Panasonic YD-350GL4 Operating Instructions Manual Download Page 53

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Circuit diagram

13.

Circuit diagram for 500GL4

100V100V

Optional parts

300

248

Summary of Contents for YD-350GL4

Page 1: ...rating Instructions Model No Before operating this product please read the instructions carefully and save this manual for future use Thank you for your purchase of Panasonic welding power source SPEC No TSM50447 04 ＹＤ３５０ＧＬ４ＹＤ５００ＧＬ４ＹＤ３５０ＧＬ４ＨＧＮＹＤ５００ＧＬ４ＨＧＮ ...

Page 2: ... this may require additional protection measures h The time of day that welding or other activities are to be carried out The user shall be observe to reduce emission disturbance as below a Welding equipment should be connected to mains supply according to the manufacture s recommendations b Welding equipment should be routinely maintained according to the manufacture s recommendations c The weldi...

Page 3: ...s pulse ON OFF wire diamete r mm extension length mm root weldin g Deepe n semi automati c automati c welding carbon steel CO2 100 CO2 DC pulse OFF 0 8 HND 10 1 0 HND 15 1 2 HND 15 20 1 4 HND 25 1 6 HND 30 MAG Ar 20 CO2 DC pulse OFF 0 8 HND 10 1 0 HND 15 1 2 HND 15 20 1 4 HND 25 1 6 HND 30 DC pulse ON 0 8 HND 10 0 9 HND 15 1 0 HND 15 1 2 HND 15 20 1 4 HND 25 1 6 HND 30 carbon steel flux core CO2 1...

Page 4: ...essing steps after welding operation 20 7 2 1 Shutting off gas 20 7 2 2 Shutting off power 20 8 Settings 21 8 1 FUNCTION settings 21 8 1 1 F ADJ 21 8 1 2 CALL and RECORD 25 8 2 CHANGE settings 26 8 4 Welding wire inching 27 8 5 Checking shield gas 27 9 Operation 28 9 1 Welding current calibration 28 9 2 NO CRATER 28 9 3 CRATER 29 9 4 INI CRATER 30 9 5 Crater repeat operation 31 9 6 ARC SPOT 32 10 ...

Page 5: ... pressure gas storage of welded products and also disposal of waste should be performed according to the operating instruction and national state and local codes and regulations 4 Prevent any unauthorized personnel to enter in and around the welding work area 5 Only educated and or skilled persons who well understand this welding power source should install operate maintain and repair the unit 6 O...

Page 6: ...d cover them with a fireproofing cover 2 Do not conduct welding near combustible gases 3 Do not bring the hot base metal near combustible materials immediately after welding 4 When welding a ceiling floor or wall remove all flammables including ones located in hidden places 5 Properly connect cables and insulate connected parts Improper cable connections or touching of cables to any electric curre...

Page 7: ...orch wire extends out from the end of the welding torch and may stick into the eye face or body 2 In case of using a torch cable with the resin liner straighten the torch cable and reduce the preset feed amount current to a half or less before applying the wire inching 3 Make sure to replace any damaged liner or cable with a new one as use of damaged liner cable may cause gas leak or insulation de...

Page 8: ...ain transformer 155 inductor 200 EMC classification A Grade Cooling method forced air cooling Applicable welding wire type flux core solid Applicable welding wire diameter mm solid 0 8 1 0 1 2 1 4 1 6 mm flux core carbon steel 1 2 1 4 1 6 flux core stainless steel 1 2 1 6 Welding wire material carbon steel carbon steel flux core stainless steel stainless steel flux core Memory 100 channels can be ...

Page 9: ...nd some diodes of this unit are protected with Thermal protector The error Err 3 Abnormal rise in temperature occurs when the temperature of those units exceeds the allowable temperature When an output other than rated value is used 2 1 3 Dimensions for YD 350GL4 100 50 100 200 300 Applicable range Duty cycle Output current A 0 350 30 Rated 60 100 270A or less Allowable duty cycle Rated output cur...

Page 10: ...ate the abnormal rise in temperature is turned on IGBT DCL and some diodes of this unit are protected with Thermal protector The error Err 3 Abnormal rise in temperature occurs when the temperature of those units exceeds the allowable temperature When an output other than rated value is used 100 50 100 200 300 Applicable range Duty cycle Output current A 0 350 30 Rated 60 100 387A or less Allowabl...

