Panasonic YD-350GY4 Operating Instructions Manual Download Page 1

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Operating Instructions

Digital IGBT controlled

MIG/MAG Arc Welding Power Source

Model N o . :

YD-350/500GY4

●

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.

：

YD-350GY4HJE, YD-500GY4HJE.

Panasonic Welding Systems (Tangshan) Co., Ltd.

TSM50886

Summary of Contents for YD-350GY4

Page 1: ...k 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 YD 350GY4HJE YD 500GY4HJE Panasonic Welding Systems Tangshan Co Ltd TSM50886 ...

Page 2: ...eel MAG welding carbon steel flux core welding welding methods welding wire material welding method shielding gas wire diameter mm extension length mm Root welding semi automatic automatic welding carbon steel CO2 100 CO2 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 0 8 HND 10 1 0 HND 15 1 2 HND 15 20 1 4 HND 25 1 6 HND 30 carbon steel flux core CO2 100 CO2 1 2 HND 20 1 ...

Page 3: ...PS AFTER WELDING OPERATION 20 8 SETTINGS 21 8 1 FUNCTION SETTINGS 21 8 2 THE WELDING MACHINE FACTORY DEFAULTS RESET 25 8 3 WELDING WIRE INCHING 26 8 4 CHECKING SHIELD GAS 26 9 OPERATION 27 9 1 WELDING CURRENT CALIBRATION 27 9 2 NO CRATER 27 9 3 CRATER 28 9 4 INI CRATER 29 9 5 CRATER REPEAT OPERATION 30 9 6 ARC SPOT 31 10 MAINTENANCE AND INSPECTION 32 10 1 DAILY CHECK 32 10 2 PERIODIC CHECK 33 10 3...

Page 4: ...t and 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 t...

Page 5: ...working 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 exha...

Page 6: ...of the wire feeder or hand finger s hair or part of your clothes may be caught 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 weldin...

Page 7: ...or 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 Welding wire material carbon steel carbon steel flux core Memory 100 channels can be called welding parameters recordable Sequence welding welding crater initial welding crater spot weldi...

Page 8: ...rformance degradation or damage The figure above shows the ideal value of cutting current and duty cycle Please use the machine within the corresponding duty cycle of cutting current YD 500GY4 2 3 Thermal protection Cutting power source is equipped with a thermal switch at the radiator fin of IGBT to monitor the temperature When the abnormal temperature happens the thermal switch takes action and ...

Page 9: ...Rated Specifications 6 L W 2 4 Dimensions YD 350GY4 YD 500GY4 Welding power source W H L YD 350GY4 380 612 692 YD 500GY4 380 820 745 H L W H ...

Page 10: ...nstallation surface Max 10 7 Do not block cooling air intake of the cutting power source From the wall 200 mm or more 8 Avoid wind to the arc Provide windshields 9 Free from abnormal amounts of dust acid corrosive gases or substances etc other than those generated by the cutting process Note In case the machine with wheels is placed on an inclined surface machine may slide by itself Please use sto...

Page 11: ...the genuine parts which comply with strength assessment The model number of the eye bolt is R825M8 Pushing the machine by hands There are wheels under the machine The machine can be pushed by hands During moving please do not make sharp turn to protect wheels and floor Please do NOT place the machine on the slope The Product has wheels which cause the machine to move on the inclined surface by its...

Page 12: ...nd breakers or leakage protectors are only for reference 2 When the machine is working at the places where are moist or on the iron plate or stand please be sure to install leakage protector Note please follow the regulations listed below to avoid any damage of parts unstable arc and overheat or damage of the machine The fluctuation range of input the allowable rated input voltage is 304V 456V Whe...

Page 13: ... or higher Gas regulator YX 25CD1HAM Grounding cable 6 mm2 or higher 10 mm2 or higher Base metal welding cable 50 mm2 or higher 70 mm2 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 affec...

Page 14: ... 2 Cautions about using connecting cable Select a model properly and use connecting cable properly or adverse impact on welding operation such as voltage drop may result Voltage drop may be resulted from the reactance caused by the conductor resistance or cable routing manner The longer the cable is or smaller the cross section is the more likely an adverse impact occurs To minimize such adverse i...

