Arc Welding Robot Package

MOTOPAC-W Series

JQA-EM0924JQA-0813

Certified forISO9001 andISO14001

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THE PACKAGE SOLUTION

High-quality Arc Welding Package with Digital Control

MOTOPAC-WL/-WHSeries

General-purpose Arc Welding Package with Digital Control

MOTOPAC-WR Series

Options and Cable

Installation Service

Arc welding robot cable installation work at the robot plant of Yaskawa Electric

Because the package components are carefully developed and selected for the workpieces and welding method, the best robotic system for your needs can be easily installed without any complications. And, Yaskawa will assist you with our full range of services.

The MOTOPAC-W series is an arc welding system in which the needed devices, such as a MOTOMAN welding robot, welding power source, and torch, are integrated as a total package.Select the package that best suits your application, and you can have a high-performance and high-productivity robotic system that is ready to go.

The combination of MOTOWELD welding power source with the latest digital control and a MOTOMAN robot enables optimum welding control in a wide variety of welding methods, offering extremely high-quality welding.

Easy to Set Up

Features

Ensured High-quality Welding

The Best Robotic System Ready to Run for Your Specific Application

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Supported welding methods : CO2, MAG, MIG, MAG pulse, and MIG pulseSupported welding materials : Iron, stainless steel, and aluminum＊

＊ : When welding aluminum, the torch & torch cable set and conduit cables for aluminum welding must be used.

The MOTOWELD-EL350Ⅲ welding power source package offers a high-quality arc welding power source with digital control that supports both short-circuit welding and pulse welding. The secondary switching circuit installed in the welding power source reduces spatter caused by short-circuiting and enables high-quality welding.

MOTOPAC-WL100

The MOTOWELD-RP500 welding power source package offers a high-quality arc welding power source with digital control that supports both short-circuit welding and pulse welding. The operation rate of 100% enables prolonged continuous welding operation.＊1

MOTOPAC-WH400

The MOTOWELD-SR350 welding power source package delivers simplified and intuitive operation by limiting its functions to those specialized for non-pulse welding of iron. Digital control using the inverter enables steady operation in welding.

MOTOPAC-WR100

The MOTOWELD-SR500 welding power source package delivers simplified and intuitive operation by limiting its functions to those specialized for non-pulse welding of iron. Digital control using the inverter enables steady operation in welding. Use this package when the required current and operation rate cannot be obtained with a 350A welding power source.

MOTOPAC-WR200

Package Lineup

High-quality Arc Welding Package with Digital Control

General-purpose Arc Welding Package with Digital Control

Supported welding methods : CO2, MAG, MIG, MAG pulse, and MIG pulseSupported welding materials : Iron, stainless steel, and aluminum＊2

＊1 : A water-cooled torch is required for continuous welding operations with a high operation rate.＊2 : When welding aluminum, the torch & torch cable set and conduit cables for aluminum welding must be used.

Supported welding methods : CO2 and MAGSupported welding materials : Iron only

Supported welding methods : CO2 and MAGSupported welding materials : Iron only

Welding power sourceMOTOWELD-EL350Ⅲ

Welding power source　MOTOWELD-RP500

Welding power source　MOTOWELD-SR350

Welding power source　MOTOWELD-SR500

□□　□　□6SDMOTOPAC-W

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Product Code forWelding Package

Arc Welding Package Product Code

Reductive code

Wire feeder type

With the shock sensor

Robot controller

Package model

Manipulator type

Product destinationA

C

:

:

Japan and other Asian countries (Input voltage 200/400 V)China (Compliant with CCC standards)

MOTOMAN-VA1400

MOTOMAN-MA1400

MOTOMAN-MH6

MOTOMAN-MA1900

MOTOMAN-HP20D

MOTOPAC-WL100

MOTOPAC-WH400

MOTOPAC-WR100

MOTOPAC-WR200

(with EL350Ⅲ)(with RP500)(with SR350)(with SR500)

Reductive Code

Example of a reductive code

When ordering a package without a torch & torch cable set, shock sensor, and labor for cable installation:The seven-digit binary number will be 100010, and the converted hexadecimal number will be 22. The reductive code is 22.