Page 11: ... or rain with less moisture and dust Ambient temperature 10 to 40 Maintain an appropriate distance of 20 cm or more from any wall or other devices Maintain an appropriate distance of 30 cm or more between power sources installed side by side Install this product in the horizontal position Places where the welding arc area is not subject to wind Protect the area from wind by a partition etc Places ...

Page 12: ...tribution box 3 phase AC 380 V power source input cable 6 mm 2 or higher 10 mm 2 or higher grounding cable 6 mm 2 or higher 10 mm 2 or higher shielding gas Same as the selected gas Note the diagram below shows the connection with the welding power source Please be sure to use the wire feeder welding gun gas regulator of the Product as set equipment Otherwise the welding performance may be affected...

Page 13: ...tion to the fol lowing points Relationship among extending length cross section allowable current and duty cycle Arrange the base metal cable corresponding to thee applied connecting cable Do not extend the cable unnecessarily A shorter cable is preferable Do not use leave the connecting cable slackened Never coil the connecting cable when welding or the welding arc may become unstable Connect the...

Page 14: ...r LED display shows software version information The software version is shown for about 4 seconds Then AC contactor is switched on and cooling fan starts to rotate 1 for details of wire feeder Section 4 1 please refer to the operation manual before use base metal connection Connect the base metal cable to the base metal terminal with the attached welding gun cable connection Connect the power cab...

Page 15: ...nlet Do not leave any obstacles near this inlet The operation of the cooling fan When the power is turned on the fan rotates If the no welding operation lasts more than seven minutes electricity until the welding operation starts for the next time After TS ON pressing the switch again the fan continues to rotate The gas regulator is equipped with the socket and fuse The output of gas regulator soc...

Page 16: ...annel can NOT be selected When the channel stored with data is selected the channel and parameters are displayed alternately and welding can start When Mode selection key 12 is set to Record Section 5 6 By turning the Jog dial 7 channel number can be selected LED shows CH setting current and voltage Flashing means welding parameters are being stored Press selection key 12 to return to Weld from Re...

Page 17: ...ers are avilable in the channel the channel can be selected else the corresponding channel can NOT be selected When the channel stored with data is selected the channel and parameters are displayed alternately and welding can start When Mode selection key 12 is set to Record Section 5 6 By turning the Jog dial 7 channel number can be selected LED shows CH setting current and voltage The flashing m...

Page 18: ...ndition being recorded Section 5 4 Record To record the present welding conditions Section 5 4 13 welding control For welding control method selection Chapter 8 crater OFF regular welding crater ON regular welding crater welding initial ON initial welding regular welding crater welding spot welding The welding lasts certain seconds according to the spot welding time being set The welding stops aut...

Page 19: ... the function Note 1 The welding material welding wire diameter and welding gas being set in 15 17 should be in line with the actual operational conditions 2 If there is no welding data in welding material welding wire diameter and welding gas it shows as shown in the picture below 2 5 NO name description 17 gas welding method select please prepare gas according to the requirement listed below CO2...

Page 20: ...ional and local codes Type and capacity of protection devices such as breaker and fuse to be applied should conform to all national and local codes Type and size of cables to be applied should conform to all national and local codes WARNING Touching current carrying parts may cause a fatal accident like an electric shock burn injury and so on To prevent physical accidents like an electric shock bu...

Page 21: ... the attached M10 bolt After connection insulate the cable connections with insulation tape 6 1 3 Connecting feeder cable Put in the plug of the feeder cable from the wire feeder to the feeder connector Connect torch cable Torch terminal Put in the plug of the feeder cable Feeder connector Connection ...

Page 22: ...cable to the load side terminal of the switch of the distribution box For reference Input power cable size 10 mm2 or more CAUTION Water supply pipes building iron frames etc do not serve as sufficient ground Do not connect any grounding wire to them 1 Ground terminal M8 bolt 2 Grounding wire 10 mm2 or more Customer preparation 3 Ground 2 3 WARNING Install one distribution box each for this product...

Page 23: ...ng port Make a cut in the grommet wall to insert wires 6 2 1 Layout of jig terminals Connect the start signal of this product to the torch switch receptacle of the wire feeder When touching a printed circuit board observe the following item to prevent electrostatic destruction of the printed circuit board Before starting an operation for example touch any metal part of the case with your hand to d...

Page 24: ... To protect you and other people from gases fumes and lack of oxygen that may be generated during the welding operation make sure to prepare ventilation facilities and use protective equipment etc Welding operations in narrow spaces may cause asphyxia due to lack of oxygen Prepare ventilation facilities to prevent the inhalation of gases and fumes generated during the welding operation Otherwise w...

