Panasonic YD-400VP1YHD Operating Instructions Manual Download Page 15

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4. Configuration

WMD078TE0PAA07

4.1.1 Semi-automatic welding

An example of using air-cooled torch:

An example of using water-cooled torch:

Mild steel/stainless steel

①

Welding power
source

YD-400VP1YHD

②

Wire feeder

YW-40GD2YAD

③

Gas regulator

YX-25AD1

④

Welding torch
(Air cooled)

YT-35ESG4

⑤

Power
distribution box

3-phase, 400 V

⑥

Gas cylinder

JIS, WES standard

⑦

Input cable

5.5 mm

or more

⑧

Grounding wire

5.5 mm

or more

⑨

Base metal

⑩

Base metal cable

⑪

Remote controller

YD-40GTR1(analog)

YD-00DCR1(digital)

Note

The customer needs to prepare the items

②

⑪

at their end.

⑪

⑦

①

⑤

⑧

⑥

③

⑩

②

⑧

⑨

④

Aluminum

①

Welding power source

YD-400VP1YHD

②

Wire feeder

YW-40DGW2YAE

③

Gas regulator

YX-503A

④

Welding torch
(Water cooled)

YT-50MFW2

⑤

Water coolant

YX-09KGC1THA

⑥

Input cable

2 m, attachment to

⑤

⑦

Cord assembly

1.5 m, attachment to

⑤

⑧

Water cooling hose

unit

⑨

Power distribution box

1-phase, 400 V

⑩

Power
distribution box

3-phase, 400 V

⑪

Gas cylinder

⑫

Input cable

5.5 mm

or more

⑬

Grounding wire

5.5 mm

or more

⑭

Base metal

⑮

Base metal cable

⑯

Remote controller

YD-40GTR1(analog)

YD-00DCR1(digital)

Note

The customer needs to prepare the items

②

⑯

their end.

①

③

④

⑤

⑥

⑧

②

⑦

⑨

⑩

⑪

⑫

⑬

⑭

⑮

⑯

Summary of Contents for YD-400VP1YHD

Page 1: ...s manual for future use Please also read the operating instructions of peripheral equipment First please read the Safety Precautions English version is the original instructions 2011 Operating Instructions Model No YD 400VP1YHD WMD078TE0PAA07 Inverter controlled GMAW DC Power Source ...

Page 2: ...he cause of which is other than the forego ing but is also not attributable to PSFS Any claim of a third party that this Product infringes the intellectual property rights of such third party that are directly or indirectly caused by User s use of this Product and relate to the method of production ANY LOST PROFITS OR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR ARISI...

Page 3: ...s 37 6 1 2 Connecting base metal voltage detection wire 38 6 1 3 Connecting grounding wire and input cables 38 6 2 Robotic welding 40 6 2 1 Applicable robot models 40 6 2 2 Connecting output cables 40 6 2 3 Connecting base metal voltage detection wire 41 6 2 4 Connecting grounding wire and input cable 41 6 2 5 Connecting cables for robot controller 43 6 2 6 Communication error 43 6 3 Connecting to...

Page 4: ...30 9 3 5 How to remove top panel 130 9 3 6 Checking consumable 131 9 3 7 Parts replacement 131 9 3 8 Precautions in performing withstand voltage test and insulation resistance measurement 131 10 Troubleshooting 132 10 1 Error No indication 132 10 2 When displays blink irregularly 134 10 3 Troubleshooting Chart 135 11 Circuit diagram 136 12 Parts list 137 13 Welding conditions table Reference 143 1...

Page 5: ...dling Electric Shock Prevention 1 Do not touch any live parts 2 Only trained and or skilled personnel should perform grounding of the case of the welding power source the base metal and jigs electri cally connected to the base metal 3 Before installation or maintenance work of the welding power unit turn off all input power including power at the power distribu tion box and leave it for five minut...

Page 6: ...ith a fireproof cover 2 Do not conduct welding near flammable gases Do not place the welding power source near flammable gases otherwise such gases may catch fire from a spark of electricity inside the welding power source as it is electric equipment 3 Do not bring hot base metal such as a piece immediately after welding or cutting near flammable materials immediately after weld ing 4 When welding...

Page 7: ...g maintenance or repair work provide a fence or similar form of protection around the welding machine to prevent unauthorized individuals from accidentally coming close to the area Welding Wire 1 Do not perform inching operation or press the torch switch with your eyes face or body close to the end of the welding torch Wire extends out from the end of the welding torch and may stick into the eye f...

Page 8: ...ding CO2 100 MAG welding Mixed gas of 80 Ar and 20 CO2 Stainless steel MIG welding Mixed MIG gas of 98 Ar and 2 O2 Aluminum MIG welding Ar 100 MIG gas Applicable wire size diameter 0 8 mm 0 9 mm 1 0 mm 1 2 mm 1 4 mm 1 6 mm Applicable wire type Mild steel MS SOLID Flux cored mild steel MS FCW Stainless steel SUS SOLID Flux cored stainless steel SUS FCW FCW Flux cored wire Hard aluminum AL HARD Soft...

Page 9: ... point of common coupling is lower than 130 m ohm and the short circuit power is higher than 6 MVA this equipment is compliant with IEC 61000 3 11 and IEC 61000 3 12 and can be connected to public low voltage systems It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the system impedance complies wit...

Page 10: ...4 20 MAG 1 2 20 Stainless steel Solid wire MIG 0 8 10 0 9 12 1 0 15 1 2 15 Pulsed MIG 0 9 12 1 0 15 1 2 15 FCW Flux cored wire CO2 0 9 12 1 2 20 MAG 1 2 20 Hard aluminum Solid wire MIG 1 0 15 1 2 15 1 6 15 Pulsed MIG 1 0 15 1 2 15 1 6 15 Soft aluminum Solid wire MIG 1 2 15 1 6 15 Pulsed MIG 1 2 15 1 6 15 1 For robot welding only mild steel and stainless steel are applicable 2 To use it with automa...

Page 11: ...tor the temperature The thermal protection functions when the welding power source goes into an abnormal temperature rise condition and stops the out put Do not use the welding power source under the following conditions At the output voltage above the rated value With the suction opening blocked Ambient temperature is above 40 C If the cooling fan does not rotate 2 7 Functions of cooling fan The ...

Page 12: ...ses or substances etc other than those generated by the welding pro cess 9 Avoid places where the metallic substances or combustible foreign materials can get into the welder through the air inlets 10 Inclination to installation surface Max 10 Note When installing the product on a inclined surface make sure to scotch the cast ers Or the casters to move unexpectedly 11 Do not place the product rear...

Page 13: ...he machine or cause generation of unstable arc a Supply stable voltage within the input voltage variation tolerance range b Use an engine generator whose capacity is twice rated input of the welding machine which is equipped with damper wire In general engine generator tends to require more voltage recovery time when load fluctuation occurs compared with a commercial power source Executing arc sta...

Page 14: ...er and welding torch see operating instructions of each product お願い Information Quality of applied gas is crucial as it directly affects welding quality For CO2 welding use a carbon dioxide gas for welding or of which water contents is 0 005 or less For MAG welding use a mixed gas for MAG welding argon gas with 5 to 20 of car bon dioxide gas For stainless MIG welding use a mixed gas for stainless ...

Page 15: ...ote controller YD 40GTR1 analog YD 00DCR1 digital Note The customer needs to prepare the items to at their end Aluminum Welding power source YD 400VP1YHD Wire feeder YW 40DGW2YAE Gas regulator YX 503A Welding torch Water cooled YT 50MFW2 Water coolant YX 09KGC1THA Input cable 2 m attachment to Cord assembly 1 5 m attachment to Water cooling hose unit Power distribution box 1 phase 400 V Power dist...

Page 16: ...ases carbon dioxide and argon use a gas mixer For argon gas for the mixed gas make sure to use high purity argon gas for welding 99 9 purity or higher お願い No Product name Robot manipulator Robot controller Teach pendant Welding torch Wire feeder Flexible conduit Wire reel stand Welding power source Communication cable Control cable RE cable Motor cable Power cable Gas regulator Gas hose Gas cylind...