（□□□□□□）bin　→　 （□□）hex

Connection cable between manipulator and welding power source 1: × 0: (No.6 to 9 in the table on page 5)

Torch & torch cable set and shock sensor 1: × 0: (No.1 and 2 in the table on page 5)

Conduit cable 1: × 0: (No.11 in the table on page 5)

Welding I/F cable 1: × 0: (No.10 in the table on page 5)

Cable installation parts for arm 1: × 0: (No.4 in the table on page 5)

Labor for cable installation 1: × 0:

Code : 01 to 7F (“00” means the complete package with all of the following components included and it can be omitted. “10” can be replace by “K”, and “30” can be replaced by “KG”)

Cannot be changed

Cannot be changed

Cannot be changed

To help reduce costs and to meet individual needs with different product specifications, some devices in the welding package can be omitted. When placing order, use the product code for the welding package along with the reductive code.

Specify each item with a binary number to obtain a seven-digit number, and then convert it to a hexadecimal number. Use the hexadecimal number as the reductive code when placing your order.

Note : ×: Not selected, :Selected

:::::

DEFGH

::::

L1H4R1R2

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Devices in the Arc Welding Package

Parts that do not depend on the manipulator model :

MOTOMAN-VA1400

Shield gas

Welding wire

Robot controller

Package Components

＊1 : Specifications for torch and torch clamp with shock sensor For MOTOMAN-VA1400 / MA1400 / MA1900 Torch : Air-cooled torch YMENS-300R made by Tokin Corp. for a 350 A welding power source. : Air-cooled torch YMENS-500R made by Tokin Corp. for a 500 A welding power source. Torch clamp with shock sensor: DX-0410260 made by Tokin Corp. For MOTOMAN-MH6 / HP20D Torch : TK-308RR made by Tokin Corp. for a 350 A welding power source. : TK-508RR made by Tokin Corp. for a 500 A welding power source. Torch clamp with shock sensor : HS9371266 made by Yaskawa Electric Corp.＊2 : Cable installation parts for arm When using MOTOMAN-VA1400 / MA1400 / MH6 with a 350 A welding power source, cables are installed in the S axis (turning axis). Otherwise, power cables should be secured around the S axis by using spring supports. ＊3 : Welding power source Specifications vary depending on the arc welding package model.＊4 : Negative (-) cable for voltage detection When using the MOTOWELD-SR350 / SR500 with a 10 m or shorter power cable, a negative (-) cable for voltage detection is not required.

Device

Torch & torch cable set

Torch clamp with shock sensor

Wire feeder

Cable installation parts for arm

Welding power source

Positive (+) power cable

Negative (-) power cable

Cable for wire feeder control

Negative (-) cable for voltage detection

Welding I/F cable

Conduit cable

Gas hose

Labor for cable installation

Default specifications (when not specified by the customer)

Varies according to manipulator and package model ＊1

Varies depending on manipulator model ＊1

YWE-X40TELC (Wire diameter:1.0 and 1.2 mm)

Varies according to manipulator and package model ＊2

Varies depending on package model ＊3

WCT60SQ × 5 m (Made by Mitsuboshi Co., Ltd.)

WCT60SQ × 5 m (Made by Mitsuboshi Co., Ltd.)

5 m (Between manipulator and welding power source)

5 m (Between manipulator and jig) Not required for some robot models ＊4

4 m (Between robot controller and welding power source)

N35 × 3 m (Made by Tokin Corp.)

SLD hose (Nominal dia. 6) × 10 m (Made by Bridgestone Corp.)

At the robot plant of Yaskawa Electric Corp.

No.

①

②

③

④

⑤

⑥

⑦

⑧

⑨

⑩

⑪

⑫

②

MOTOMAN-MA1400

MOTOMAN-MH6

MOTOMAN-MA1900

MOTOMAN-HP20D

④

④

④

④

⑨

④

③

③

③

③

③

①

②

②

①

②

①

①

①

⑪

⑦

⑥

⑫

⑩⑤⑧

②

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Optional Devices

□□ : Cable type 01= Without an encoder signal conversion unit, 02=With an encoder signal conversion unit ＊

△△ : Cable length Specify the length in increments of 5 m.＊ : Cable 02 is recommended when a cable of 10 m-15 m is needed. When a cable length of 15 m or more is needed, cable 02 must be used.

This signal cable connects a manipulator with a welding power source and controls the wire feeder (See No.8 in the table on page 5). Different lengths of the cable can be ordered as needed, depending on the installation layout of the devices. When ordering this cable for wire feeder control, select “1” in the binary code for itemized purchases to indicate that the connection cable between the manipulator and the welding power source has not been selected. Welding power cables (both positive and negative) and one negative (-) cable for voltage detection are also required.