Page 25: ... Control NO Menu contents Set range Increment Default Note P00 SLOW DOWN 1 5 5 0 1 0 1 Fine adjustment of slowdown speed Increase the set value to increase the slow down speed P04 PRE FLOW TIME 5 s 5 s 0 1s 0 1s It specifies time to feed wire after starting gas supply by turning on the torch switch P05 AFTER FLOW TIME 5s 5 s 0 1s 0 1s It specifies time to stop gas supply after stop ping the arc by...

Page 26: ...ltage after stopping the arc by turning off the torch switch It is to burn up excess wire fed out of the end of the torch tip due to inertia of the wire NO Menu contents Set range Increment Default Note feed motor Pulse OFF Pulse ON 2 P12 Loop resistance Compute When using or replacing a cable for the first time you need to calculate the loop resistance P21 P22 Special purpose machine and Robot NO...

Page 27: ... current of arc Pulse ON Fine adjustment of the peak time of arc It increases when the direction is adjusted positive value P02 Arc ignition voltage compensation 5 5 1 0 1 Fine adjustment of the arc voltage value The peak current of the arc is increased when the direction is adjusted positive value P03 Arc ignition time compensation 50 50 1 0 The role of micro adjustment of the arc voltage Positiv...

Page 28: ...nt value Note After the linkage percentage is set the initial current will not exceed the maximum value of the welding current 350 A 500 A P27 INIT CRATER Switch 0 or 1 1 0 1 AUTO 0 Manual Others NO Menu contents Set range Increment Default Note P24 Arc shape 99 99 1 0 The higher value you set the more concentrated arc you get The lower the less concentrated arc P25 Welding display mode 0 or 1 1 0...

Page 29: ...ht C H O F F 2 Select channel CH1 CH100 to be called in 7 It alternately shows CH and current set value in 2 channel and voltage set value in 5 3 At present welding condition is already being called welding can start 4 After operation finishes select 12 and return to welding mode Record operation Reminder During Record operation welding can t start Gas check works No Operation 7 segment LED 1 Sele...

Page 30: ...ter turning ON the power source the damage of internal data may happen Please follow the steps here to restore machine to factory settings The operation sequence 1 Disconnect power source 2 After connecting the power source at the moment when the software version is shown hold lock and welding control button at the same time for 2 seconds After welding machine finishes the display of the software ...

Page 31: ...he eye face or body which can cause injury Do not perform wire inching operation or pull the torch switch with your eyes face or body close to the end of the welding torch Wire may stick into your eye face or body CAUTION Applying high speed wire inching with the torch cable bent may cause the wire to run through the resin liner and the cable In case of using a torch cable with the resin liner str...

Page 32: ... need readjustment with moved welding parameters such as torch angle wire type shieling gas and other welding conditions 9 2 NO CRATER Operation Turn the torch switch on and off to start and stop welding arc respectively Welding current 50A 100A 150A 200A 250A 300A 350A Extended wire length Tip Base metal distance 0 9 wire 0 8 wire 12 12 12 15 18 1 2 wire 1 0 wire 15 15 15 18 18 22 25 Torch ON Tor...

Page 33: ... Torch OFF Arc ON Arc continues Self hold Change arc type Arc for crater Arc OFF Tpf Gas pre flow time Arc start Arc end ON ON Tpf Wire Burn back time Main welding slow down OFF OFF OFF ON Crater Torch switch Gas supply Wire feed Weld voltage Weld current Weld conditions Self hold Operation ...

Page 34: ...rt crater operation Torch ON Torch OFF Torch ON Torch OFF Arc ON For initial welding Change arc type For main welding Self hold Change arc type For crater Arc OFF Tpf Gas pre flow time Arc start Arc end ON Tpf Wire Burn back time Main slow down OFF OFF ON Crater welding Initial welding ON OFF Self hold Torch switch Gas supply Wire feed Weld voltage Weld current Weld conditions Operation ...

Page 35: ... OFF Torch ON Torch OFF Arc ON Arc continues Self hold Change arc type Arc for crater Arc OFF Crater repeat Torch ON within Trep time Torch OFF Repeat 3 and 4 to repeat crater welding Change arc type Arc for crater Arc OFF To stop welding raise the torch until arc is cut Taf Gas after flow time Trep Crater repetition time Arc start Arc end Taf Burn back Wire slow down OFF OFF ON Crater ON OFF Crat...

