SERVO TORCH FOR MOTOWELD YWE-WFE2WD INSTRUCTIONS › getmedia › C103E820-2EBB-4B... · flammables...

HW1484722MANUAL No.

1

SERVO TORCH FOR MOTOWELDYWE-WFE2WD INSTRUCTIONSYWE-WFE2WD-T series:

・YWE-WFE2WD-TSS300R (H-type)

・YWE-WFE2WD-TSS308R (H-type)・YWE-WFE2WD-TSS500R (H-type)・YWE-WFE2WD-TSS508R (H-type)・YWE-WFE2WD-TSS500W (H-type)・YWE-WFE2WD-TSS508W (H-type)

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

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DANGER • This manual explains the servo torch YWE-WFE2WD of the MOTOWELD system

and general operations. Read this manual carefully and be sure to understand its

contents before using the MOTOPAC.

• General items related to safety are listed in Chapter 1: Safety of the YRC1000

Instructions. To ensure correct and safe operation, carefully read the YRC1000

Instructions before reading this manual.

CAUTION • Some drawings in this manual are shown with the protective covers or shields

removed for clarity. Be sure all covers and shields are replaced before operating

this product.

• The drawings and photos in this manual are representative examples and differences

may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to product

improvements, modifications, or changes in specifications.

• If such modification is made, the manual number will also be revised.

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

order a new copy. The representatives are listed on the back cover. Be sure to tell

the representative the manual number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized modification of

its products. Unauthorized modification voids your product's warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of

the YWE-WFE2WD.

In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”,

“CAUTION”, or “NOTICE”.

Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. Safety Signs

identified by the signal word DANGER should be used

sparingly and only for those situations presenting the most

serious hazards.

Indicates a potentially hazardous situation which, if not

avoided, will result in death or serious injury. Hazards

identified by the signal word WARNING present a lesser

degree of risk of injury or death than those identified by the

signal word DANGER.

Indicates a hazardous situation, which if not avoided, could

result in minor or moderate injury. It may also be used

without the safety alert symbol as an alternative to

“NOTICE”.

NOTICE is the preferred signal word to address practices

not related to personal injury. The safety alert symbol

should not be used with this signal word. As an alternative

to “NOTICE”, the word “CAUTION” without the safety alert

symbol may be used to indicate a message not related to

personal injury.

Even items described as “CAUTION” may result in a serious accident in some

situations. At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure to follow all

instructions, even if not designated as “DANGER”, “WARNING” and

“CAUTION”.

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DANGER

In order to prevent from a serious accident involving a human life, be sure to

observe the following.

• Although this welder has been designed/manufactured giving full consideration to

safety, when using the welder, be sure to observe the cautionary instructions in this

manual.

When using without observation, a serious accident involving a human life such as

death or serious injury may occur.

• Regarding the selection of the installation place, handing of the high pressure

gas/storage and piping, storage of the manufacturing products after welding and

disposal of scrapped material, place follow in accordance with the regulations in law

and your company’s standard.

• Do not let others enter curelessly around the welder and the surroundings of the

welding work place.

• A person who is using a pace maker of heart shall no access to the welder in

operation or the surroundings of the welding work place without a doctor’s approval.

The welder generates a magnetic field around the surroundings during electrification

and the pace maker will be adversely affected.

• When a water cooled torch or a cooling water circulation system is used, clean the

cooling water passage once a month. The passage obstruction may provoke

explosion or burning.

• In order to secure safety, installation, maintenance/inspection and repairing of this

welder shall be carried out by a well-trained person who has a good knowledge about

welder, or a qualified person.

• In order to secure safety, the operation of the welder shall be operated by a

knowledgeable and skilled person who can understand very well about the contents

of the manual and can handle the welder safety.

• Never use this machine for a purpose other than welding.

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WARNING

Touching the electrically charged portion may result in a fatal

electric shock or burns.

• Do not touch the live parts.

• Be sure to turn off all power sources on the input side by the switch in the distribution

box before performing installation or maintenance/inspection operation.

• Do not use damaged cables, those of small capacity or of which the conductors are

exposed.

• Be sure to fasten the connections of cable and insulate them.

• Do not use the welder without its case or cover.

• Do not use broken or wet gloves. Be sure to always use insulated gloves.

• When working at a high position, use a life rope.

• Perform maintenance and inspection periodically. If a damaged portion is found,

repair it at once before the machine. (Never use a damaged machine.)

• When the welder is not used, turn off the power on the input side of all devices.

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WARNING

• Be sure to observe the following warnings and use protectors to

protect yourself or other people from the fumes or gases

generated at welding and short of the oxygen.

