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DX200 Servo Torch

INSTRUCTIONS

TYPE

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

MOTOMAN INSTRUCTIONS

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

HW1483707
HW14837072.1 Outfit

1 Equipment configuration .................................................................................................. 11


2 Set up ............................................................................................................................... 12
2.1 Outfit ......................................................................................................................... 12
2.2 ControllerDX200(hardware) ...................................................................................... 13
2.3 Welding Power Source RL350(Hardware)................................................................. 16
2.4 ControllerDX200(Software) ....................................................................................... 17
2.5 Welding Power Source RL350 (Software) .................................................................. 20
2.6 Servo Pack (Software) .............................................................................................. 21
3 Periodic inspection and maintenance ................................................................................ 22
3.1 Daily Inspection and Maintenance .............................................................................. 22

..................................................................................................................................... 22
3.2 List of Inspection and Maintenance Items ................................................................... 23
3.3 The procedure for replacing the feed roller ................................................................. 24
3.4 The procedure for replacing of the torch cable of the inner tube . ............................... 26
3.5 Replacement procedure of the torch body .................................................................. 27
3.6 Replacement procedure of the torch cable ................................................................. 28
3.7 The procedure for replacing the grease ...................................................................... 30
4 Spare parts and consumables........................................................................................... 31
5 Troubleshooting ................................................................................................................ 35
5.1 Serbo pack Alarm ....................................................................................................... 35
5.2 Trouble and countermeasures .................................................................................... 40
6 Servo pack Parameters Setting......................................................................................... 41
6.1 Servo pack Parameters Setting .................................................................................. 41

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1 Equipment configuration

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2 Set up

2.1 Outfit

(1) Wire Feeder (format: YWE-WFR42DX2) will be mounted on the manipulator, but
does not use. To release the pressure handle of the Wire Feeder first, and then
release the pressure lever. So that the pressure roller is not in contact with the wire,
be sure to bind the pressure lever to each other in the insulation lock. In addition,
since the feed roller is prevented from rubbing the wire, remove the feed roller.
- (+)Power Cable
- (+)Voltage Detection Cable

(2) Fix the torch cable to the conduit holder.


(3) it will connect the servo feeder shoulder cable (HS1370283-A1.4). Overtighten the
connector screws, be careful not to lose the rubber packing of the connector portion.

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HW14837072.2 ControllerDX200(hardware)

2.2 ControllerDX200(hardware)

(1) Turn off the controller of the breaker before work, please drop a breaker of the primary
power supply side.
And put the power of the controller, please make sure that the power of the controller does
not rise. (the fact that power is not being supplied to the board in the secondary side).
(2) In the controller to secure the servo pack. Loss or of screw, note the fall of the control
panel in.
(3) To the control panel in the secondary side of the servo pack power line (QF1-2, QF1-4,
QF1-6, E) should be wiring.

(4) N-base is fixed to the controller, please through the servopack control cable
(HS1370158-A.05) to N-base. Servopack control cable, the side on which the
YEW-connector and the ferrite core is attached, is an internal controller.
(5) And CN1 connector of the servo pack SGDV-CN1 connector of the servopack control
cable, connect each of the YEW connector to CN322 connector of YEW board. so that each
connector does not fall off, do crowded securely tighten the fixing screws of the connector.
(6) Please through the servo feeder control cable(HS1370282-A10) to N- base.

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HW14837072.2 ControllerDX200(hardware)

(7) The servo motor main circuit cable and encoder cable, connect the servo motor
connection terminal and the ground terminal of the servo pack, the CN2 connector,
respectively. Loss of the screw of the ground terminal, note the omission of the control panel.

(8) Power line of the servo pack, servo pack of control cables, servo motor main circuit cable,
encoder cable, please maneuverability so as not to interfere with the internal controller.
(9) YEW the station setting switch of the board should be changed from 1 to 2.

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HW14837072.2 ControllerDX200(hardware)

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HW14837072.3 Welding Power Source RL350(Hardware)

2.3 Welding Power Source


RL350(Hardware)

(1) Turn off the power switch of the welding power sourse, drop the primary power source.
Please make sure that you also on the power switch of the welding power source before work
does not rise welding power source.
(2) Remove the cover of the welding power source (above).
(3) Open a thin film on the back of the welding power supply cable bush (grommet), please
draw welding power source into the servo pack control cable .
(4) Earth cable is connected to the ground terminal on the back of the welding power source.
(5) Encoder connector (marker display: EC1, EC2) and speed command connector (marker
display: MB50) each Pr (MB) -030 of the board EC1, EC2, MB50 to the connector. Remove
the cables that are connected to the EC1 connector in the initial state. Since EC1 connector
and MB50 connectors are the same shape, Note pointing mistake.
(6) Pr (MB) -030 the SW700 of the board of the standard setting (1, 2) = (ON, ON) should be
changed from the (OFF, OFF).

