RL 350 PDF

MOTOWELD-RL350
INSTRUCTIONS
TYPE: YWE-RL350-AJ0 / YWE-RL350-CC0
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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Read this manual carefully and operate the MOTOWELD-RL350 properly.
Thank you for purchasing the MOTOWELD-RL350. The product is the welding power source
for a high performance robot of CO2/MAG/MIG controlled by the digital inverter.
Read this manual carefully and understand the contents before handling the MOTOWELD-
RL350. For the wire feeder, the welding torch, and the gas regulator, read each instruction
manual carefully.
CAUTION
• This instruction manual is intended to explain operating instructions
and maintenance procedures for the MOTOWELD-RL350.
• To ensure the safety for installation, maintenance, service of this welding machine, under-
stand the machine well and allow only trained or authorized personnel to perform the opera-
tion.
• To ensure the safety, allow only personnel who have understood the welding machine well
and have the knowledge and ability enough to handle safely to perform the operation.
• Do not modify the product. Doing so could cause electric shock, injury, or damage to the
product.
• After reading this manual, keep it handy and safely for future reference and read again as
necessary.
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1 Basic Specifications
2 Welding Power Source Installation and Connection

2.1 Installation Site and Welding Power Source
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Precautions on Grounding . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Power Supply Installed Capacity and Connection
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Combination with Earth Leakage Breaker . . . . . . . . . . 2-3
2.5 Setting of Switching Input Voltage . . . . . . . . . . . . . . . . . 2-3
2.6 Connection of Electrical System . . . . . . . . . . . . . . . . . . . 2-5
2.7 Connection of Welding Voltage Sensing Cable . . . . 2-10
2.7.1 Connection in the Welding Power Source Side. . . . . . . . . . . .2-11
2.7.2 Connection to the Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.8 Connection of Shielding Gas System . . . . . . . . . . . . . 2-15
2.8.1 For Mixed Gas or Carbon Dioxide Gas Welding . . . . . . . . . . .2-15
2.8.2 Installation Site and Gas Cylinder Environment . . . . . . . . . . .2-15
2.9 Ambient Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.10 Precautions on Transporting . . . . . . . . . . . . . . . . . . . . 2-18
3 Welding Preparation
3.1 Selecting of Digital Communication / Analog
Communication (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 In the Case of Digital Communication . . . . . . . . . . . . . . 3-2
3.3 In the Case of Analog Communication (Option) . . . . 3-4
4 Operations on Panel
4.1 Explanation of Welding Source Panel . . . . . . . . . . . . 4-1
4.2 Settings on Welding Source Panel . . . . . . . . . . . . . . . . . 4-5
4.2.1 Changing Common (C) Parameters . . . . . . . . . . . . . . . . . . . . .4-5
4.2.2 Communication Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.2.3 Saving Welding Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.2.4 System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.3 Settings on Welding Source Panel
(Analog Communication (Option)) . . . . . . . . . . . . . . . . 4-10
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4.3.1 Changing Welding Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.3.2 User Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.3 Changing P Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.4 Changing D Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.3.5 Checking the Flow Amount of Shielding Gas . . . . . . . . . . . . . 4-14
4.3.6 Selecting Feeding Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.3.7 Monitoring of Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
5 Setting in the Robot Control Unit Side

5.1 Digital Communication Setup . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Welding Unit Characteristics Setup . . . . . . . . . . . . . . . . . 5-2
5.3 Welding Power Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 Security Mode Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Welding Power Setup Screen Display . . . . . . . . . . . . . . . . . . . 5-5
5.3.3 Feeder Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4 Welding Method Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5 Welding Job Making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
6 Welding Power Customization

6.1 MOTOWELD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 MOTOWELD Screen (Online/Offline) . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Parameter Discrepancy Screen . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.1.3 Note and Procedure When Switching the Welding Power
Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2 Welder prm. Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.1 Gas/Wire Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.2 Other Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.3 All PRM. screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3 Customize Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.3.1 Start Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.3.2 End Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3.3 Short-circuit Welding Characteristics . . . . . . . . . . . . . . . . . . . 6-12
6.3.4 Pulse Welding Characteristics . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.3.5 Aluminum MIG Pulse Welding Characteristics . . . . . . . . . . . . 6-15
6.3.6 Welding Current Output Characteristics . . . . . . . . . . . . . . . . . 6-16
6.3.7 Heat And Wave Form Control (HAWC) Screen . . . . . . . . . . . 6-18
6.3.8 All PRM. Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.4 Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.5 External Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.5.1 Setting Contents Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.5.2 Setting Contents Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
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7 Welding Operation
7.1 Checking the Welding Conditions . . . . . . . . . . . . . . . . . . 7-1
7.2 Wire Stickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Direction of Welding and Torch Angle . . . . . . . . . . . . . . 7-1
7.4 Precautions on Using Extension Cable . . . . . . . . . . . . 7-2
8 Precautions on Welding
8.1 Error Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Tripped Power Supply Switch . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Precautions on Welding Operation . . . . . . . . . . . . . . . . . 8-1
9 Location and Setting of Printed Boards

9.1 Location of Printed Boards . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Internal Selecting Switches . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.1 DIP Switch Settings for Pr(MB)-030 Board . . . . . . . . . . . . . . . .9-2
9.2.2 DIP Switch Settings for Pr(CR)-030 Board . . . . . . . . . . . . . . . .9-2
10 Maintenance and Inspection

10.1 Cleaning of Dust Protective Filter. . . . . . . . . . . . . . . . 10-3
10.2 Replace Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
11 Failure Analyses
11.1 Confirming Setting conditions . . . . . . . . . . . . . . . . . . . 11-1
11.2 Cause and Remedy of Welding Section Failure . 11-3
11.3 Cause and Remedy of Failure at Electrical Circuit
Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
12 Robot Interface Signals

12.1 Specifications of Robot Digital Interface Signals . 12-1
12.2 Specifications of Robot Interface Signals . . . . . . . . 12-1
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12.3 Connection of Gas Pressure Shortage sensor and

Wire Shortage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.3.1 Wiring of sensor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.3.2 Edit of Concurrent I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.4 Description and Function of Signal Output
Terminals for Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12.5 Meaning and Function of Signal for Starting Point
Detecting Function
(Optional board Pr (OP) -003 [for RL350]) . . . . . . . . 12-6
13 Connection System Diagram
14 Welding Source Condition File of the Robot

Controller
15 Operation by External Remote Mode

(Analog Communication (Option))
15.1 Switch of User Files
(Analog Communication (Option)) . . . . . . . . . . . . . . . . . 15-2
16 List of Service Parts
17 List of Parameters
17.1 List of Process Parameters . . . . . . . . . . . . . . . . . . . . . . 17-1
17.2 List of Common Parameters . . . . . . . . . . . . . . . . . . . . . 17-3
17.3 List of D Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7
18 List of Welding Types
19 List of Errors
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20 External form
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
MOTOWELD-RL350.
In this manual, the Notes for Safe Operation are classified as "WARNING", "CAUTION",
"MANDATORY", or "PROHIBITED".
Indicates a highly potentially hazardous situation which, if not

DANGER avoided, could result in death or serious injury to personnel.
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 suf-
fer aftereffects, hospitalization, or prolonged out-patient medical treatment.
"Moderate injury" indicates injuries, burns, or electric shock which does not require hospital-
ization 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.
1. 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.
2. 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.
3. Do not let personnel to approach the welder or welding sites unnecessarily.
4. Any person using a pacemaker must not approach the welder or welding site under oper-
ation unless permitted by doctor.
The welder generates a magnetic field around it during current conduction, resulting in
bad influence on the pacemaker.
5. Clean the cooling-water path once a month when using a water-cooled torch and the cool-
ing water circulator.
Failure to observe this warning may result in explosion or burns due to the choked path.
6. 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.
7. In order to secure safe operations, only a person that has understood this instruction man-
ual and has knowledge and techniques to handle the welder safely must operate the
welder.
8. 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.
1. Never touch the charged parts.
Touching the charged parts may result in critical electric shock or burns.
2. 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.
3. 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.
4. Do not use any cable of insufficient capacity or damaged or with its conductor exposed.
5. Tighten the cable connecting sections firmly and insulate them.
6. Do not use the welder with its case or cover removed.
7. Do not use worn, damaged or wet gloves. Always use dry insulated gloves.
8. Use lifelines when working at heights.
9. Perform maintenance and inspection periodically. Repair damaged parts immediately.
10. Turn OFF all equipment input power supplies when not being used.
11. When performing AC arc welding in a small space or at heights, 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 peo-
ple from the fumes or gases generated at welding and short of the oxygen.
1. 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.
2. 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.
3. 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 oxy-
gen shortage.
Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom.
4. 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.
5. Do not perform welding near degreasing, cleaning, or spraying operations.
Failure to observe this warning may generate extremely noxious gases.
6. 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.

1. 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.
2. 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.
3. Do not make hot base metals immediately after welding close to inflammables.
4. Remove inflammables at the hidden side when welding ceiling, floor, or wall.
Failure to observe this caution may result in fire.
5. 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.
6. Connect the cable at the base metal as close to the welding part as possible.
7. 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.
8. Locate fire extinguishers near the welding site.
CAUTION
Be sure to observe the following cautions and use protectors to protect yourself or other peo-
ple from arc beams, spatters, slugs or noise generated from welding.
1. Wear welding mask or shaded glasses appropriate for welding.
2. Wear protective glasses to protect your eyes from spatters or slags.
Scattered spatters or slags may damage eyes or burn the skin.
3. Use such protectors as leather gloves, clothes with long sleeves, leg covers, or leather
aprons for welding.
4. Install protective curtains around the welding site to protect your eyes from arc beams.
Arc beams may irritate eyes or burn skins.
5. 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 falling or a gas regu-
lator from rupturing.
1. 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.
2. Use the attached gas regulator or our recommended one.
3. Read carefully the instruction manual of the gas regulator and observe the precautions
before using it.
4. Hold the gas cylinder in the exclusive-use gas cylinder stand.
A gas cylinder falling may result in personal injury.
5. Do not expose the gas cylinder to high temperature.
6. Do not bring your face close to the discharging opening when opening the valve of the gas
cylinder.
7. Be sure to attach the protective cap when the gas cylinder is not used.
8. Do not hang the welding torch over the gas cylinder or keep the electrode away from the
gas cylinder.
CAUTION
Observe the following cautions to prevent personal injury due to improper handling.
1. Do not use the welder with the case or cover removed.
2. 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.
3. Do not contact the rotating cooling fan or feeding roll of the wire feeder with hands, fin-
gers, 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 welding wire.
1. 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.
2. Do not bring the welding torch end close to eyes, face, or body to perform inching or pull-
ing the torch switch.
CAUTION
When hanging the wire feeder, observe the following cautions to pre-
vent wire from being removed from the spool shaft.
1. 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.
CAUTION
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.
1. Do not put your hands and fingers near the chip and the electrodes of the torch end during
cutting operation.
2. Do not grasp near the base metal during cutting operation.
3. 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.
1. 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 result-
ing in accidental fire.
2. Be sure to perform maintenance and inspection periodically to prevent deterioration of
insulation caused by accumulation of dust and dirt.
3. 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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1 Basic Specifications
Item Specifications
Model MOTOWELD-RL350
Type YWE-RL350-CC0 (Compliance with CCC standards)

YWE-RL350-AJ0 (Non-Compliance with CCC standards)
Number of Phases, Rated Three-phase, 200/220 V 10 % and 380/400V 10 %

Input Voltage (When the factory is shipped, can it be assumed 380V/400V setting,
and change the switch of the input voltage with the back switch.
Nameplate is assumed to be 380V/400V when the factory is
shipped, and other voltage display plate is assumed to be an attach-
ment.)
Rated Frequency 50/60 Hz common
Rated Input 18 kVA
15 kW
Welding Current Adjustment 30 to 350 A (depends on the wire diameter)

Range
Welding Voltage Adjustment 12 to 36 V (depends on the wire diameter)

Range
Rated Operational Ratio 60% (for 10 minutes)
Welding Type CO2 short-circuit welding, MAG/MIG short-circuit welding, pulse

welding, EAGL1
Welding Object Material Iron, stainless steel, aluminum
Feeding Motor Types of feeding motors can be selected among;

0: Print servomotor
1: Minertia servomotor for servo torch
2: 4-roller servomotor (Default setting) (YWE-WFX40TELC)
10: EAGL motor
Wire Feeding speed 1.5 to 18 m/min
Wire Feeding CO2 short-circuit welding: Approx. 3 m/min

Slow-down Speed (adjustable range by panel operation: 1.5 to 6 m/min)
MAG/MIG short-circuit welding and pulse welding: Approx. 2 m/min
(adjustable range by panel operation: 1 to 4 m/min)
Wire Feeder Cable 5 m (standard), 7 m max.

(Optional: 25 m max with a cable extender)
Gas Running-in Time Approx. 20 seconds (Can be adjusted by panel operation)
Gas Pre-flow Time Approx. 0.06 seconds (Can be adjusted by panel operation)
Gas After-flow Time Approx. 0.5 seconds (Can be adjusted by panel operation)
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Item Specifications
Wire-stick Prevention Time Approx. 0.2 seconds (Can be adjusted by panel operation: 0.02 to
0.4 seconds)
Voltage for Starting Point Peak value: 220 V 20% (full-wave rectification)
Detecting Function (Optional)
External Dimensions 371 × 636 × 602 (width × depth × height)

[mm] (excluding the projections such as screws or eyebolts)
Mass Approx. 60 kg
Interface for Robot Controller Refer to " 12 Robot Interface Signals ".
Error Output Outputs the arc failure signal to the robot side. (Error contents are
indicated on the welding power source panel.)
Output for Arc Outputs the signal corresponding to current or voltage to the robot
Monitoring side. The output terminal stand for analog indicator is also available.
Power Supply of the Heater None

for the Gas Regulator
Standard Accessory Fuse contained in glass tube of 2A (1 fuse)

Fuse contained in glass tube of 10A (1 fuse) for Pr(SD)-006 board
Remarks Front panel: Written in Japanese / English / Chinese
1.EAGL: Enhanced Arc weldinG for Low spatter
 In the Case of Digital Communication
Welding Voltage Setting Auto adjustment command / Individual command

Method Read from the welding unit characteristics file of the robot control
unit.
Arc Touch Start Function Setting is made on the setting screen of the robot control unit.
User File Number of files: 16
Adjustment of Voltage and Adjustable on the setting screen of the robot control unit.
Current Waveform Control
 In the Case of Analog Communication (Option)
Welding Voltage Setting Can be switched by "Auto Adjustment / Individual" (Synergic / Inde-
Method pendent) button on the welding power source.
Arc Touch Start Function This function can be used by the parameters D2-1, D2-2, D2-3, and
D2-4.
User File Number of files: 4

"Panel" or "robot" can be switched by the parameter D1-11.
Adjustment of Voltage and Can be changed by P parameters in the user file.

Current Waveform Control
Output Setting Analog Input 0 to 14 V (The set voltage, current, and wire feeding speed are dis-
played on the welding power source panel.)
1-2
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2.1 Installation Site and Welding Power Source Environment
2 Welding Power Source Installation and

Connection
2.1 Installation Site and Welding Power Source Envi-

ronment
CAUTION
• The welding power source can be moved easily by using the caster.
After installation, use the stopper to fix the welding power source
before starting operations. Please use stays to fix the welding power
source as necessary. (See the figure below. Bolts, nuts and metal angles
are provided by customers.)
• For precautions on transporting, see " 2.10 Precautions on Transporting
".
The welding power 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C to 45C
• Altitude less than 1000 m
• Free from direct splash of welding spatter or metallic fine powder at grinding
V A m/min Type
P %
C + No.1
No.2
L R
No.3
_
MOTOWELD
ON
ON
OFF
【ご注意】
電源スイッチがトリップした場合は絶対再投入しないで
お近くのサービスステーションにご連絡ください。
Caution Do not turn on again
Bolt and nut

if the power switch trips due to a
fault contact a service technician.
【注意】
ᔧЏ⬉⑤ᓔ݇䏇㜅ᯊǃ㒱ᇍϡ㛑‫ݡ‬ᓔਃǄ
䇋䖲㒰ᔧഄᡔᴃ᳡ࡵਬǄ
Stay
Anchor bolt 350A YWE-RL350-AJ0
1203809120001
Soft CPU 1.00001A

Ver DB 1.00001A
Machine Ver.
AA
Setting Ver. 1.00
2-1
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2.2 Precautions on Grounding
2.2 Precautions on Grounding
CAUTION
• Be sure to turn OFF the main switch of the switchboard before perform-
ing the grounding work.
1. Be sure to perform secure grounding work (ground resistance must be 100  or less)
on the welding power source so as not to charge its case or lead to unstable operation.
2. In the case of input voltage 200/220 V, connect a grounding cable of 14 mm2 or thicker
to the terminal marked "GROUND" or "EARTH".
In the case of input voltage 380/400 V, connect a grounding cable of 8 mm2 or thicker
to the terminal marked "GROUND" or "EARTH". (See " Fig. 2-3 Connection Diagram
of welding power source at Rear Face ". )
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 power 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.
2.3 Power Supply Installed Capacity and Connection

Cables
The rated input voltage for the welding power source is three-phase, 200/220 V and three-
phase, 380/400 V. The welding power 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 power 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.
2-1 Power Supply Installed Capacity and Cables ". Install a non-fuse breaker (NFB) or a
switch with fuse for each welding power source.
The non fuse breaker used should be the same capacity of the fuse indicated in " Table. 2-1
Power Supply Installed Capacity and Cables ", and the tripping time at 600 % of the rated cur-
rent 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 power source is turned ON.
2-2
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2.4 Combination with Earth Leakage Breaker
Table. 2-1 Power Supply Installed Capacity and Cables
Rated input voltage 200 V/220 V 380 V/400 V
Installed Capacity 20 kVA
Fuse Rated Current 75 A 45 A

(rated voltage: 200/220 V) (rated voltage: 380/415 V)
Input Cable 14 mm2 or more 8 mm2 or more
Exclusive-use base metal cable 60 mm2 or more *1
Grounding Cable 14 mm2 or more 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 250 A or more. Small gauge cables may result in
poor welding and cause abnormal heating in burn or fire.
2.4 Combination with Earth Leakage Breaker
When the welding power 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 power source. The welding
power 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.
2.5 Setting of Switching Input Voltage
The rated input voltage for the welding power source is three-phase, 200V/220 V or 380V/
400V. 200V/220V or 380V/400V(Default setting) can be switched with the switch in rear face
of welding power source. When the factory is shipped, it is set for 380V/400V. When using it
with 200V/220V, it is necessary to set the input voltage switch for 200V/220V. Please switch
according to the following.
i)When using it by input voltage 200V/220V.

　① Four screws of the cover are detached. 　．．．(a)
　② The cover is detached.　．．．(b)
　③ The switch lever is raised up. 　．．．(c)
　④ The cover is turned inside out and obtained. ．．
．(d)
2-3
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2.5 Setting of Switching Input Voltage
　⑤ Four screws of the cover are installed. ．

．．(d)
(a)The screw of the cover is removed. (b)The cover is detached. (c)The lever is raised. (d)The cover is installed.
Fig. 2-1 Input voltage selection (200V/220V)
ii)When using it by input voltage 380V/400V.