Page 17: ...m Mild steel Stainless steel Applicable wire dia mm 1 2 1 6 Cable length 3 m 3 m Cooling method Air cooled Water cooled Duty cycle CO2 300 A 60 350 A 45 500 A 100 MAG 350 A 35 450 A 100 500 A 80 MIG 350 A 35 450 A 100 500 A 80 Pulsed MAG 350 A 20 500 A 60 Pulsed MIG 350 A 10 500 A 60 To apply a welding process or wire type indicated in brackets an optional part sold separately is needed If the opt...

Page 18: ... operating instruction of the digital remote controller Therefore make sure to read 6 3 2 Digital remote controller on page 45 prior to use 4 2 6 Water coolant Model No YX 09KGC1THA 4 2 7 Welding table expansion unit This unit is to add a welding table that contains welding characteristics Note Welding table expansion unit is applicable from the software version 2 00 or later To check the current ...

Page 19: ... except special work type such as elongated workpiece Make sure to use a proper connection cable Voltage drop can adversely affect welding results The longer the connection cable or the smaller the cable diameter is the larger the negative affect becomes Note Do not expose the connection portion of the extension cable to water If such could be the case wrap the connection portion with a drip proof...

Page 20: ...nection cable without fail Otherwise cables may burn out For cable size other than the above table please contact Panasonic representatives Cross section Distance Connection cable Model No 60 mm2 5 m YV 605GB2A 10 m YV 610GB2A 15 m YV 615GB2A 20 m YV 620GB2A 80 mm2 5 m YV 805GB2A 10 m YV 810GB2A 15 m YV 815GB2A 20 m YV 820GB2A Cross section Distance Connection cable Model No 60 mm2 5 m YV 605GE2A ...

Page 21: ...rts 5 2 Output terminals 5 2 1 Terminal name WARNING If switching the power switch to the on side does not turn on power to the unit contact Panasonic representatives Power switch Output terminals Operation panel Power switch WARNING Prior to connection and disconnec tion works turn off power at the power distribution box to prevent electrical shock and malfunction After the connection work put th...

Page 22: ...is turned on the cooling fan starts to rotate The fan stops its rotation if the welding power source stays in the standby state for 7 minutes or longer to conserve energy The fan is reactivated the next time welding operation is started 6 Input terminal cover Remove it to connect input terminals and ground terminal Note After connecting the cables fix the sad dle and then put the input terminal co...

Page 23: ... When Mode indicator DETAIL see page 82 is lit It indicates setting group number and setting submenu At that time Output Setting display 2 indicates its set value When Mode indicator CALL see page 120 is lit Immediately after switching to CALL mode or when oFF is selected using Dial 2 it indicates the current set current and alter nately At that time it is possible to perform welding operation usi...

Page 24: ... indicate no act and the inching operation is disabled In case a self diagnosable error occurs The Err blinks on the display At that time the error number that indicates the error contents blinks on Output Setting display 2 Output Setting dis play1 select button Use it to select current wire feed speed or thickness Press the button until the LED of the intended Output Setting display 1 item indica...

Page 25: ... speed are indicated It also indicates rEt to move to the previous item When Mode indicator DETAIL see page 82 is lit It indicates the set value of the selected item At that time Output Setting display 1 indicates setting group number and setting submenu When Mode indicator CALL see page 120 is lit Immediately after switching to CALL mode or when oFF is selected using Dial 2 it indicates the curre...

Page 26: ...ndi cates a 3 digit channel number When Setting indicator FREQUENCY PULSE PEAK CURRENT PULSE BASE CURRENT or WIRE FEED ADJUST is lit It indicates the set value of the wave control or wire feed adjust ment Use Dial 2 to set When Setting indicator DIRECT see page 126 is lit It indicates the set value of the selected item While switching items in DIRECT function it indicates the submenu number While ...

Page 27: ... Mode indicator WELD CALL or RECORD see pages 120 and 117 is lit The LED selected by Output Setting display 2 select button is lit When Mode indicator WELD NAVI or DETAIL see page 77 and 82 is lit LED is turned off Control process select button CONTROL Use it to select No crater Crater or Ini Crater As you select a control process the LEDs of Control process indicator are lit as follows Note In Cr...

Page 28: ...d ing condition For each LED of Control process indicator over this MAIN but ton LED is on the condition is set LED blinks condition is changeable Use Output Setting indicator1 select button Output Setting indicator2 select button Dial 1 and Dial 2 to specify the main welding condition Crater welding CRA TER button When Mode indicator WELD is lit and the selected control process is Crater or Ini C...

Page 29: ... tor button LOCK Enter button ENTER Use it to lock the operation Long press of the button lights the LED above the button and locks the operation Long pressing again to turn off the LED and release the lock state While locking the operation all buttons and dials except GAS CHECK and INCHING buttons do not function When Mode indicator WELD is lit The button is disabled When Mode indicator WELD NAVI...

Page 30: ...lue displayed on the Output Setting display1 When Mode indicator WELD is lit Use it to specify the set value of the item current wire feed speed or thickness selected by Output Setting display1 select button in Initial Main or Crater welding operation In case ANALOG RC setting is set to With the remote controller use the remote controller to set the system see section 8 6 Group3 SYSTEM settings on...

Page 31: ...o set the joint shape wire feed speed and thickness When Mode indicator DETAIL see page 82 is lit Use it to specify the set value of the selected item When Mode indicator CALL see page 120 is lit Use it to select the channel number to call Only recorded channel numbers are indicated on Output Settings indicator 2 When Mode indicator RECORD see page 117 is lit Use it to select a channel and then se...

Page 32: ...ca tor It indicates the wire diameter to be applied The LED corresponding to the wire diameter selected by Wire diame ter select button is lit The LED blinks if there is no welding table Wire diam eter select button WIRE DIA Use it to select a wire diameter to be applied The LED of Wire diameter indicator corresponding to the speci fied wire diameter is lit Welding process indicator It indicates a...

Page 33: ...ET Use it to select FREQUENCY PULSE PEAK CURRENT PULSE BASE CUR RENT WIRE FEED ADJUST or DIRECT function The button is enabled only when Mode indicator WELD is lit The LED corresponding to Settings indicator is lit While selecting a settings Output Setting display2 select button and mode SELECT button are disabled All LEDs of Output Settings display2 item indicator are turned off Unitary Individua...

Page 34: ... is lit Starting welding operation during inching operations cancels the inch ing operation At that time the wire feed amount specified in welding sequence is applied If the inching button is pressed in a mode other than the above the word no Act is displayed on Output Settings displays1and 2 The inching operation is executed while the inching button is held down During inching operation the LED a...

Page 35: ...nt of the controller No Name Functions LCD 16 letters x 2 lines It indicates status details or set value In case it is set to with ENERGY SAVING the backlight is turned off after a specified period of time In case it is set to with GUIDE LCD CTRL the backlight is lit if there is an indication on the LCD and the backlight goes off if there is no indication on the LCD However in case a SUB MONITOR i...

Page 36: ...ted equipment such as jig and leave it for five minutes to discharge the capacitors Attention Prior to touching a P C Board dis charge static electricity through metallic part such as case Otherwise electric parts may be damaged お願い 5 5 1 DIP switch SW1 This DIP switch is to expand the functions of the product Change the default settings of the switch only when an optional function is added or fun...

Page 37: ...ize of base metal cable and output power cable Reference For power cable select a cable with the situation of welding operation and rating of the welding power source in mind that is if manual welding is used select a cable that operator does not feel overloaded and if an automatic welding is used select a cable that withstands continuous welding operation WARNING Prior to connection work make sur...

Page 38: ...3 Connecting grounding wire and input cables Attention Only trained and or qualified personnel who understand electrical knowledge should perform grounding work お願い Note The following cable and wire are customer sup ply items Please prepare them accordingly Grounding wire Wire cross section is 5 5 mm2 or more Input cable Wire cross section is 5 5 mm2 or more Recommended crimp terminal To avoid ele...

Page 39: ...he input cable L1 U L2 V L3 W through the saddle to the input terminal Tightening torque 1 7 N m to 2 3 N m Note No particular phase order to connect Do not use a wrench to avoid overtighten ing of the crimp terminal 4 Wrap the input cable with the grounding wire with the supplied rubber cover and then set the saddle over the rubber cover to fix the cable Note Cut the rubber cover to fit the input...