(7) Please be routed so as not to interfere in the internal welding power servo pack control
cable.
(8) Close the cover (above) of the welding power source.

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HW14837072.4 ControllerDX200(Software)

2.4 ControllerDX200(Software)

Fig1. Modify the CI/O programming

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HW14837072.4 ControllerDX200(Software)

Fig2. User Alarm Setting

Fig3. Security Mode

Fig4. Arc Start Condition File

Fig5. Welder setting

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HW14837072.4 ControllerDX200(Software)

Fig6. Welder prmeters setting

Fig7. Feeder prmeters setting

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HW14837072.5 Welding Power Source RL350 (Software)

2.5 Welding Power Source RL350


(Software)

Please check whether the software version of the welding power source RL350 is a
"Ver.1.00-020-A." Later. Please perform the version up in the case of older versions. Please
been upgraded in the case of older versions. Please refer to the instruction manual of the
welding power source.

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HW14837072.6 Servo Pack (Software)

2.6 Servo Pack (Software)

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HW14837073.1 Daily Inspection and Maintenance

3 Periodic inspection and


maintenance

WARNING
• Be sure to turn off the power switch and the robot controller before accessing the
main body of wire feeder, torch or other equipment for inspection or maintenance.
Failing to do so may result in injury. electric shock, or damage.

CAUTION
• Inspection and maintenance must be performed only by authorized
personnel.Failure to observe this caution may result in injury and electric shock.
Contact us or our authorized service company if disassembly or repair is needed.

The periodical inspection and maintenance should be carried out for efficient use.

3.1 Daily Inspection and Maintenance

The noise level during welding may be high in some welding types. Especially do
not forget to perform items 5 through 7 to prevent a failure caused by noise.

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HW14837073.2 List of Inspection and Maintenance Items

3.2 List of Inspection and Maintenance


Items

Inspection Equipment Interval Method


Wire feeder 6.000H Grease supply
Feeder roller Dairy Wear inspection
2.000H Replace
Torch body Dairy Check for any screw, removed coating, missing or
broken part.
Conduit cable Dairy Check for any clogging in the cable or damaged inner
liner tube.
Perform cleanup or replacement.
Overall appearance Dairy Clean dust, spatter, or other residues.
Check for any missing or damaged part.
Each installation section Dairy Clean dust, spatter, or other residues.
Check for any missing or damaged part.
Inside of feeder roller cover Dairy Clean dust, spatter, or other residues.
Check for any missing or damaged part.
Torch cable Dairy Check for any removed coating or connecting section.
(Power cable, Liner, Liner tube,
500H Replace
and gas hose)
Each cable Dairy Check for any removed coating or connecting section.
Power cable Dairy Check for any removed coating or connecting section.
(Torch side/Base metal side)
2.000H Replace
Servo motor Dairy Check that noise is not bigger than before.
2.000H Check that three is no conductivity.
Servo amplifier Dairy Clean dust and other residues.

Consumables such as contact tip, feed roller, torch, and conduit cable adversely
affect the welding quality if their performance deteriorates due to wear or other
cause. If the welding quality is adversely affected, immediately replace them with
new ones. Note that the replacement frequency depends on the use environment.

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HW14837073.3 The procedure for replacing the feed roller

3.3 The procedure for replacing the feed


roller
(1) loosen the slit bolt at minus driver.

(2) Open the cover and remove the pressure lever.

(3) Insert the special tool that comes with the four-sided milling of the drive shaft, to
loosen hex nut (M6).

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HW14837073.3 The procedure for replacing the feed roller

(4) Remove the hexagon nut Nord-Lock washers and plastic washer, and then
remove the feed roller and the insulator.

(5) Install the new feed roller and the insulator, Install the resin washer-Nord-Lock
washers, hex nut. The procedure when tightening the nut (3) and the plug just
as a special tool to four-sided milling, tighten the hex nut.
※ tightening torque of the hexagon nut is 6 [N · m].

(6) It sets the pressure lever, and tighten the slit bolt with a flathead screwdriver
Replace the cover.

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HW14837073.4 The procedure for replacing of the torch cable of the inner tube .

3.4 The procedure for replacing of the


torch cable of the inner tube .