　① Four screws of the cover are detached. 　．
．．(a)
　② The cover is detached.　．．．(b)
　③ The switch lever is lowered. . 　．．．(c)
　④ The cover is turned inside out and obtained. ．．．(d)
　⑤ Four screws of the cover are installed. ．
．．(d)
(a)The screw of the cover is removed. (b)The cover is detached. (c)The lever is lowered. (d)The cover is installed.
Fig. 2-2 Input voltage selection (380V/400V)
CAUTION
・Please note it to cause the power line failure when it makes a mistake in the setting of
the input voltage.
・A front panel doesn't light when 200V/220V is input when 380V/400V is set (It is not a
breakdown). Please confirm the setting of the input voltage switch.
・Please note that there is a possibility that the power supply is damaged though Err001 is
displayed when 380V/400V is input by 200V/220V setting.
2-4
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2.6 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 power source Side
See " Fig. 2-3 Connection Diagram of welding power source at Rear Face " for proper
connections.
1) Input cable
Connected bolt of the input voltage terminal is M6.
2) Ground cable
2. Connection on the Welding Side

See " Fig. 2-4 Connection Diagram of welding power source at Front Face " for proper
connections.
1) Torch-side Power Cable
The torch-side power cable connects between the welding torch and the output
terminal (+) of the welding power source.
2) Base metal-side Power Cable
The base metal-side power cable connects between the base metal and the out-
put terminal (-) of the welding power source.
3) Base metal-Side Welding Voltage Sensing Cable
The base metal-side welding voltage sensing cable connects to the base metal
via the wire feeder cable.
3. Connection of Control Cables

As shown in " Fig. 2-3 Connection Diagram of welding power source at Rear Face ",
connect cables to connectors at the rear face of the welding power source. When con-
necting the cables, tighten the plug until it stops rotating.
2-5
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 In the Case of Digital Communication

① Connect the welding interface cable from the robot controller to the connector "CON 8".
② Connect the wire feeder cable to the connector "CON 6".
③ Connect the control cable of the robot controller side to the connector "CN104" (for
LAN) which is located on the CPU unit inside of the robot controller.
* For details, refer to DX100 WELDCOM Function Operation Manual.
Robot I/F Circuit Board

PCI Slot for Sensor Board x 1 JANCD-YIF01-E
(CN114) Control Circuit Board

IO I/F( Communication with YIU) JANCD-YCP01-E
LED
(CN107)
Compact Flash
CN107 (CN113)
Drive I/F( Communication with EAXA)
(CN106)
USB
(CN105)
PCI Slot X2 For Programming Pendant
CN106
(CN104)
For LAN
CN105
CN104
CN103
(CN103)
Serial Port(RS232C)
Battery
2-6
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Welding power source side
Please use a cable clamp so that force is not added to LAN cable and CON8 connector.
CON8
 In the Case of Analog Communication(Option)

① Connect the welding interface cable from the robot controller to the connector "CON 3".
② Connect the wire feeder cable to the connector "CON 6".
2-7
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6JGKPRWVRQYGTUWRRN[XQNVCIGOWUVDGYKVJKPr8
HTQOVJGTCVGFKPRWVRQYGTUWRRN[XQNVCIG
4GHGTVQ6CDNGHQT
HWUGECRCEKVKGU 6JTGGRJCUG#%88CV*\
6JTGGRJCUG#%88CV*\
#VVCEJQPGUYKVEJHQT
GCEJYGNFGT
5YKVEJKP
CON8(RJ45) VJGUYKVEJIGCT
Connector for robot interface(Digital)
101((
TM1
External,connected terminal
(Ammeter,voltmeter,wire inching)
SW1(L21-22A8)
Voltage sensing cable select switch Ground resistance
100 ǡQTNGUU
CON6(ASJ3102A20-27S) Ground cable

Connector for wire feeder cable
Use a cable of 14mm2
ﾛﾎﾞｯﾄｲﾝﾀｰﾌｪｲｽ
（ｱﾅﾛｸﾞ用) ﾌﾟｯｼｭﾓｰﾀ用
or more for grounding.
ﾛﾎﾞｯﾄｲﾝﾀｰﾌｪｲｽ（ﾃﾞｨｼﾞﾀﾙ用)
Interface For Robot(Analog) For Push Motor
電圧検出線 CON 8 Interface For Robot(Digital)
ᴎ఼Ҏ᥹ষ῵ᢳ䆃ো 侚ࡼ偀䖒⫼ Voltage Sensing ᴎ఼Ҏ᥹ষ᭄ᄫ䆃ো
CON3(ASJ3102A28-12S) ⬉य़Ẕߎ㒓
SW1
Input cable
Connector for robot interface (Analog) 出力端子
Output
Terminal
䕧ߎッᄤ
母材
Base
Metal
母材
TM1
CON 3 CON 6
Inching
100V
A V
電源入力
POWER INPUT
⬉⑤䕧ܹ
5.5mm2 or more.
%CTDQPFGQZKFGICUTGIWNCVQT

YKVJHNQYOGVGT Remove the input terminal cover,

'ZCORNG(%4# and connect three cables surely.
%CTDQPFGQZKFGICU Please install it without forgetting
%1
2
14mm以上のｹｰ
必ず接地してくだ
To be grounded
cable of 14mm2 or
14mm2 以上接地
the input terminal cover after it
7UGECTDQPFGQZKFGICU
器
lector
connects it.
)CUE[NKPFGT
HQTYGNFKPIQTYJCV AUTOMATIC WELDING POWER SOURCE

AC200V/220V
AC200V/220V
EQPHQTOUVQVJG%NCUU
TYPE YWE-RL350-AJ0
INPUT VOLTS 200/220V / 380/400V 3Ø
RATED CAPACITY 350A FREQUENCY 50/60Hz AC380V/400V
RATED INPUT 18.0kVA 15kW
URGEKHKGFKP,+5-
LOAD VOLTS 36V
MFG. No.
NO LOAD VOLTS 103V
DUTY CYCLE 60% MASS 67kg
DATE 2012
YASKAWA ELECTRIC CO.
MADE IN TAIWAN NJ3261R
必ず入力電圧の切替設定を確認してください。
Input voltage selector switch
Please confirm the switch setting
of the input voltage.
䇋⹂䅸䕧ܹ⬉य़ᓔ݇ⱘߛᤶԡ㕂。
&QPQVRWVVJKUYJGTG This machine serves as AC380V/400V input.

VJGCODKGPVVGORGTCVWTG
Please confirm that the indicated
GZEGGFU͠
voltage of the face of the cover corresponds
6QYKTGHGGFGT to the input voltage before connection of the
primary input cables.
)CUJQUG Rear Face
Cover
Input voltage terminal
Ground cable
6JGOCKPUYKVJQHRQYGTFKUVTNDWVQTRCPGN
OWUVDGVWOQHHYJKVGYKTKPI
Fig. 2-3 Connection Diagram of welding power source at Rear Face
2-8
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Wire feeder cable

：connect to CON6
at the rear face
Rear face of the welding power source
MOTOWELD
ON
ON
OFF
【ご注意】
お近くのサービスステーションにご連絡ください。 Output terminal Wire feeder cable SW1
： Base Metal side
【注意】
当主⬉源ᓔ݇跳脱ᯊ、㒱ᇍ不能再ᓔਃ。 cover ：connect to CON6
䇋䖲㒰当地技ᴃ服ࡵਬ。
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Output terminal
Soft CPU 1.00001A
Ver DB 1.00001A AA
Setting Ver. 1.00
Remove the output

terminal cover and
connect the cable.
After connection,
be sure to reattatch
the output terminal
cover.
Base metal-side
power cable Torch-side power cable
60mm2 or more 60mm2 or more
Wire feeder
Torch S-axis of robot
Gas hose
+
- Base
metal
Base metal
Torch-side Base metal-side

Ground cable power cable welding voltage
sensing cable
Ground resistance
: 100Ω or less Base metal-side welding voltage sensing cable
Fig. 2-4 Connection Diagram of welding power source at Front Face
2-9
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4. Setting of the welding voltage sensing cable select switch

When using the welding voltage sensing cable, set the welding voltage sensing cable
select switch in the rear side of the welding power source to the "Base Metal" side as
shown in the graphic ① .
When not using the welding voltage sensing cable, set the welding voltage sensing
cable select switch in the rear side of the welding power source to the "Output terminal"
side as shown in the graphic ② .
When using a welding voltage sensing cable, refer to " 2.7 Connection of Welding Volt-
age Sensing Cable ".
ﾛﾎﾞｯﾄｲﾝﾀｰﾌｪｲｽ（ｱﾅﾛｸﾞ用) ﾌﾟｯｼｭﾓｰﾀ用
⬉य़Ẕߎ㒓
SW1
TM1
出力端子母材
Output Base
Terminal Metal
䕧ߎッᄤ 母材
CON 3 CON 6
A V Inching
電圧検出線
Voltage Sensing
⬉य़Ẕߎ㒓
SW1
出力端子母材
Output Base
Terminal Metal
䕧ߎッᄤ 母材
ﾛﾎﾞｯﾄｲﾝﾀｰﾌｪｲｽ（ｱﾅﾛｸﾞ用) ﾌﾟｯｼｭﾓｰﾀ用
⬉य़Ẕߎ㒓
SW1
TM1
出力端子母材
Output Base
Terminal Metal
䕧ߎッᄤ 母材
CON 3 CON 6
A V Inching
電圧検出線
Voltage Sensing
⬉य़Ẕߎ㒓
SW1
出力端子母材
Output Base
Terminal Metal
䕧ߎッᄤ 母材
5. Grounding
Ground terminal (crimp contact M6, 14mm2) is provided under the input terminal on the
rear face of the welding power source for safe operation. Connect the grounding cable
of 14 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. 2-4 Connection Diagram of welding power 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 power source and the base metal with
exclusive-use base metal cable.
2-10
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2.7 Connection of Welding Voltage Sensing Cable
When the power cable is so long (5 m or more) that the welding work is unstable, it is
advisable to use the welding voltage sensing cable.
1. Connect the base metal-side welding voltage sensing cable from the wire feeder cable
of the robot side connection part to the base metal side. (Refer to " Fig. 2-5 Connec-
tion Diagram of Welding Voltage Sensing Cable ")
2. Connect the base metal-side welding voltage sensing cable as close to the position
where welding is performed as possible.
3. The base metal-side welding voltage sensing cable and the base metal-side power
cable must separate as far as possible. (The distance is required 100 mm or more.)
S-axis of robot Rear face of the welding power source

Gas hose
Base metal
Base metal-side
welding voltage
sensing cable
Wire feeder cable SW1
Wire feeder cable Connection Torch-side power cable : connect to CON6 ： Base Metal side
Welding power source

Connection
Torch Torch-side welding voltage
sensing cable
Connect the base metal-side (Inside the robot)
voltage sensing cable as close
to the position where welding
MOTOWELD
is performed as possible
Base metal
+ 㪦㪥
㪦㪥
㪦㪝㪝
䇼䈗ᵈᗧ䇽
㔚Ḯ䉴䉟䉾䉼䈏䊃䊥䉾䊒䈚䈢႐ว䈲⛘ኻౣᛩ౉䈚䈭䈇䈪
䈍ㄭ䈒䈱䉰䊷䊎䉴䉴䊁䊷䉲䊢䊮䈮䈗ㅪ⛊䈒䈣䈘䈇䇯
㩷㩷㪚㪸㫌㫋㫀㫆㫅㩷㪛㫆㩷㫅㫆㫋㩷㫋㫌㫉㫅㩷㫆㫅㩷㪸㪾㪸㫀㫅
㫀㪽㩷㫋㪿㪼㩷㫇㫆㫎㪼㫉㩷㫊㫎㫀㫋㪺㪿㩷㫋㫉㫀㫇㫊㩷㪻㫌㪼㩷㫋㫆㩷㪸㩷
㪽㪸㫌㫃㫋㩷㪺㫆㫅㫋㪸㪺㫋㩷㪸㩷㫊㪼㫉㫍㫀㪺㪼㩷㫋㪼㪺㪿㫅㫀㪺㫀㪸㫅㪅
䇼ᵈᗧ䇽
ᒰਥ⬉Ḯᓔ݇〡⣕ᯊ䇮㒱ᇍਇ⢻ౣᓔแ䇯
䇋䖲㒰ᒰ࿾ᛛᴃ᦯ࡵਬ䇯
S-axis of robot
Wire feeder cable 㪊㪌㪇㪘㩷㪰㪮㪜㪄㪩㪣㪊㪌㪇㪄㪘㪡㪇
㪈㪉㪇㪊㪏㪇㪐㪈㪉㪇㪇㪇㪈
㪪㫆㪽㫋㩷㪚㪧㪬㪈㪅㪇㪇㪇㪇㪈㪘
㪭㪼㫉㩷㪛㪙㪈㪅㪇㪇㪇㪇㪈㪘
㪤㪸㪺㪿㫀㫅㪼㩷㩷㪭㪼㫉㪅
㪘㪘
㪪㪼㫋㫋㫀㫅㪾㩷㩷㪭㪼㫉㪅㪈㪅㪇㪇
Base metal-side welding _

voltage sensing cable The distance is required 100mm or more
Base metal-side power cable

r
Fig. 2-5 Connection Diagram of Welding Voltage Sensing Cable
2-11
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2.7.1 Connection in the Welding Power Source Side

1. Set the voltage sensing cable select switch in the rear side of the welding power
source to the "Base Metal" side.
電圧検出線
ﾛﾎﾞｯﾄｲﾝﾀｰﾌｪｲｽ（ｱﾅﾛｸﾞ用)
Interface For Robot(Analog)
ﾌﾟｯｼｭﾓｰﾀ用
For Push Motor
Voltage Sensing
（ﾃﾞｨｼﾞﾀﾙ用)
ᴎ఼Ҏ᥹ষ῵ᢳ䆃ো 侚ࡼ偀䖒⫼ Voltage Sensing ⬉य़Ẕߎ㒓
ᴎ఼Ҏ᥹ষ᭄ᄫ䆃ো
⬉य़Ẕߎ㒓
SW1
SW1
TM1
出力端子母材
Output Base
Terminal Metal
䕧ߎッᄤ 母材
CON 3 CON 6
A出力端子
V Inching 母材
Output Base
Terminal Metal
䕧ߎッᄤ 母材
2-12
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2.7.2 Connection to the Work

In the connection of the welding voltage sensing cable, be sure to observe the following items.
If the following items are not observed, the amount of the spatter generation might increase.
(1) Since the torch-side welding voltage sensing cable and the base metal-side welding
voltage sensing cable are twisted inside of the wire feeder cable, be sure to use the
wire feeder cable. The area S surrounded by the two welding voltage sensing cables
should be as small as possible as shown in " Fig. 2-6 Welding Voltage Sensing Circuit ".
Making the inductance of the welding voltage sensing circuit smaller reduces the effect
of induction noise.
Torch-side welding voltage sensing cable

+
Torch
MOTOWELD
_
Base metal ON
ON
OFF
【ご注意】
【注意】
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Soft CPU 1.00001A

Ver DB 1.00001A AA
Setting Ver. 1.00
Base metal-side welding voltage sensing cable
Torch-side
welding voltage sensing cable
Inside of the
wire feeder cable +
Torch
_
MOTOWELD
Base metal ON
ON
OFF
【ご注意】
【注意】
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Soft CPU 1.00001A

Ver DB 1.00001A AA
Setting Ver. 1.00
Base metal-side
Fig. 2-6 Welding Voltage Sensing Circuit
2-13
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(2) When two or more stations are used, connect the welding voltage detecting line with a
station as far away from the welding power source as possible as indicated in " Fig. 2-
7 Connection of Welding Voltage Detecting Line when Multiple Stations are Used ".
.
Robot Welding power source
MOTOWELD
ON
ON
OFF
【ご注意】
【注意】
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Soft CPU 1.00001A

Ver DB 1.00001A AA
Setting Ver. 1.00
Station Station Station
Base metal-side power cable

Base metal-side welding voltage sensing cable
Fig. 2-7 Connection of Welding Voltage Detecting Line when Multiple Stations are Used
(3) When a rotation axis is used, connect the base metal-side welding voltage sensing cables
with the screw of the cover that exists in the base of MOTOPOS (See " Fig. 2-8 Connec-
tion of the Welding Voltage Sensing Cables when using Rotation Axis and Two Welding
Power Sources "). Do not connect the power cable and the welding voltage sensing cable
with the same part. (Do not connect the welding voltage sensing cable with the route
where the welding current flows.) Please confirm the electrical continuity between the
welding workpiece and the screw of the cover by a circuit tester before wiring.
Two base metal-side

Two base metal-side welding voltage
welding voltage sensing cables
sensing cables
Two base metal-side

power cables
(a) Connection of the base metal-side (b) Connection of the base metal-side
welding voltage sensing cables power cables
Fig. 2-8 Connection of the Welding Voltage Sensing Cables when using Rotation Axis and Two Welding Power Sources
2-14
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(4) When you use two or more welding power sources, connect the each base metal-side
power cable of the welding power source as close to the position where welding is per-
formed as possible. Separate the power cable A from the welding voltage sensing
cable B, and separate the power cable B from the welding voltage sensing cable A as
far as possible. (Distance between the Cable A and the cable B is required 100 mm or
more.)
Do not connect the welding voltage sensing cable with the route where the welding cur-
rent flows.
Welding power source A

Robot A CON6
㪤㪦㪫㪦㪮㪜㪣㪛
㪦㪥
㪦㪥
㪦㪝㪝
䇼䈗ᵈᗧ䇽
䇼ᵈᗧ䇽
㪊㪌㪇㪘㩷㪰㪮㪜㪄㪩㪣㪊㪌㪇㪄㪘㪡㪇
㪈㪉㪇㪊㪏㪇㪐㪈㪉㪇㪇㪇㪈㪤㪸㪺㪿㫀㫅㪼㩷㩷㪭㪼㫉㪅
㪭㪼㫉㩷㪛㪙㪈㪅㪇㪇㪇㪇㪈㪘㪘㪘
Base metal-side − +
welding voltage sensing cable A
Base metal-side power cable A
Welding power source B

Robot B CON6
Base metal 㪤㪦㪫㪦㪮㪜㪣㪛
㪦㪥
㪦㪥
㪦㪝㪝
䇼䈗ᵈᗧ䇽
䇼ᵈᗧ䇽
㪊㪌㪇㪘㩷㪰㪮㪜㪄㪩㪣㪊㪌㪇㪄㪘㪡㪇
㪈㪉㪇㪊㪏㪇㪐㪈㪉㪇㪇㪇㪈㪤㪸㪺㪿㫀㫅㪼㩷㩷㪭㪼㫉㪅
㪭㪼㫉㩷㪛㪙㪈㪅㪇㪇㪇㪇㪈㪘㪘㪘
Base metal-side − +
welding voltage sensing cable B
Base metal-side power cable B
Fig. 2-9 Connection of Base metal-side Welding Voltage Sensing cables and Base metal-side Power
Cables when using two or more Welding Power Sources
CAUTION
• Be sure to connect the welding voltage sensing cable. If the welding
voltage sensing cable is not connected, the error "Err702: Voltage Sens-
ing Cable Error" may occur, and welding cannot be performed.
• When the welding voltage sensing cable is not used, be sure to set the
welding voltage sensing cable select switch to the "Output terminal"
side.
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2.8 Connection of Shielding Gas System
2.8.1 For Mixed Gas or Carbon Dioxide Gas Welding

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.
3. The 100 V AC power supply is required for a heater of carbon dioxide gas regulator.
2.8.2 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.
1. Installation SIte of Gas Cylinder