• In order to prevent gas poisoning or suffocation, be sure to ventilate sufficiently or use

an inhaler, etc. when welding at a place specified by regulations such as labor safety

and sanitary regulations or hypoxia preventive regulations.

• In order to prevent dust trouble or gas poisoning due to the fumes or gases, use a

local air exhaust facility specified by regulations such as labor safety and sanitary

regulations or dust trouble preventive regulations or use effective protectors for

breathing.

Fumes or gases generated at welding may harm your health.

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

ventilate sufficiently or use an inhaler, etc. in order to prevent or offset any actual or

potential oxygen shortage.

Gas heavier than air such as carbon dioxide gas or argon gas stays at the bottom.

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

inhaler. At the same time, operations must be done under trained supervisor.

Welding operations at a small space may result in short of the air, causing a

person to be suffocated.

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

Failure to observe this warning may generate extremely noxious gases.

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

for breathing.

Welding such coated steel plates generates noxious fumes or gases.

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WARNING

Observe the following cautions to prevent fire, explosion, or

rupture.

• Spatter and heated base metal just after welding may cause fire.

• Unstable electrical contacts (e.g. between the terminals, between

the jig and the workpiece, etc.) may cause fire.

• Generating arc in a vessel containing gasoline or other

flammables may result in explosion.

• Welding a sealed tank or pipe may result in burst.

• Remove inflammables so that they will not get spattered. If they cannot be removed,

use the inflammables with nonflammable covers.

Spatters or hot base metal immediately after welding may result in fire.

• Do not weld near flammable gases.

If arc is generated in a container (for inflammables) in which gasoline or the like is

put, the container may explode.

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

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

Failure to observe this caution may result in fire.

• Tighten and insulate the cable connections.

Imperfect cable connections or imperfect contacting section of the current path at

the base metal such as iron framework may result in fire due to heat generation by

current conduction.

• Connect the cable at the base metal as close to the welding part as possible.

• Do not weld a gas tube having gas inside or an enclosed tank or pipe.

Welding an enclosed tank or pipe may result in rupture.

• Locate fire extinguishers near the welding site.

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WARNING

Be sure to observe the following cautions and use protectors

to protect yourself or other people from arc beams, spatters,

slugs or noise generated from welding.

• Wear welding mask or shaded glasses appropriate for welding.

• Wear protective glasses to protect your eyes from spatters or slags.

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

• Use such protectors as leather gloves, clothes with long sleeves, leg covers, or

leather aprons for welding.

Install protective curtains around the welding site to protect your eyes from arc

beams. Arc beams may irritate eyes or burn skins.

• Use noise protector when there is excessive noise. Noise may damage hearing.

WARNING

Be sure to observe the following cautions to prevent a gas

cylinder from falling or a gas regulator from rupturing.

• Observe the regulations and your own references for the handling of gas cylinders.

Since a gas cylinder is filled with high pressure gas, improper handling may cause

high pressure gas to blow up, resulting in personal injury.

• Use the attached gas regulator or our recommended one.

• Read the instruction manual of the gas regulator carefully and observe the

precautions before using it.

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

A gas cylinder falling may result in personal injury.

• Do not expose the gas cylinder to high temperature.

• Do not bring your face close to the gas exhaust port when opening the valve of the

gas cylinder.

• Be sure to attach the protective cap when the gas cylinder is not used.

• Do not hang the welding torch over the gas cylinder.

Keep the electrodes away from the gas cylinder.

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WARNING

As the rotating section may cause an injury, be sure to observe

the followings.

• Bringing hands, fingers, hair or cloth to the rotating sections such

as cooling fans or feeder rollers of wire feeder may cause an

injury.

• Keep all covers and cases closed when using the product.

• Maintenance, inspection and repair must be performed only by a qualified person

and/or person who has understood the product. While performing, putting up a guard

fence or the like to keep away unauthorized persons.

• Do not contact the rotating cooling fan or feeding roll of the wire feeder with hands,

fingers, hair, or clothes.

WARNING

As the welding wire tip may cause an injury, be sure to observe

the followings.

• Wire ejected from the tip of a welding torch may pierce your eyes,

face or body.

• Do not look into the chip hole.

• Do not perform inching or pulling the torch switch with person’s eyes, face or body

close to the welding torch end.

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WARNING

Observe the following cautions to prevent burns due to the

plasma arc.

• Do not touch the plasma arc with hands, fingers or any part of

your body directly, or you may burn yourself.

• Do not put your hands and fingers near the chip and the electrodes of the torch end

during operation.