(1) It will remove the tip parts (nozzle orifice-insulator chip Body auxiliary power
feeding guide).

(2) Knob the inner tube tip with pliers, pull it out.

(3) The crowded firmly a new inner tube to the back, and attached to the torch body
to put an auxiliary power supply guide to the chip body.*Tightening torque of the
chip body is 10 [N · m].

(4) It will install the remaining tip parts (nozzle orifice-insulator).

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HW14837073.5 Replacement procedure of the torch body

3.5 Replacement procedure of the torch


body

(1) Remove the rubber cover, and unplug the torch body to loosen the hexagon bolt
(M6-L25).

(2) Insert surely a new torch body to the base, and tighten the hex bolts
(M6-L25). * tightening torque of the hexagon bolt is 12 [N · m].

(3) It is covered with a rubber cover.

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HW14837073.6 Replacement procedure of the torch cable

3.6 Replacement procedure of the torch


cable

(1) It will remove the gas hose.

(2) Remove the power supply cover fasteners, also remove the power supply
cover.

Hexagon head bolt(M6X20) from completely removed, and unplug the cable.※
If you do not completely remove the bolt, cable can not be removed.

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HW14837073.6 Replacement procedure of the torch cable

(3) Through the feed cover and fasteners to the new cable, plug in the cable.
※ If the cable is not inserted all the way, you can not tighten the bolt.

(4) And tighten the retaining bracket by setting the power supply cover. ※ Please
cut the feed cover is set to face downward.

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HW14837073.7 The procedure for replacing the grease

3.7 The procedure for replacing the


grease

(1) Remove the four very low head bolts of the GearBOX, remove the lid and insert
the eggplant driver not in the groove.

(2) From φ24 hole it will replenish the grease.


※ grease: Shell Albania EP Grease

(3) Silicon is coated on the surface of the gear case, install the lid. ※ silicon: Three
Bond 1221H liquid gasket white ※ The tightening of the hexagon bolt (M4-L12)
torque: 4 [N · m].

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HW14837073.7 The procedure for replacing the grease

4 Spare parts and consumables

Name Type

ACC-308RX torch body Assy 3002031

WFE2WD Torch clamp body Assy (003) DX-1304151

WFE2WBF-U Feeder unit DX-1307240

WFE2WD-T Power cable (HA Type) DX-1507192

Name Type

Block insulating cover for RX DX-1304160

YMES-308R Torch body(ACC-308 spec) 3002032

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HW14837073.7 The procedure for replacing the grease

Name Type

N Nozzle 16 001002
N Orifice S 003002

N Insulator S 004002

N TIp 1.2 002003


ACC-308RR Tip body 016503

ACC-308RRSUS Guide tube 016504

WFE2WD Inner tube(002) DX-1302093

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HW14837073.7 The procedure for replacing the grease

Name Type

WFE2WD Insulator DX-1109106

WFE2WD Feed roller DX-1109105

Resin washer

Nord-Lock washer
Hex nut (M6)

Name Type

WFE2WD-U Feed roller replacement tool DX-1210120

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HW14837073.7 The procedure for replacing the grease

Name Type

WFE2WD-T Gas hose DX-1508200-1700

WFE2WD-T Feeding cover DX-1405312

WFE2WD-U Power supply cover fasteners DX-1307294


Cross hole with pan head screws (M3-L6)
WFE2WD-T Power cable (HA. Type) DX-1507192

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HW14837075.1 Serbo pack Alarm

5 Troubleshooting

5.1 Serbo pack Alarm

Fig8. Panel Operator Display

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Fig9. IN/OUT

Fig10. DISPLAY-DETAIL

Fig11. 25092

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Fig12. IO simulation

Fig13. IO simulation

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Fig14. Alarm reset

Fig15. Release the IO simulation

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HW14837075.2 Trouble and countermeasures

5.2 Trouble and countermeasures

Trouble Cause Confirmation Workaround


method
Servo motor does not move Of the servo motor wiring is wrong. Wiring I to confirm. Correctly wiring.
then, but moving moment.
Wiring of the encoder is wrong. Wiring I to confirm. Correctly wiring.

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HW14837076.1 Servo pack Parameters Setting

6 Servo pack Parameters Setting

6.1 Servo pack Parameters Setting

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Appendix.Servopack alarm
and Troubleshooting of Alarms
List of Alarms
It will show the alarm list below. (Quoted from the User's Manual)

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Troubleshooting of Alarms
It will show the alarm list below. (Quoted from the User's Manual)

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