Place the gas cylinder in a specified gas container posi-
tion that is not exposed to direct sunlight. If the gas cyl-
inder 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 car- Fix the gas cylinder to prevent
bon dioxide gas regulator is not applicable to siphon it from falling.
type cylinder. If the regulator is connected to a siphon Fig. 2-10 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 cylin-
der 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 opera-
tion immediately, confirm the reason, and take appropri-
ate 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. 3 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, 190 W
2 FCR-225 CO2, MAG, Ar Meter: Indicates primary pressure and

float-type flow amount
Heater: 100 VAC*1, 190 W
*1 The power supply for the heater is not provided with the welding power source. Pre-
pare a 100V AC power supply for the heater of the gas regulator.
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2.9 Ambient Environment
2.9 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 counter-
measures 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 ventila-
tion fan or exhaust duct.
Ventilating fan
Torch
Torch
Screen
Wind
Object to be welded
Fig. 2-11 Shielding Wind for Welding Fig. 2-12 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 power 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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2.10 Precautions on Transporting
Helmet
Handshield
Jacket must be
long-sleeved.
Welding gloves
Foot covers
Safety boots
Fig. 2-13 Protection Example
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 power source consists of precision components. Failure to observe this cau-
tion may affect its performance.
• Use the pallet used by factory shipment for transporting welding power
source.
1. Transporting with Using Casters

When using the casters, move the welding power source slowly so that it can be
stopped quickly at any time. Moving the welding power source with casters quickly
may result in an accident due to inertia, and you cannot control the direction of move-
ment.
Moreover, be sure to stop the welding power source with casters at a step and move it
slowly to prevent any shock sudden. Do not move the welding power source with cast-
ers 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 power source by referring to " 1 Basic Specifi-
cations ". 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 power source using the crane after the above confirmation.
Wire rope
Eyebolt M8
60 degrees
or more
MOTOWELD
ON
ON
OFF
【ご注意】
【注意】
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Soft CPU 1.00001A

Ver DB 1.00001A AA
Setting Ver. 1.00
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 power
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 power source on the transporting pallet and fix firmly to prevent
falling or shifting. Employ a stopper on the casters to fix the welding power
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 power source at yield speed when using the forklift.
4. Others
1) Do not climb up on the welding power source or place anything on it.
2) Do not pass a rope directly around the welding power source case during trans-
porting. Failure to observe this caution may deform the shape of the case or
cause malfunction.
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3.1 Selecting of Digital Communication / Analog Communication (Option)
3 Welding Preparation
3.1 Selecting of Digital Communication / Analog

Communication (Option)
This welding power source supports two communication types: digital communication (default)
and analog communication (option). The fatrory default setting is degital communication.
In order to use the analog communication, SW101 on the Pr(MB)-030 board must be set as
follows. For details, refer to " 9 Location and Setting of Printed Boards ".
SW101 SW101
ON 2 ON 2
ON 1 ON 1
Digital communication Analog communication

(default) （option）
Pr(MB)-030
1
2
3
4
Front face of the welding power source
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3.2 In the Case of Digital Communication
The preparation procedures for welding are shown in " Table. 3-1 Welding Preparation Proce-
dure "
Table. 3-1 Welding Preparation Procedure
Step Item Details
1 Setting welding wire Set a wire suitable to the welding method. Make sure that the
diameter of the roller of wire feeder matches the wire diameter.
2 Checking torch Confirm that a contact tip suitable to the diameter of the wire is
installed on the torch.
3 Turning ON the switch Confirm that connections are correct, then turn ON the switch of
in the switch gear the switch gear of the welding source.
4 Turning ON switches Turn ON the power switch. The power indicator lamp lights and the
for the welding source built-in cooling fans start rotating. The fans except top one stop
after fifteen minutes unless the welding starts. The fans automati-
cally restart rotating when the welding starts.
5 Set the communication Set the communication parameter in the welding power side.
parameter C50: Welding power IP address setting (Default value: 0)
6 Saving welding condi- Save the conditions before turning OFF the welding source.
tions Keep on pressing the "Record" button for more than three seconds
to save changes. Do not turn OFF the welding source while sav-
ing. The 7-segment LED indicators light up again at the comple-
tion of the saving. Confirm that the 7- segment LED indicators light
again.
7 Reboot the welding To validate the communication setting of the welding power, turn
power OFF the welding power once, then turn it ON.
8 Setting at the robot Set the following items in the robot side:
side • Welding unit characteristics file (Voltage command type
(Auto adjustment/Individual))
• Welding power type
• Wire feeding unit type
• Welding method
Setting is performed under the condition where the communication
between the welding power and the robot control unit is enabled.
9 Communication check Check to confirm that the welding current command and the weld-
ing voltage command which were set on the robot control unit are
displayed normally on the panel.
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Step Item Details
10 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 C00.)
(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 - 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).
11 End
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3.3 In the Case of Analog Communication (Option)
The following table describes the preparation procedure to start actual welding.
Step Item Details
Setting welding wire Set a wire suitable to the welding method. Make sure that the
1
diameter of the roller of wire feeder matches the wire diameter.
Checking torch Confirm that a contact tip suitable to the diameter of the wire is
2
installed on the torch.
Turning ON the switch Confirm that connections are correct, then turn ON the switch of
3
in the switch gear the switch gear of the welding source.
Turning ON switches Turn ON the power switch. The power indicator lamp lights and
for the welding source the built-in cooling fans start rotating. The fans except top one
4
stop after fifteen minutes unless the welding starts. The fans auto-
matically restart rotating when the welding starts.
Setting feeding motor The feeding motor type can be set by the parameter C09.
0: Print servomotor
1: Minertia servomotor for servo torch
2: 4-roller servomotor(default setting)
(YWE-WFX40TELC,YWE-WF340TELC,YWE-WF340MELC)
Incorrect setting of the feeding motor precludes proper welding
because the wire cannot be fed at wire feeding speed as directed
5 by the set value.
When the parameter was changed, keep on pressing the
"Record" button for more than three seconds to save changes.
Do not turn OFF the welding source while saving. Confirm that
the 7-segment LED indicators light again, then turn OFF the weld-
ing source once and ON again. In the case of analog communi-
cation, the servo feeding unit is not available. For details, refer to
" 4.3.6 Selecting Feeding Motor ".
Setting welding source Set the welding source voltage control: either "Synergic (auto
voltage control adjustment)" or "Independent (individual)".
6 When "Synergic" is set, the LED indicator lamp above "Auto
Adjustment/Individual" button will light up.
"Synergic (auto adjustment)" is set before shipping.
Setting at the robot side Set the welding source condition files (including “Synergic (auto
adjustment)” or “Independent (individual)”).
7
For details, refer to " 14 Welding Source Condition File of the
Robot Controller ".
Selecting welding type Before Setting; Select the welding type according to the type of
8 shielding gas and wire, or short-circuit / pulse.
See " 18 List of Welding Types " for selectable welding types.
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Step Item Details
Checking the indicated Check the settings for the voltage, current, wire feeding speed,
value on the welding and welding type of the digital meter on the welding source panel.
9
source panel Check the indicated value on the panel by changing command
value from the robot controller.
Wire inching Output the inching command from the robot controller.
10
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 C00. Refer to " 4.3.5
Checking the Flow Amount of Shielding Gas ".)
11
(2) Turn the valve of the gas cylinder counterclockwise to open.
(3) Turn the knob of the gas regulator to adjust the flow accord-
ing to welding conditions. Proper gas flow rate is 10 to 25
liters per minute. The flow rate must be increased in propor-
tion to the welding current (the higher the current, the larger
the flow rate).
Saving welding condi- Save the conditions before turning OFF the welding source.
tions Keep on pressing the "Record" button for more than three sec-
onds to save changes. Do not turn OFF the welding source while
12
saving. The 7-segment LED indicators light up again at the com-
pletion of the saving. Confirm that the 7-segment LED indicators
light again.
13 End
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4.1 Explanation of Welding Source Panel
4 Operations on Panel

Pressing the panel buttons during welding does not change any operation other than user
NOTE file selection.
Be sure to stop welding before starting the panel operations.
1 2 3 4
6 8 9 10
7 11
12 13 14
Fig. 4-1 Welding Source Panel
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The following table explains the display of the meters ① , ② , ③ and ④

The content of the display differs according to the status as follows:
8 # m/min Type
Status
① Welding Volt- ② Welding Cur- ③ Wire Feeding ④ Welding

age Indicator rent Indicator Speed Indicator Type Indicator
During When Displays the set Displays the set Displays the Displays the
standby Parameter welding voltage welding current feeding amount welding type
C32=0, value (V). value (A). (m/min) of the (Type).
Displays set welding cur-
Setting rent value.
Conditions.
When Displays 0.0V Displays 0A Displays 0.0m/ Displays the

Parameter min welding type
C32=1, (Type).
Displays
Stanby
During welding Displays the Displays the Displays the Displays the
During wire inching welding voltage welding current feeding amount welding type
value (V) that is value (A) that is (m/min) of the (Type).
fed-back. fed-back. motor that is
fed-back, or the
motor current.
(Can be
switched by the
parameter D1-
5.)
During setting param- Displays the Normally dis- Displays Displays the
eter parameter num- plays "---". -P parameter: welding type
ber. ratio (%) (Type).
-C parameter:
value
(in decimal)
-D parameter
ON/OFF
Display Lamps
Item Content Explanation
⑤ Power Lamp Lights when the power supply is turned ON.
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Setting Buttons
Item Content Explanation
⑥ Parameter Select  In the case of digital communication

(P parameter) Not used in the digital communication mode. Set on the setting
screen of the robot control unit.
When the "PRM Select" button is pressed during standby status,
the display changes to the P parameter setting display. The 7-seg-
ment LED indicator ① displays "P.00", and the 7-segment LED indi-
cator ③ displays the parameter set value. (Effective only when the
user file is selected.)
 In the case of analog communication (option)
When the "PRM Select" button is pressed during standby status,
the display changes to the P parameter setting display. The 7-seg-
ment LED indicator ① displays "P.00", and the 7-segment LED indi-
cator ③ displays the parameter set value. (Effective only when the
user file is selected.)
Press this button again to return to the standby display.
⑦ Common Parameter When the "Common PRM Select" button is pressed during standby
Select (C parameter) status, the display changes to the common parameter setting dis-
play. The indicator ① displays "C.00", and the indicator ③ displays
the common parameter set value.
Press this button again to return to the standby display.
⑧ Auto Adjustment/Indi-  In the case of digital communication

vidual (synergic/inde- Not used in the digital communication mode. Set on the setting
pendent) Switch screen of the robot control unit.
- Auto adjustment: LED indicator lamp lights.
(Output voltage is set at % from the robot controller.)
- Individual: LED indicator lamp turns OFF.
(Output voltage is set by welding voltage command from the robot
controller.)
Switches the control type of welding voltage.
- Auto adjustment: LED indicator lamp lights.
(Output voltage is set at % from the robot controller.)
- Individual: LED indicator lamp turns OFF.
(Output voltage is set by welding voltage command from the robot
controller.)
⑨ Parameters Setting When setting parameters or common parameters, the numbers and
the parameter set values can be switched. The blinking 7-segment
LED indicator is the selected item.
⑩ Selecting of Welding  In the case of digital communication

Type Not used in the digital communication mode. Set on the setting
Press the button ⑩ "Weld Type" button during standby status to
change the welding type (Type), and the 7-segment LED indicator
④ blinks. The welding type setting is confirmed with pressing of
this button again, and the 7-segment LED indicator ④ stops blink-
ing.
⑪ Right to Left or Up and Used to change the settings. Press "L" or "R" to move the digit.
Down Move Button Press "+" or "-" to increase or decrease the value.
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⑫ Saving Conditions Used to save the setting. The LED indicator lamp blinks when the
setting is changed.
To save the changed setting, keep pressing the "Record" 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. Wait until the 7-segment LED indicators are
lit again. If the welding source is turned OFF and back ON after the
7-segment LED indicators are lit again (the conditions are saved),
the settings return to the status where the conditions were saved.
Turn the welding source OFF and back ON without pressing this
button so as not to save the changed settings.
⑬ Checking Gas Checks the gas. The LED indicator lamp lights when pressing the
"Gas" button, and the gas flows for 20 seconds. (The default set-
ting for the gas flow time is 20 seconds. This time can be changed
by C00 parameter.) When this button is pressed again during the
gas check, the gas stops flowing.
⑭ Selecting of the User  In the case of digital communication

File Not used in the digital communication mode. Set on the setting
In the digital communication mode, all the LED's of user file num-
bers 1, 2, and 3 are lighted.
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)
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4.2.1 Changing Common (C) Parameters

The C parameter is the common parameters for the welding source.
Follow the instructions to change C parameter value as follows:

(1) Press the button ⑦ "Common PRM Select" during standby status. The 7-segment LED
indicator ① voltmeter (V) displays "C.00" blinking, and the 7-segment LED indicator ③
"Wire m/min" (WF) displays the parameter value lighting.
(2) Press the button ⑪ "L" or "R" to change the number of blinking digits to one. Press the
button ⑪ "L" to move the blinking to the left, and press the button ⑪ "R" to move the blink-
ing to the right.
(3) Using the button ⑪ "L" or "R", moves the blinking digits to the number to be changed.
(4) Use the button ⑪ "+" or "-" to increase or decrease the value.
(5) Press the button ⑨ "PRM Set", and the parameter value on the 7-segment LED indicator
③ "Wire m/min" blinks. The set value of parameter is ready to be changed. If the set
value is four digits or more, use the button ⑪ "L" to move the cursor to the indicator ②
ammeter (A). The indicator ② ammeter (A) displays the number(s) above the forth digit.
For changing the parameter number, press the button ⑨ "PRM Set" again.
The blinking digits move as shown below with each pressing of the button ⑨ "PRM Set".
8 # m/min Type
8 # m/min Type
(6) After changing the value, press the button ⑦ "Common PRM Select" to return to the
standby display.
Press the button ⑫ "Record" for three seconds or more to save the changed values (con-
ditions). Do not turn OFF the welding source during saving conditions. When the 7-seg-
ment LED indicators are lit again, the saving of conditions is completed.
In the case of digital communication, parameters other than the C (common) parameter listed
in the table below are set by the robot controller side. For details about C (common) parame-
ters, refer to " 17.2 List of Common Parameters ".
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Display Factory
Item Contents
No. setting
C23 System reset 0 When C23 is set to "2004", the system is reset,
returning to the factory setting. Before executing the
system reset, be sure to memorize the changed
parameters. After executing the system reset, turn
OFF the power and then turn it ON again.
When the power is turned OFF, C23 is returned to
"0".
C50 Welding power side IP 0 Set the fourth digit of the welding power side IP
address address. (Addition value to the reference value 210)
When the set value is 0: 192.168.255.210
4.2.2 Communication Setting

When this unit is used in the digital communication mode, the following parameters must be
set properly.
Any changes in parameters are activated by rebooting the welding power.
After changing any parameter setting, take condition memory, turn OFF the welding power,
and turn ON the welding power again.
Display Factory
Item Contents
No. setting
C50 Welding power side IP 0 The 4th digit of the welding power side IP address is
address set. (Additional value of the reference value)
- When the set value is 0: 192.168.255.210
- When the set value is 1: 192.168.255.211
In the combination of one robot control unit and one welding power unit, the factory setting
can be used.
In the combination of one robot control unit and two or more welding power units, be careful
not to duplicate the welding power side IP address C50.
(Example) When one robot control unit and two welding power units are connected:
Welding power unit No. 1 C50=0
Welding power unit No. 2 C50=1
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When the communication between the welding power and the robot control unit is not
established, the following display is shown:
V A m/min Type
CAUTION
If data communication is not established, check the following items:
• Check to confirm that the power of the robot control unit is turned ON.
• Check to confirm that the communication cable between the robot con-
trol unit and the welding power is properly connected.
• Check to confirm that the proper communication cable is used.
When an Ethernet hub is used, use an Ethernet straight cable.
When an Ethernet hub is not used, use an Ethernet cross cable.
• Check to confirm that the communication setting of the robot control
unit is properly set.
• Check to confirm that the communication setting (C50) of the welding
power B67is properly set.
If the communication setting is changed, perform condition memory and
turn OFF the welding power, then turn it ON again.
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4.2.3 Saving Welding Conditions

In the case of analog communication, the parameter value is changed by the operations on
the wlding source panel.
In the case of digital communication, the parameter value is changed by the operation on the
robot controller.
The following describes how to save the settings.

(1) Referring to " 4.3.2 User Files (Analog Communication (Option))", specify the file number
where the data are to be saved.
(2) Press the button ⑫ "Record" for 3 seconds or more, and the 7-segment LED indicators
display dashes "- - -".
(3) When the saving is completed, the 7-segment LED indicators return 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 7 segment LED indicators are lit again before turning
OFF the power supply.
CAUTION
• For P 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.
4.2.4 System Reset

System Reset initializes all the setting data in the welding source. Reset the system only
when the software is updated.
CAUTION
• Be sure that executing System Reset initializes all the internal data.
If some parameters must be retained, write them down on a sheet of
paper before System Reset. The data cannot be restored after the sys-
tem reset operation.
• After System Reset, set the welding method and parameters using the
robot control unit. If the welding is performed without setting the weld-
ing method, the error "Err602 (Welding method not set)" is output.
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The following describes how to reset the system.

