Panasonic YC-500WX Operating Instructions Manual Download Page 1

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Operating Instructions

IGBT Controlled

AC/DCTIG arc welding power source

Model N o . :

YC-500 WX

●

Thank you for your purchase of Panasonic welding power source.

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Before operating this product, please read the instructions carefully and save this manual

for future use.First of all

please read “Safety precautions” or “Safety manual”.

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SPEC. No.

：

YC-500WX4HGX

Panasonic Welding Systems (Tangshan) Co., Ltd.

WTC017TEOPAA02

Summary of Contents for YC-500WX

Page 1: ...you for your purchase of Panasonic welding power source Before operating this product please read the instructions carefully and save this manual for future use First of all please read Safety precautions or Safety manual SPEC No YC 500WX4HGX Panasonic Welding Systems Tangshan Co Ltd WTC017TEOPAA02 ...

Page 2: ......

Page 3: ...5 OPERATION PANEL 6 6 CONNECTIONS 8 6 1 TIG WELDING 8 6 2 DC STICK WELDING 9 7 METHOD OF OPERATION 10 7 1 OPERATING METHOD OF TIG WELDING 10 7 2 TORCH CABLE 12 7 3 OPERATION METHOD OF STICKWELDING 15 8 MAINTENANCE AND INSPECTION 16 9 PRECAUTIONS FOR FILTER 17 10 CONNECTION WITH OTHER EQUIPMENTS 19 10 1 SWITCH ON P BOARD 19 10 2 JIG TERMINAL AND EXAMPLE OF ITS USAGE 20 11 TROUBLESHOOTING 21 12 CIRC...

Page 4: ... ACCESSORIES Number Name Type Member Unit 1 Gas hose TBV6X11 1 EA 2 Host Clamp WHB12FJ 2 EA 3 Bolt R9074 17M8X25 2 EA 4 Washer R95D8 2 EA 5 Nut R6170M8 2 EA 6 Filter CJX3010 口口 1 EA 7 GLASS TUBE FUSE 61NR050H 1 EA ...

Page 5: ...periodical check of this product Any problem arising out of any force majeure including but not limited to act of god Any malfunction or defect of this product that is directly or indirectly the result of any malfunction or defect of one or more related parts or products that are not supplied by PWST Or any problem arising out of or directly or indirectly attributable to the combination of this pr...

Page 6: ...rking above floor level 9 Turn off all equipment when not in use 10 Perform periodic checks without fail and repair or replace any damaged parts before using the power source Ventilation and protective equipment Oxygen deficit fume and gas generated during welding can be hazardous 1 When conducting welding in the bottom of the tank boiler or hold as well as legally defined sites use a local exhaus...

Page 7: ...aught by the parts resulting in injury 2 Keep all covers panels and cases closed when using the product 3 Maintenance work and repair should be perform only by educated and or skilled persons who thoroughly understand welding machines While performing maintenance work or repair work provide fence or the like around the welding machine so that unauthorized person can not come close carelessly Weldi...

Page 8: ...MIX TIG A 20 500 A C STD TIG A 20 500 A C HARD TIG A 40 500 A C SOFT TIG A 20 330 DC TIG A 5 500 Upslope time S 0 or 0 1 5 Downslope time S 0 or 0 2 10 Gas preflow time S 0 3 Gas postflow time S 2 20 Cleaning width MIX TIG AC STD HARD SOFT TIG Pulse frequency Low pulse Hz 0 5 25 Middle pulse 10 500 Pulse width 15 85 MIX TIG frequency Hz 0 5 10 Crater control process ON OFF REPEAT Outside dimension...

Page 9: ...cycle to a level lower than the result of the formula Output current values for pulsed welding are the average of the base and peak current values Allowable Duty Cycle vs Output Current 10 minutes cycles 40 C ambient temperature Output current A 100 387A 0 50 100 387 450500 Duty cycle 60 100 200 300 For your reference Duty cycle The percentage ratio of loading time to full time A cycle of the full...

Page 10: ... 8 Avoid wind to the arc Provide windshields 9 Free from abnormal amounts of dust acid corrosive gases a or substances Note When the product is installed on the floor where it is too low to operate customers are required to prepare a table to mount the product on Such table should be provided with flanges on the mounting surface to prevent the product to slide off the table 4 2POWER SUPPLY AND CON...