Page 15: ...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 5 2 The output terminal area Regarding connection and disconnection of the cable to avoid electric shock and malfunction please be sure to cut off the switch of distribution box and then start the operation base metal connection Connect the ...

Page 16: ...he fan intakes cool air from this inlet Do not leave any obstacles near this inlet The operation of the cooling fan Whenthepoweristurnedon thefanrotates Iftheno weldingoperationlastsmorethansevenminutes it automatically stops to saveelectricity until the welding operation starts for the next time After TS ON pressingtheswitchagain thefancontinuesto rotate The gas regulator is equipped with the soc...

Page 17: ...cted 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 8 1 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 ke...

Page 18: ...n8 1 By turning the Jog dial 7 channel number can be selected LED shows CH setting current and voltage The flashing means welding parameters to be stored Press selection key 12 to return to Weld from Record and the corresponding parameters are recorded in the channel being selected When a self diagnosable error occurs For troubleshooting Section 11 1 It shows alarm signal number 6 setting voltage ...

Page 19: ... record the present welding conditions Section 8 1 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 automatically when the spot welding time is up ...

Page 20: ...nd wires Avoid contact with the welding arc part at wiring For safety reasons provide base material with grounding work Wiring and grounding work should be done by qualified electricians Observe the followings to prevent a fire caused by overheat of cables Use cables with specified size or larger Fasten all cable connections securely 6 1 The connection of output cable Connecting cable from base me...

Page 21: ...able U V W wire please be sure to use wire clipping board to fix them Note Please insert the serrated spacer between the ground connection terminal and grounding wire After connecting input terminal block use the clamping board to fasten the input cables avoiding loose connection or dropping off 4 Install the input terminal cover Recommended crimping terminal Note Do not use wrench Tightening torq...

Page 22: ...from a jig or another device To send out the current detection signal to a jig or another device Location On the chassis inside the product 2 Jig terminal 2 To install an external voltmeter or ammeter Location On the chassis inside the product Note Keep the communication cables away from the welding arc area the welding torch the base material side cable etc to prevent troubles caused by incorpora...

Page 23: ...gloves and safety shoes to protect the exposed parts of your eyes and skin Prepare light shielding glasses or a welding face shield with a light shielding filter plate appropriate to the applied welding current Pre operation check Check if all connections are correct and complete Check if settings of the switches on the P C Board are correct Check if wire is set to the wire feeder Turning on power...

Page 24: ...nt 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 thearcbyturningoffthetorch switch P10 UNITARY respect...

Page 25: ...nd Robot NO Menu contents Set range Increment Default Note P09 Wire adhesion detection ON OFF 0 or 1 1 0 When the Product works with special purpose machine or robot the setting can be used When welding finishes or starts the adhesion between welding wire and base metal can be detected automatically P23 Given current and voltage setting 0 1 or 2 1 Input signal voltage setting corresponding to the ...

Page 26: ...n 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 Positive value direction of the arc voltage adjustment time longer ...

Page 27: ...current 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 valueyouset themore concentratedarcyouget The lower the less concentrated arc P25 Welding display mode 0 or 1 1 0 ...

Page 28: ... 12 and return to welding mode Till now data recording finishes Note During Call operation 13 14 15 16 17 operation does not function 8 2 The welding machine factory defaults reset If 7 segment LED cannot display correctly after 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 ...

Page 29: ...ch wires please feed the wire at low speed or contact Panasonic representatives Press the INCHING 8 button on the operation panel to feed the wire manually The wire is fed forward while this button is pressed And the lamp is on while feeding the wire Inching is available when the welder is in standby state Current set value for the main welding is used to determine the wire inching speed If this b...

Page 30: ...1 Welding current calibration Welding current is tested and calibrated with following welding wire extension it may need read justment with moved welding parameters such as torch angle wire type shieling gas and other welding conditions 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...

Page 31: ...Operation 28 9 3 CRATER Operation Turn the torch switch on and off twice ...

Page 32: ...on 29 9 4 INI CRATER Operation Turn the torch switch on and off twice Turn the torch switch ON to start initial welding and turn it OFF to switch to main welding Then turn it ON again to start crater operation ...