(1) Press the button ⑦ "Common PRM Select" during standby status. The 7-segment LED
indicator ① voltmeter (V) displays "C.00" blinking, and the 7-segment LED indicator ③
8 # m/min Type
(2) Use the button ⑪ "+", "-", "L" or "R" to display the parameter "C23".
8 # m/min Type
(3) Press the button ⑨ "PRM Set", and the parameter value on the 7-segment LED indicator
③ "Wire m/min" blinks. Change the setting value of parameter "C23" to "2004". When the
setting value is four digits or more, use the button ⑪ "L" to move the cursor to the 7-seg-
ment LED indicator ② ammeter (A). The indicator ② ammeter (A) displays the number (s)
above the forth digit. The system reset will be executed at C23=2004.
Wait until "sys rst" is displayed..
8 # m/min Type
(4) Turn OFF the welding source when "sys rst" is displayed. This is end of the initialization.
8 # m/min Type
(5) Turn ON the power supply and the parameters return to the default setting. Set the
recorded parameters again if necessary.
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4.3 Settings on Welding Source Panel (Analog Communication (Option))

4.3.1 Changing Welding Type

The following describes how to change the welding type.For details about welding type, refer
to " 18 List of Welding Types ".
(1) Press the button ⑩ "Weld. Type", and the 7-segment LED indicator ④ "Type" blinks.
8 # m/min Type
(2) Use the button ⑪ "+" or "-" to increase or decrease the value. Use the button ⑪ "L"
or "R" to move the digit.
(3) After changing the value and pressing the button ⑩ "Weld. Type", the 7-segment
LED indicator ④ "Type" lights.
8 # m/min Type
Press the button ⑫ "Record" for 3 seconds or more to save the changed value. Do
not turn OFF the welding source while pressing this button. The saving of condi-
tions is completed when the 7-segment LED indicators are lit again.
The welding types available for software version 1.00-001-A (CPU) are listed in " 18
List of Welding Types ".
Welding types other than listed in " 18 List of Welding Types " are not available.
Using improper welding type will result in unstable welding, which causes excessive
spatters or imperfect bead appearance. Before starting welding, confirm that the
welding type has been correctly selected.
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4.3.2 User Files

The conditions changed by the P parameter concerning any welding type are saved in the
user files: File No. 0, File No. 1, File No. 2, and File No. 3.
Also, the user file can be called up from the manipulator controller to perform welding.
1. When the content of P parameter is to be changed, confirm that the user file can be
changed by the panel operation (D1 parameter D1-11=OFF), then select the user file:
file No. 0, 1, 2, or 3. The file No. is changed each pressing of ⑭ “User File Select” but-
ton, 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. Press the button ⑩ “Weld.Type” to change the welding type (Type).
Refer to " 4.3.1 Changing Welding Type " for details on changing of the welding type.
When conditions are changed, the LED indicator lamp for "Record" blinks.
SUPPLE Keep pressing the button ⑫ "Record" for three seconds or more to save the changed con-
-MENT
tent. Do not turn OFF the welding source while pressing this button. The saving of condi-
tions is completed when the 7-segment LED indicators are lit again.
CAUTION
• When the welding type which is set in the user file is changed, the P
parameters are initialized and everything becomes the value at 100 %.
4.3.3 Changing P Parameters

The P parameters are used for welding adjustment. The P parameters are changed by multi-
plying the internal set data of the selected welding type by the modification ratio. The change
of the P parameters is allowed only when the user file: file No.0 ,No.1, No.2, or No.3 is
selected.
For details on the P parameter, refer to " 17.1 List of Process Parameters ".
Follow the instructions to change P parameter value as follows:

(1) Press the button ⑥ "PRM Select" during standby status. The 7-segment LED indi-
cator  voltmeter (V) displays "P.00" blinking, and the 7-segment LED indicator ③
(2) Press the button ⑪ "L" or "R" button to change the number of blinking digits to one.
Press the button ⑪ "L" button to move the blinking to the left, and press the button
⑪ "R" to move the blinking to the right.
(3) Using the button ⑪ “L” or “R”, move the blinking digits to the number to be changed.
(4) Use the button ⑪ “+” or “-“ to increase or decrease the value.
(5) Press the button ⑨ “PRM Set”, and the parameter value on the 7-segment LED
indicator ③ “Wire m/min” blinks. The set value of parameter is ready to be
changed. Change the set value in the range between 10 and 200 %.
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For changing the parameter number, press the button ⑨ “PRM Set” again.
The blinking digits move as shown below with each pressing of the button ⑨ “PRM
Set”.
8 # m/min Type
8 # m/min Type
(6) After changing the value, press the button ⑥ “PRM Select” to return to the standby
display.
Press the button ⑫ "Record" for three seconds or more to save the changed values
(conditions). Do not turn OFF the welding source during saving conditions. When
the 7-segment LED indicators are lit again, the saving of conditions is completed.
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4.3.4 Changing D Parameters

D parameters specify the setting or operation conditions for the welding source by ON/OFF.
The D parameters consist of D-1 parameter, D-2 parameter, D-3 parameter, and D-4 parame-
ter. The setting items for each parameter are: No.1 to No.16, altogether 64 setting items are
available. For details about D parameters, refer to " 17.3 List of D Parameters ".
Follow the instructions to change D parameter as follows:

(1) Keep pressing the button ⑦ "Common PRM Select" and press the button ⑥ "PRM
Select" during standby status. The 7-segment LED indicator  voltmeter (V) dis-
plays "d-1" blinking, the 7-segment LED indicator ② ammeter (A) displays the soft-
ware switch number blinking, and the 7-segment LED indicator ③ "Wire m/min"
(WF) displays ON or OFF lighting.
(2) Push the button ⑪ "+" or "-" to switch "d-1" and "d-2"
(3) The blinking digits move as shown below with each pressing of the button ⑨ "PRM
Set".
8 # m/min Type
8 # m/min Type
8 # m/min Type
Use the button ⑪ "L","R", "+", or "-" to change the parameter number and the set
contents.
When the 7-segment LED indicator ② ammeter (A) is blinking, the software switch
numbers (1 to 16) can be selected.
When the 7-segment LED indicator ③ "Wire m/min" is blinking, the setting of soft-
ware switch (ON/OFF) can be changed. ON and OFF are switched with each press-
ing of the button ⑪ "+" or "-".
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(4) After changing the setting, press the button ⑦ "Common PRM Select" to return to
the standby display.
<Example>
When the parameter D1-11 is ON (enabled):
8 # m/min Type
Press the button ⑫ "Record" for three seconds or more to save the changed values
(conditions). Do not turn OFF the welding source during saving conditions. When
the 7-segment LED indicators are lit again, the saving of conditions is completed.
4.3.5 Checking the Flow Amount of Shielding Gas

The shielding gas flow amount can be checked.
Press the button ⑬ "Gas" button. The LED indicator lamp above the "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 C parameter C00, while, the default setting is 20 seconds (unit: second).
Press the button ⑫ "Record" for 3 seconds or more to save the changed value.
NOTE Do not turn OFF the breaker until the 7-segment LED indicators are lit again when the
“Record” button was pressed.
4.3.6 Selecting Feeding Motor

The feeding motor can be selected by change in the numerical value of C parameter C09.
C09: 0 Print servo
C09: 1 Servo torch
C09: 2 4-roller servo(Default setting)(YWE-WF-X40TELC, YWE-WF-340MELC,YWE-
WF-340TELC)
C09: 10 EAGL motor (For details, refer to "ARC WELDING PACKAGE MOTOPAC-
WL200+INSTRUCTIONS FOR MOTOMAN-MA1440".)
Press the button ⑫ "Record" button for 3 seconds or more to save the changed value.
To validate the change in setting, turn OFF the welding source and ON again after saving the
conditions.
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NOTE Do not turn OFF the breaker until the 7-segment LED indicators are lit again 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.
• The change in the motor setting will be first reflected when the welding
source is restarted (turned OFF ON) after saving the conditions.
4.3.7 Monitoring of Motor Current

The motor current of rotating feeding motor can be displayed in the 7-segment LED indicator
"Wire m/min" by setting D parameter D1-5 to "OFF". During the standby status, the 7-seg-
ment LED indicator displays the command of wire feeding amount (m/min).
8 # m/min Type
When the 7-segment LED indicator displays the motor current, "A" is indicated at the third digit
of the indicator.
In the figure above, the motor current is 0.5 A.
When the 7-segment LED indicator does not display "A" at the third digit, D parameter D1-5 is
set to "ON" status, and the indicator shows the feedback speed of wire feeding.
• Motor current error

Outputs Err502 "motor overcurrent" and ends wire feeding and welding when the motor
current is passed more than the rated current.
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5.1 Digital Communication Setup
5 Setting in the Robot Control Unit Side
5.1 Digital Communication Setup
With the program pendent of the robot control unit, set the following items.
The characteristics (voltage command type) of

Welding unit characteristics setup
the welding unit to be used are set.
(5.2 Welding Characteristics Setup)
The welding power type and the motor model

Welding power basic setup
are set.
(5.3 Welding Power Basic Setup)
The welding method to be used and the

Welding method setup parameters are set.
(5.4 Welding Method Setup)
Welding job making The welding job to be used is made.

(5.5 Welding Job Making)
CAUTION
• To perform the welding power setup, turn ON the welding power to be
online (communication enable state).
• The welding method is not set before shipping. Be sure to set a welding
method.
• If communication is disable, "Welding power: Ethernet communication
error" is displayed in the lower side of the screen.
Be sure to check to confirm that this is not displayed before performing the welding power setup.
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5.2 Welding Unit Characteristics Setup
Fig. 5-1 WELDER:Ethernet Communication Error Display
Select the welding unit characteristics file for the RL350 ("MOTOWELD-E series 350A" class).
For the voltage command type, there are the auto adjustment setting and the individual set-
ting. Select one between them.
Operation Description
1 Select [ARC WELDING] 
[POWER SOURCE COND.] on
the Main Menu.
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2 Select [DATA]  [READING].
3 Set the characteristics of the

welding power to be used.
Select the welding characteris-
tics file of the auto adjustment
setting or the individual setting
according to the voltage com-
mand type.
For the RL350, select the auto

adjustment data or the individ-
ual data of "MOTOWELD- E
Series 350A class".
4 Change the setting from "Not

completed" to "DONE".
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5.3 Welding Power Basic Setup
Basic setup of the welding power is performed. Change the security mode of the robot control
unit to the administrator mode. In the editor mode, setup cannot be made and only browsing
is allowed.
5.3.1 Security Mode Change
1 Select [SYSTEM INFO] 
[SECURITY] on the Main
Menu, and set the security
mode to [MANAGEMENT
MODE]. Enter the password of
the administrator mode.
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2 The display indicates the
administrator mode.
5.3.2 Welding Power Setup Screen Display
[ARC START COND.] on the
Main Menu.
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2 Select [OTHER] tab of the ARC
START COND. screen, and
press [Welder setting] button.
3 The MOTOWELD screen is

displayed.
When the communication with

the welding power is estab-
lished, the welding power type
and voltage command are
automatically acquired from the
welding power and they are
set.
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5.3.3 Feeder Motor Selection

By changing the C parameter C09 value, the feeder motor selection can be changed.
C09: 0 Print servo
C09: 1 Servo torch
C09: 2 Mechanical servo (YWE-WF-X40TELC, YWE-WF-340MELC, YWE-WF-340TELC)
(Factory setting)
C09: 10 EAGL motor
1 Press [Welder prm.] button on
the MOTOWELD screen.
2 Select [Gas/Wire] tab of the

Welder prm. screen, and set
feeder unit from Feeder Type
(C09).
After the setup, be sure to
press [SAVE].
3 Turn OFF the welding power

source and turn ON it again.
Fig. 5-2 Feeder Unit Setup Screen
CAUTION
• If the feeder unit setup is made erroneously, the wire cannot be fed at
the instructed wire feeding speed, resulting in defective welding.
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5.4 Welding Method Setup
The welding types available for software version 1.00-001-A (CPU) are listed in " 18 List of
Welding Types ".
The welding method has not been set before shipping. When welding is performed with a
user file which has no setting of welding method, Welding method not set Err602 is generated.
Be sure to set the welding method before executing welding.
Main Menu.
2 Press [Welder setting] button of

the [OTHER] tab.
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3 Select the welding power user
file to be used from the welding
method list, and press [Weld
type] button.
The user file describes the
setup content of the parameter
for optional welding method.
Max. 16 welding power user
files can be registered.
4 Select the wire type, the wire

diameter, the shield gas, and
the pulse, select the welding
method to be used among the
displayed welding methods,
and press [SAVE] button.
If there are two or more weld-
ing method options, select one
from the list.
If the welding method is not
displayed, it means there is no
corresponding welding
method.
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5.5 Welding Job Making
1 Select [JOB] on the Main
Menu.
2 A job is made and [ARCON] is
registered at the start point of
welding.
In this case, the setting method
of ARCON is made as the
welding start condition file
[ASF#(x)].
* x: Optional file number
3 Press the direct open button on

the ARCON command on the
job screen to display the weld-
ing start condition screen, and
select the other tab.
Set the [Weld user file No:] as
the welding power user file
number which was set in
" 5.4 Welding Method Setup "
The user file number to be used
is in the range of 1 to 16.
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4 Press the welding power setup (Example: When "1" is selected as the user file number in the
button and check the welding welding start condition file, "Weld No.10" of the welding power
method registered in the user user file 1 is used.)
file.
With the above procedure, setup of the welding power digital communication is completed.
CAUTION
• The user file is changed to the number which was specified with the
user file number when executing the ARCON command. On the welding
power panel, the welding method which was registered in the selected
user file is displayed.
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6.1 MOTOWELD Screen
6 Welding Power Customization
6.1 MOTOWELD Screen
6.1.1 MOTOWELD Screen (Online/Offline)

The setup items on the MOTOWELD screen are described.
1 2
3 4
5 6
7 8 9
Fig. 6-1 MOTOWELD Screen (Online)
1 2 10
3 4
5 6
7 8 9
11
Fig. 6-2 MOTOWELD Screen (Offline)
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6.1 MOTOWELD Screen
Description
1 Welder Set the power type.

When the communication with the welding power is established,
the welding power type is automatically acquired from the welding
power and it is set.
2 Welder No. Select the welding power No. connected to the robot control unit.
• When there is only one welding power, "1" is displayed.
• When there are two welding powers, select between "1" and "2."
3 Weld-V:synergic Check the setup status of the auto adjustment or the individual
setup.
Selection of the auto adjustment setting or the individual setting is
switched by reading the welding unit characteristics file.
4 Feeder Type The setting status of the feeder unit is displayed.

Set the feeder unit from [⑥ Welder prm.].
5 Maintenance The display shifts to the maintenance menu.
6 Welder prm. The display shifts to the adjustment menu for the motor and gas.
7 Weld type The list of the set user files (16 files) is shown.
8 Weld type Set the welding method in the user file selected in the welding
method list.
The display shifts to the welding method selection menu.
9 Customize Used to change the welding parameter from the default value.
If the selected user file number is not registered, it cannot be
selected.
The display shifts to the Customize screen.
10 OFFLINE Indicates the communication status with the welding power.

When the communication with the welding power is established:
No display is shown.
When the communication with the welding power is not estab-
lished:
"Offline" is displayed.
When the operation is performed in the offline mode, the set con-
tents are not reflected on the welding power. To set the content
which is set in the offline to the welding power, turn ON the weld-
ing power to establish the communication and execute data writ-
ing (DX  Welding power).
11 to ONLINE Displayed during the offline mode.

When the offline shift button is pressed under the state where the
communication with the welding power is established, the display
shifts to the online mode.
The welding power setting can be edited either in the online mode or in the offline mode.
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6.1 MOTOWELD Screen
 Online Mode
The welding power is ON and the communication is established. Use this online mode nor-
mally to change the welding power setting.
 Offline Mode
The offline mode is used when there is no welding power or when the communication with the
welding power is not established.
In the offline mode, the welding power parameter can be set by the robot control unit alone.
To reflect the set contents on the welding power, switch to the online mode and execute the
auto adjustment writing to the welding power. (Refer to " 6.4 Maintenance Screen ") If the
auto adjustment writing to the welding power is not executed, the parameter set content of the
welding power and that of the robot control unit may be out of synchronization and welding
setting may be invalid.
6.1.2 Parameter Discrepancy Screen

When setting the welding power in the digital communication, parameters of the welding
power are read by the robot control unit and edited and written into the welding power.
When opening the welding power setting screen, the parameter setting of the robot control
unit and that of the welding power are compared. If they are out of synchronization, the dialog
shown in " Fig. 6-3 Parameter Discrepancy Screen " is displayed.
To validate the setting in the robot control unit side, execute "DX  Welder".
To validate the setting in the welding power side, execute "Welder  DX".
Fig. 6-3 Parameter Discrepancy Screen
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6.1 MOTOWELD Screen
6.1.3 Note and Procedure When Switching the Welding

Power Source
When switching the welding power source, use the following procedure to write parameters
from the robot control unit into the welding power source. If the parameters are not written,
Err602 is output when executing the ARCON command since the welding method has not
been set before shipping.

Main Menu.
2 Select [OTHER] tab of the ARC

START COND. screen, and
then press [Welder setting].
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6.1 MOTOWELD Screen
3 The parameter discrepancy

screen is displayed.
Execute "DX  Welder".
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6.2 Welder prm. Screen
6.2.1 Gas/Wire Screen
Fig. 6-4 Gas/Wire Screen
Description
1 Feeder Type (C09) Set the feeder unit model.

C09: 0 Print servo
C09: 1 Servo torch
C09: 2 Mechanical servo (YWE-WF-X40TELC, YWE-WF-
340MELC, YWE-WF-340TELC) (Factory setting)
C09: 10 EAGL motor
2 Gas pre-flow time (C01) Set the gas pre-flow time. (Set time range: 0.056 sec - 3 sec)
During gas pre-flowing, the robot stops at the arc start point.
3 Gas after-flow time (C02) Set the gas after-flow time. (Set time range: 0.1 sec - 10 sec)
4 Gas check time (C00) Set the gas adjustment time in the welding power side. (Unit: sec,
Default: 20 sec)
When the gas adjustment button of the welding power is pressed,
the LED lights up. When the set time passes, gas flow is automat-
ically stopped. When the gas adjustment button is pressed again
during gas check, shielding gas is stopped.
5 Motor curr. warning (C25) When the motor current of the feeder motor exceeds the alarm
level C25, the wire feeding speed indicator blinks. Welding opera-
tion and wire inching operation are not interrupted by this alarm.
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6.2.2 Other Screen

This menu is to set the welding power panel display, the output current monitor parameter, the
external resistors, etc.
Fig. 6-5 Other Screen
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6.2.3 All PRM. screen

For parameters C and D, the number is specified and the value is entered.
This menu is used to set parameters which are not described in " 6.2.2 Other Screen ".
Press the list display button to select between parameter C and parameter D.
For parameter D, press the ON/OFF select button to change the setting.
Fig. 6-6 Parameter C Menu
Fig. 6-7 Parameter D Menu
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6.3 Customize Screen
Fig. 6-8 Customize Screen
The welding parameters of the welding power can be changed.