Page 36: ...c ON Arc ON Arc OFF Arc OFF Example of wrong operation Torch ON and keep it down Torch OFF End of Tspt Note Releasing the torch switch before the end of the Tspt arc spot time turns off the welding arc immediately without completing preset welding operation Arc ON Arc OFF Tpf Gas pre flow time Taf Gas after flow time Tspt Arc spot time Arc start Arc end ON OFF OFF ON Tpf Wire Burn back time Main w...

Page 37: ...t Check if any foreign matter is attached to the cooling air intake vent Top panel Bottom panel Side panel Eyebolts and other bolts Breakage or loose attachment If there is any defect additional fastening parts replacement etc are required Casters Breakage or loose attachment Panels Loose attachment Overall Appearance Check if there is any trace of heat generation such as discoloration If there is...

Page 38: ... regulator Follow the operating instructions of the individual devices Gas hose If joint is fastened securely In case a hose band is used if there is any loose attachment If there is any defect additional fastening hose replacement etc are required If hoses are worn or damaged Maintenance and inspection ...

Page 39: ...c parts Plastic parts may be melted or deformed when they are subjected to organic solvent benzin toluene kerosene gasoline etc When cleaning them soak a soft cloth with a small amount of water or diluted mild detergent for home use and wring it and use for wiping those parts Check item Guideline Removal of inside dust Remove the top panel before cleaning Blow off internally accumulated dirt and d...

Page 40: ...input terminals collectively total 3 terminals 4 Turn the power switch ON side 5 Short circuit between the anode wire 7 and cathode wire 8 of the diode D1 The capacitors may still have voltage Wait for 5 minutes or more after the power is OFF before starting to work 7 Short circuit load side terminal of IGBT Q1 wire 11 load side terminal of IGBT Q2 wire 10 8 Collectively short circuit the above 3 ...

Page 41: ...can NOT be automatically turned off until the power switch is turned OFF even when the cause is removed after connecting the power source 7 segment display cannot be shown normally Err S N Error type Group Probable causes and remedy Err 001 emergency stop B The connection of external equipment emergency stop on the output terminal block Turn power switch OFF refer to the list below and remove the ...

Page 42: ...B When the Product works with special purpose machine or robot wire adhesion at the end of welding switch off power source switch and cut the welding wire Err 025 motor encoder error B Abnormal encoder feedback Switch off power source switch to eliminate arc abnormal ignition factor Err 028 wire feeder over current error B The wire feeding route is blocked causing over load of the motor clean the ...

Page 43: ...he front panel Blown fuse Wire feeder Size of the wire for feed roller SUS tube is wrong Crack clogging or breakage at the feed roller Insufficient fastening of pressure rod Accumulation of wire powder at SUS tube inlet Fuse for voltage detection wire is blown Torch cable Cables for power and torch switch are severed Loose connection to the wire feeder Signs of dropping impact Torch cable is bent ...

Page 44: ...2 1 Parts list for 350GL4 The digital S N is in accordance with the same on parts configuration diagram Front view Rear view Top view 16 18 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 35 33 34 36 37 38 39 42 Parts list ...

Page 45: ...41 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 40 41 43 44 45 Right view Left view Parts list ...

Page 46: ... TSML0089 1 10 R300 R301 Discharge Resistor RJG274L7W223J 2 11 C4 C5 Anti Magnetic Biasing Capacitor MKPHR1 5UF750V AC 2 12 R4 R7 Secondary Power Resistor RX274H40W5R0JW 4 13 D2 D3 Diode Module FRS300BA70 2 14 Thp1 Thermal Relay 0HD3 75B02 1 15 FAN Fan 200FZY6 S FC 1 16 FAN Fan Protective Cover WZ TG22580 1 17 MS AC Contactor PT323001LS 1 18 TM1 TM2 Output Terminal Block T64 T12 2 19 R14 Cement Re...

Page 47: ...Output Terminal TSM15748 2 33 TR2 Control Transformer TSMU0949 口口 1 34 TR1 Control Transformer TSMU0913 口口 1 35 FU7 FU8 Fuse 660GH63ULTC 2 36 LF1 Input Filtering Assembly TSMW2271 口口 1 37 PC Board Switch Power Source PC Board 1 38 Wire Feeding PC Board 1 2 40 CPU Pc Board TSMPA246 口口 1 41 Interface PC Board TSMP638口 1 42 Operation PC Board TSMPA300 口口 1 43 R1 R2 Cement Resistor SFW40A201 2 44 CT C...

Page 48: ...2 2 Parts list for 500GL4 The digital S N is in accordance with the same on the parts list 18 17 19 35 33 34 36 37 38 39 42 Front view Rear view Top view 16 20 21 22 23 24 25 26 27 28 29 30 31 32 Parts list ...

