas poisoning due to the fumes or

Fumes or gases generated at welding may harm your health.

• When welding within such areas as a tank, a boiler, or a ship’s hold, be

• When welding in a small space, be sure to ventilate the site sufficiently

• Do not perform welding near degreasing, cleaning, or spraying

Failure to observe this warning may generate extremely noxious gases.

• Before welding coated steel plates, be sure to ventilate sufficiently or

Welding such coated steel plates generates noxious fumes or gases.

• Remove inflammables so that they will not get spattered.

• Do not weld near flammable gases.

• Do not make hot base metals immediately after welding close to

• Remove inflammables at the hidden side when welding ceiling, floor, or

Failure to observe this caution may result in fire.

• Tighten and insulate the cable connections.

Welding an enclosed tank or pipe may result in rupture.

• Locate fire extinguishers near the welding site.

• Wear welding mask or shaded glasses appropriate for

• Wear protective glasses to protect your eyes from

Scattered spatters or slags may damage eyes or burn the skin.

Arc beams may irritate eyes or burn skins.

• Use noise protector when there is excessive noise.

Noise may damage hearing.

• Observe the regulations and your own references for

• Use the attached gas regulator or our recommended one.

• Hold the gas cylinder in the exclusive-use gas cylinder stand.

A gas cylinder falling may result in personal injury.

• Do not expose the gas cylinder to high temperature.

• Do not use the welder with the case or cover removed.

• Only a qualified person or a person who has understood the

• When hanging the wire feeder, remove the anti-fall fastening

Failure to observe this caution may cause the wire to

• Do not grasp near the base metal during cutting operation.

• Perform all welding and grinding away from welder to

• Be sure to perform maintenance and inspection periodically to prevent

• If spatter or metal powder enters the inside of the welder, remove it by

2 Installation and Connection

4.2.10 Lock Of Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

7 Maintenance and Inspection