• Do not grasp near the base metal during operation.

• Turn OFF the power supply before replacing the chip or the electrodes of the torch.

WARNING

Observe the following cautions to prevent a fire accident

caused by deterioration of welder insulation.

• Be sure to perform maintenance and inspection periodically to prevent deterioration

of insulation caused by accumulation of dust and dirt.

• If spatter or metal powder enters the inside of the product, remove it by forced air

spray after turning OFF the welder and robot controller.

WARNING

Observe the following instructions to prevent any transport

accident or damage to the product.

• Before transporting or moving this product, remove the wire and to turn off the

welding power source and the robot controller.

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Contents 1. Specifications ..................................................................................................... 1-1

1.1. Basic specifications .................................................................................... 1-1

1.2. Dimension diagram ..................................................................................... 1-3

1.2.1. YWE-WFE2WD-TSS300R/500R (H-type) for

AR1440/AR1730/AR2010/AR1440E ................................................................... 1-3


AR1440/AR1730/AR2010/AR1440E ................................................................... 1-4

1.2.3. YWE-WFE2WD-TSS300R/508R (H-type) for AR700/900 ..................... 1-5


AR1440/AR1730/AR2010/AR1440E ................................................................... 1-6

1.2.5. YWE-WFE2WD-TSS500W(H-type) for AR1440/AR1730/AR2010 ........ 1-7

1.2.6. YWE-WFE2WD-TSS508W (H-type) for AR1440/AR1730/AR2010 ....... 1-8

2. Preparation and process..................................................................................... 2-1

2.1. Charged parts ............................................................................................. 2-1

2.2. Wire setting ................................................................................................ 2-2

2.3. Installation of the servo torch ...................................................................... 2-2

2.4. Electrical wiring of the servo torch ............................................................... 2-2

2.5. Installing protection covers .......................................................................... 2-3

3. Adjustment and exchange procedure of each parts ............................................. 3-1

3.1. Parts name ................................................................................................. 3-1

3.2. Feed roller assy replacement ...................................................................... 3-2

3.3. Welding wire pressurizing power adjustment ............................................... 3-5

3.4. Grease replenishment................................................................................. 3-8

3.4.1. Notes on grease replenishment ........................................................... 3-8

3.4.2. Grease replenishment ......................................................................... 3-9

3.5. Cleaning ................................................................................................... 3-10

4. Maintenance and inspection ............................................................................... 4-1

4.1. Feed roller assy .......................................................................................... 4-1

4.2. Wire guide .................................................................................................. 4-3

4.3. Motor .......................................................................................................... 4-4

4.4. Inner tube and Liner .................................................................................... 4-4

5. Parts list ............................................................................................................. 5-1

5.1. Standard parts ............................................................................................ 5-1

5.2. Parts for AR1440 ........................................................................................ 5-8

5.3. Parts for AR1730 ........................................................................................ 5-8

5.4. Parts for AR2010 ........................................................................................ 5-9

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5.5. Parts for AR700/ AR900 ............................................................................ 5-11

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1 Specifications 1.1 Basic specifications

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1. Specifications Servo torch YWE-WFE2WD series are motorized torches for arc welding, especially for

EAGL (*1) welding method.

(*1) Enhanced Arc robot weldinG for Low spatter

1.1. Basic specifications

Table 1-1 Basic specifications

Type YWE-WFE2WD

Welding method • CO2 short-circuiting welding

• MIG / MAG short-circuiting welding

• MIG / MAG pulsed welding

• CO2 / MAG EAGL welding

Torch type Motorized torch for robot arc welding

Rated duty cycle

In the case of the TSS300R/TSS308R

• 60% 350A (every 10 minutes)

• 100% 270A

In the case of the TSS500R/TSS508R

• 60% 500A (every 10 minutes)

• 100% 380A

Shield gas type • CO2

• MAG (Ar 80%, CO2 20%)

• MIG (Ar 92%, O2 8%)

• MIG (Ar 98%, O2 2%)

Conduit cable length Max. 5m

Wire diameter φ0.8mm, φ0.9mm, φ1.0mm, φ1.2mm

(solid wire only)

Welding material • Mild steel

• Stainless steel

Wire speed 1.5m/min - 18 m/min

Type of cooling Air

Torch connection By the special liner and clamp

Temperature range of ambient air:

-when operating

-10 ℃ - +45 ℃

Relative atmospheric humidity Up to 90% at 20 ℃

Elevation above sea level Up to 1,000m

Temperature range of ambient air: -25 ℃ - +55 ℃

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1 Specifications 1.1 Basic specifications