The following welding characteristics can be adjusted by the welling parameters.
① Start characteristics Characteristics from arc on to stabilization of the welding

conditions.
② End characteristics From arc off to deletion of arc.
③ Short-circuit welding characteristics Characteristics of welding during short-circuit welding.
④ Pulse welding characteristics Characteristics of welding during pulse welding.
⑤ Other characteristics Current output characteristics.
The parameters of start, short-circuit (pulse), and end are changed by changing the above
tab.
After changing the tab, press [SAVE] button in the lower side to reflect the change to the weld-
ing power user file.
The welding characteristics of the digital inverter welding power MOTOWELD-RL350 are
determined by the database loaded in the welding power. The characteristics value can be
changed to 10% - 200% of the database value by adjustment the P parameter. Normally the
characteristics value of the database can be used. If, however, there is any need for changing
the characteristics depending on the environmental conditions or preferences, adjust as fol-
lows referring to the descriptions below.
The factory setting when shipping is "100 (%) = Operate according to the database character-
istics."
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6.3.1 Start Characteristics

The parameters on the initial generation of arc when arc is on.
Parameter No. Meaning Adjustment reference
P00 Wire speed until the wire The wire lead tip is left  Small
reaches the work. No arc is generated  Great
P01 Wire speed of returning when Greater spatter at arc start  Great
arc is generated until the wire Arc flaming at arc start  Small
reaches the work. (Valid at
touch start only)
P02 Peak current of the pulse current Greater spatter at arc start  Great
flowing for generation of arc. Arc flaming at arc start  Small
P04 Peak time of the pulse current

flowing for generation of arc.
P05 Average current of the hot con- Greater spatter at arc start  Small
dition for stabilizing the melt Greater arc flaming at arc start  Great
pool.
P06 Average voltage of the hot con- Greater spatter at arc start  Great
dition for stabilizing the melt Arc flaming at arc start  Small
pool.
P07 Output time of the hot condition Melts and Drops at arc start  Small
for stabilizing the melt pool. Considerable time for stabilizing arc  Great
P43 Shift time from the hot condition Melts and Drops at arc start  Small
to this condition. Considerable time for stabilizing arc  Great
Fig. 6-9 Start/End Screen
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6.3.2 End Characteristics

Characteristics parameters after turning off arc until arc is extinguished completely.
P11 Average current for crater Crater makes a hole.  Small

process after turning OFF arc Crater is not covered.  Great
(Only when the end process
is enable)
P12 Average voltage for crater

process after turning OFF arc
(Only when the end process
is enable)
P13 Time for crater process after

turning OFF arc (Only when
the end process is enable)
P14 Average current for adjust- The wire adheres to the chip.  Small
ing flaming after welding The wire adheres to the work.  Great
P15 Average voltage for adjusting

flaming after welding
P16 Arc time for adjusting flaming

after welding
P20 Time for preventing the wire The wire melts and adheres to the work.  Great
from adhering to the work Arc is generated in a section other than the weld-
ing section when air cutting.  Small
P44 Shift time from this condition to Crater makes a hole.  Small
the crater condition (Only when Crater is not covered.  Great
the end process is enable)
Fig. 6-10 End Screen
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6.3.3 Short-circuit Welding Characteristics

"Soft arc" mode and "Hard arc" mode are presetted for simple adjustment.
• Soft arc: Use this mode to reduce spatters. Do not use this mode when the welding is not stable
or when high-speed welding is applied.
• Hard arc: Use this mode when the welding is not stable or when the high-speed welding is applied.
For detailed adjustment, choose "Professional" mode and set the parameters below to change
the short-circuit welding characteristics.
P08 Peak current of the pulse Arc flaming  Small

Arc spatter  Great
P10 Peak time of the pulse
P24 Sensitivity of necking Change P24 arbitrary and adjust the arc
P37 Current rising speed (First half) Much spatter  Small

when short-circuiting Unstable arc  Great
P38 Current rising speed (Latter half)

when short-circuiting
P47 Target value of short-circuit cur- Much spatter  Small

rent Unstable arc  Great
P33 Arc current decrease speed • No drop, long-term arc  Great

• Unstable arc  Great
• Bead is made flat with stainless steel
 Small
• Long-term short-circuit  Small
• Drop of melted metal  Great
Fig. 6-11 Short Screen
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6.3.4 Pulse Welding Characteristics

Parameters of characteristics of the MAG/MIG pulse welding which uses mixed gas with Ar
98% or less.
Parameters A00 - A02 are adjusted by adding parameter values to the database values.
To adjust with the conventional P parameter ratio (P08 - P10), refer to " 6.3.8 All PRM. Screen ".
Parameter No. Range Meaning Adjustment reference
A00 -100 A to +150 A Pulse peak current for droplet Much spatter  Great
transfer Much flaming  Small
A01 -50 A to +150 A Base current for maintaining arc
A02 -1.0 ms to +2.0 ms Pulse peak time for droplet

transfer
P31 10 to 200% Pulse current rise speed Arc flaming  Small

P33 10 to 200% Pulse current fall speed Arc flaming  Great

Arc spatter  Small
Fig. 6-12 MAG Pulse Screen
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Arc length vibration great
Arc length control

NG gain too much
Welding direction
OK
Arc length 1
Arc length control gain

P61 NG Arc length following problem
Arc length gain

insufficient Transient state Steady state
Fig. 6-13 Arc Length Control
P61 Arc length control gain in pulse Arc length vibration  Small
welding Ark length following problem  Great
CAUTION
• If there is a following problem of robot with COMARC (arc sensor),
increase the arc length gain (target: P61=110 - 120%).
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6.3.5 Aluminum MIG Pulse Welding Characteristics

Characteristic parameters of the aluminum MIG pulse welding under the condition.
Parameters A00 - A02 are adjusted by adding parameter values to the database values.
To adjust with the conventional P parameter ratio (P08 - P10), refer to " 6.3.8 All PRM. Screen ".
Parameter No. Range Meaning Adjustment reference
A00 -100 A to +150 A Pulse peak current for droplet Much spatter  Great
transfer Much flaming  Small
A01 -50 A to +150 A Base current for maintaining arc
A02 -1.0 ms to +2.0 ms Pulse peak time for droplet

transfer
P35 10 to 200% Pulse current rise speed Arc flaming  Small

P36 10 to 200% Pulse current fall speed Arc flaming  Great

Arc spatter  Small
Fig. 6-14 Aluminum MIG Pulse Screen
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6.3.6 Welding Current Output Characteristics
P62 Welding current output charac- The actual welding current value is great. 
teristics 1 (150 A or less) Small
The wire feed amount is The actual welding current value is small. 
adjusted so that the actual weld- Great
ing current value coincides with
the welding current command.
P63 Welding current output charac- The actual welding current value is great. 
teristics 2 (250 A or above) Small
The wire feed amount is The actual welding current value is small. 
adjusted so that the actual weld- Great
ing current value coincides with
the welding current command.
The welding current output adjustment (coincidence of the welding current command and the
welding current feedback value) can be made by setting P62 and P63.
Fig. 6-15 Curr. Character Screen
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Correction by Interpolation between Correction by Wire feed amount

parameter P62 calibration 1 and 2 parameter P63 after correction
Wire feed amount

P63
Wire feed before correction
speed
command
P62
Calibration current 1 Calibration current 2 Welding current command

Example: 150A Example: 250A (Panel display current)
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6.3.7 Heat And Wave Form Control (HAWC) Screen

The Heat And Wave Form Control (HAWC) is the function that automatically adjusts the wire
feeder speed so that the heat input is consistently provided at constant rate even when the
length of wire stickout is changed due to strained base metal.
Usually, if the length of wire stickout is changed, the welding current is changed, and then the
heat input (melting) of a base metal and bead width are changed. If the heat input wave con-
trol is enabled, the welding current is kept at constant rate, and then this helps to keep a cer-
tain amount of the heat input (melting) of a base metal and bead width.
Fig. 6-16 HAWC Screen
CAUTION
• If the heat input wave control is enabled, the amount of spatter may
increase.
• If an arc sensor or the aluminum welding is carried out, disable the Heat
And Wave Form Control.
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6.3.8 All PRM. Screen

For the user file parameter, specify the number and enter the value.
Use this setting to set parameters which are not described from " 6.3.1 Start Characteristics "
to " 6.3.5 Aluminum MIG Pulse Welding Characteristics ".
Fig. 6-17 All PRM. Screen
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6.4 Maintenance Screen
6.4 Maintenance Screen
Fig. 6-18 Maintenance Screen
Description
1 All write Execute when the welding power is changed or when the system is
(DX100 welder) reset.
All the set parameters saved in the DX controller are written into the
welding power.
2 All read The welding power setting is saved in the DX controller.

(welder DX100)
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6.5 External Memory
6.5 External Memory
The welding power setting can be saved to or read from the external memory (compact flash
or USB memory) of the DX controller.
There are following two kinds of setting files of the welding power.
• Welding method condition file: WELDTYPE.CND
• Digital welding power characteristics: DIG_WELD.DAT
6.5.1 Setting Contents Save
1 Select [EX. MEMORY] 

[SAVE] on the Main Menu.
2 Select [FILE/GENERAL DATA].
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6.5 External Memory
3 Select [WELD TYPE] and

[DIGITAL WELDER CONDI-
TION], and execute the save
process.
6.5.2 Setting Contents Reading
1 Select [EX. MEMORY] 

[LOAD] on the main menu.
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6.5 External Memory
2 Select [FILE/GENERAL DATA].
3 Select [WELD TYPE] and

[DIGITAL WELDER CONDI-
TION], and execute the load
process.
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7.1 Checking the Welding Conditions
7 Welding Operation
7.1 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.
7.2 Wire Stickout
The wire length from the torch tip to the arc point is called wire stickout. Keep this length con-
stant during welding.
The standard length (  ) of wire stickout varies depending on the wire diameter. When the wire
diameter is 1.2 mm, the standard length of wire stickout is 15 mm. When the wire diameter is
0.9 mm, the standard length of wire stickout is between 10 and 15 mm.
7.3 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 car-
ried 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
l
Gas
Base metal
Forward welding is preferred in CO2/MAG welding.

Fig. 7-1 Direction of Welding and Torch Angle
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7.4 Precautions on Using Extension Cable
7.4 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. 7-2 Reference for Voltage Drop along Extension Cable " shows a refer-
ence 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
between voltage drop and welding current
(one way)
25m when an extension cable of 60 mm2 is
Voltage 20m used. If extension cables are used for
drop (V) 2
15m
10m both ways, the voltage drop becomes
twice as much as the value indicated in
0 this graph.
100 200 300 500
Welding current (A)
This graph indicates the relationship
4
Extension cable length between voltage drop and welding current
(one way)
25m when an extension cable of 80 mm2 is
Voltage 20m used. If extension cables are used for
drop (V) 2
15m both ways, the voltage drop is twice as
10m
much as the value indicated in this graph.
0
100 200 300 500
* If an extension cable is used for pulse
Welding current (A)
welding, the response for the pulse wave-
Fig. 7-2 Reference for Voltage Drop form control may be delayed, which may
along Extension Cable
prevent the spatter-less pulse welding.
Use a cable as short as possible for high
quality welding.
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8.1 Error Detection Function
8 Precautions on Welding
8.1 Error Detection Function
Error detection is performed for the items listed in " 19 List of Errors ", and the welding power
source stops automatically when an error is detected.
Please refer to " 19 List of Errors " for the details.
8.2 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.
8.3 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 one seconds after the welding ends due to the two-second
delay set for the welding source. Also, do not touch the welding wire during the starting
point detection (optional function) since the voltage of approx. 200 V is applied to the
wire.
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%
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8.3 Precautions on Welding Operation
Table. 8-1 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 -
4. Power switch operation

The inverter welding source is the forced air-suction cooling type. After welding, do not
turn OFF the power supply switch before the cooling fans except top one stop com-
pletely.
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 fans start rotating as soon as the welding power source is turned ON. The
fans except top one stop if approx. 15 minutes passes without start welding. The fans
restart rotating when welding starts, and they stop after approx. 15 minutes from the
welding ends.
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 spat-
ter 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 weld-
ing torch close to the 100 VAC cable.
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9.1 Location of Printed Boards
9 Location and Setting of Printed Boards
9.1 Location of Printed Boards
The printed boards are located under the top cover of the welding power source.
RC2 RC5 RC7

32A 600VAC
tend
10.3x38
32A 600VAC
tend
10.3x38
RC4
SD2-1
SD2-2 PS35
SD2-3
PS32
SD5 PS33
Pr(SD)-006
SD1
Pr(IF)-008B
PS29
SD6 PS23
PS7
SD3
PS6 PS2
1 3
DJ1
PS1
SD4
IF32
3 1
3 1
DJ2 DJ1
J1
IF31 IF35
Pr(MB)-030
200V
(OPTION)
1
2
3
4
Pr(CR)-030
Front face of the welding source
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9.2 Internal Selecting Switches
9.2 Internal Selecting Switches
9.2.1 DIP Switch Settings for Pr(MB)-030 Board

The internal selecting switches are set as follows before shipping.
The internal switches exept SW101 are not allowed to change settings since the switches are
prepared for adjustment and maintenance performed by manufacturers.
Table. 9-2 Settings of DIP Switches
DSW Default Setting Spare

1 OFF
2 ON
SW100
3 OFF
4 OFF
ON:Digital communication
1 ON
SW101 OFF:Analog communications
2 ON
SW200 ON
SW600 ● side
1 ON
SW700
2 ON
9.2.2 DIP Switch Settings for Pr(CR)-030 Board

The internal selecting switches are set as follows before shipping.
The internal switches are not allowed for change since the switches are prepared for adjust-
ment and maintenance performed by manufacturers.
Table. 9-3 Settings of Jumper Pins
DSW Default Setting

1 OFF
2 OFF
SW301
3 OFF
4 OFF
CAUTION
• Be sure not to switch the selecting switch which is designated as
"switch disabled" by mistake. Failure to observe this caution may result
in a trouble.
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10 Maintenance and Inspection
Perform periodical maintenance and inspection for safe and efficient operations of the welding
source.
Before maintenance or inspection, or wiring, be sure to turn OFF the switch in the switchgear
on the input side. 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.
Table. 10-4 Maintenance and Inspection Items
Daily inspection items Bimonthly to semiannual inspection items
(1) The switches operate without fail. (1) Removal of dust and dirt
(2) The cooling fan rotates smoothly by turning Remove dust and dirt by spraying dry com-
ON/OFF the power supply switch and draws pressed air. Carefully clean spaces between
the air in from the rear face. the transformer and reactor windings, and
(3) There is no abnormal vibration, beat, or odor. semiconductors.
There is no leakage of gas. To clean circuit boards, use the exclusive-
(4) The cable connecting section is not exces- use dust remover device.
sively heated. (2) Inspection of electric connecting sections
(5) The power cable and its connecting section Check that the bolts are firmly tightened and
are not excessively heated. rust or the like does not deteriorate the con-
(6) There is no damage on the connection cable tacts in the connecting sections with the
such as a cable on the input side or on the external wiring such as input/output terminals
base metal side, resulting in imperfect insula- or with the internal wiring. Retighten the
tion. bolts if necessary or use a file to remove rust,
(7) Each connecting section is tightened if any, so that the metallic faces contact with
securely. each other.
(3) Inspection of ground line
Confirm that the case is grounded properly.
Annual overhaul and repair
Carry out the integrated repair such as replacement of defective components, case repair, and rein-
forcement of insulation deteriorated parts. When replacing defective components, replace them with
the components which are ordered at monthly inspection. 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 deteri-
orated part must be repaired.
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Table. 10-5 Lifetime of Parts
Lifetime of welding power parts
The welding source is composed of many components. Unless all these components operate nor-
mally, 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).
① Electrolytic capacitor: Approx. 5 years
② Cooling fan: Approx. 5 years
③ Breakers, relays: Depends on how often they are used. It is recommended that they be replaced
approximately every 5 years.
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10.1 Cleaning of Dust Protective Filter
10.1 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 rear face of the welding source as illustrated in "
Fig. 10-3 Cleaning of Filter ". Clean the filter by following procedures below.
(1) Remove the filter cover2.

(2) Remove the filter installed on the filter cover2.
(3) Clean the filter.
Tap at the filter with a rod, etc. to remove dust and dirt.
(4) Clean the filter.
Tap at the filter with a rod, etc. to remove dust and dirt.
(5) Install the filter in filter cover 2.
(6) Install the filter cover2 on the rear face of the welding source.
Fig. 10-3 Cleaning of Filter
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10.2 Replace Fuse
10.2 Replace Fuse
If any failure shown below occurs, check the fuse. When the new fuse has blown again even
after replacing, please contact the service representative.
When the following phenomenon occurs, please confirm a fuse. When a fuse performs blow-
out again even if I change a fuse, please refer to Yaskawa service.
Table. 10-6 Fuse
Item Fault
Fuse 10A blown. • Although the start signal is ON or the wire inching signal is ON,Motor
does not operate.
• Cooling fan does not rotate.
Fuse 2A blown. • Although power switch is ON,the Digital Meter does not display.
Fuse 2A
RC2 RC5 RC7
32A 600VAC
tend
10.3x38
32A 600VAC
tend
10.3x38
RC4
Fuse 10A SD2-1
SD2-2 PS35
SD2-3
PS32
SD5 PS33
Pr(SD)-006
SD1
Pr(IF)-008B
PS29
SD6 PS23
PS7
SD3
PS6 PS2
1 3
DJ1
PS1
SD4
IF32
3 1
3 1
DJ2 DJ1
J1
IF31 IF35
Pr(MB)-030
200V
(OPTION)
1
2
3
4
Pr(CR)-030
Fig. 10-4 Fuse
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10.2 Replace Fuse
Fig. 10-5 Fuse holder
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11.1 Confirming Setting conditions
11 Failure Analyses
Confirm that the junctions between the metal receptacle and the cable, and the connectors on
the printed boards are connected securely. 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.
1. Before maintenance, inspection, or wiring, be sure to turn OFF the switch in the pri-
mary side switch gear. Failure to observe this warning may result in electric shock or
injury.
2. To connect a nylon connector, insert the connector after matching the connector num-
ber 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.
If any fault occurs, check the following items.
Table. 11 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.
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 ⑧ "Auto Adjustment/Individual" on the weld-
ing source panel. When "synergic (auto adjustment)" is selected, the LED indicator
"Auto Adj." lights. 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 C parameter C09 to check if the motor is correctly
selection selected. (0: Print servo 1: Servo torch, 2: 4-roller servo (YWE-WF-X40TELC,
YWE-WF-340MELC, YWE-WF-340TELC))
If the motor is not correctly selected, the wire is not fed as instructed by the com-
mand value and welding performance becomes unsatisfactory.
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Table. 11 Check Items
Item Contents
Voltage If the voltage detection wire is disconnected, the 7-segment LED indicator for weld-
detection wire ing voltage  on the welding source panel displays approx. 0 V. Then the error
ERR702 "Voltage detection wire error" is displayed on the 7-segment LED indica-
tors. Check if the voltage detection wire is correctly connected.
P Parame-  In the case of digital communication

ters cannot P parameters can be changed only in the robot control unit side.
be changed.
User files  In the case of digital communication

cannot be The user file can be changed only in the robot control unit side.
selected.
D parameter D1-11 is used to specify whether the user file is selected from the
panel or the robot. (D1-11 OFF: from panel, ON: from robot)
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 P parameters are deleted.
WIre feeder When the wire feeder cable is damaged, or the cable is not connected properly, the
cable wire feeding speed may become excessively fast. In addition, the 7-segment LED
indicator for wire feeding speed ③ displays 0 and the error Err501 "Improper feed-
ing amount" is issued. Check the condition of the wire feeder cable.
Shielding gas Check if the shielding gas suitable for the welding type is selected. For pulse weld-
ing, the argon ratio must exceed 80% to execute one pulse per drop. If short-circuit
occurs excessively during pulse welding, check the argon ratio.
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11.2 Cause and Remedy of Welding Section Failure

Table. 12 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 qual-
is poor. ity.
The nozzle is too far from the Keep the proper length of the wire stickout (10 mm
arc point. to 15 mm) to perform welding. Increase the gas
flow amount.
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Fault Cause Remedy
Arc is Power supply voltage exces- Use a different power supply from that of other
unstable. sively fluctuates. machines that cause power supply voltage fluctua-
tion. 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 set-
correct. tings 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 connec-
loose. tions 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 with-
out 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 dis- Check each terminal connection and the connec-
torted. tions with base metal. Polish the contacting face
and tighten them securely.
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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 appear- welding torch can constantly aim at a target. Or
ance is change the welding speed.
poor.
The shielding gas has a prob- Since the gas flow amount is not sufficient, let the
lem. 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 weld-
ing wire The welding conditions are not Check that the welding voltage set value is not too
sticks to the correct. large or that the wire feeding set value is not too
end of the small.
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 buck- Pull the welding wire from the inside of the conduit
les. and pass the welding wire again through the con-
duit.
11-5
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11.3 Cause and Remedy of Failure at Electrical Circuit Section
11.3 Cause and Remedy of Failure at Electrical Circuit