Page 40: ... cable and torch cable as per the figure on the right Or it will result in unstable arc due to its cable impedance Tightening torque 10 10 N m 13 40 N m Note Size of output power cable Reference Select a cable with the situation of welding operation and rating of the welding power source in mind that is in case of manual weld ing select a cable that operator does not feel overloaded and in case of...

Page 41: ...nd electrical knowledge should perform grounding work お願い Note The following cable and wire are customer sup ply items Please prepare them accordingly Grounding wire Wire cross section is 5 5 mm2 or more Input cable Wire cross section is 5 5 mm2 or more Recommended crimp terminal To avoid electric shock and short circuit of input cable make sure to insulate the crimping part and bare conductor par...

Page 42: ...he input cable L1 U L2 V L3 W through the saddle to the input terminal Tightening torque 1 7 N m to 2 3 N m Note No particular phase order to connect Do not use a wrench to avoid overtighten ing of the crimp terminal 4 Wrap the input cable with the grounding wire with the supplied rubber cover and then set the saddle over the rubber cover to fix the cable Note Cut the rubber cover to fit the input...

Page 43: ... The product pro vides terminals for external voltmeter and amme ter Precautions for handling jig terminals Do not tighten the jig terminal screws too tight otherwise the terminal block may be damaged Tightening torque 0 45 N m 0 55 N m Recommended crimp terminal Lay signal cables from other devices away from welding torch cable output cable and so on to avoid any trouble caused by noise Cable sho...

Page 44: ...t to each terminal EMER GENCY STOP Open the terminals to bring the welding power source to an emergency stop At that time welding output gas supply and wire feed functions are stopped How to reset Turn the power switch OFF and close the terminals and then turn the power switch back ON again OUTPUT USER OUTPUT Use it when the contact output of the management function is set to Valid See section 8 5...

Page 45: ...ting instructions of the digital remote controller 1 Operation sheet CONTROL FUNCTION A button 1 B button 1 INCHING button Organic light emitting panel Dial 1 2 Dial 2 2 button button 1 2 1 HOLD means long press the button for 2 seconds or longer 2 To change a value with a Dial turn clockwise to increase and otherwise press the button less than 2 seconds turn counter clockwise to reduce ...

Page 46: ...e software version of the remote controller Normal It displays welding conditions stored in the weld ing power source Y D 0 0 D C R 1 P L E A S E W A I T W S D P S 0 0 3 2 7 V E R 1 0 0 Welding current set value Welding voltage set value Welding control process Display contents vary with stored data 120A 17 0V I N I M A I N C R T An example Probable causes Defective communication circuit Not appli...

Page 47: ... individual setting 5 GAS CHECK Perform terminate gas check function 6 Pulse setting Whether to use pulse 7 WELD CONDITION Display weld conditions displayed on the panel of the welding power source E R R 0 0 1 Displays the error number and content in case of an error E S T O P N O W L O C K E D While LOCK is applied on the welding power source the remote controller cannot be used C A N N O T U S E...

Page 48: ...e specified operation are indicated in boldface NO CRATER 120A 17 0 V M A I N CRATER 120A 17 0 V I N I M A I N C R T INI CRATER 120A 17 0 V I N I M A I N C R T ARC SPOT 120A 17 0 V A R C S P O T 8 0A 17 4 V M A I N C R T A 8 0A 17 4 V I N I M A I N C R T A 100A 17 8V I N I M A I N C R T A A ...

Page 49: ...O T adjust value ARC SPOT Time 12 0A 10 0 se c A R C S P O T time ARC SPOT Voltage voltage 12 0A 17 0V A R C S P O T ARC SPOT Time 12 0A 10 0 se c time A R C S P O T 2 Edit B HOLD 2 Edit B HOLD 2 Edit B HOLD 2 Edit HOLD B 2 Edit B HOLD WELDING CURRENT 120A 17 0V M A I N WIRE FEED RATE 10 0 mp m 17 0V M A I N THICKNESS 10 0mm 17 0V M A I N 120A 17 0V M A I N In INCHING operation 120A 17 0V N o w I ...

Page 50: ...17 0V M A I N CH CALL 120A 17 0V 1 C H C A L L CH RECORD 120A 17 0V 2 C H R E C O R D SETTING 120A 17 0V 3 S E T T I N G UNITARY INDIVIDUAL 120A 17 0V 4 U N I I N D 2 2 2 2 GAS CHECK 12 0A 17 0V 5 G S C K PULSE 12 0A 17 0V 6 P U L S E WELDING CONDITIONS 12 0A 17 0V 7 W E L D C O N D 2 2 ...

Page 51: ...nt of the CH number CH 0 01 A B C D E F 0 1 2 3 4 5 CH 1 00 A B C D E F 0 1 2 3 4 5 Do not call Initial screen 120A 1 7 0V M A I N B B 2 B 1 B Initial screen 120A 1 7 0V M A I N 220A 2 3 6V M A I N About displayed comment Up to 12 letters of comment are indicated Turn the dial 1 clockwise to display the remain ing comment if appears at the upper right edge of the display appears after displaying t...

Page 52: ...V Change channel No CH 0 01 1 20A 17 0 V CH 1 00 1 20A 17 0 V Do not record Initial screen 120A 1 7 0V M A I N B B 2 B Recording Example Select CH 001 CH 0 01 N O R E C D E L CH 0 01 N O R E C D E L CH 0 01 N O R E C D E L NO Cancell REC Record contents to the specified specified CH No DEL Delete the original contents of the specified CH No 120A 17 0 V M A I N B 2 B 2 B ...

Page 53: ...20A 17 0V 12 0A 10 f r e q 3 2 F R E Q M A I N Peak current 120A 17 0V 12 0A 5 p ea k 3 3 P E A K C U R M A I N Base current 120A 17 0V 12 0A 10 b as e 3 4 B A S E C U R M A I N WFS adjustment 120A 17 0V 12 0A 15 w f s 3 5 W F S A D J M A I N Initial screen 120A 1 7 0V M A I N B B 2 Voltage Edit 2 B 2 Frequency Edit 2 B 2 Peak cur Edit 2 B 2 Base cur Edit 2 B 2 Adj value Edit ...

Page 54: ...3 5 WFS ADJ CH CALL and CH RECORD functions are not applicable during operation After displaying an edit screen by pressing button if you would like to edit a differ ent item for example from wave control to voltage press and select 3 Setting and then re do the above procedure B ...

Page 55: ...AL Set voltage at unitary individual setting 120A 17 0V 4 U N I I N D ON is indisated when UNITARY is selected 120A 17 0V 12 0A 17 0V on 4 U N I I N D U M A I N 120A 17 0V 12 0A 17 0V 4 U N I I N D I M A I N Initial screen 120A 1 7 0V M A I N B B 2 B ...

Page 56: ...ction WMD078TE0PAA07 56 5 GAS CHECK Perform gas check operation 120A 17 0V 5 G S C K Stop gas 120A 17 0V 5 G S C K O F F Out put gas 120A 17 0V Stop gas 5 G S C K O N Initial screen 120A 17 0V M A I N B B 2 B ...

Page 57: ...erefore specify the weld ing condition first 120A 17 0V 6 P U L S E 120A 17 0V 120A 17 0V P 6 P U L S E O N M A I N 120A 17 0V 120A 17 0V 6 P U L S E O F F M A I N Initial screen 120A 17 0V M A I N B B 2 B With Individual Voltage settings With Unitary Voltage settings Without pulse Without pulse 120A 17 0V 12 0A 17 0V on M A I N M A I N With pulse With pulse 120A 17 0V P 12 0A 17 0V oP M A I N M A...

Page 58: ...PAA07 58 7 WELDING CONDITIONS Display weld conditions displayed on the panel of the welding power source 120A 17 0V 7 W E L D C O N D Display weld conditions M S S 1 2 ｍｍ C O 2 H A N D Initial screen 120A 18 4V M A I N B B ...

Page 59: ...ce as it is electric equip ment Do not bring hot base metal such as a piece immediately after welding near combus tible materials When weld ing a ceiling floor or wall remove all combustible materials i including one located in hidden places WARNING Prior to welding operation ensure workplace safety to pre vent fire explosion and blow out Firmly connect cables and insulate the connected parts Conn...