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-when being transported or stored

Related input voltage of the servo

amplifier

3AC200-230V 50/60Hz 3A (wire feeder)

Voltage range of input -15% - +10%

Overvoltage category III (wire feeder)

Pollution degree 3 (IEC60664-1)

(Servo amplifier: 2 (IEC60664-1))

Shielding gas pressure 0.2MPa

Protection Torch nozzle IP0X

Coupling IPXX

Cable IP3X (Dia. 2.5mm)

Other parts IP2X (Dia. 12.5mm)

Wire feed motor AC servo motor

Drive 2rollers – 1 drive system

Approx. weight 4kg

European directive Low Voltage Directive 2014/35/EU EN60974-7 (partly EN60974-1 and EN60974-5)

Special

instruction

Corresponding

manipulator

• MOTOMAN-

AR1440,AR1730,AR2010,AR1440E

AR700,AR900

However, AR1440E,AR700 and AR900

can only correspond with 350 A.

Corresponding

welding power source

• MOTOWELD-X350

• MOTOWELD-X500

Accompanying items • Dedicated tool for exchanging the feed

roller: YJ1707141

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1 Specifications 1.2 Dimension diagram

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1.2. Dimension diagram

1.2.1. YWE-WFE2WD-TSS300R/500R (H-type) for AR1440/AR1730/AR2010/AR1440E

• However, AR1440E can only correspond with 350 A.

Fig 1-1 Dimention diagram: YWE-WFE2WD-TSS300R/500R (H-type) for

AR1440/AR1730/AR2010/AR1440E

Serial No.

War

ning

lab

el

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• However, AR1440E can only correspond with 350 A.


AR1440/AR1730/AR2010/AR1440E

Serial No.

War

ning

lab

el

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1.2.3. YWE-WFE2WD-TSS300R/508R (H-type) for AR700/900


AR700/AR900

Serial No.

War

ning

lab

el

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AR700/AR900

Serial No.

War

ning

lab

el

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1.2.5. YWE-WFE2WD-TSS500W(H-type) for AR1440/AR1730/AR2010

Fig 1-2 Dimention diagram: YWE-WFE2WD-TSS500W (H-type)

forAR1440/AR1730/AR2010

War

ning

lab

el

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1.2.6. YWE-WFE2WD-TSS508W (H-type) for AR1440/AR1730/AR2010

Fig 1-3 Dimention diagram: YWE-WFE2WD-TSS508W(H-type)

forAR1440/AR1730/AR2010

War

ning

lab

el

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2 Preparation and process 2.1 Charged parts

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2. Preparation and process 2.1. Charged parts

WARNING Do not touch the charged parts. Be sure to turn off all power sources on the input side

by the switch in the distribution box before performing installation, maintenance or

inspection.

Fig 2-1 Charged parts

Parts contacting welding wire

Inside of the covers

Terminal part

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2 Preparation and process 2.2 Wire setting

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2.2. Wire setting

Fig 2-2 Wire setting

2.3. Installation of the servo torch

This product is only for MOTOWELD. Refer the each MOTOPAC manuals.

2.4. Electrical wiring of the servo torch

This product is only for MOTOWELD. Refer the each MOTOPAC manuals.

Shoulder unit for servo torch

EAGL conduit cable (“Easy Glide”) Max. length: 5m. Do not use other conduit cable

Pail pack (Do not use wire reel)

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2 Preparation and process 2.5 Installing protection covers

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2.5. Installing protection covers

Fasten the cover B with two knurled screws.

Fig 2-3 Protection covers

Cover A

Cover B

Cover A

Cover B

Set the cover B so that the edge comes under the edge of cover A

Knurled screws

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3 Adjustment and exchange procedure of each parts 3.1 Parts name

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3. Adjustment and exchange procedure of each parts 3.1. Parts name

Fig 3-1 Parts name

Pressure arm

Feed roller assy

Hexagon nut

Pressure lever

Pressure roller

Nord-lock washer

Resin washer

Pressure scale

Pressure nut

Nord-lock washer

Resin bolt

Resin lock cap

Resin cap

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3 Adjustment and exchange procedure of each parts 3.2 Feed roller assy replacement

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3.2. Feed roller assy replacement

1 Remove welding wire from the servo troch and release pressure lever.

Fig 3-2 Pressure lever operation

Pressure lever

Remove welding wire

Pressure arm

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Remove the resin cap and remove the nut fixing the feed roller with the box spanner

and dedicated tool (DX-1401065).

Fig 3-3 Removing hex. nut

Dedicated tool: YJ1707141 Box spanner (M6)

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2 Remove the nut, nord-lock washer, resin washer and feed roller assy.