Page 49: ...45 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 40 41 43 44 45 Right view Left view Parts list ...

Page 50: ...ML0089 1 10 R300 R301 Discharge Resistor RJG274L7W223J 2 11 C4 C5 Anti Magnetic Biasing Capacitor MKPHR1 5UF750V AC 2 12 R4 R7 Secondary Power Resistor RX274H40W5R0JW 4 13 D2 D3 Diode Module FRS300BA70 4 14 Thp1 Thermal Relay 0HD3 83B02 1 15 FAN Fan 200FZY6 S FC 1 16 FAN Fan Protective Cover WZ TG22580 1 17 MS AC Contactor NDC1T 5011MS 1 18 TM1 TM2 Output Terminal Block T64 T12 2 19 R14 Cement Res...

Page 51: ...Z 1 6 1 32 Output Terminal TSM15748 2 33 TR2 Control Transformer TSMU0949 口口 1 34 TR1 Control Transformer TSMU0913 口口 1 35 FU7 FU8 Fuse 660GH80ULTC 2 36 LF1 Input Filtering Assembly TSMW2271 口口 1 37 PC Board Switch Power Source PC Board TSMP576口 1 38 Wire Feeding PC Board TSMP655口 1 39 Drive PC Board TSMP549口 2 40 CPU Pc Board TSMPA248 口口 1 41 Interface PC Board TSMP638口 1 42 Operation PC Board TS...

Page 52: ...Circuit diagram 48 13 Circuit diagram 13 1 Circuit diagram for 350GL4 100V 100V Optional parts 300 246 ...

Page 53: ...Circuit diagram 49 13 1 Circuit diagram for 500GL4 100V 100V Optional parts 300 248 ...

Page 54: ... 40 50 15 15 20 Back 1 2 1 5 1 2 230 260 24 26 40 50 15 15 20 9 Front 1 2 1 5 1 2 320 340 32 34 40 50 15 15 20 Back 1 2 1 5 1 2 320 340 32 34 40 50 15 15 20 Butt Joint Welding Square groove joint Thickness mm Route gap G mm Wire diameter mm Current A Voltage V Speed cm min Tip to work distance mm Gas flow L min Copper backing With backing 0 6 0 0 6 40 16 60 10 15 20 1 0 8 0 0 6 40 16 5 45 10 15 20...

Page 55: ... 1 6 270 380 29 35 40 45 25 20 25 12 7 8 1 2 1 6 300 380 32 35 35 40 25 20 25 1 0 2 0 45 Fillet Welding Flat position Thickness mm Leg length mm Wire diameter mm Current A Voltage V Speed cm min Tip to work distance mm Gas flow L min 1 0 3 0 9 60 65 16 17 30 10 10 15 1 2 3 3 5 0 9 70 80 17 18 40 50 10 10 15 1 6 3 5 4 0 9 90 130 19 20 40 50 10 10 15 2 3 4 4 5 1 2 120 160 20 21 40 45 10 10 20 3 2 4 ...

Page 56: ... 50 60 10 10 15 1 6 3 0 6 0 8 100 110 18 19 5 50 60 10 10 15 2 4 3 5 0 8 1 0 115 125 19 5 20 50 60 10 10 15 3 2 4 0 8 1 2 130 140 19 5 21 50 60 10 10 15 Thickness TopxBottom Wire diameter mm Welding time s Welding current A Welding voltage V Bead diameter mm Tip to work distance mm Gas flow rate L m 0 6 x 0 6 0 6 0 5 0 75 100 22 24 8 10 12 0 6 x 0 6 0 8 0 75 1 0 95 22 7 12 12 0 8 x 0 8 0 6 1 25 1 ...

Page 57: ...ditions UNITARY INDIVIDUAL INITIAL WELD CRATER SPOT TIME WAVEFORM CONTROL Welding current A A A s Welding voltage V V V F ADJ settings FUNCTION Item Contents P00 P01 P02 P03 P04 P05 P06 DIP switch DSW1 settings C REP Crater repeat ON OFF ARC CTL Leg length control ON OFF P BBK Burnback 2 ON OFF MATERIAL WIRE DIA GAS settings Item Contents MATERIAL MS SOLID MS FCW SUS SOLID SUS FCW OPTION WIRE DIA ...

Page 58: ...estriction 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 ATTENTION The disposal of the product In case of disposal of the product please sign the assignment agreement on disposal treatment with the authoriz...

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