Page 60: ...hem on the operation panel For details see section 7 1 2 Specifying welding conditions material wire diameter gas and pulse on page 63 5 Specify control process Specify them on the operation panel For details see section 7 1 3 Specifying CONTROL process on page 66 6 Pre operation check Check GAS CHECK function wire extension length INCHING function and shield gas Details are described below 1 Chec...

Page 61: ...as If it is necessary to check the shield gas such as flow rate press the GAS CHECK button 1 Check if flow rate adjust ment knob is in the SHUT position Then open the main valve of the gas cylinder 2 Press the GAS CHECK but ton on the operation panel 3 Gradually turn the flow rate adjustment knob to the OPEN position until the flow meter indicates the suitable value 4 After completing the flow rat...

Page 62: ...rce before turning off power at the welding power source お願い 1 Arc start 2 Welding operation 1 Shut off the gas valve Shut off the gas valve at the gas cylinder and then press the GAS CHECK button to remove residual pressure from the pipe 2 Turn off power at the welding power source Turn off the power switch of the welding power source 3 Turn off the earth leak age breaker Turn off power at the po...

Page 63: ...fy welding conditions Material Wire diameter Gas and Pulse Select a material wire diameter and gas Press any one of MATERIAL WIRE DIA GAS select buttons then all 3 lighted LEDs turns blinking While LEDs are blinking the welding power source is searching the welding table of the combination Example of welding conditions Mild steel 1 0 mm in dia and CO2 gas MODE SELECT button Display1 LCD Panasonic ...

Page 64: ...ms turns solid If a weld table for the selected material wire diameter and gas does no exist All 3 LEDs remains blinking LCD shows the message THERE IS NO WELDING DATA Displays1 2 on the operation box show ーー and the following opera tions are disabled Welding output Receiving torch switch TS Inching and Gas check Select different welding conditions mate rial wire diameter and gas type Changed weld...

Page 65: ...lumn of Display1 and press ENTER but ton Turn Dial 1 again to display 02 on the remaining columns of Display1 and press ENTER button The current set value is indicated on Display2 Change the set value to 0 Display 2 indicates 0 and press ENTER button to return to the previous select a group of DETAIL mode process Redo from the procedure 1 Select a mode WIRE EXT LENGTH Group number Submenu number W...

Page 66: ...r welding Press ARC SPOT select button LED above the button is lit If arc spot is selected regard less of CONTROL process set ting it performs only main welding just like setting to NO CRATER Use Output Settings display2 select button to select TIME arc spot time unit second Use Dial2 to specify arc spot time Press ARC SPOT select button once again to cancel the arc spot setting MODE SELECT button...

Page 67: ...ng The item is settable while LED is blinking Note At that time the selected item is indicated on the first line of LCD in the upper right of the operation panel indicates Use Dial1 to specify a current preset value Use Dial2 to specify a voltage preset value Press the button corresponding to the blinking LED to save the change The blinking LED turns solid The item is not settable when LED is lit ...

Page 68: ...Inching operation is executed while holding down the INCHING button While the button is pressed the LED above the button is lit In other modes such as WELD NAVI DETAIL or RECORD mode Inching does not function Once the button is pressed the message no Act is displayed on Displays1 2 as per the figure on the right Panasonic VP1 series A mm V V INCHING INCHING HOLD CURRENT m mom WIRE FEED THICKNESS V...

Page 69: ...he torch switch to start stop welding arc respectively 7 2 2 CRATER Apply main welding followed by crater weld ing With crater welding it is possible to fill the pit at the weld stop Suitable for middle thick plate welding Operation Turn on off the torch switch twice Arc ON Arc OFF Torch ON Torch OFF Weld conditions Torch switch Tpf Gas pre flow time Taf Gas post flow time Arc start Arc end ON OFF...

Page 70: ...at this operation over and over Note The crater repeat function is canceled if the torch switch is not turned on within the preset Trep time Arc OFF Torch OFF Torch ON Arc ON Torch ON Torch OFF Arc for Initial Self hold Change arc type Arc for Main Change arc type Arc for Crater Wire run in speed Burnback time Torch switch Gas supply Wire feed Weld voltage Weld current Weld conditions ON OFF ON OF...

Page 71: ...ions Tpf Gas pre flow time Taf Gas post flow time Trep Crater repeat time Arc start Arc end OFF Tpf OFF ON Crater crater welding Previous self hold OFF Trep repeat Crater ON Crater Torch switch Gas supply Wire feed Weld voltage Weld current Wire run in speed Burnback time Burnback time Arc spot welding using arc spot nozzle Arc ON Torch ON Arc OFF Note The arc stops if the torch switch is turned o...

Page 72: ...86 03 Raise the FTT level 02 Make the wire burning at the weld start larger Increase the hot voltage 01 Reduce the run in speed see page 86 00 Extend the start time 51 Extend the hot time 52 Increase the hot current 53 Eliminate kickback at arc start Reduce the FTT level 02 Reduce the start slope 50 In fillet welding weld the corner accurately Reduce the voltage set value Dial2 Create soft arc Rai...

Page 73: ... pulse peak time see page 83 17 With Aluminum pulsed MIG welding create ripple of the bead Use Low pulse see page 83 20 In Low pulse welding create clear ripple of the bead Reduce low pulse levels current and or voltage see page 83 21 22 Increase the low pulse A B ratio see page 83 24 In Low pulse welding widen the ripple of the bead Reduce the low pulse frequency see page 83 23 Resolve wire stick...

Page 74: ...e them as indications Fine tune them to suit for your workpiece The standard settings are recommendation values for the case of fillet welding joint type at 0 3 m min welding speed The leg length becomes 70 when the thickness is 12 mm The thinner the workpiece is the larger the leg length becomes And the thicker the workpiece is the smaller the leg length becomes It is possible to adjust the recom...

Page 75: ... Example Set to 400 A Select mm THICKNESS The value is not changed using remote controller Dial1 With THICKNESS settings current is automatically set Display1 does not indicate automat ically set value Example If THICKNESS is 12 0 then current is automatically set to 296 A Select A CURRENT using a Remote controller The current value set in the previous procedure 1 takes a priority 400 A b Dial1 Cu...

Page 76: ... 0 1 5 to 12 0 1 5 to 12 0 3 0 to 12 0 1 0 to 8 0 1 0 to 8 0 1 4 2 3 to 16 0 3 2 to 12 0 1 6 2 0 to 10 0 2 0 to 10 0 FCW Flux cored wire Note Relationship between thickness and current value Proper current for each thickness has a range The current value to be that is set automatically is the mini mum value in the range Actual settable thickness is beyond the above mentioned range exceeds either u...

Page 77: ...wn to the end to reset welding conditions determined by WELD NAVI Then main welding current and volt age can be set by the remote controller That is if the adjuster on the remote control ler is turned counter clockwise down to the end set values determined by the WELD NAVI will be reset therefore automatic set tings using WELD NAVI won t function cor rectly Note About WELD NAVI setting items After...

Page 78: ...Welding speed m min WELDING SPEED Minimum 1 m min Minimum 1 0 2 to 1 0 3 Increment 0 1 rEt Return go to THICKNESS1 setting 1 Minimum the smallest value of the setting range of material wire diameter or gas 2 Thickness1 Thickness2 Thickness of workpieces to be welded No particular order See the figure on the right 3 Setting range for thickness varies with material wire diameter and gas settings Pan...

Page 79: ...t WELD NAVI mode Press mode SELECT button several times until LED for WELD NAVI is lit Setting item is indicated on the first line of LCD The first item JOINT SELECT Set value of the setting item is indicated on Display2 Contents of the set value is indicated on the second line of LCD mode SELECT button Panasonic VP1 series Dial1 Dial2 ENTER button Display1 Display2 LCD Display1 Display2 Selected ...

Page 80: ...l2 until the desired set value for THICKNESS 2 is dis played Select rEt to return the previous setting item JOINT SELECT Press ENTER button Clockwise Counter clockwise Direction of Dial2 rotation for display value rise fall JOINT SELECT 1 FILLET JOINT SELECT 2 LAP JOINT SELECT 3 BUTT JOINT SELECT 1 FILLET to to THICKNESS1 RETURN THICKNESS1 0 8 mm Set values vary with material wire diameter and gas...

Page 81: ... first line of LCD Turn Dial2 until the desired set value for WELDING SPEED is dis played Select rEt to return the previous setting item THICKNESS 1 Press ENTER button The operation panel indicates the automatically selected welding conditions WELDING SPEED RETURN WELDING SPEED 0 3 m min Panasonic VP1 series ...