3 After inserting new feeder roller, resin washer and nord-lock washer, insert and fasten

the hexagon nut (tightening torque: 7N･m).

Fit together the key and the key slot when inserting the feed roller assy.

Nord-lock washer is installed in pairs, cam face to cam face.

Fig 3-4 Feed roller assy replacement

Feed roller assy (*1)

Hexagon nut (torque: 7N･m) Nord-lock washer (*2) Resin washer

Fit together the key and the key slot.

Nord-lock washer is installed in pairs, cam face to cam face.

(*1) (*2)

Cap

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3 Adjustment and exchange procedure of each parts 3.3 Welding wire pressurizing power adjustment

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3.3. Welding wire pressurizing power adjustment

1 Insert the welding wire between the feed roller assy and the pressure roller. After

confirming that the welding wire is set in the groove of the feed roller assy, close the

pressure arm and pressure lever.

Fig 3-5 Confirming welding wire position

2 Remove the Resin bolt and Resin lock cap.

Fig 3-6 How to remove the parts

OK

NG

Welding wire

Feed roller assy

Press the Resin lock cap by wrench to prevent bolt racing.

Resin lock cap

Nord-lock washer

Resin bolt

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3 Adjust pressurizing power by turning the pressure nut using screw driver. Set the milling

surface of the pressure nut and the pressure scale indicate surface in parallel.

Pressurizing power values listed in the table below are reference values. It may be the

incorrect value by wire type and welding conditions.

Table 3-1 Wire type vs. pressurizing power

Welding wire material Welding wire diameter Pressurizing power

Mild steel φ1.2 4

Mild steel φ1.0 4

Mild steel φ0.9 4

Mild steel φ0.8 4

Fig 3-7 Welding wire pressurizing power adjustment

Screw driver

Weaken

pressurizing

power

Milling surface: In parallel with pressure scale indicate surface.

Pressure nut

Strengthen

pressurizing

power

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4 Attach the resin lock cap and resin bolt

Fig 3-8 How to attach the resin lock cap and resin bolt

CAUTION • . To prevent electrical shock and fire, do not use metal bolts instead of resin bolts.

torque: 1.8N･m

･In parallel with milling surface. ･Press the Resin lock cap by wrench to prevent bolt racing.

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3 Adjustment and exchange procedure of each parts 3.4 Grease replenishment

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3.4. Grease replenishment

3.4.1. Notes on grease replenishment

Replenish grease to the servo torch at regular interval. Recommended grease and the

interval are as follows.

Table 3-2 Grease and replenishment interval for servo torch

Grease replenishment interval Every 6,000 hours

Recommended grease Shell Alvania EP Grease 2

Amount of grease About 1g

Make sure to follow the instructions below at grease replenishment. Failure to observe

the following instructions or notes may result in damage to servo torch.

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3 Adjustment and exchange procedure of each parts 3.4 Grease replenishment

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3.4.2. Grease replenishment

1 Remove the cover of the gear box and clean up the silicone gasket from the sealing

surface.

Fig 3-9 Removing the cover of the gear box

2 Remove the grease inside of the gear box and apply the new one to the teeth of bevel

gears. Do not leave any contamination (welding spatters, pieces of wiping rugs,

removed gaskets, etc.) inside of the grease and/or gear box.

3 Apply silicone liquid gasket (ThreeBond, 1221H) to the sealing surface of the gear box

cover and fasten the cover with two ultra-low head cap screws. Do not apply the gasket

inside of the gear box.

Fig 3-10 Sealing surface of the gear box cover

Gear box cover

Bevel gear

Hexagon bolt (M4 - L12),Spring washer (GTS 4)

(torque: 3N･m)

Sealing surface

Gear box cover

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3 Adjustment and exchange procedure of each parts 3.5 Cleaning

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3.5. Cleaning

In order to maintain the long-term function of the servo torch, clean the following

sections on a regular basis.

About other maintenance and inspection, please refer “4 Maintenance and inspection”

and each MOTOPAC manuals.

Fig 3-11 Cleaning sections and methods

WARNING Clean charged parts on a regular basis. Adhesion of abrasion powder, welding

spatter and dust on these parts cause electrical shock and fire.

Main body

・ Adhesion of abrasion powder, welding spatter and dust.

Blow with compressed dried air.

Inside of the cover

・ Adhesion of abrasion powder, welding spatter and dust.

Blow with compressed dried air.

・ Adhesion of oil and/or grease.

Remove with wiping rugs.