Section
Table. 13 Fault Analyses for Electrical Circuit Section
No. Failure Cause Remedy
No image is displayed in the Fuse (2 A) blown Investigate the cause and

operation panel even if the power replace the fuse.
supply switch is turned ON.
1 Wrong setting of input volt- Check the input voltage
age setting.
See " 2.5 Setting of
Switching Input Voltage ".
The cooling Power lamp Defect in the cooling fan, Check the cooling fan
fan does not lights control circuit or SW power and the printed board
rotate even if +24 V supply Pr(MB)-030 and Pr(SD)-
the power 006.
supply switch
is turned ON. Fuse (2A) blown Investigate the cause and
replace the fuse.
2
Fuse (10 A) on the Pr(SD)- Investigate the cause and
006 board blown replace the fuse.
Power lamp Wrong setting of input volt- Check the input voltage
does not light age setting.
See " 2.5 Setting of
Switching Input Voltage ".
The welding source does not start The start signal is not sent to  In the case of digi-
although the start signal is turned the welding source. tal communication
ON.. Check the communica-
tion setting in the welding
power side and in the
robot control unit side.
• Check to confirm that
the communication
3
cable is securely con-
nected.
 In the case of ana-

log communication
(option)
• Check for the welding
command cable..
11-6
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Although the Voltage is Motor failure Replace the motor.

start signal is applied to the
ON, only the motor terminals
motor does (between #G and
not operate. #H of the con-
nector CON6)
The voltage is Disconnection of the wire Replace the device con-

not applied to the feeder cable, or improper trol cable or check con-
4 motor terminals contact of the connector tacting sections.
(between #G and
#H of the con- Fuse (10A) on the board Upon investigating the
nector CON6). Pr(SD)-006 blown error cause, replace the
fuse (10A) on the printed
board Pr(SD)-006.
Printed board Pr(SD)-006 Check and replace the

failure printed board Pr(SD)-
006.
Welding cur- Welding current The analog command sent  In the case of digi-
rent cannot command can- from the robot side is not nor- tal communication
be changed. not be changed mal. Check the communica-
from the robot tion setting in the welding
side. power side and in the
Check to confirm that the
communication cable is
5
securely connected.

log communication
(option)
Check the analog com-
mand output on the robot
side.
Welding volt- Welding voltage The analog command sent  In the case of digi-
age cannot command can- from the robot side is not nor- tal communication
be changed. not be changed mal. Check the communica-
from the robot tion setting in the welding
side. power side and in the
Check to confirm that the
communication cable is
6
securely connected.

log communication
(option)
Check the analog com-
mand output on the robot
side.
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Error indication on the digital See " 19 List of Errors ". See " 19 List of Errors ".
7
meter
The power supply switch is Damage to the input diode Contact your Yaskawa
tripped and the power is not representative.
8
turned ON. Damage to the main circuit
transistor (IGBT)
Shielding gas cannot be adjusted Failure of the gas solenoid Investigate the gas sys-
or stopped. valve tem.
Fuse (10 A) on the board Upon investigating the

Pr(SD)-006 blown error cause, replace the
9 fuse (10 A) on the printed
board Pr(SD)-006.
Failure of the printed board Check or replace the

Pr(SD)-006 printed board Pr(SD)-
006.
The starting point detection can- The starting point detection Check the connection
not be detected. command is not sent to the signal cable.
welding source or the power
supply for starting point I/F is
not supplied to the welding
10
source.
The starting point detection

signal is not sent from the
welding source.
11-8
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12.1 Specifications of Robot Digital Interface Signals
12 Robot Interface Signals
12.1 Specifications of Robot Digital Interface Signals
Communication with the robot control unit is made through an Ethernet cable. Connect the
Ethernet connector to connector CON8.
Item Content
Communication cable Ethernet cable (Category 5 or above, with shield)

Direct connection: Cross cable
Hub connection: Straight cable
Communication speed 100 Mbaud
Connector RJ45/IP67
The voltage for detecting wire adhesion is not displayed on the panel of the welding power.
12.2 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 " 13 Connection System Diagram "
Pin No.
Correspon Signal Direction Signal
No. Function
ding to Meaning *1 Form
Connector
A-B Arc voltage Gives the compensation value of the arc R W Analog
(0V side) adjustment voltage when set to "Synergic." voltage
1
instruction (When set to "independent," the arc volt- input of
age is sent directly.) 0V to 14V
C-D Welding Gives the set value of the output current R W Analog
(0V side) current (wire feeding amount) for the welding voltage
2
instruction source. input of
0V to 14V
F-G Wire inch- Performs the wire inching. R W Contact

ing instruc- input
3
tion (Valid at
closed)
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Pin No.
No. Function
Connector
H-J Wire retract Withdraws the wire. R W Contact

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

ARCOF input
5
instruction (Valid at
closed)
M-N Wire stick Sends the output terminal voltage of the WR Welding
("-" side) detection welding source. source
The wire stick detection voltage output
6
(approx.15 V) is input from the robot voltage
side. (Analog
value)
P-E Arc occur- The signal is output when the current is WR Contact
(COM) rence detected continuously for 16 ms after output
detection the gas pre-flow upon receiving the arc (Valid at
start signal. If the current is not detected closed)
for 48 ms or more continuously after the
signal is output, the signal stops being
7
output.
The process described above is
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 W R Contact
(COM) detection start is not detected for 1.5 seconds output
after the gas pre-flow upon receiving (Valid at
the arc start signal. closed)
2. After the arc occurrence is detected
within 1.5 seconds, the signal is out-
put 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 com-
mand of welding source is released.
4. The signal is output also when an
error occurs in the welder.
S-E Reserved
9
(COM)
T-E Reserved
10
(COM)
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Pin No.
No. Function
Connector
E Common Common for detection line WR Return

line of
11
contact
output
W-X Monitoring Sends the monitoring signal of the out- WR Analog
output for put current. voltage
12
output cur- 3.0 V/600 A
rent
U-V Monitoring Sends the monitoring signal of the out- WR Analog
output for put voltage. voltage
13
output volt- 3 V/60 V (66 V for 66 V or more)
age
b-Z User file Externally switches the user file selec- R W +24V
14 selection tion by connecting each signal to com- 10%,
OP1 mon (Z). current
* Connected to the pin terminals "OP1" capacity
Y-Z User file and "OP2" of the standard welding of 50mA
selection instruction cable. or more
15
OP2 * To externally switch the user file, set D
parameter D1-11 to "ON".
a-Z Gas check Turns ON/OFF the gas solenoid valve R W Contact
GAS by connecting to common (Z). input
16
(Valid at
closed)
Z (531) Common Com R W Return

COM line of
17
contact
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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12.3 Connection of Gas Pressure Shortage sensor and Wire Shortage sensor
12.3 Connection of Gas Pressure Shortage sensor and

Wire Shortage sensor
This welding power source has no interface to cennect the gas shortage sensor and the wire
shortage sensor. In order to use these sensors, cennect the sensor cables to the terminal
block inside of the robot controller.
12.3.1 Wiring of sensor cables

A terminal block (option) connected to CN308 on the I/O unit JZNC-YIU01-E inside of the
robot controller DX100 is required. Connect the sensor cables to the terminal referring to the
following figure.
Terminal block (CN308)
A1 ＋
Gas shortage sensor
− (Valid at closed)
B3 ＋
Wire shortage sensor
− (Valid at closed)
B7
12.3.2 Edit of Concurrent I/O

Edit the concurrent I/O referring to the following figures.
Gas shortage signal

Default GAS SHORTAGE : 1
#22550 #51540 #51542 #70067 #70042
After
GAS SHORTAGE : 1
editing
#20011 #51540 #51542 #70067 #70042
Wire shortage signal

Default WIRE SHORTAGE : 1
#22551 #51540 #51541 #70067 #70043
After
WIRE SHORTAGE : 1
editing
#20014 #51540 #51541 #70067 #70043
12-4
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12.4 Description and Function of Signal Output Terminals for Monitor
12.4 Description and Function of Signal Output

Terminals for Monitor
The following shows the correspondence between the signals and the cable numbers of the
connection terminal block.
TM1
① ② ③ ④ ⑤ ⑥ ⑦ ⑧
A V Inching
"R" indicates the robot side while "W" indicates the welding source side.
No. Signal Description Function Direction
1
Ammeter terminal*1 Outputs 400 A/ 60 mV. WR
2
3
Directly outputs the
Voltmeter terminal*1 output voltage.
WR
4
5 Conducts the opera-

tion of wire inching.
Wire inching RW
(only as for the analog
6
communications)
―
7 ― ―
―
*1 The external meters connected to the terminals are analog meters of ammeter (400 A/
60 mV) and voltmeter (75 V). While in the welding standby status, the analog voltmeter
may indicate some voltage of 10+ V due to wire stick or ground-fault detection at the
robot controller side. However, this is not a failure of the device.
CAUTION
• The output voltage (400 A/60 mV) of the ammeter terminal is different
from the 500 A power supply
12-5
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12.5 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr (OP) -003
[for RL350])
12.5 Meaning and Function of Signal for Starting Point

Detecting Function
(Optional board Pr (OP) -003 [for RL350])
Read this section only when the starting point detection function is used.
The following table shows the cable number of connection terminal block and corresponding
signals.
Connection
Terminal Signal Direc-
No. Function Signal Form
Block Cable Meaning tion*1
No.
Power supply Power supply for starting point +24V10%,

for starting detecting instruction and sending current capac-
1 520 R W
point detec- /receiving of the starting point ity of 30mA or
tion I/F detection signal more
The signal is output when the Transistor out-

Starting point output "+" (torch side) of welding put
2 521 detection sig- source drops to approx. 0V while W R (ON when 0V),
nal the starting point detecting sink current of
instruction is ON. 50mA or less
Power cable on 0V side of the

3 522 Common power supply for starting point R W
detection I/F.
While this signal is ON:

The high voltage (full-wave recti-
Starting point fication, peak value of 220V) for Contact output
4 523 detection the starting point detection is R W (Valid at
instruction applied between welding closed)
source’s output "+" (torch side)
and "-" (base metal side).
Monitoring Monitoring signal for output volt-

5 V output for out- age W R Analog voltage
put voltage 5V/50V (For arc sensor)
Monitoring Monitoring signal for output cur-

6 A output for out- rent: W R Analog voltage
put current 3.5V/350A (For arc sensor)
Common of the monitoring sig-

7 COM Common W R
nal
*1 "R" indicates the robot side while "W" indicates the welding source side.
12-6
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12.5 Meaning and Function of Signal for Starting Point Detecting Function (Optional board Pr (OP) -003
[for RL350])
CAUTION
• The starting point detection function is an optional function. The
optional board Pr(OP)-003 is included when the starting point detection
function is ordered, that is, not included in standard package.
12-7
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5
EL135A
754
755
1 T1
Pr(VR)-
GF002
G3
CN1 309+ EL133
2
AC 200V/ (309) 320
1 CN2 309 BUS1 TB3
(8SQ) TB1.TB3 G1 S2 G1 (204)
400V MCB (8SQ) TP1 TP7
S1 G2 CT1 (12AWG)
REC1 TP2 TP6
Pr(PT) TB1
(8SQ) 301 304 (8SQ)
Pr(DL)-GF006
{ {
Pr(PT) G1
W -GF005 Pr(FE)-GF005 -GF005 Pr(DI)-GF007
(8SQ) 302 305 (8SQ) A CN3 A CN4 G2 A (5.5SQ)
V 310 G3 TB7
TP4 S4 Pr(SH)-GF003
(8SQ) S3 TP9 TB2
(8SQ) 303 306 (8SQ) TP5 G4 CLR
U { TP8
3P BUS2 TB4
{
F306A TB2.TB4
3092 DCL3
(306) F305A (3091) TB3
E (305) (8SQ) SH3
3101
(8SQ)
313
TB5
314
TB4
FG (5.5SQ)
Pr(DI)-GF008
{
Pr (IF) - 008
MCB
TB6
1P 318 R36
2P 3091 319
757
EL135A
756
(206) (2061) 207
(8SQ) T2 P
G3 C E
3102
(3101) DCL2
EL133 T21
G
R22 E11
(8SQ) Pr(IF)
TB1.TB3 BUS1 TB3 G1 G11
G1 S2 E12 -008
TP1 TP7 Pr(VR)-GF001
206
S1 G2 CT2 D1 C1
Pr(PT)
{ TP2 TP6
Pr(PT)
G12
} 1
Pr(DL)-GF006 R35 2
{
310- -GF005 Pr(FE)-GF005 -GF005 Pr(DI)-GF007 237 238
(310) B CN5 G2 C E (2061)
B CN6 B CN2 CN1
(8SQ) G3 S4 T22
TP4 TP9 1
S3 G4 RC5
G
{ TP5 TP8 R23 3
TB2.TB4 BUS2 TB4
{
204
(38SQ) D2 C2
Pr(SN)-GF002
Pr(PT)-GF005 CN1 D3 C3
211 SH2
FG
209
+5V
+5V
8
N
SW1
SW2
SW3
SW4
PS2{
GND
SW1
SW2
SW3
SW4
TX+
TX-
RX+
4
RX-
GND
7
+15F
DRU
GND
DRV
DRV1
211
1 4 1 7 1 8
RC5 { 209 202
SW1
1 CN303 8 1 1 8 MB50 1 IF1 7 CN401 1
+5V MB30 MB1
1 1
CR10 GND
CN302 TX
EC2
8
5
MB20
RX-
4
RX+
7
TX-
TX+
Pr (CR) - 030 RX 2 EL119A
4
4 CN300 4 +5VA (5T)
8
7
6
5
4
3
2
1
1 7 GND 1
KCF-100-B 136 1 E1A E1A
8 13 A UDP/IP
166 EC1 E1B GND_A
B (CON8)
131 4 GND_A E1B
C
130 AIF1 D
531 E
530 KCF-100-B F MOTOR Pr(FE)-GF005 Pr(FE)-GF005
540 552 FG 16 A A
529 1 1 G (CON6)
8 S20 181 5 10
H (AMS3102A 20-27)
{
{
{
{
KCF-100-B 181 113 16 108

I
S1
G1
S3
G3
S2
G2
S4
G4
112 +24V 10 100 J

General view of connection system diagram
263 +12V S1V SD1 108 +5VA

MB13 SD3 K
262 S1V S1U 1 6 1 6
111 L 7
259 S1U S2U 100 207 DRV
AIF2 M CN3 CN4
531 Pr (MB) - 030 +15S +15V 202B
8 8 1 N
KCF-100-B Pr(MB)-030 DRV1
1 Pr (SD) - 006 DRU
+5V 1 MB1 CN1
1P Connector MIF8 +15F
256 4 GND GND
MB14 SD4 Pr(PT)-GF005
13-1
-5V
MB42
5
{ 1
2561 531 3Y
1 5 2
THS1 256 13 109 1 Pr(MB)-030 +15V
3P Connector +24V SD2-1 GND CN2
2562 3 8 14 MB5
FG 2
2P Connector MB40
{ 1
THS2 2561 FG 528 2 CN6 CN5
1 1 6
531 531 SD2-2 1 6 1
THS3 2562 1 540 2 SD6
G8
S8
G6
S6
G7
S7
G5
S5
531 +24V 1
FG FG Pr(PT)-GF005 MB6 1
PTLSE11A3 542 SD2-3
{
{
{
{
5A 18 CN2 541 2
TM +12V SD5 Pr(FE)-GF005 Pr(FE)-GF005
1 3
{
B B
Pr(SD) - 006 529 1
18
17
SD5
GND
+15V
8 MB5 MB3 1 MB15 7 MB12 4 MB10 1 MB4
22V 17 6 1 1 8 1 6 5 1
170
K5B RC
104
-5V
S-L
DV
DV5
2071
TM1
+12V
217
F306A(306) 240V 19.5V 170
GND
IFB
+5V
GND
GND
+15V
VFB
+15V
+15V
GND
(156)
+15V
GND
+15V
26x30x13
541
528
531
540
542
-MG
PWR_DTCT
+24V
+12V
OVR_CUR1
F1 TR1
202
(306B) 200V 0.2A 104 6 1 1 6 1 6 1 2 1 8

19V 753 3 1 PS6 8 PS32 PS23 PS1 RC2 1 KCF-100-B
IF32 209
757
756
755
754
752 IF31 209
211 } SH2
1 211
4A 751 202
}
}
26V 760 CT2 CT1 RC5 206 IGBT
1
F305A(305) FG 202B
(305B) 207B
0.3A 761 6
8V 762 1 SW1
207 202 202
3
202B 202B 202B
13 Connection System Diagram
Pr (IF) - 008B RC7 2

(307) 240V 0.2A 763 202B 202B
3 1
12V 764 IF35 1
3P Connector (L21-22A8)
(306A) 200V RC1
0.2A 765
4
F306A(306) 8V 766 A
CP᎖‫ܗ‬൷រ RC9 RC8
0.2A 767 1 1 207
8 202B
F305A(305) 8V IGBT TB2 2 2
(305A) ֊ང ຏൄ
200V
TB2-6
TB2-5
TB2-4
TB2-3
TB2-2
TB2-1
F2 0.2A 4 1 PS7 PS35 RC3 PBॾᇆ֊ང
200 PS29 PS33 PS2 RC4
26V 2 1 2 1 3 1 3 1 2 1 6 1
313
314
VQ
VIG
722
IQ
209
211
527
526
527
526
536
535
534
533
532
528
723
PTC1 722
t
0 0.2A 723 T31x19x16
(2T) KCF-100-B
(2T)
E11
G11
209
211
E12
G12
14P 16P KCF-100-B
Connector Connector
}
SH3
}
SH2
t
PTC2
5
PTC3 9
t
Pr(MB)-030 TM
}
166
136
131
130+15VDC
531
530
529
528
532
533
534
535
536
526
527
259
263
531
262
VO
VIG
IO
12
209
211
526
527
529
531
3YA CON3 (WPS3102A28-12S-R)

TM1
AC FANx3 A B CD d L KG F J H P RS T EM Na b Z Y UVWX
1 2 3 4 5 6 7 8
+- +-
}
}
+- +-
}
}
VI
DC DC IV
HW1481552
200V-Connector Inching
0-14V 0-14V
HW1481552
116/147　　　
HW1481552
Enlarged view of connection system diagram (left part)
Pr(VR)-
GF002
754
755
1
CN1 309+ EL133
2
AC 200V/ 1 CN2
(309)
{
309 TB1.TB3 BUS1 TB3
(8SQ) G1 S2 {
400V MCB (8SQ) S1
TP1 TP7
G2 CT1
REC1 TP2 TP6
(8SQ) 301 Pr(PT)
W 304 (8SQ)
Pr(DL)-GF006 -GF005 Pr(FE)-GF005
Pr(PT)
-GF005
V (8SQ) 302 A
{
305 (8SQ) CN3 A CN4
U (8SQ) 303 306 (8SQ)

310
(8SQ)
G3
S3
TP4
TP5
TP9
S4
G4
{
TP8
3P
F306A TB2.TB4 BUS2 TB4
3092
E (306) F305A
(305)
(3091)
(8SQ)
3101
(8SQ)
FG
MCB
2P 1P
757
3091
756
(8SQ)
3102
(3101) EL133
(8SQ)
{
TB1.TB3 BUS1 TB3
G1
S1
TP1
TP2
TP7
TP6
S2
G2
{ CT2
Pr(DL)-GF006 Pr(PT) Pr(PT)
310- -GF005 Pr(FE)-GF005 -GF005
(310) B CN5
{
B CN6
(8SQ) G3
S3
TP4
TP5
TP9
S4
G4
{
TP8
TB2.TB4 BUS2 TB4
{
Pr(PT)-GF005 CN1
+5V
GND
SW1
SW2
SW3
SW4
+5V
SW1
SW2
SW3
SW4
GND
RX+
TX+
DRV1
RX-
+15F
TX-
DRU
GND
DRV
8
5
4
7
1 4 1 7 1 8
1 CN303 8 1 1 8 MB50 1 IF1 7 CN401
1
+5V
1
MB30 MB1 1
GND
CN302 CR10 EC2
TX MB20
Pr (CR) - 030 RX
4
2
4 CN300 4 +5VA
1 7 GND 1
KCF-100-B 136 1 E1A
8 13
166 EC1 E1B
131 4 GND_A
130 AIF1
531 KCF-100-B
530
529 1 540
8 S20
KCF-100-B 181
112
263 MB13 +12V
262 S1V
259
531 AIF2 Pr (MB) - 030 S1U
+15S
8
KCF-100-B 1
+5V
1P Connector MIF8
256 GND
4 MB14
-5V
MB42
2561 531 1 5
THS1 256
3P Connector
2562 3 8
FG
2P Connector THS2 2561 FG MB40 528
531 1
531
THS3 2562 1 540
531 +24V
FG FG Pr(PT)-GF005 MB6
PTLSE11A3 542
5A 18 CN2 541
TM +12V
{
Pr(SD) - 006 529 1