Page 82: ...ignored Set item Submenu LCD display 1st line Setting range Increment Default Run in speed 1 00 RUN IN SPEED 50 to 50 1 0 Hot voltage 01 HOT VOLTAGE 50 to 50 1 0 FTT level 4 02 FTT LEVEL 99 to 99 1 0 Burnback time 1 4 03 BURNBACK TIME 99 to 99 1 0 1 4 Penetration adjustment 04 PENETRATION 30 to 30 1 0 Pre flow time second 05 PRE FLOW TIME 0 to 10 0 0 1 0 2 Post flow time second 06 POST FLOW TIME 0...

Page 83: ...22 LOW PULSE VOL 5 to 50 0 2 20 2 Low pulse frequency 1 23 LOW PULSE FREQ 0 5 to 10 0 1 2 0 Low pulse A B ratio 1 24 LOW PULSE DUTY 10 to 90 5 50 Low pulse delay time 1 25 LOW PUOLSE DELAY 0 to 9 9 0 1 0 Result display time sec ond 30 DISPLAY TIME 1 to 30 1 5 1 Control of penetration increase 32 PENET INC 0 Invalid 1 Valid 2 Automatic 2 1 Terms are described later in this section 2 Pulse frequency...

Page 84: ... PCOUNT 10 to 10 1 0 Fine tune of initial base pulse current 55 INIT PLS IB CUR 99 to 99 1 0 Fine tune of initial peak pulse current 56 INIT PLS IP CUR 99 to 99 1 0 Fine tune of initial pulse frequency 57 INIT FREQ 99 to 99 1 0 Number of burnback pulse 58 BBK PULSE 5 to 5 1 0 End shift voltage 59 END SHIFT VOLT 99 to 99 1 0 Wave control2 60 WAVE CONTROL 2 99 to 99 1 0 IAC 61 IAC 99 to 99 1 0 Short...

Page 85: ...ME 99 to 99 1 0 Initial start slope 91 INIT START SLOP 99 to 99 1 0 Initial down slope 92 INIT DOWN SLOP 99 to 99 1 0 Initial current limit 93 INIT LIMIT CUR 50 to 50 2 0 Crater condition Cur rent 94 CRAT COND CUR 50 to 50 2 0 Crater condition Volt age 95 CRAT COND VOL 50 to 50 2 0 Crater condition Time 96 CRAT COND TIME 99 to 99 1 0 Crater down time 97 CRAT DOWN SLOP 99 to 99 1 0 Crater skip time...

Page 86: ...speed without changing current waveform at welding unit Wire feed speed Preset value Preset value x Adjustment value Wave control It fine tunes the current waveform at initial short circuit portion of short circuit current Standard 0 Normal setting Adjust to direction To obtain soft arc or reduce spatter Adjust to direction To obtain hard arc or improve arc stability in high speed welding Applicat...

Page 87: ...SOFT soft aluminum Adjust the pulse frequency in the following manner if needed Do not change the pulse fre quency significantly otherwise it can cause spatter generation and wire burning To increase the frequency reduce the pulse peak current or pulse base current To reduce the frequency increase the pulse peak current or pulse base current Administrator setting items The following items require ...

Page 88: ... voltage different from the UNITARY is indi cated if INDIVIDUAL is selected the INDIVIDUAL voltage is inidcated Low pulse frequency 23 The higher the frequency is the shorter the distance between the specific ripples Low pulse A B ratio 24 In low pulse set the ratio of width of Condi tion A to the sum of the widths of Conditions A and B Then the width of Condition B is 100 Ratio of width of Condit...

Page 89: ... The following items require the administrator s password to set See submenu 40 of Group 1 in DETAIL mode on page 93 Submenu LCD display 1st line Remarks 88 INIT COND CUR It adjusts the current value of the main welding of the initial condition 89 INIT COND VOL It adjusts the UNITARY voltage value for the current value of the initial condition 90 INIT COND TIME It adjusts the initial condition tim...

Page 90: ...al condition Time Time Current Main welding Crater Torch switch sequence 91 93 90 92 94 88 97 96 Current sequence when the crater control is disabled Time from Current detection to End of the main welding Crater skip time A Current Current ON OFF Torch switch sequence Time Time A 98 detection detection ...

Page 91: ...f Display1 indicates 1 for Group 1 Press ENTER button 2 Specify a DETAIL group Turn Dial1 until the desired group number 1 to 4 is displayed Example Select group 1 Press ENTER button mode SELECT button 溶接溶接ナビ詳細再生記憶選択 Panasonic VP1 series Dial1 Dial 2 ENTER button Display1 Display2 LCD Display1 Display2 Group number ADVANCED LCD Contents of the group No in Diplay1 Clockwise Counter clockwise D...

Page 92: ...the current set value is the standard value the value on Display2 blinks If not the value lights solidly 4 Change the set value of the submenu Turn Dial2 until the desired set value of the submenu is displayed on Display2 Example Set 1 Press ENTER button Display2 is cleared Display1 becomes selectable 5 To edit other submenus of the mode Repeat the previous procedures 3 Specify a submenu and 4 Cha...

Page 93: ...TEM mode SELECT button How to enter the password Submenu 40 Enter password Turn Dial2 until 40 submenu 40 is displayed on Display1 and then press ENTER button Turn Dial2 to display password on Display2 and then press ENTER button Default password is 123 If the password is correct OK is displayed on LCD Display2 is cleared Display1 becomes selectable If the password is wrong OK won t be displayed o...

Page 94: ... Dial2 until 41 submenu 40 is displayed on Display1 and then press ENTER button Display2 indicates the current password Turn Dial2 to display the new password on Display2 and then press ENTER button Display2 is cleared Display1 becomes selectable CHANGE PASSWORD STANDARD VALUE 123 INPUT PASSWORD ...

Page 95: ... 59 m 59 s Amount of wire used 2 M6 kg 6 SUB MONITOR 6 WIRE USAGE 999 9 kg Fan rotation time 2 M7 h m s 7 SUB MONITOR 7 FAN ROT TIME 9 999 h 59 m 59 s Primary input voltage 1 M8 V V V 8 SUB MONITOR 8 INPUT PRE VOLT 1 It indicates the current value Use it only as a guide 2 To count the item it is necessary to set the counter for each of those items ON To set a target value change the Target value f...

Page 96: ...t upper limit detec tion 14 MTR A DET MOVE 0 Continue Indica tion only 1 Stop at the end of the current welding Then press ENTER but ton to reset 0 Welding current upper lower limit detection Welding current upper lower limit detection ON OFF 20 WELD A MONITOR 0 OFF 1 ON 0 Welding current upper lower limit detection time s 21 WELD A DETECT T 0 1 to 99 9 0 1 1 0 Welding current upper limit set valu...

Page 97: ...R but ton to reset 0 Welding voltage upper lower limit detection Welding voltage upper lower limit detection ON OFF 30 WELD V MONITOR 0 OFF 1 ON 0 Welding voltage upper lower limit detection time s 31 WELD V DETECT T 0 1 to 99 9 0 1 1 0 Welding voltage upper limit detection set value Note Upper limit Preset value Preset value x Adjustment value Eg Preset value 18 4 V Adjustment value 10 Upper limi...

Page 98: ...er minal contact closes See section 6 3 1 Jig terminals on page 44 Welding counter Counting the number of welding ON OFF 40 WELD COUNTER 0 OFF 1 ON 0 Check reset welding counter 41 WELD COUNT CHECK 0 Check 1 Reset welding counter The ini tial screen of MANAGEMENT setting dialog box is displayed 0 Welding counter target value 42 TGT WELD COUNT 1 to 30 000 1 30 000 Contents Sub menu No LCD display 1...

Page 99: ...alue 0 Accumulated arc time target value h 52 TGT ARC T INTEGR 1 to 9 999 1 9 999 Wire usage Monitoring wire usage ON OFF 60 WIRE USAGE 0 OFF 1 ON 0 Check reset wire usage Note Count up to 999 9 kg of wire usage Wire usage beyond that amount won t be counted The counter won t be reset to zero 0 auto matically Select 1 Reset to return to the initial screen of the MAN AGEMENT group 61 WIRE USAGE CHE...