Feed Roller

Remove Adhesion of powder

and oil on insulating part

and roller with wiping

rugs. Roller

Insulating part

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4 Maintenance and inspection 4.1 Feed roller assy

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4. Maintenance and inspection In order to maintain the long-term function of the servo torch, clean the following

sections on a regular basis.

Since the wire feeding section is the drive mechanics part for the stable feeding of

wires, perform the maintenance and the inspection thoroughly.

One year is calculated as about 1,800 hours. Product life is depend on usage

environment.

4.1. Feed roller assy

Standard life time is about 2,000 hours.

Table 4-1 Checking points

Check point Abnormality Treatment

Does the wire size match

with the marking of feed

roller?

Inspection : at changing

feed roller assy or wire .

The wire size does not

match with the marking.

Change to the correct feed

roller.

(Reference :3.2 Feed

roller assy replacement)

Does pressure match with

the wire size?

Inspection : daily

The pressure is too strong

or too weak.

Readjust the pressure.

Note: Excessive pressure

may cause wire feeding

failure and it may shorten

the product life.

(Reference : 3.3 Welding

wire pressurizing power

adjustment)

Does not scraped powder

or dust accumulate on the

feed roller and around

them?

Inspection : daily

Scraped powder or dust

accumulates.

Remove scraped powder

or dust.

Note: Torch liner may be

clogged with them.

(Reference : 3.5 Cleaning)

Is feed roller assy greasy?

(Include a peripheral)

Inspection : daily

Adhesion of oil and/or

grease.

(Include a peripheral)

Remove with wiping rugs.

(Reference : 3.5 Cleaning)

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4 Maintenance and inspection 4.1 Feed roller assy

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Condition of the insulating

part of feed roller assy.

Inspection : At changing

feed roller assy or wire

diameter.

Cracked.

Replace with a new one

(Reference : 3.2 Feed


Condition of the wire

contact surface.

Inspection : every month

The groove is worn.




Covered with rust. Remove the rust by

clothes (Do not use the

sandpaper). Otherwise

change the feed roller.



Wire is damaged large Readjust the pressure.

Otherwise change the

feed roller.


roller assy replacement,

3.3 Welding wire

pressurizing power

adjustment)

Insulating part

OK

NG

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4 Maintenance and inspection 4.2 Wire guide

4-3

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The groove of roller is not

aligned with the inserting

line for wire.

Fit together the key and

the key slot when inserting

the feed roller assy.



Condition of the insulating

part of roller.

Inspection : At changing

feed roller assy or wire

diameter.

Cracked.




4.2. Wire guide




or dust accumulate?

Inspection : every week

Scraped powder or dust or

accumulates in the hole.


or dust by blowing with

compressed dried air.

Note: Torch liner may be

clogged with them.

Condition of the wire

contact surface.


The hole is spread or worn

into an ellipse.

The end of inlet or outlet is

deformed.


There are some burrs or

returns on the end.

Remove the burrs.

OK

NG

Wire

Feed roller assy

Resin washer

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4 Maintenance and inspection 4.3 Motor

4-4

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4.3. Motor

Standard life time is about 6,000 hours.



Welding power source

error occurrence


“Feeder error”

“Motor overcurrent”

“Servo Amplifier Alarm”


or dust.

Change the servo feeder

unit.

Sound


Sound is abnormal Replace with a new one

4.4. Inner tube and Liner




or dust accumulate?


Scraped powder or dust or

accumulates in the hole.

・ Blowing with

compressed dried air

and remove scraped

powder or dust.

・ Check the length of

inner tube and liner.

The end of liner or outlet is

deformed.

Replace with a new one.

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5 Parts list 5.1 Standard parts

5-1

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5. Parts list

CAUTION • Make sure to use recommended spare parts only.

• If parts not recommended by YASKAWA are used, product performance cannot be

guaranteed. YASKAWA is not responsible for incidents arising from using not

recommended parts.

5.1. Standard parts

Table 5-1 Parts name (Refer Fig 5-1)