Cable for Wire Feeder Control

MOTOPAC-WOP-FC□□-△△

□□ : Cable size 60 = 60 sq mm, 80=80sq mm, 100=100 sq mm△△ : Cable length Specify the length in increments of 5 m. 20 m max.○　 : Cable type 0= WCT made by Mitsuboshi Co., Ltd.＊, 1=E-WRCT made by Mitsuboshi Co., Ltd.＊ : Omitted when “0”.

MOTOPAC-WOP-WPC□□-△△（-○）

□□ : Welding power source model 01=EL350Ⅲ, 02=SR350, SR500 or RP500△△ : Cable length Specify the length in increments of 5 m. 20 m max.

MOTOPAC-WOP-VDC□□-△△

□□ : Welding power source model 03=EL350Ⅲ, SR350 or SR500, 10=RP500△△ : Cable length Specify the length in increments of 5 m. 20 m max. When not specified, the cable length will be 4 m (standard).

MOTOPAC-WOP-WC□□（-△△）

This cable can be used as a positive (+) power cable as well as a negative (-) power cable (See No.6 and No.7 in the table). A positive cable is used to connect a manipulator with a welding power source and a negative cable is used to connect a welding power source with a welding jig. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. When ordering this power cable, select “1” in the binary code for itemized purchases to indicate that the connection cable between manipulator and welding power source has not been selected. One cable for wire feeder control and one negative (-) cable for voltage detection are also required.

Power Cable

Note : When ordering power cables, “one set” means one cable.

This cable connects a manipulator with a welding jig and detects welding voltage (See No.9 in the table). Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. When ordering this cable, select “1” in the binary code for itemized purchases to indicate that the connection cable between manipulator and the welding power source has not been selected. Power cables (both positive and negative) and one cable for wire feeder control are also required.

Negative (-) Cable for Voltage Detection

This cable for control signal conects a robot controller and a welding power source and controls the welding power source (See No.10 in the table). Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. When ordering this welding I/F cable, select “1” in the binary code for itemized purchases to indicate that the welding I/F cable has not been selected.

Welding I/F Cable

StandardOptions

Customize your package to meet the needs of your installation environment

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This cable connects a manipulator with a spool container for welding wire (See No.11 in the table). Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. When ordering this conduit cable, select “1” in the binary code for itemized purchases to indicate that the conduit cable has not been selected.

Conduit Cable

This is a set of optional rollers for the wire feeder. They are each for different sizes of wire. Be sure to order the correct size rollers for your wires. (A set of rollers for diameter 1.0 and 1.2 mm wires is installed in the wire feeders when shipped.)

Roller for Wire Feeder

This gas regulator controls the pressure of shield gas contained in the gas cylinder that can be used for both CO2 and MAG welding. When using it for CO2, an antifreeze heater can be used by connecting the heater to a 100 VAC power source.

Gas Regulator

By applying high voltage to the tip of the welding wire, the start point for welding can be detected. The function can be used to correct a welding start point when the start point varies due to a variance in a workpiece size or position.

Welding Start-point Detection Function

This bulb unit is for optional devices that supply air to a welding torch, such as a wire clamp and an air blow unit. A terminal block must be installed in the robot controller to wire this air bulb unit. An air regulator and materials for piping to the robot must be prepared and installed by the customer.

Air Bulb Unit

□□ : Cable type 01=N35, 02=N55, 03=Simplified type [All made by Tokin Corp.]△△ : Cable length　 Specify the length in increments of 1 m. 20 m max. For N35, 15 m max.