Page 33: ...preset time Trep after turning off the previous crater operation In this manner it is possible to repeat the cra ter operation again and again Trep About 2 seconds Note If the torch switch is not turned on within the preset time the function is cancelled To stop welding raise the torch until arc is cut ...

Page 34: ...on and hold down the torch switch until the welding arc is turned off automatically Note If the torch switch is released while generating the welding arc before Tspt ends the welding arc is turned off immediately Example of wrong operation ...

Page 35: ...tachment 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 t...

Page 36: ...p the proper performance of this product for a long time In the periodic check check the product thoroughly including checking and cleaning of the inside of this product Conduct the periodic check every 6 months normally If there is a mass of fine dust oily smoke etc around this product perform the regular check every 3 months as a guideline Check guideline While details for checking are shown bel...

Page 37: ...arts list 10 3 1 Test preparation Connection cables and signal wires 1 Turn off power at distribution box customer preparation and then disconnect the input cables from the load side terminal of the distibution box and from the input power terminal of this unit Turn off power to all related devices jigs 2 Disconnect cables and signal cables connected to the following terminals and connectors Front...

Page 38: ...may malfunction Remove all the short circuited cables for the test and return the disconnected cables as they were according to the following procedure Reconnect the ground cables and connectors on the PC board as they were Return the dust cover top panel right panel and left panel as they were Connect the input power cable to the input terminal and return the terminal cover Connect the input powe...

Page 39: ... The displays 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 Turnpower switchOFF refer to the list below and...

Page 40: ...etected when the power switch is turned on Remedy Turn power switch OFF and then check the followings to remove the cause s This product is defective Check if the current or voltage is applied to the secondary side of this product from an external device Err 010 external interruption 1 A The external equipment the connecting to output terminal block receives interruption signal temporary stop 1 Re...

Page 41: ... on the 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 ...

Page 42: ...Parts list 39 12 Parts list 12 1 Parts list for YD 350GY4 Front view Rear view Top view ...

Page 43: ...Parts list 40 Right view Left view ...

Page 44: ...301 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 Resistor SFW40A471 1 20...

Page 45: ...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 TSMP5760E 口口 1 38 Wire Feeding PC Board TSMP6550 口口 1 39 Drive PC Board TSMP5491C 口口 2 40 CPU PCBoard TSMPA246GR 口口 1 41 Interface PC Board TSMP638 口 1 42 Operation PC Board TSMPA300 口口 1 43 R1 R2 Cement Resistor SFW...

Page 46: ...Parts list 43 12 3 Parts list for YD 500GY4 Front view Rear view Top view ...

Page 47: ...Parts list 44 Right view Left view ...

Page 48: ... 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 D4 D5 Diode Module FRS300BA70 4 14 Thp1 Thermal Relay OHD3 80BO2 1 15 FAN Fan 200FZY6 S FC 2 16 FAN Fan Protective Cover WZ TG22580 2 17 MS AC Contactor NDC1T 5011MS 1 18 TM1 TM2 Output Terminal Block T64 T12 2 19 R14 Cement Resistor SFW40A471...

Page 49: ...99 口口 1 34 TR1 Control Transformer TSMU0913 口口 1 35 FU7 FU8 Fuse 660GH100ULTCF 2 36 LF1 Input Filtering Assembly TSMW2723 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 WTYET10001 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 Current ...

Page 50: ...Circuit diagram 47 13Circuit diagram 13 1 Circuit diagram for YD 350GY4HJE ...

Page 51: ...Circuit diagram 48 13 2 Circuit diagram for YD 500GY4HJE ...

Page 52: ...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 With backing 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 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 53: ...7 1 2 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 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 5 1 2 ...

Page 54: ... 15 3 2 3 5 4 1 0 1 2 150 170 21 22 45 50 15 15 20 4 5 4 5 5 1 0 1 2 180 200 23 24 40 45 15 15 20 6 5 5 5 1 2 230 260 25 27 40 45 20 15 20 8 9 6 7 1 2 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 14 3 Arc spot welding conditions table Reference Thickness TopxBottom Wire diameter mm Welding time s Welding current A Welding voltage V Bead diameter mm Tip to work dista...

Page 55: ...pplies 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 authorized organization a...

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