Item

No. Parts code No. Parts name

Q’ty/

unit

001 YU1307249 WFE2WD feeder unit cover B 1

002 NRSS4-10 Knurled screws 1

003 SKNTR6 Hexagon nut 1

003A FC12722 Nut cap 1

004 NLDF6 Nord-lock washer 1

005 FWZJN-D17-V11-

P6H2-T4 Resin washer 1

006 YU1307247 WFE2WD-U pressure nut 1

007 DX-1509052 Resin lock cap 1

008 NLDF5 Nord-lock washer 1

009 RENB5-8 Resin bolt 1

010 606ZZ Pressure roller 1

011 YU1307248 WFE2WD feeder unit cover A 1

012 CBSS4-6 Ultra-low head cap screw M4×6 4

013 HS1400538-1 Motor radiating cover（For X350） 1

016 HS1370835 Motor radiating cover（For X500） 1

014 YT1405230 WFE2WD-TSS unit assy 1

015 YJ1707141 WFE2WD-U feed roller assy exchange

tool 1

201 DX-1805080-08 WFE2WD feed roller assy (0.8) 1

202 DX-1805080-09/10 WFE2WD feed roller assy (0.9/1.0) 1

204 DX-1805080-12 WFE2WD feed roller assy (1.2) 1

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5 Parts list 5.1 Standard parts Standard parts

5-2

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Table 5-2 Parts name for Air-cooled Torches (Refer Fig 5-2,5-3)

Item No. Parts code No. Parts name Q’ty/

unit

205 YEA003010-IL YMES-300R torch body assy (inner tube less) 1

400 001002 N nozzle 16 1

401 003002 N orifice S 1

402 004002 N insulator S 1

403 016051 TK-308RR tip body 1

404 YEA003012 YMES-300R torch body 1

405 Y0000FP10 O-ring 1

406 DX-1405152-A WFE2WD-TSS300R inner tube

(283.5mm)φ0.6～0.9 1

DX-1405152-B WFE2WD-TSS300R inner tube (283.5mm)φ1.0～1.2 1

206 DX-0202011-IL YMES-308R torch body assy (inner tube less) 1

400 001002 N nozzle 16 1

401 003002 N orifice S 1

402 004002 N insulator S 1

403 016051 TK-308RR tip body 1

400 DX-0202012 YMES-308R torch body 1

405 Y0000FP10 O-ring 1

408 DX-1405172-A WFE2WD-TSS308R inner tube (371mm)

φ0.6～0.9 1

DX-1405172-B WFE2WD-TSS308R inner tube (371mm) φ1.0～1.2 1

207 DX-1801100-IL WFE2WD-500R torch body assy (inner tube less) 1

400 001001 N nozzle 19 1

401 003001 N orifice L 1

402 004001 N insulator L 1

403 016403 TK-508RR tip body 1

407 DX-1801101 WFE2WD-500R torch body 1

405 Y0000FP10 O-ring 1


(283.5mm)φ0.6～0.9 1


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5-3

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unit

208 DX-0701051 TK-508RX torch body assy (inner tube less) 1

400 001001 N nozzle 19 1

401 003001 N orifice L 1

402 004001 N insulator L 1

403 016403 TK-508RR tip body 1

407 DX-1801101 WFE2WD-500R torch body 1

405 Y0000FP10 O-ring 1

408 DX-1405172-A WFE2WD-TSS308R inner tube (371mm)

φ0.6～0.9 1


Table 5-3 Common parts name

Item


Q’ty/

unit

600 002005 N tip 0.8mm 1

601 002001 N tip 0.9mm 1

602 002002 N tip 1.0mm 1

603 002003 N tip 1.2mm 1

Using not specified parts may cause damage to the product and be not covered by

warranty.

36a/43


5-4

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Fig 5-2 Parts name

011

001

012

002 00

5 004 00

3 20

5/ 2

06/ 2

07/ 2

08

/ 701

/ 702

015

406/

408

014

006

013/

016

007

008

009

010

201/

202

/ 203

/ 204

003A

604/

605

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5-5

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Fig 5-3 Parts name(300R/500R)

Fig 5-4 Parts name(308R/508R)

600/ 601/ 602/ 603

400 401

402

403/409 404/410

405 “YMES TypeA2”

406

600/ 601/ 602/ 603

400

401

402

403/409

407/411

405

“YMES TypeD2”

408

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5-6

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Table 5-4 Parts name for Water-cooled Torches (Refer Fig 5-4,5-5)