MOTOPAC-WOP-CC□□-△△

□　 : Welding power source type 4=EL350Ⅲ / RP500, 5=SR350 / SR500△△ : Length of cable connecting robot controller with welding power source Specify the length in increments of 5 m. 20 m max. When not specified, the cable length will be 4 m (standard).○　 : Robot controller group axis configuration A=Robot only (can be omitted), B=Robot + Traverse axis, C=Robot + Positioner, D=Robot + Two positioners, F=Robot + Traverse axis + Positioner, G=Robot + Traverse axis + Two positioners, H=Two robots that work in coordination

MOTOPAC-WOP-TOUCH□（-△△-○）

□　 : Bulb type C= for wire clamp, B=for air blowing△　 : Manipulator type　D=MOTOMAN-VA1400, E=MOTOMAN--MA1400, 　 F=MOTOMAN-MH6, G=MOTOMAN-MA1900, H=MOTOMAN-HP20D

MOTOPAC-WOP-ABU-□-△

□□ : Roller type 01= diameter 1.0/1.2 mm, 02= diameter 0.8/1.0 mm, 03= diameter 0.9/1.2 mm, 04= diameter 1.2/1.4 mm ［Distributed by Tokin Corp.］

MOTOPAC-WOP-WFR□□ Note : Available in a set of two rollers (one set/wire feeder).

MOTOPAC-WOP-GR01 [FCR-2025 made by Yutaka Engineering Corp.]

Optional Devices

Ｎ35 / 55

Simplified type

YMENS-500W wire clamp(water-cooled)

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The wire clamp unit is used to reduce excess play in the wire in the torch cable section when the welding start-point detection function is applied. An air bulb unit is required when using a wire clamp unit. The wire clamp unit is dedicated to air-cooled torches for robots in the MOTOMAN-MH and HP series. For water-cooled torches and robots in the MOTOMAN-VA and MA series, use a torch with a built-in wire clamp unit.

Wire Clamp Unit

□□ : Torch type 01=YMENS-300R, 11=YMENS-500R, 02=YMENS-308R, 12=YMENS-508R, 31=YMENS-500R with a wire clamp, 41=YMES-500W (water-cooled), 61=YMES-500W with a wire clamp (water-cooled), 72=TK-308RR, 82=TK-508RR, 92=WX451R (water-cooled), A2=WX451R with a wire clamp (water-cooled) [The YME(N)S models are for only MOTOMAN-VA / MA series of robots. All torches are made by Tokin Corp.]△　 : Manipulator type D=MOTOMAN-VA1400, E=MOTOMAN-MA1400, F=MOTOMAN-MH6, G=MOTOMAN-MA1900, H=MOTOMAN-HP20D

We offer a variety of torches to choose from for your arc welding package. When ordering one of these optional torches, select “1” in the binary code for itemized purchases to indicate that the torch & torch cable set and shock sensor have not been selected.

Optional Torch

□□ : Water hose length Specify the length in increments of 5 m. 20 m max.

This is a water circulation device for water-cooled torches. A single-phase 200 VAC must be used for this device.

Water Circulator

□□ : Cable length between robot controller and wire cutter Specify the length in increments of 5 m. 20 m max.

This device cuts the tip of the welding wire automatically when required, including when the welding start-point detection function is applied. To use the wire cutter, a terminal block must be installed in the robot controller. Materials for piping to the air regulator and wire cutter must be prepared and installed by the customer.

Wire Cutter

YMENS-300R

WX451R (Water-cooled)

YMENS-308R

WX451R wire clamp (water-cooled)

YMENS－508R

YMENS-500R wire clamp

YMENS-500R YMENS-500W(Water-cooled) TK308RR

TK508RR

MOTOPAC-WOP-WCL [Wire clamp unit made by Tokin Corp.]

MOTOPAC-WOP-TCH-□□-△ Note : All models are equipped with a torch clamp with 　　　 a shock sensor.

MOTOPAC-WOP-WPT-□□ [WR-100 made by Tokin Corp.]

MOTOPAC-WOP-WCT-□□ [TKC-A2 made by Tokin Corp.]

This coaxial cable combines positive and negative welding power cables (See No.6 and 7 in the table). The coaxial structure maximizes the performance of the welding power source by reducing the deterioration of waveforms when the welding power source is installed away from the welding robot. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. When ordering this cable, select “1” in the binary code for itemized purchases to indicate that the connection cable between the manipulator and the welding power source has not been selected. The cable for wire feeder control, a negative (-) cable for voltage detection, and a negative (-) power cable are also required.

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□□ : Length Specify the length in increments of 1 m.

This conduit cable has built-in roller bearings that have extremely low frictional resistance (See No.11 in the table). The roller bearings help to reduce load during wire feeding. Different lengths of cable can be ordered as needed, depending on the installation layout of the devices. When ordering this high-performance conduit cable, select “1” in the binary code for itemized purchases to indicate the conduit cable has not been selected.

High-performance Conduit Cable

□□ : Length Specify the length in increments of 1 m.