Page 11: ...the following equipment and materials for welding TIG welding Torch for TIG welding YT 30TSW2HAF Products to be purchased separately Welding argon gas Products to be purchased separately Argon gas adjustor YX 25AJ1 Products to be purchased separately Base metal side cable Stick welding Products to be purchased separately 4 4SELECTION OF TUNGSTEN ELECTRODES Use the following table as reference for ...

Page 12: ...5 4 5FILER WIRE Standard for selection of filler wire diameter Welding current A Filler wire diameter mm 10 20 1 0 20 50 1 6 50 100 1 0 2 4 100 200 1 6 3 0 200 300 2 4 4 5 300 500 4 5 6 0 ...

Page 13: ... when this warning display lamp goes on Remove the cause and switch back to ON again 4 Crater control switch This switch the crater control ON OFF REPEAT of crater control of TIG welding 5 Initial current adjustor Regulates the initial current during ON REPEAT of crater control of TIG welding 6 Welding current adjustor Regulates the we lding current 7 Crater current adjustor Regulates the crater c...

Page 14: ...o WELD when performing ordinary welding and to CHECK when regulating the flow rate of argon gas 12 Pulse frequency control Selects a low pulse of 0 5 25Hz or a middle pulse of 10 500Hz when switched from TIG welding to pulse TIG welding 13 Pulse width adjustor It is used to adjust the pulse current rate in pulse welding The pulse current rate is time ratio of pulse current to the sum of welding ba...

Page 15: ...he cooling water unit on the top panel of welder according to the instruction manual of the cooling water unit This welder is operable without armeotecontroller Incase of theuse connect it to the receptacle for the remote controller Option Then the control of welding and crater current adjustments is automatically switched over to the remote controller side While the remote controller is set in it...

Page 16: ...9 6 2DC STICK WELDING Connect the holder and base metal cable according to the proper polarity of the stick welding rod used Base metal Output terminal Holder Output terminal Distribution box ...

Page 17: ...ecking Draw the torch near to the base metal and press the torch SW Be sure to close the plug of the argon gas cylinder after finishing welding work Set the welding method select switch located on the operation panel Turn ON the distribution box switch Turn ON the power switch on the operation panel Check the gas flow rate Start welding work Welding work completed Turn OFF the power distribution b...

Page 18: ...rrent as table below Solid line when pulsation SW is OFF Broken line when pulse is LOW MID Upslope time 0 or 0 1 5 sec Downslope time 0 or 0 2 10 sec Perform adjustment of cleaning width according to the condition of weld piece in case of AC TIG welding or MIX TIG welding Refer to cleaning width adjustment page 12 ...

Page 19: ...f the arc cleaning action can be controlled when performing AC TIG welding or MIX TIG welding 7 2TORCH CABLE Use the torch cable and base metal side cable without coiling whenever practicable When the output overvoltage warning lamp lights up lay the torch cable and the base metal side cable as straight as possible O X ...

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Page 22: ...le 60 In case of STICK welding please keep Max welding current DC 400A or less This welder is equipped with a voltage reducing function When the voltage reducing function is not necessary set the voltage reducing ON OFF connector on the printed circuit board TSMPA 015 口 to OFF This is set to ON at time of shipment ...

Page 23: ...re not loose rust does not worsen the electric contact and check for any problem in insulation 2 Grounding line Ensure that the welding machine case is completely grounded 3 Removing dust inside the welding machine If dust is accumulated between windings of the transformer for example insulation may deteriorate accordingly therefore remove the side top plates of the welding machine at least once p...

Page 24: ...ter once or twice per month The way of cleaning 1 Remove the adapter 2 Take out the filter 3 Remove dust or fur accumulated on the wire net of the filter by washing or brushing 4 Set the filter Water pressure This machine uses a flow rate switch to prevent the water cooled torch from burning For the flow rate switch since the water amount becomes small in a low water pressure place WARN indicator ...

Page 25: ... whereby may cease to operate therefore periodically clean the flow rate switch To do this follow the steps below Remove the right side plate right as viewed from the front power supply Remove the nut of water inlet hardware Remove the flow rate switch Detach the cap at the upper part of flow rate switch from main unit Remove fur and rust from the shaft float and interior flow rates witch Re insta...