+15V
GND
SD5 MB5 MB3 1 MB15 7 MB12 4 MB10 1 MB4

8
22V 17 6 1 1 8 1 6 5 1
PWR_DTCT
2071
+12V
DV5
170
OVR_CUR1
TM1
+15V
+15V
+15V
+15V
+15V
104
(156)
GND
GND
GND
GND
GND
-5V
S-L
K5B RC
DV
VFB
+5V
217
IFB
F306A(306) 240V 19.5V 170

26x30x13
F1 -MG
(306B) 200V 0.2A 104 6 1 1 6 1 6 1 2
19V 753 3 1 PS6 8 PS32 PS23 PS1
IF32
757
756
755
754
752 IF31
4A 751 1
}
}
26V 760 CT2 CT1

1
F305A(305) FG
(305B)
0.3A 761
8V 762
(307) 240V 0.2A 763 Pr (IF) - 008B

12V 764 IF35
(306A) 200V
0.2A 765
F306A(306) 8V 766 A
CP᎖‫ܗ‬൷រ
0.2A 767
8 TB2
F305A(305) 8V IGBT
(305A)
TB2-6
TB2-5
TB2-4
TB2-3
TB2-2
TB2-1
200V
F2 0.2A PS29 4 PS33 1 PS2 PS7 PS35
200
26V 2 1 2 1 3 1 3 1
313
314
VIG
722
209
211
527
526
723
VQ
IQ
PTC1 722
t
0 0.2A 723 T31x19x16

(2T) KCF-100-B
G11
G12
E11
E12
209
211
(2T)
}
14P 16P KCF-100-B

}
Connector Connector SH3

PTC2 SH2
t
130+15VDC
5
PTC3 9 Pr(MB)-030 TM
t
8
VIG
166
136
131
531
530
529
528
532
533
534
535
536
526
527
259
263
531
262
VO
IO
12
209
211
526
527
529
531
3YA CON3 (WPS3102A28-12S-R)

TM1
AC FANx3 A B CD d L KG F J H P RS T EM Na b Z Y UVWX
1 2 3 4 5 6 7 8
+- +-
+- +-
}
}
VI
}
}
200V-Connector DC DC IV Inching
0-14V 0-14V
13-2
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Enlarged view of connection system diagram (right part)
EL135A
T1
G3
320
G1 (204)
(12AWG)
TB1 G1
Pr(DI)-GF007
G2 A (5.5SQ)
TB7
TB2 Pr(SH)-GF003
CLR
DCL3
TB3
SH3
313
314
TB4 TB5
(5.5SQ)
Pr(DI)-GF008
{
Pr (IF) - 008
TB6
318 R36
319
T2
EL135A (206)
C E
(2061) 207 P
G3
DCL2
}
T21 E11
R22
G
G11 Pr(IF)
G1
E12 -008 Pr(VR)-GF001
206
D1 C1
G12
1
Pr(DI)-GF007 R35 238 2
237
(2061)
G2 B C E CN2 CN1
T22
RC5 1
R23 3
G
204
D2 C2
(38SQ) Pr(SN)-GF002
D3 C3
SH2
PS2{
211
209
FG
N
211
RC5 { 209 202
RX+ SW1
RX-
TX+
TX-
8
EL119A
4
7
(5T)
E1A
8
7
6
5
4
3
2
1
A UDP/IP
GND_A
B (CON8)
E1B
C
D
B E
F MOTOR Pr(FE)-GF005 Pr(FE)-GF005
552 FG 16 A A
1 G (CON6)
{
{
{
{
181 5 10
H (AMS3102A 20-27)
113 16 108
I
G1
G3
G2
G4
S1
S3
S2
S4
+24V 10 100 J
S1V SD3 SD1 108 +5VA
K 1
S1U 6 1 6
{
111 L 7
S2U 100 207 DRV CN3 CN4
M
+15V 8 202B
1 N DRV1
1
Pr (SD) - 006 Pr(MB)-030
MB1 DRU CN1
+15F
SD4
GND
Pr(PT)-GF005
5 1
{
3Y 2
13 109 1 Pr(MB)-030 +15V
14 +24V SD2-1 MB5 GND CN2
2 1
1 2 CN6 CN5
6 1 6 1
SD2-2
2 SD6
G8
G6
G7
G5
S8
S6
S7
S5
1
1
{
{
{
{
SD2-3
2
SD5 Pr(FE)-GF005 Pr(FE)-GF005
1 3 B B
18
{ 17
+24V
+12V
541
528
531
540
542
TR1
202
1 8
RC2 1 KCF-100-B
209
211
202
209
211 } SH2
RC5 206 IGBT
202B
207B
6
1 SW1
207 202 202
3
RC7 202B 202B 202B
2
202B 202B
3 1
1
3P Connector (L21-22A8)
RC1
4
RC9 RC8
1 1 207
202B
2 2
֊ང ຏൄ
RC4 RC3 PBॾᇆ֊ང
2 1 6 1
527
526
536
535
534
533
532
528
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14 Welding Source Condition File of the

Robot Controller
Welding condition files for the MOTOWELD-RL350 are as follows.
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-RL350 uses a mechanical servomotor for its standard model, the
SUPPLE motor stops within 0.1 seconds. To reduce the manipulator’s cycle time, Yaskawa recom-
-MENT
mends that the wire-stick monitoring time on the robot side be set short.
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15 Operation by External Remote Mode

Remote switching of user files is available for MOTOWELD-RL350.
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.
OP1
Pin terminals for
switching user files (OP1, OP2) OP2
Pin terminal: Common (COM) COM
To robot To welding
controller power source
Welding command cable (analog)
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15.1 Switch of User Files(Analog Communication (Option))
15.1 Switch of User Files(Analog Communication

(Option))
Perform the settings as follows to select a user file by external command.

1. Set the D parameter D1-11 to "ON". Then save conditions by referring to " 4.2.3 Sav-
ing 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
User file No.0 OFF OFF
User file No.1 ON OFF
User file No.2 OFF ON
User file No.3 ON ON
CAUTION
• The user files cannot be selected externally when the D parameter D1-11 is set
to "OFF".
Additionally, the switch of user files is only enabled either by the external com-
mand or the welding source panel.
With the D parameter D1-11, change the user file selection method: by the external command or
by the welding source panel.
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16 List of Service Parts

501
502
V A m/min Type
102
P %
C + No.1
No.2
L R
No.3
_
MOTOWELD
301
101
ON
ON
OFF
䇼䈗ᵈᗧ䇽
Ǐ⊼ᛣǐ
401
105
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Soft CPU 1.00001A

Ver DB 1.00001A AA
Setting Ver. 1.00
Front Face
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Front Face)

Item Q’ty per
Parts Code No. Parts Name
No. Welding Source
101 UNITF-WPS-A01 Front panel unit 1
102 UNITF-WPS-A02 Panel-CR30 unit 1
105 PVC-HV019 Terminal cover 1
301 UNITF-WPS-A03 Side cover (right) 1
401 UNITF-WPS-A04 Side cover (left) 1
501 UNITF-WPS-A05 Cover (top) 1
502 IRON-F56B Eyebolt M8 2
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601
605
604
602
603
Base Section
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Base Section)

Item Q’ty per
No. Welding Source
601 UNITF-WPS-A06 Base unit 1
602 PVC-HV026 Terminal seat (lower) 1
603 PVC-HV011 Terminal seat (upper) 1
604 PVC-HV020 Terminal guard 1
605 BAR-S-201A Terminal seat 2
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305
304 306
Pr(SH)-GF003
SHUNT UNIT
TB1
303
307
302 Pr(SN)-GF002A
308
Pr(DI)-GF007
310 309 606

Pr(VR)-GF001 Pr(DI)-GF008
Right Side Face
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Right Face)

Item Q’ty per
No. Welding Source
302 UNITF-WPS-A07 CLR support 1
303 UNITF-WPS-CLR02A Current-limiting reactor (CLR) 1
304 UNITF-WPS-A08 Dust partition (right side) 1
305 HTSKK12620001 Heat sink (IGBT unit) 1
306 HV001 IGBT (CM600HU-12F) 2
307 UNIT-Pr(SN)-GF002A Printed board set (SN)-GF002A 1
308 UNIT-Pr(DI)-GF007 Printed board set (DI)-GF007 2
309 UNIT-Pr(DI)-GF008 Printed board set (DI)-GF008 1
310 UNIT-Pr(VR)GF001 Printed board set (VR)-GF001 1
606 WEL015 Caster 4
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315
DCL3
314 317
Pr(SH)-GF003
SHUNT UNIT
TB1
Pr(SH)-GF003
316
312
318
DCL2
319
608
320
607 321
322
324 323
Resistors Section
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Resistor and Electrolytic

Capacitor)
Item Q’ty per
No. Welding Source
312 UNITF-WPS-DCL2 DC reactor (DCL2) 1
314 UNIT-Pr(SH)-GF003 Printed board set (SH)-GF003 1
315 CHLSE7608 DC reactor (DCL3) 1
316 ER63005000A01 Resistor (300W) 1
317 ER6400250BA01 Resistor (400W) 1
318 ESF08506 Thermal guard (85C) 1
319 BAR-S-207B Main Diode Busbar (upper) 1
320 ED20600010003 Diode Module 7
321 BAR-S-206B Main Diode Busbar (lower) 1
322 BAR-S-219B Reset Diode Busbar 4
323 HTSKMO1320002 Heat sink (Rectifier unit) 1
324 UNITF-WPS-PT02A Transformer set 1
607 SH-011A Shunt 1
608 BAR-S-202C Extended busbar (N) 1
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Left Side Face
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Left Face)
Item Q’ty per

No. Welding Source
106 UNIT-Pr(CR)-030 Printed board set Pr(CR)-030 1
403 UNITF-WPS-NFB02C MCB unit 1
404 UNIT-Pr(VR)-GF002 Printed board set (VR)-GF002 1
503 MT2U0F25001 PE terminal 6
405 UNIT-Pr(PT)-GF005 Printed board set Pr(PT)-GF005 1
408 UNITF-WPS-A09 Inverter unit 1
411 UNITF-WPS-A10 Dust partition (left side) 1
412 CTHFO3201 CTHFO3201 2
413 EL134 CORE 2
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410 409
Pr(FE)-GF005A
406A
Pr(DL)-GF006
Pr(FE)-GF005B
Inverter Unit (Item No.408)
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Inverter unit: Item No.408)
Item Q’ty per

No. Welding Source
406A UNIT-Pr(DL)-GF006 Printed board set Pr(DL)-GF006 2
409 ED51600010001 Diode Bridge 1
410 ESF08506 Thermal guard (85C) 1
- Unit-Pr(FE)-GF005A * Printed board set Pr(FE)-GF005A 1
- Unit-Pr(FE)-GF005B * Printed board set Pr(FE)-GF005B 1
* Printed board set Pr(FE)-GF005A and printed board set Pr(FE)-GF005A

are inseparable with inverter unit (item No.408).
16-6
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506
505
(including connector
and cable (506))
Top F
T Face
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Partition Board)

Item Q’ty per
No. Welding Source
504 UNIT-Pr(MB)-030 Printed board set Pr(MB)-030 1
505 UNITF-WPS-A11 Interface panel unit 1
506 UNITF-WPS-A13 LAN relay cable (connector integrated) 1
507 UNIT-Pr(SD)-006 Printed board set Pr(SD)-006 1
508 EF3000211 Fuse 2.0A/500V 2
509 EF431 Fuse holder (2P) 1
510 ESJTD02415 Relay 1
512 UNIT-Pr(IF)-008B Printed board set Pr(IF)-008B 1
513 PTLSE11A3 Control transformer (TR1) 1
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ﾛﾎﾞｯﾄｲﾝﾀｰﾌｪｲｽ（ｱﾅﾛｸﾞ用)
Interface For Robot(Analog)
机器人接口(模拟讯号)
ﾌﾟｯｼｭﾓｰﾀ用
For Push Motor
駆动马达用
電圧検出線 CON 8
Interface For Robot(Digital)
217
Voltage Sensing 机器人接口(数字讯号)
电压检出线
SW1
TM1
出力端子母材
Output Base
Terminal Metal
输出端子母材
CON 3 CON 6
A V Inching
電源入力
POWER INPUT
电源输入
201 208
2
14mm以上のｹｰﾌﾞﾙで
必ず接地してください。
To be grounded by
cable of 14mm2 or more.
210 209
14mm2 以上接地电缆。
入力電圧切替器
Input voltage selector
输入电压切换开关
AC200V/220V
211
AUTOMATIC WELDING POWER SOURCE
AC200V/220V
212
TYPE YWE-RL350-AJ0
INPUT VOLTS 200/220V / 380/400V 3Ø
LOAD VOLTS 36V NO LOAD VOLTS 103V
MFG. No. DATE 2012
ᚲ䛪ධຊ㟁ᅽ䛾ษ᭰タᐃ䜢☜ㄆ䛧䛶䛟䛰䛥䛔䚹
请确认输入电压开关的切换位置。
Rear Face
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Rear Face)

Item Q’ty per
No. Welding Source
201 CAS048-433B Rear cover plate 1
208 UNITF-WPS-AC-INPUT Input terminal 1
209 PVC-041A Cover 1
210 PVC-042A Cable clamp 1
211 UNITF-WPS-SW02A Switch 1
212 CAS048-430A CP cover (switch) 1
217 MK201 LAN cable clamp 1
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Rear cover
216
214
215
213
List of YWE-RL350-AJ0 / YWE-RL350-CC0 Service Parts (Filter Unit)
Item Q’ty per

No. Welding Source
213 Filter cover set

MESH-F09A 3
214 (Filter cover2,Filter cover1)
215 ALUM-F09C Air Filter 3
216 LE-R9017B Cooling fan 3
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17.1 List of Process Parameters
17 List of Parameters
Parameters P are set in the robot control unit side. In the case of analog communication
(option), setting is made in the welding power side.
By changing the set values of Parameter P, the welding characteristics determined by the
database in the welding power can be adjusted according to your environment and prefer-
ences. All the factory setting are 100 (%) (The operations follow the database characteristics).
When an adjustment for the welding characteristics is required, refer to " 6.3 Customize
Screen "
Display Display
Item Item
No. No.
P00 C Wire slow down speed P31 P MAG/MIG pulse current increasing
speed
P01 C Wire speed at start P32 - System reservation
(Do not change this item)
P02 C Start pulse peak current P33 S Welding current decreasing speed
P MAG/MIG pulse current decreasing
speed
P03 - System reservation P34 - System reservation
(Do not change this item) (Do not change this item)
P04 C Start pulse peak time P35 A Increasing rate of aluminum MIG
pulse current
P05 C Hot average current value P36 A Decreasing rate of aluminum MIG
pulse current
P06 C Hot average voltage value P37 S Short current increase speed 1
P07 - System reservation P38 S Short current increase speed 2
P08 P Pulse current P39 - System reservation
P09 P Base current P40 - System reservation
P10 P Pulse time P41 - System reservation
P11 C End average current P42 - System reservation
P12 C End average voltage P43 C Hot slope time
P13 C End time P44 C End slope time
P14 C Flaming average current value P45 - System reservation
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Display Display
Item Item
No. No.
P15 C Flaming average voltage value P46 - System reservation
P16 C Flaming time P47 S Short current target value 1
P17 C Drop pulse peak current P48 - System reservation
P18 C Drop pulse peak time P49 S Arc control 1
P19 - System reservation P50 S System reservation
(Do not change this item) (Do not change this item)
P20 C Adhesion prevention time P51 S System reservation
P21 - System reservation P52 S System reservation
- (Do not change this item) - (Do not change this item)
P30 P54
P55 A Low pulse frequency ratio
(welding type 91 for aluminum)
Changes the frequency on the basis
of the parameter C-C03.
Example: If C03=100 and P55=50%,
the frequency is 5.0 Hz.
P56 A Low pulse wire feed speed ratio
Changes the amplitude on the basis of
the parameter C-C04.
Example: If C04=10 and P55=200%,
C04 x 200% = 20%.
P57 - System reservation
- (Do not change this item)
P59
Display
Item Content
No.
P61 P Arc length control gain
P62 C Current output characteristics 1 Correction rate 1 of the wire feed speed (Unit: %)
P63 C Current output characteristics 2 Correction rate 2 of the wire feed speed (Unit: %)
P64 S Offset voltage Voltage correction factor (Unit: %)
-1.0V in case of 90%
+1.0V in case of 110%
- (Do not change this item.)
P67
*1 P: For pulse welding (including aluminum pulse)
A: For aluminum welding
S: For short-circuit welding
C: Common for all the welding types
Unit: %
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17.2 List of Common Parameters
These parameters determine the operation of the welding power. Set them according to your
environment. For parameters C50 to C59, setting can be made only in the welding power side.
For the other parameters, setting is made in the robot control unit side. In the case of analog
communication (option), setting is made in the welding power side.
Display Factory
Item Contents
No. setting
C00 Gas adjustment time 20 Gas check time, Unit: sec
C01 Gas pre-flow time 56 Gas time before starting the welding output
(Min. time 56 ms), Unit: ms
C02 Gas after-flow time 500 Gas time after delivering the welding out-
put, Unit: ms
C03 Low pulse frequency 100 Low pulse frequency, Unit: 0.1 Hz
C04 Low pulse frequency 20 Low pulse wire feed speed amplitude,
(welding type 91 for aluminum) Unit: A
C05 Low pulse frequency 120 Current at low pulse acceleration,
(welding type 91 for aluminum) Unit: %
C06 Low pulse frequency 100 Current at low pulse deceleration,
(welding type 91 for aluminum) Unit: %
C07 Digital meter display speed 1000 Average time of display shift between cur-
rent and voltage,
Unit: (ms)
C08 External resistor set value 505 Electric resistance value of the welding
current path (power cable, jib base, etc.)
connected to the welding power
Unit: (x 10-5 )
C09 Motor setting 2 Motor selection
0: Print servo
1: Minertia servo (for servo torch)
2: Mechanical servo (WE-WF-X40TELC,
YWE-WF-340MELC, YWE-WF-
340TELC) (Factory setting)
10: EAGL motor
C10 System reservation 50 Do not change this item.
C11 Current calibration 150 Standard current 1 for user file 0
Standard current 1 (file 0) Unit: A
(for analog communication) (valid only at analog communication)
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Display Factory
Item Contents
No. setting
C23 System reset 0 When C23 is set to "2004, " the system is
reset, returning to the factory setting.
Before executing the system reset, be sure
to memorize the changed parameters.
After executing the system reset, turn OFF
the power and then turn it ON again.
When the power is turned OFF, C23 is
returned to "0."
C25 Motor power alarm criterion 70 Criterion value for delivering an alarm for
value an overcurrent in the feed motor.
Unit: (% for the rated current of the motor)
C28 Output current range abnormal- 2 0: When the output current is out of the
ity range, the error (Err790, Err791) is
delivered.
1: When the output current is out of the
range, the error (Err790, Err791) is
delivered during welding, terminating
welding.
2: When the output is out of the range, no
error message is delivered.
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Display Factory
Item Contents
No. setting
C29 Setting range for output current 70 The abnormality range of the output cur-
range abnormality rent (Err790, Err791) is set.
When the current is in the range of the
welding current command ± C29, no error
message is delivered. If the current
exceeds the range, the error (Err790,
Err791) is delivered.
Unit: A
C31 Operation time after welding the 900 The operation time of the cooling fan after
cooing fan completion of welding is set.
When the upper limit is set to 30000, the
cooling fan operates all the time.
Unit: sec
C32 Meter section display during 0 Used to select the meter section display
standby during standby.
0: Command value display
1: Standby (0.0 V, 0 A, 0 n/min) display
C43 Adjustment range of Heat And 20 Adjustment range of Heat And Wave Form
Wave Form Control Control
C50 Welding power side IP address 0 Set the forth digit of the welding power side
IP address. (Addition value to the refer-
ence value 210)
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Display Factory
Item Contents
No. setting
C54 System reservation 192 IP address subnet.
Do not change this item.
C59-C99 System reservation 0 Do not change this item.
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17.3 List of D Parameters
These parameters determine the operating conditions of the welding power source. Set them
according to your environment.
Parameters D are set in the robot control unit side. In the case of analog communication
(option), setting is made in the welding power side.
D-1
Factory
No. Item ON OFF
setting
1 System reservation Do not change this item. OFF
2 System reservation Do not change this item. ON
4 End event Valid Invalid ON
(for analog communication)
5 Feed speed/Motor Feed speed display Motor current display ON
current display
11 User file switch Switch with robot Switch with panel OFF
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D-2
Factory
No. Item ON OFF
setting
1 Touch start Valid Invalid (normal start) OFF
For user file 0
For user file 1
For user file 2
For user file 3
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D-3
Factory
No. Item ON OFF
setting
5 Heat And Wave Form Valid Invalid OFF
Control (HAWC) (File 0)
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D-4
Factory
No. Item ON OFF
setting
• Auto adjustment voltage: The voltage that we assumed to be proper is regarded as 100%.
When the voltage is changed by 10% from 100%, the voltage is changed by approx. 1 V.
(Example: When 100% is 20 V, 90% is 19 V and 110% is 21 V.)
The adjustment range is 50% - 150% (± 5 V). The auto adjustment voltage set in the
robot control unit is displayed on the welding unit.
• In the CO2 short arc welding method, the touch start is not used, but the normal start is
used.
• In case of the aluminum welding, because the crater processing is automatically exe-
cuted, it is recommended to set the end event "parameter D1-4" to ON(valid). It takes
about 2 seconds to finish the crater processing after arc off. Therefore add a timer
instruction to stop the manipulator for 2 seconds at the welding end. Or set the wire-stick
prevention processing time of the welding condition file to 2 seconds before using it.
• When select aluminum for the welding type, the welding starts by the touch start.
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18 List of Welding Types