High-performance Power Cable

High-quality torch clamps with a shock sensor made by the manufacturers of welding torches. Each shock sensor works ideally with the specified torch. These durable shock sensors are perfect for use in a demanding environment. When ordering this high-grade shock sensor, select “1” in the binary code for itemized purchases to indicate that the torch & torch cable set and shock sensor have not been selected.

High-grade Shock Sensor

Comparison of waveform deterioration in 100 m cable

Type T1 Type T2 Type B1 Type B2

Coaxial structure of (+) and (-) power cables 1,806

500.0

400.0

300.0

200.0

100.0

0.01,810 1,815 1,820 1,825 1,830 1,833

Time (sec)

□□ : Shock sensor type T1=Tokin shock torch for MOTOMAN-MH / HP robots + TK308RR, T2=Tokin shock sensor for MOTOMAN-VA / MA robots + 308R, B1=BINZEL CAT2 for MOTOMAN-MH / HP robots + 350GC, B2=BINZEL iCAT for MOTOMAN-VA / MA robots + 350GC△　 : Manipulator type D=MOTOMAN-VA1400, E=MOTOMAN-MA1400, F=MOTOMAN-MH6, G=MOTOMAN-MA1900, H=MOTOMAN-HP20D

The standard options and high-grade options made by Tokin Corp. or Alexander Binzel Schweisstechnik GmbH & Co. KG can also be ordered from each company’s sales representatives, provided that no labor for cable installation is required before robot delivery and that the optional product is for modification of a robot currently being used.

Coaxial cable

Conventional cable

MOTOPAC-WOP-TCP-□□-△△（-○） Note : These high-grade sensors are sold with a torch as a set.

[Coaxial cable with an inner conductor of 80SQ × 2 made by Tokin Corp.] MOTOPAC-WOP-WPCD8-□□

MOTOPAC-WOP-CC05-□□ [Micro Glide made by Tokin Corp.]

High-gradeOptions

The Pursuit of High Quality and Constant Improvement

Optional Devices

Connected roller bearing shells enable smooth wire feeding, even when the wire is bent.

Wel

din

g cu

rren

t ( A

)

MOTOPAC-W Series

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

© 1997-2011 YASKAWA ELECTRIC CORPORATION. All rights reserved.

YASKAWA ELECTRIC CORPORATION

In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply.

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LITERATURE NO. CHE-C945-510LPublished in Japan Nobember 2011 97-10

Sales Department

11-8-26

HEAD OFFICE2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyushu, Fukuoka 806-0004, JapanPhone: +81-93-645-7745 Fax: +81-93-645-7746

YASKAWA America, Inc.100 Automation Way Miamisburg, OH 45342, U.S.A.Phone: +1-937-847-6200 Fax: +1-937-847-6277

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YASKAWA Nordic ABBredbandet 1vån. 3 varvsholmen 392 30 Kalmar, SwedenPhone: +46-480-417-800 Fax: +46-480-417-999

YASKAWA Electric (SHANGHAI) Co., Ltd.12F, Carlton Bldg., No.21 HuangHe Road, HuangPu District, Shanghai 200003, ChinaPhone: +86-21-5385-2200 Fax: +86-21-5385-3299

Shougang MOTOMAN Robot Co. Ltd.No.7 Yongchang North Road, Beijing E&T Development Area China 100176Phone: +86-10-6788-2858 Fax: +86-10-6788-2878

YASKAWA Robotics India Limited#426, Udyog Vihar Phase-IV, Gurgaon, Haryana, IndiaPhone: +91-124-475-8500 Fax: +91-124-475-8542

YASKAWA Electric Korea Co., Ltd9F, Kyobo Securities Bldg., 26-4, Yeouido-dong, Yeongdeungpo-gu, Seoul 150-737, KoreaPhone: +82-2-784-7844 Fax: +82-2-784-8495

YASKAWA Electric (Singapore) PTE Ltd151 Lorong Chuan, #04-02A New Tech Park, Singapore 556741Phone: +65-6282-3003 Fax: +65-6289-3003

YASKAWA Electric (Thailand) Co. Ltd.252/246, 4th Floor Muang Thai-Phatra Office Tower 2 Rachadapisek Road,Huaykwang Bangkok, 10320 ThailandPhone: +66-2-693-2200 Fax: +66-2-693-4200