Page 100: ...5 g cm3 respectively wire usage may vary with applied wire type Wire usage is counted in inching operation but not counted in wire retract operation Contents Sub menu No LCD display 1st line Setting range Incre ment Default Output management function Motion flow When the counter reaches the target value of Welding count Arc time wire usage and fan rotation time Any one of the monitoring items exce...

Page 101: ...e desired group number 1 to 4 is displayed Example Select group 2 Press ENTER button Submenu No 00 is indicated on Display1 Contents of the submenu 00 is indicated on the second line of LCD mode SELECT button 溶接溶接ナビ詳細再生記憶選択 Display1 Panasonic VP1 series Display2 Dial1 Dial2 ENTER button LCD 溶接溶接ナビ詳細再生記憶選択 Display1 Display2 Group number ADVANCED LCD Contents of the group No on Display1 Cl...

Page 102: ...the standard value If the current set value is the standard value the value on Display2 blinks If not the value lights solidly 4 Change the set value of the submenu Turn Dial2 until the desired set value of the submenu is displayed on Display2 Example Set 1 Press ENTER button Display2 is cleared Display1 becomes selectable 5 To edit other submenus of the mode Repeat the previous procedures 3 Speci...

Page 103: ...ED for the desired mode is lit ADVANCED SYSTEM mode SELECT button In the previous procedure Change the set value of the submenu if Display2 indicates Lcd In DETAIL mode select submenu 42 The current set value is displayed in the second line of LCD not Display2 The new set value updated using Dial2 is displayed in the second line of LCD Example Set the target value to 12345 Press ENTER button Displ...

Page 104: ...LL RECORD function ON OFF 04 PLY REC USE SEL 0 OFF 1 ON ー 1 Max voltage for current voltage preset value of remote controller set value V 05 INPUT VOLTAGE 0 15 V 1 12 V 2 10 V ー 0 Output limit A Setting the max output cur rent 06 OUTPUT CONTROL 30 to 400 10 400 Energy saving Specify a standby time for all LED to be turned off minute 07 ENERGY SAVING 0 to 10 1 0 Guide LCD ON OFF Whether to turn OFF...

Page 105: ...elect language 16 LANGUAGE 0 1 English ー 1 Crater repeat expiration sec ond 17 CRATER REP TIME 0 5 to 5 0 0 1 2 0 Reset items Whether to reset welding parameters memory chan nels RECORD mode 18 RESET 0 ADVANCED 1 DETAI MEMORYCH 2 RETURN ーー Not in use 19 OPT COND UNIT 0 OFF 1 ON ー 0 Specify voltage detection method 20 VOLT DETECT 0 Normal TERM 1 External TERM ー 0 When the digital remote controller...

Page 106: ...til the desired group number 1 to 4 is displayed Example Select group 3 Press ENTER button Submenu No 00 is indicated on Display1 Contents of the submenu 00 is indicated on the second line of LCD mode SELECT button Panasonic VP1 series Dial1 Dial2 ENTER button Display1 Display2 LCD 溶接溶接ナビ詳細再生記憶選択 Display1 Display2 Group number of DETAIL mode ADVANCED LCD Contents of the group No on Display1 C...

Page 107: ...isplay2 blinks Because it is not the stan dard value the value lights sol idly 4 Change the set value of the submenu Turn Dial2 until the desired set value of the submenu is displayed on Display2 Example Set 400 Press ENTER button Display2 is cleared Display1 becomes selectable 5 To edit other submenus of the mode Repeat the previous procedures 3 Specify a submenu and 4 Change the set value of the...

Page 108: ... at shipment Use this setting to record actual date and time of error occurrence The product has a rechargeable battery for time data memory Turning on power at the product recharges the battery With brand new battery it takes about five minutes to charge and the fully charged battery lasts about one month Accuracy of the clock is about 30 s month Re set the clock as needed Turn Dial2 until submen...

Page 109: ... and month set tings turn Dial2 to two grad uation position and press ENTER button Display2 indicate day based on the current setting Day indication on LCD is changed to Turn Dial2 to set the day and press ENTER button Example Set to 15 4 Display time Turn Dial2 clockwise to a grad uation position Press ENTER button To set only time i e skip DATE settings turn Dial2 to three graduation position an...

Page 110: ...s ENTER button Display2 indicates time based on the current setting Minute indication on LCD is changed to Turn Dial2 to set the minute and press ENTER button Example Set to 00 Return to Select a submenu procedure 7 To cancel Time setting Turn Dial2 clockwise to five graduation position and press ENTER button DATE TIME 09 41 RETURN DATE TIME 41 RETURN DATE TIME 09 41 RETURN DATE TIME 10 RETURN DAT...

Page 111: ...eset 1 RETURN If you select 2 Return to Select a submenu procedure Note ADVANCED DETAIL mode MEMORYCH RECORD mode Select 0 Advanced or 1 DETAI MEMORYCH and Select 0 INITIALIZATION POWER OFF is displayed on LCD Turn the breaker off to start initialization of the selected item i e 0 for welding parameters or 1 for weld ing parameters and memory channels RECORD mode Select 1 RETURN Return to Select a...

Page 112: ...ING Provide sufficient ventilation or wear breathing equipment Toxic fumes and gases generated during welding can be hazardous Fill flow function enables continuous gas supply Use fill flow alone Turn ON and OFF the torch switch at a quicker pace than pre flow time Note The following shows sequences when the ON and OFF of the torch switch takes longer than the preset pre flow time The sequence var...

Page 113: ...w process by turning ON and OFF the torch switch quickly Quit fill flow process in the middle Press GAS CHECK but ton in the middle of fill flow process to quit fill flow and start GAS check Press GAS CHECK but ton once again to stop the GAS CHECK In the process of Arc generation ON OFF fill flow Torch switch Gas valve Output Preset post flow time Fill flow ON OFF No arc generation Torch switch Ga...

Page 114: ...nasonic VP1 series Indicates set value Dial1 Dial2 ENTER button Submenu No Use Dial1 to select Press ENTER to set Set value Use Dial2 to select Press ENTER to set To quit the setting in the middle Press mode SELECT button to return to the beginning of the current Mode settings 1 Select DETAIL mode Press mode SELECT button sev eral times until LED for DETAIL is lit The far left column of Display1 i...

Page 115: ...lue in the figure on the right is 0 3 which is the standard value therefore the value blinks 4 Change the set value of the submenu Turn Dial2 until the desired set value of the submenu is displayed on Display2 Example Set 0 8 Press ENTER button DIsplay2 is cleared Display1 becomes selectable Clockwise Counter clockwise Direction of Dial2 rotation for display value rise fall ADVANCED MANAGEMENT SYS...

Page 116: ... submenu you want to edit See section 8 7 1 Setting items on page 114 6 To exit from this group and edit another group of DETAIL mode Press mode SELECT button once Turn Dial1 until the desired group number 1 to 4 is displayed Example Select group1 7 To exit from DETAIL mode Press mode SELECT button until LED for the desired mode is lit CUSTOMIZATION ADVANCED mode SELECT button ...

Page 117: ...rrent set value voltage set value and oFF are indicated on Displays 1 2 alter nately Turn Dial2 until the channel num ber CH you want to store the welding conditions to is dis played Current set value voltage set value and CH channel number are indicated on Dis plays 1 2 alternately Example Store in CH 001 Press ENTER button At this moment the data has not stored yet mode SELECT button Panasonic V...

Page 118: ... char numbers alphabets upper case alphabets lower case symbols Up to three candidate texts are displayed on the upper right of LCD Every time a new text is added to the far right the text on the far left is deleted The blinking text is the selected text Press ENTER button to display the selected blinking text in the second line of LCD Then repeat the procedure from turning Dial2 to enter texts TU...

Page 119: ...e to WELD mode Or press ENTER button to enter the 9th letter to automatically exit from ENTER text operation and change to WELD mode Turn Dial2 clockwise TXT ENTRY 01 CH 001 12345 Blinking Selected text TXT ENTRY CH 001 12345 TXT ENTRY CH 001 1234 Press ENTER button Enter 12 Delete 5 TXT ENTRY CH 001 123 To delete more texts press ENTER button again Delete 4 until blinks TXT ENTRY CH 001 eZ TXT EN...