Page 26: ...rt process when the arc is generated at the same position repeatedly the arc may not be generated smoothly In this case change EP ON OFF switch on the front panel to EP OFF side At shipment EP ON OFF switch is set to OFF side Change of arc start hard soft SW3 In PC board TSMPA015口 On AC TIG welding change of arc start current is selected At shipaent arc start hard soft switch is set to soft side H...

Page 27: ...terminal The welder will not operate if the short circuit line of A B are disconnected Use this when it is desired to stop the welder from the outside C D Current detecting signal terminal A contact point which closes at the time of detecting the current is provided in C D Contact point rating AC 125V 0 5A DC 30V 2A E F Pulse detecting signal terminal actuates only at LOW pulse A normal open conta...

Page 28: ...e output cable at the time of AC TIG welding or MIX TIG is coiled too small Lay the output side cable in an uncoiled condition as much as practicable or coil in large loops High frequency and arc does not generate Welding method control switch is set to stick welding The torch switch plug socket is not connected Arc is not generated while high voltage is generated Base metal side cable is not conn...

Page 29: ...lectrode is dirty Welding current for welding rod is too small compared with current suitable for the diameter of rod Arc dies Distance between torch electrode and base metal is too long Tungsten electrode 1s excessively worn Welding current for tungsten electrode is too high compared with current suitable for the diameter of electrode Shielding gas flow is short or gas postflow time is short Shie...

Page 30: ...23 12 CIRCUITDIAGRAM ...

Page 31: ...24 13 PARTS LAYOUT DRAWING ...

Page 32: ... C2 Roupling coil SMKPHS2UF1200VD 2 21 R22 23 25 27 Resistor Z91W50 2 22 R2 5 Resistor SFW40A501J 1 23 R2 9 3 2 Resistor RXGB120W200J 4 24 R5 R6 Resistor RX274H20W5R0JW 2 25 S 1 Switch ASW220TK392 1 26 S 2 3 Switch ADS850CF1A02 2 27 S4 Switch VLA04B1 2 1 28 S 5 Switch SRM125F2098N 1 29 S6 Switch VLA04B1 2 1 30 S 7 Switch VLA04B1 2 1 31 T6 Control transformer TSM05334 1 32 SOL Gas valve J540 716 1 ...

Page 33: ...45 IEC81 YH 35 60245 IEC81 YH 70 Thermal Relay 0HD3 75B02 Electromagnetic valve JZ540 745 Insulating paint R 611 9 FOR TSM95831 TSM95786 CLU00016 TSM95545 Insulating paper YT511 23X750X126 TSM95786 YT516 2X750X126 YT511 23X720X115 CLU00016 YT516 5X720X115 YT516 5X200X160 TSM95545 YT516 10X99X50 TSM95831 YT516 10X480X93 YT516 5X320X100 Paper Covered Copper Wire 2XCCU25X5 5 TSM95831 Bare aluminum wi...

Page 34: ...27 15 OUTLING DRAWING ...

Page 35: ...to the values on the ammeter 4 Output current may slightly vary according to the adjustment of cleaning width See the figure below 16 2 A C SOFT TIG Output waveform Features 1 Output current forms sine pulse waveform in both periods of electrode positive EP and electrode negative EN 2 Sine this method generates soft arc it is suitable for butt welding of thin plates and of works having wide gap an...

Page 36: ...G frequency Make sure to refer the output value on the ammeter Note Make sure to turn OFF the pulsation when welding in MIX TIG mode 16 4 A C STD TIG Output waveform Features 1 Output current forms rectangular pulse waveform which has the same peak value in the periods of both electrode positive EP and electrode negative EN 2 Wide range of applicable work thickness form thin to thick 3 This rectan...

Page 37: ...rect current in the range from low to high current LOW low pulse waveform Features CD Suitable for welding of works having significantly different heat capacity such as thick and thin plates or for welding which requires ripple of reverse sidebead MID middle pulse waveform Features CD Suitable for welding of thine plates fillet welding and butt welding ...

Page 38: ...bear in mind that this product may not be brought as is into the EU after January 1 1995 The same restriction also applies to any country which has signed the EEA accord Please be absolutely sure to consult with us before attempting to relocate or resell this product to or in any EU member state or any other country which has signed the EEA accord The standard of the product This product is design...

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