unit

701 YM1403081 YMSA500W torch body assy 1

603 002003 N tip 1.2mm 1

801 034115 β/ WX nozzle 16 1

802 034135 β/ WX tip adapter 1

803 034120 β/ WX orifice 1

804 061445 Centered ceramic 1

805 061447 WX450 Nozzle adapter 1

806 061448 WX450 Nozzle setting nut 1

807 061449 WX450 Nozzle spacer 1

808 DX-1403082 YMSA-500W Torch body 1

809 YM1403087 YMSA-500W Body block insulation cover 1

810 Y90201009 O-ring 1

811 Y90201015 O-ring 2

812 Y90201016 O-ring 1

405 Y0000FP10 O-ring 1

813 KAL06-01SW2(SMC) Elbow union 2


(283.5mm)φ0.6～0.9 1


702 YM1411201 TSS508W torch body assy 1

603 002003 N tip 1.2mm 1

801 034115 β/ WX nozzle 16 1

802 034135 β/ WX tip adapter 1

803 034120 β/ WX orifice 1

804 061445 Centered ceramic 1

805 061447 WX450 Nozzle adapter 1

806 061448 WX450 Nozzle setting nut 1

807 061449 WX450 Nozzle spacer 1

814 DX-1411202 YMSA-508W Torch body 1

809 YM1403087 YMSA-500W Body block insulation cover 1

810 Y90201009 O-ring 1

811 Y90201015 O-ring 2

812 Y90201016 O-ring 1

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5-7

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unit

405 Y0000FP10 O-ring 1

813 KAL06-01SW2(SMC) Elbow union 2


(371mm) φ0.6～0.9 1


Fig 5-4Parts name(500W)

Fig 5-5Parts name(508W)

600/ 601/ 602/ 603

801

802

803

804

809

405

805

806 807/811/812

406

808/810/811

813

600/ 601/ 602/ 603

801

802

803

804

809

405

805

806

807/811/812

408

814/810/811

813

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5 Parts list 5.1 Standard parts Parts for AR1440

5-8

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5.2. Parts for AR1440

Table 5-5 Parts name (Refer Fig 5-6,5-7)

Item


Q’ty/

unit

209 DX-1506302 WFE2WD-TSS300R bracket assy(H-type) 1


211 YJ1307086 YMH gauge bracket 1

212 DX-0412101-A-1630 WFE4D shock sensor cable （004）1630mm 1

213 DX-1508200-1630 WFE2WD-T gas hose 1

214 HS1370498-A1.2 Servo feeder shoulder cable 1

215 DX-1511110-1130 Cable cover 1

216 DX-1506306 WFE2WD-TSS power cable (H-type) 1

217 016076 Liner 1

227 FS-4-6X4-BU Air hose(X500)1240mm & 1280mm 2

228 DX-1711050-2000 Water hose(In the case of a Water-cooled torch) 2



Item


Q’ty/

unit




212 DX-0412101-A WFE4D shock sensor cable （004）1630mm 1



215 DX-1511110-1130 Cable cover 1

216 DX-1506306 WFE2WD-TSS power cable (H-type) 1

217 016076 Liner 1

227 FS-4-6X4-BU Air hose(In the case of the X500)1500mm & 1525mm 2


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5-9

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Item


Q’ty/

unit




212 DX-0412101-A2030 WFE4D shock sensor cable （004）2030mm 1



215 DX-1511110-1500 Cable cover 1

216 DX-1506306-2010-

12 WFE2WD-TSS power cable (H-type) 1

217 016076 Liner 1

227 FS-4-6X4-BU Air hose(In the case of the X500)1790mm & 1815mm 2


39a/43


5-10

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Fig 5-6 Parts name (AR1440/AR1730/AR2010/AR1440E)

Fig 5-7 Parts name (AR1440/AR1730/AR2010/AR1440E)

227 228

214

212

213

215

209/ 210

211

216

217

Cut and adjust the length of part 217

216

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5 Parts list 5.1 Standard parts Parts for AR700/ AR900

5-11

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5.5. Parts for AR700/ AR900

Table 5-8 Parts name (AR700/AR900)

Item

No. Parts cod No. Parts name

Q’ty/

unit

218 DX-1702230 WFE2WD-TSS300R bracket assy(H-type) (AR700/AR900) 1

219 DX-1611070 WFE2WD-TSS308R bracket assy(H-type) (AR700/AR900) 1

220 DX-1611030 YMH gauge bracket (AR700/AR900) * small plate 1

221 DX-0412101-A WFE4D shock sensor cable （004）1900mm 1


223 HS1370658-A1.9 Servo feeder cable 1

224 DX-1511110-1300 Cable cover 1

225 DX-1506306 WFE2WD-TSS power cable （H-type,AR700/900） 1

226 016076 liner 1

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5 Parts list 5.1 Standard parts Parts for AR700/ AR900

5-12

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Fig 5-5 Parts name(AR700/AR900)

Fig 5-6 Parts name(AR700/900)

225

223

218 /219

220

221

222

224

226

Cut and adjust the length of part 226.

225

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1

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Specifications are subject to change without notice for ongoing modifications and improvements.

MANUAL No.

© Printed in Japan September 2018 17-06

SERVO TORCH FOR MOTOWELD YWE-WFE2WD INSTRUCTIONS

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