The welding type available for the software version 1.00-001-A (CPU) are listed below.
Refer to " 5.4 Welding Method Setup " for details on changing of the welding type.
Using improper welding type will result in unstable welding, which causes excessive spatters
or imperfect bead appearance. Before starting welding, confirm that the welding type has
been correctly selected.
Pulse or Wire Weld

Shielding Gas Wire Remarks
Short-circuit Diameter Type No.
φ0.8 42
φ0.9 32
CO2 Soft steel Fe Short-circuit
φ1.0 22
φ1.2 12
φ0.8 40
MAG
φ0.9 30
(Ar 80%, Soft steel Fe Short-circuit
CO2 20%) φ1.0 20
φ1.2 10
Super
sunarc242
Soft steel Fe Short-circuit φ1.2 19 For zinc-plated steel plate
φ0.8 41
φ0.9 31
MAG φ1.0 21
(Ar 80%, Soft steel Fe Pulse φ1.2 13 Middle-peak pulse
CO2 20%)
High-peak pulse
φ1.2 11 (For zinc-plated steel plate
and wire for CO2)
MIG
(Ar 92%, Soft steel Fe Pulse φ0.9 33 For zinc-plated steel plate
CO2 8%)
Super
sunarc242
Soft steel Fe Pulse φ1.2 14 For zinc-plated steel plate
φ0.8 82
MAG Stainless
φ0.9 72
(Ar 80%, steel Pulse
CO2 20%) SUS φ1.0 62
φ1.2 52
φ0.8 80
MIG Stainless
φ0.9 70
(Ar 98%, steel Short-circuit
O2 2%) SUS φ1.0 60
φ1.2 50
18-1
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Pulse or Wire Weld

Shielding Gas Wire Remarks
Short-circuit Diameter Type No.
φ0.8 81
MIG Stainless φ0.9 71
(Ar 98%, steel Pulse φ1.0 61
O2 2%) SUS
φ1.2 51 High-peak pulse
φ1.2 54 Middle-peak pulse
MIG Stainless
(Ar 98%, steel Pulse φ1.2 53
O2 2%) SUS
5000 series Pulse φ1.2 90 Servo torch recommended
Ar
aluminum Low pulse φ1.2 91 Servo torch required
4000 series
Ar
aluminum
Pulse φ1.2 92 Servo torch required
Applicable from
φ1.0 26 Ver100-023-A
EAGL Arc small/anti blow
φ1.0 27 Applicable from
Ver100-040-A
EAGL Soft Arc(lap joint)
CO2 Soft steel Fe EAGL φ1.2 16 Applicable from
Ver100-020-A
EAGL Normal Arc(Steel, Zn)
Ver100-020-A
Ver100-040-A
Applicable from
φ1.0 25 Ver100-024-A
MAG Ver100-042-A
(Ar 80%, Soft steel Fe EAGL
CO2 20%) Applicable from
φ1.2 15 Ver100-020-A
Ver100-041-A
MIG Stainless φ1.0 67 Applicable from
(Ar 98%, steel EAGL Ver100-043-A
O2 2%) SUS Applicable from
φ1.2 55 Ver100-023-A
18-2
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19 List of Errors
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 error number is displayed in the digital meter on the panel face for 10
seconds. For the contents of errors, refer to the following table.
At error detection, an arc failure signal is output at the robot side.
Error No.
Alarm
in the
No. in
welding Item Contents Remedy
the robot
power
DX side
side
Err001 4244 Input overvolt- An input voltage which is Check the input voltage.
age greater than the rated
input voltage + 15% is
applied for 2 sec.
Err002 4246 Input insuffi- An input voltage which is Check the input voltage.
cient voltage smaller than the rated
input voltage -15% is
applied for 2 sec.
Err102 4245 Temperature The temperature in the (1) Check the ambient tempera-
Err103 abnormality primary side or the sec- ture (45C or below) and the
Err105 ondary side control circuit usage rate (60%).
Err340 or the MB circuit exceeds (2) Check for no dirt or clogging in
the specified level of the the dust-proof filter. Check or
welding power. replace as needed.
Err107 4242 Input An overcurrent flows (1) Check for any short-circuit or
overcurrent through the primary side grounding of the power cable.
control circuit. (2) The power circuit may be bro-
ken. Contact our servicing
agent.
In order to reset this error, turn
OFF the welding power source
and turn ON it again.
(3) If turning ON again, be sure to
check that 30 seconds have
elapsed after turning OFF.
Err108 4279 Output instan- An instantaneous over- (1) Check for any short-circuit or
taneous overcurrent flows through the grounding of the power cable.
current secondary side control (2) The power circuit may be bro-
circuit. ken. Contact our servicing
agent.
In order to reset this error, turn
OFF the welding power source
and turn ON it again.
Err110 4274 Voltage sensing The welding voltage is Contact our servicing agent.
unit abnormality not detected. In order to reset this error, turn OFF
the welding power source and turn
ON it again.
Err111 4275 Aux. circuit Overcurrent flows in the The board may be broken. Contact
overcurrent auxiliary circuit. your Yaskawa representative.
19-1
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Error No.
Alarm
in the
No. in
the robot
power
DX side
side
Err119 4276 DSP ADC error The main board broken. Contact your Yaskawa representa-
tive.
Err310 4284 Unit model set- Discrepancy in the model The hardware and the software
to 339, ting abnormality settings of the hardware may not be set properly. Contact
Err341 and the software. out service agent.
to 399 In order to reset this error, turn OFF
the welding power source and turn
ON it again.
Err400 4284 Software mal- Watch dog error of the (1) Reboot the power source.
function PLD. (2) Replace the main board {Pr(MB)
-030} if this error recurs.
Contact your Yaskawa represen-
tative.
Err401 4248 Communica- A communication error Check the following items.
tion abnormality occurs between the weld- (1) Check to confirm that the com-
between the ing power and the robot munication cable is securely
welding power control unit. connected.
and the robot (2) Check to confirm that the IP
control unit address setting is properly
made. Check parameter C of
the welding power, the trans-
mission and RS parameters of
the robot control unit.
Err404 4251 User file num- A non-existing user file is Set the user file number in the
ber abnormality set. range of 1 - 16.
Err406 4283 Welding An erroneous welding Set the proper welding method
method num- method is set to the user number.
ber abnormality file.
Err407 4283 Illegal welding A welding type is not set Set a wedling type to user file of
method in a user file of the MOTOWELD. The user file can
MOTOWELD. setup in the editor screen for ARC
START CONDITION FILE or ARC
END CONDITION FILE of the
DX100.
Err501 4258 Feed unit The welding wire is not Check the following items.
abnormality fed according to the feed (1) Check the wire feeder cable for
amount command. any damage. If there are any
damage of the cable, the wire
feed speed may be increased
abnormally, causing the feed
amount error. Check and
replace the wire feeder cable.
(3) Check that the wire load is not
too great. Be careful that the
torch cable and the conduit
cable are not bent excessively.
Err502 4259 Motor overcur- An overcurrent exceed- Check that the wire load is not too
rent ing the rated current level great. Be careful that the torch
flows through the motor. cable and the conduit cable are not
bent excessively.
19-2
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Error No.
Alarm
in the
No. in
the robot
power
DX side
side
Err601 4269 Start signal An arc start signal is Check the operation timing and
abnormality inputted before booting connection of the signal cable.
the main power of the A same error may occur in the case
welding unit. of an instantaneous service inter-
ruption.
Err602 4270 No welding • A welding type is not set (1) Set a welding type in the user
type in a user file. file.
(2) Install the latest software on the
• The selected welding
welding power source.
type does not exist.
Err701 4243 Output overcur- An overcurrent flows Check the following items:
rent through the secondary (1) Check to confirm that the torch
side control circuit. cable, torch clamp and the
power cable are not shorted to
the ground.
(2) Check to confirm that the con-
tact chip and the welding work
are not in contact. Cancel the
contact if any, and weld them.
(3) Check the wire feeder cable for
any damage. If there are any
damage of the cable, the wire
feed speed may be increased
abnormally, causing an output
overcurrent. Check and replace
the wire feeder cable.
Err702 4271 Voltage sensing The welding voltage is (1) Check to confirm that the weld-
cable abnor- not detected. ing voltage sensing cable select
mality switch is set to "Base Metal".
When the welding voltage sens-
ing cable is used, check to con-
firm that the base metal-side
connects between the base
metal and the welding power
source via wire feeder cable.
(2) Check to confirm that the con-
tact chip and the welding work
are not in contact. Cancel the
contact if any, and weld again.
(3) An instantaneous service- inter-
ruption may have occurred.
(4) Check to confirm that the torch
cable, torch clamp and the
power cable are not shorted to
the ground.
Err704 4281 Power supply The switching power sup- Replace the switching power supply
Err705 4282 error ply unit broken. unit. (Service parts code:
AJ0E35055)
19-3
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Error No.
Alarm
in the
No. in
the robot
power
DX side
side
Err790 4277 Output current An actual welding cur- (1) Check to confirm that the motor
set range over rent exceeds the welding selection is proper and the set
(Exceeding the current command value contents of parameter C09 is
upper limit) too much. proper.
Err791 4278 Output current (2) Check to confirm that the weld-
set range over ing wire does not slip and that it
(Exceeding the is fed according to the feed
lower limit) command.
(3) Check to confirm that the wire
extrusion length is proper.
(4) Check to confirm that the set
range of C29 is enough.
(5) Check to confirm that the set-
tings of the wire, the shield gas,
the welding method, and
grounding are properly made.
Err800 - Communica- The communication error (1) Please confirm whether the
tion error of the of the main board connection of Connector MB20
main board {Pr(MB)-030} and the of the main board {Pr(MB)-030}
{Pr(MB)-030} panel board {Pr(CR)-030} and Connector CR10 of the
and the panel occurred. panel board {Pr(CR)-030} does
board {Pr(CR)- not have a problem. After con-
030} firmation, please turn on a
power supply again.
(2) Please change the panel board
{Pr(CR)-030}.
(3) Please change the panel board
{Pr(MB)-030}.
* during the loading of the software
will be displayed "Err800".
For digital data on the panel "888 888 888 888"
Item Contents Remedy
Communication error Communication error (1) Please confirm whether the connection
of main board {Pr(MB)- The communication error of Connector MB20 of the main board
030} and panel board of the main board {Pr(MB)-030} and Connector CR10 of the
{Pr(CR)-030} or The {Pr(MB)-030} and the panel board {Pr(CR)-030} does not have
DSP abnormality panel board {Pr(CR)-030} a problem.After confirmation, please turn
occurred. on a power supply again.
(2) Please change the panel board {Pr(CR)-
030}.
(3) Please change the panel board {Pr(MB)-
030}.
DSP abnormality Please change the panel board {Pr(MB)-

The main board {Pr(MB)- 030}.
030} does not work nor-
mally.
19-4
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HW1481552
Top face
576.4
20 External form
22.0 518.2
371.0 44.1
38.0
（ｱﾅﾛｸﾞ用) ﾌﾟｯｼｭﾓｰﾀ用
電圧検出線 CON 8 Interface For Robot (Digital)
V A m/min Type ⬉य़Ẕߎ㒓
20-1
SW1
TM1
出力端子母材
P % Output Base
Terminal Metal
䕧ߎッᄤ 母材
No.1
C + CON
CON 3 CON 6
No.2 A V Inching
L R
No.3
_
電源入力
POWER INPUT
⬉⑤䕧ܹ
MOTOWELD
547.2
2
14mm 以上のｹｰﾌﾞﾙで
必ず接地してください。
635.3
To be grounded by
ON cable of 14mm2or more.
14mm2ҹϞ᥹ഄ⬉㓚Ǆ
ON
入力電圧切替器
OFF Input voltage selector
䕧ܹ⬉य़ߛᤶᓔ݇
【ご注意】
AC200V/220V
AUTOMATIC WELDING POWER SOURCE
【注意】 AC200V/220V
ᔧЏ⬉⑤ᓔ݇䏇㜅ᯊǃ㒱ᇍϡ㛑‫ݡ‬ᓔਃǄ TYPE YWE-RL350-AJ0
䇋䖲㒰ᔧഄᡔᴃ᳡ࡵਬǄ INPUT VOLTS 200/220V / 380/400V 3Ø
LOAD VOLTS 36V NO LOAD VOLTS 103V
MFG. No. DATE 2012
必ず入力電圧の切替設定を確認してください。
䇋⹂䅸䕧ܹ⬉य़ᓔ݇ⱘߛᤶԡ㕂。
350A YWE-RL350-AJ0
1203809120001 Machine Ver.
Soft CPU 1.00001A

Ver DB 1.00001A AA
Setting Ver. 1.00
7.0
55.0
64.2 40.0 28.0

264.0
10.0 400.0 112.2 43.7
355.0
488.0
HW1481552
Left Side Face Front Face Right side face Rear Face
146/147　　　
MOTOWELD-RL350
INSTRUCTIONS
TYPE:YWE-RL350-AJ0 / YWE-RL350-CC0
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbHRobotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.

22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
C Printed in Japan September 2015 11-20

YASKAWA ELECTRIC CORPORATION
MANUAL NO.
147/147　　　
HW1481552 6

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MOTOWELD-RL350

YASKAWA ELECTRIC CORPORATION

Read this manual carefully and operate the MOTOWELD-RL350 properly.

2 Welding Power Source Installation and Connection

4.3.1 Changing Welding Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

5 Setting in the Robot Control Unit Side

6 Welding Power Customization

9 Location and Setting of Printed Boards

10 Maintenance and Inspection

12 Robot Interface Signals

12.3 Connection of Gas Pressure Shortage sensor and

13 Connection System Diagram

14 Welding Source Condition File of the Robot

15 Operation by External Remote Mode

16 List of Service Parts

18 List of Welding Types

Notes for Safe Operation

Indicates a highly potentially hazardous situation which, if not

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.

Observe the following cautions to prevent fire, explosion, or rupture.

Type YWE-RL350-CC0 (Compliance with CCC standards)

Number of Phases, Rated Three-phase, 200/220 V 10 % and 380/400V 10 %

Rated Frequency 50/60 Hz common

Rated Input 18 kVA

Welding Current Adjustment 30 to 350 A (depends on the wire diameter)

Welding Voltage Adjustment 12 to 36 V (depends on the wire diameter)

Rated Operational Ratio 60% (for 10 minutes)

Welding Type CO2 short-circuit welding, MAG/MIG short-circuit welding, pulse

Welding Object Material Iron, stainless steel, aluminum

Feeding Motor Types of feeding motors can be selected among;

Wire Feeding speed 1.5 to 18 m/min

Wire Feeding CO2 short-circuit welding: Approx. 3 m/min

Wire Feeder Cable 5 m (standard), 7 m max.

Gas Running-in Time Approx. 20 seconds (Can be adjusted by panel operation)

External Dimensions 371 × 636 × 602 (width × depth × height)

Power Supply of the Heater None

Standard Accessory Fuse contained in glass tube of 2A (1 fuse)

Remarks Front panel: Written in Japanese / English / Chinese

1.EAGL: Enhanced Arc weldinG for Low spatter

 In the Case of Digital Communication

Welding Voltage Setting Auto adjustment command / Individual command

User File Number of files: 16

 In the Case of Analog Communication (Option)

User File Number of files: 4

Adjustment of Voltage and Can be changed by P parameters in the user file.

2.1 Installation Site and Welding Power Source Environment

2 Welding Power Source Installation and

2.1 Installation Site and Welding Power Source Envi-

Bolt and nut

Soft CPU 1.00001A

2.2 Precautions on Grounding

2.3 Power Supply Installed Capacity and Connection

2.4 Combination with Earth Leakage Breaker

Table. 2-1 Power Supply Installed Capacity and Cables

Rated input voltage 200 V/220 V 380 V/400 V

Installed Capacity 20 kVA

Fuse Rated Current 75 A 45 A

Input Cable 14 mm2 or more 8 mm2 or more

Exclusive-use base metal cable 60 mm2 or more *1

Grounding Cable 14 mm2 or more 8 mm2 or more

　⑤ Four screws of the cover are installed. ．