Page 120: ...ltage set value and oFF are indicated on Displays1 2 alter nately 2 Set a channel number to CALL When the remote controller is used Turn Dial2 to select a channel number CH No to call Current set value voltage set value and CH channel number are indicated on Dis plays1 2 alternately Example CALL CH 001 Welding operation becomes available It is possible to change the channel to CALL by turning Dial...

Page 121: ... value and CH channel number are indicated on Dis plays1 2 alternately Example CALL CH 001 Press ENTER button Call the contents of the selected CH No Displays1 2 indicate current set value voltage set value respectively LCD display is cleared Welding operation becomes available Displayed alternately TURN DIAL TO SEL PRESS TO START Without remote control ...

Page 122: ...quency significantly otherwise it can cause spatter generation and wire burning To increase the frequency reduce the pulse peak current or pulse base current To reduce the frequency increase the pulse peak current or pulse base current 1 Select WELD mode Press mode SELECT button sev eral times until LED for WELD is lit SET button is enabled only in WELD mode 2 Select PULSE FREQUENCY Press SET butt...

Page 123: ...mes until LED for WELD is lit SET button is enabled only in WELD mode 2 Select PULSE PEAK CURRENT Press SET button a few times until LED for PULSE PEAK CURRENT is lit 3 Fine tune the pulse peak current Use Dial2 to adjust Display2 indicates the pulse peak current set value Dis play1 indicates the current set value 4 Press ENTER button mode SELECT button Panasonic VP1 series Dial2 ENTER button Disp...

Page 124: ...times until LED for WELD is lit SET button is enabled only in WELD mode 2 Select PULSE BASE CURRENT Press SET button a few times until LED for PULSE BASE CURRENT is lit 3 Fine tune the pulse base current Use Dial2 to adjust Display2 indicates the pulse base current set value Dis play1 indicates the current set value 4 Press ENTER button mode SELECT button Panasonic VP1 series Dial2 ENTER button Di...

Page 125: ...tton sev eral times until LED for WELD is lit SET button is enable only in WELD mode 2 Select WIRE FEED ADJUST Press SET button a few times until LED for WIRE FEED ADJUST is lit 3 Fine tune the set value Use Dial2 to adjust Display2 indicates the wire feed adjust set value Display1 indicates current set value 4 Press ENTER button mode SELECT button Panasonic VP1 series Dial2 ENTER button Display2 ...

Page 126: ...LSE BASE CUR 99 to 99 1 0 9 PULSE RISE CUR 30 to 30 1 0 10 PULSE FALL CUR 30 to 30 1 0 11 WFS FINE ADJ 1 50 to 50 1 0 13 WAVE CONTROL 1 99 to 99 1 0 14 PULSE FREQ 2 99 to 99 1 0 17 PULSE WIDTH 99 to 99 1 0 18 CRATER DC 0 Invalid 1 Valid 0 19 INIT PLS DC 0 Invalid 1 Valid 0 20 LOW PULSE SET 0 Invalid 1 Valid 2 Automatic 3 0 21 LOW PULSE CUR 30 to 400 2 120 22 LOW PULSE VOL 5 to 50 0 2 20 2 23 LOW P...

Page 127: ...DIRECT Press SET button a few times until LED for DIRECT is lit 3 Allocate setting items Long press SET button until LED for DIRECT blinks Turn Dial2 and select a setting item to allocate Setting range 0 to 39 0 to 39 Weld parameters in DETAIL mode Display2 indicates the selected number 4 Press ENTER button mode SELECT button Panasonic VP1 series Dial2 ENTER button Display2 LCD SET button 溶接溶接ナビ ...

Page 128: ...on turns on off correctly Check if cooling fan rotates smoothly Ground cable Check that input ground connections are secured at power source Check that ground connections are secured at base metal Input cable Check cable jackets for wear and damage Check that no heavy item is placed on the cable Check that terminal connections are secured at load side terminals of distribution box and at input ter...

Page 129: ...asy fumes more than usual perform the periodic inspection every third month 9 3 Inspection items Here are standard check items It is recom mended to add check items of your own depend ing on work environment and usage 9 3 1 Cleaning fin As you use the product longer the fin that pro motes heat loss of semiconductor gets clogged causing temperature rise inside the product resulting in temperature e...

Page 130: ...ace after inspection 9 3 3 Overall inspection Mainly check the following points Signs of odor tarnish and heat generation Loose connections Over tightening Items that are difficult to check in daily inspection 9 3 4 Checking cables and ground cable 1 Check input output and base metal cables and ground cable Refer to the inspection points of cables in the previous Daily inspection and check those p...

Page 131: ...oltage test and insulation resistance measurement Prior to conducting withstand voltage test and insulation resistance test prepare the following items and also connect ground wire cross sec tion about 1 25 mm2 Note After completion of the test s and prior to re installing the case or cover do the following without fail Remove all conductor cables for short circuit Reconnect all cables connectors ...

Page 132: ... wise it may result in electric shock or death or serious injury CAUTION T ensure safe inspection work make sure to wear protective equipment prop erly Improper handling of the product and crack of the plastic parts due to time degradation can cause physical injury A The error indication is automatically turned off if the cause of the error is eliminated Automatic reclosing B The error indication ...

Page 133: ... tuation range Then turn on the power switch again 06 ARC START ERR Arc start error A Failed to detect voltage at torch switch ON Turn off welding output wire feed motor and gas output Turn off the power switch and remove the cause of arc start error If base metal voltage detection wire is used a check the detection wire for breaking or bad connection b check the voltage detection method setting G...

Page 134: ...tor MOTOR OVER CURR Motor over current error 3 Over current to the motor MOTOR CURR ERR Motor overload error 4 Motor rotation fre quency is low 60 62 ー Other 422 communica tion error B Communication cable or welding power source itself is influ enced by noise Review wiring work Lay cables such as commu nication cable away from the source of the noise 63 65 ー Other 232 communica tion error B Commun...

Page 135: ...O Gas hose Gas hose damage Connection Looseness O O Wire feeder Feed roller Wire guide Wrong wire diameter Feed roller Crack Groove clogging Pressure rod Improper settings Wire guide wire dust buildup O O O O O Torch cable Breaks for power and for torch switch Poor connection to wire feeder Trace of heavy drop O O O O O Cable piled coils sharp bending O O O O Welding torch Tip Liner Wrong wire dia...

Page 136: ...11 Circuit diagram WMD078TE0PAA07 136 11 Circuit diagram ...

Page 137: ...quote the Part number The numbers in the No column correspond to the circled numbers in the figures Note The underline __ in a part number rep resents a given alphanumeric character which does not affect compatibility On P C Board On chassis Front Left Front Right Rear mounting plate ...

Page 138: ...ble with 274H40W5R0JW 31 LF4 LF5 LF6 Ferrite core YABD125 J0KG00000014 3 43 ZUEP1 P C Board WSYEP10254 WSYEP10254 1 Control board ZUEP1588 50 ZUEP8 Communication board ZUEP1295_B ZUEP1295_B_ 1 51 ZUEP9 Conversion board ZUEP1571 ZUEP1571_ 1 52 SWPS1 Switching power source YCAD133 LFA15F24CJ1 1 57 R15 Resistor YMAD113 SFW40E501 1 62 FAN3 Fan assy WSDEX00021 WSDEX00021 1 Fan guard KXFP6F9HA00 ...

Page 139: ...former WSUTU22710 WSUTU22710 2 44 ZUEP2 Governor board ZUEP1555_A ZUEP1555_A_ 1 46 ZUEP4 DC power source ZUEP1585 ZUEP1585_ 1 DC power board 58 TR3 Control transformer WSUTU22700 WSUTU22700 1 60 ZUEP11 Communication board ZUEP1295_C ZUEP1295_C_ 1 61 ZUEP12 Conversion board ZUEP5733_A ZUEP5733_A_ 1 On P C Board mounting plate On chassis ...

Page 140: ... block N510012056AA N510012056AA 1 Input terminal cover Outside WSDKK008TA Inside WSDEK00009 Maker s No OTB 358N 4PTUV 40 Terminal block MTNE000339AA MTNE000339AA 1 Jig terminal cover DKK00105 45 ZUEP3 P C Board WSYEP10200 WSYEP10200 1 Operation board ZUEP1597 47 ZUEP5 Liquid crystal module MTNS000066AA MTNS000066AA 1 Liquid crystal board 53 FU2 Fuse YMAD81 BET3 15A 1 Safety part For voltage detec...

Page 141: ...00008 WSDEX00008 1 14 C19 C20 Capacitor assy WSDEX00001 WSDEX00001 2 17 R6 R7 Resistor YMAD112 SFW40E5R0AP 2 Interchangeable with 274H40W5R0JW 18 R8 Resistor YZA97 SFW40E101J 1 19 R9 Resistor YRAD61 SFW40E3R3J 1 21 THM2 Thermistor WSDWX00080 WSDWX00080 1 Safety part 34 CT CT YCA6 TN300A4VB15A 1 35 SH2 Shunt MSH600A MSH600A 1 Interchangeable with HY600A 49 ZUEP7 Start board ZUEP1509 ZUEP1509_ 1 65 ...

Page 142: ...P 8 Interchangeable with 274H40W5R0JW 20 THM1 Thermistor WSDWX00081 WSDWX00081 1 Safety part 22 NFB No fuse breaker YMAD199 DCP73BH60AMS 1 Safety part Breaker cover PEK00018 30 LF3 Ring core YCA35 ESDR38C1 1 31 LF4 LF5 LF6 Ferrite core YABD125 J0KG00000014 3 48 ZUEP6 Driver board ZUEP1574 ZUEP1574_ 1 59 ZUEP10 Gate board ZUEP1520 ZUEP1520_ 1 SCR gate board 63 MG1 Magnet switch MTNC000774AA MTNC000...

Page 143: ...15 15 6 0 Front 1 2 1 2 1 5 230 260 24 26 0 40 0 50 15 15 20 Back 1 2 1 2 1 5 230 260 24 26 0 40 0 50 15 15 20 9 0 Front 1 2 1 2 1 5 320 340 32 34 0 40 0 50 15 15 20 Back 1 2 1 2 1 5 320 340 32 34 0 40 0 50 15 15 20 Butt joint welding Square groove joint With backing Thickness mm Wire diameter mm Root gap G mm Current A Voltage V Speed m min Tip to work distance mm Gas flow L min Copper backing 0 ...

Page 144: ... 270 380 29 35 0 40 0 45 25 2 20 25 12 7 8 1 2 1 6 300 380 32 35 0 35 0 40 25 2 20 25 Lap Joint Fillet At low speed Thickness Wire diameter Current Voltage Speed Tip to work distance Position 1 2 3 Gas flow mm mm A V m min mm L min 0 8 0 8 0 9 60 70 16 17 0 40 0 45 10 1 10 15 1 2 0 8 0 9 80 90 18 19 0 45 0 50 10 2 10 15 1 6 0 8 0 9 90 110 19 20 0 45 0 50 10 2 10 15 2 3 0 8 0 9 100 130 20 21 0 45 0...

Page 145: ...38 0 45 0 50 15 20 10 20 8 6 1 2 300 350 30 36 0 40 0 45 15 20 10 20 8 9 1 6 430 480 38 42 0 40 0 45 15 20 10 20 12 10 1 6 430 480 38 42 0 30 0 40 15 20 10 20 12 13 1 6 450 480 38 42 0 25 0 30 20 25 10 20 Type Welding position Wire diameter Leg length Pass Current Voltage Speed Weaving mm mm A V m min Metal Horizontal position 1 2 6 1 270 28 0 42 Without 9 1 270 28 0 24 With 12 1 280 29 0 34 Witho...

Page 146: ... 0 8 0 9 0 60 70 15 16 0 30 50 10 10 15 1 6 0 8 0 9 0 100 110 16 17 0 40 0 60 10 10 15 3 2 0 8 1 2 1 0 1 5 120 140 16 17 0 25 0 30 15 10 15 4 0 1 0 1 2 1 5 2 0 150 160 17 18 0 20 0 30 15 10 15 Fillet welding Horizontal position At low speed Thickness Leg length Wire diameter Current Voltage Speed Tip to work distance Position 1 2 Gas flow mm mm mm A V m min mm L min 0 6 2 0 4 0 6 30 40 14 0 40 0 5...

Page 147: ... Butt joint I shape 1 6 0 80 100 16 18 0 50 13 13 2 0 90 110 16 18 Corner or TJoint 1 6 0 80 100 16 18 0 40 10 10 2 0 100 120 16 18 Joint type Thickness Root gap Current Voltage Speed Tip to work distance Gas flow mm mm A V m min mm L min Butt joint I shape 3 2 0 150 170 18 19 0 50 15 15 4 5 220 240 22 25 6 0 280 300 28 30 0 40 20 20 9 0 280 330 28 32 Corner or TJoint 2 3 0 140 170 18 20 0 50 15 1...

Page 148: ...e Welding speed Tip to work distance Argon gas flow mm mm mm A V cm min mm L min Butt Joint Welding Flat 2 0 1 2 0 80 18 80 15 15 1 2 90 18 110 15 15 3 0 1 2 0 100 20 60 15 20 1 2 140 22 100 15 20 6 0 1 6 0 180 23 60 15 25 1 6 220 24 90 18 25 10 0 1 6 0 300 27 30 22 25 1 6 300 28 50 22 25 Posture Thick ness Groove shape Leg length Number of pass Wire diameter Welding current Welding voltage Weldin...

Page 149: ...Argon gas flow mm mm A V cm min mm L min Butt Joint Welding Flat 1 2 1 2 60 70 17 18 50 60 10 12 15 17 1 5 80 90 18 19 50 60 10 12 15 17 2 0 90 18 19 50 60 10 12 15 17 3 0 110 150 19 21 40 50 12 15 17 20 4 0 180 200 21 22 40 50 12 15 17 20 Fillet Welding Horizontal 1 2 60 70 16 17 40 50 10 12 15 17 1 5 80 90 17 18 40 50 10 12 15 17 2 0 100 110 17 18 40 50 10 12 15 17 3 0 140 150 19 20 40 50 12 15 ...

Page 150: ...5 0 75 130 22 24 9 12 12 1 0 x 1 0 0 8 1 25 1 5 155 24 26 12 12 12 1 0 x 1 0 1 2 0 25 260 25 10 16 20 1 2 x 1 2 0 8 1 75 155 24 26 12 12 12 1 2 x 2 3 1 6 0 6 320 25 15 16 20 1 2 x 3 2 1 2 0 35 320 24 26 15 16 20 1 2 x 3 2 1 6 0 6 350 31 15 16 20 1 2 x 6 0 1 6 1 1 390 32 15 16 20 1 6 x 1 6 1 2 0 8 320 32 16 16 20 1 6 x 2 3 1 6 0 6 340 33 15 16 20 1 6 x 3 2 1 6 0 7 370 32 15 16 20 1 6 x 6 0 1 6 0 7 ...

Page 151: ...TERIAL WIREDIA GASsettings Channel CH number Material to be welded Remarks Prepared on Prepared by INITIAL WELD CRATER SPOT TIME WAVEFORM CONTROL Current A A A s Voltage V V V Item Settings Item Settings 00 RUN IN SPEED 14 PULSE FREQ 01 HOT VOLTAGE 17 PULSE WIDTH 02 FTT LEVEL 18 CRATER DC 03 BURNBACK TIME 19 INIT PLS DC 04 PENETRATION 20 LOW PULSE SET 05 PRE FLOW TIME 21 LOW PULSE CUR 06 POST FLOW...

Page 152: ...14 Welding condition recording sheet WMD078TE0PAA07 152 Channel List Channel CH number Material to be welded Prepared on Prepared by Channel CH number Material to be welded Prepared on Prepared by ...

Page 153: ...ase dispose of this item only in designated national waste electronic collection schemes and not in the ordinary dust bin For business users in the European Union If you wish to discard electrical and electronic equipment please contact your dealer or supplier for further information Information on Disposal in other Countries outside the European Union This symbol is only valid in the European Uni...

Page 154: ...A07 パナソニックスマートファクトリーソリューションズ株式会社 571 8502 大阪府門真市松葉町 2 番 7 号 Panasonic Smart Factory Solutions Co Ltd 2 7 Matsuba cho Kadoma City Osaka 571 8502 Japan Panasonic Smart Factory Solutions Co Ltd Printed in Japan 2018 ...

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