Panasonic YD-500KR Operating Instructions Manual Download Page 39

Page: 39 / 51

OTHER TROUBLE AND ERROES

When the power switch of the welding machine is turned on, but the POWER indicator lamp does
not go on



When the power indicator lamp goes on, but welding cannot be done (no arc is produced)

3-phase

rated

voltage being applied to

the input end of the

welding power unit ?

Is the switch of the
switch box turned on ?

When the POWER switch
[14] is turned on, does
the cooling fan start?

Is the electromagnetic
contactor turned on ?

What is a voltage at both
ends

the

POWER

indicator, lamp [2l] ?

The fuse(Fu1) is gone.
The

cooling

fan

defective.

The

printed

circuit

board is defective.

The POWER indicator lamp
is defective.

Is the switch of the
switch box turned on ?

The

printed

circuit

board is defective.

YES

DC24V

YES

Is the electromagnetic
contactor turned on ?

The electromagnetic

contactor

defective.

the

output

cable

properly connected and

the

cable

condition

normal?

When the torch switch is

turned on, is the wire

fed ?

the

output

voltage

generated?



The

printed

circuit

board is defective.



The thyristors SCR1 ～

SCR6 are damaged.



The control transformer

is defective.

Is the wire

fed

turning on

the inching

switch.



The

fuse(Fu2)

is gone.



The

printed

circuit board is

defective.



the

wire

feeder

properly

connected?



the

feed

roller of the wire

feeder

properly

set?



Is the chip not

clogged.



The

printed

circuit board

is defective.

Connect

properly and

firmly.

YES

Summary of Contents for YD-500KR

Page 1: ...the instructions carefully and save this manual for future use First of all please read Safety precautions or Safety manual SPEC No YD 500KR2HD0 YD 500KR2HU0 Panasonic Welding Systems Tangshan Co Ltd Model No YD 500KR Operating Instructions Thyristor Controlled MIG MAG Arc Welding Power Source TSM50262 02 ...

Page 2: ...reliability Good welding performance With individual and Simple Unitary mode Various kinds of user friendly design ACCESSORIES We1ding power source Name Code No Q ty Glass tube fuse 1 A 61NR010H 1 Glass tube fuse 3 A 61NR030H 1 Glass tube fuse 8 A 61NR080H 1 ...

Page 3: ...g the Wire by Inching Operation 20 WELDING BY MANUAL OPERATION 21 Welding Crater Control Enable Self holding Crater Operation 21 Welding with crater control disabled torch switch synchronous operation 22 DUTY CYCLE 23 EXTENDED FUNCTIONS 24 Connecting the Extension Cable Extension Cable is Optional 24 Switch and Controls on the Printed Circuit Board 25 Setting the Selector Switch on the Printed Cir...

Page 4: ...e also used on the warning labels attached on the machine Warning symbol Signal phrase Description Danger When you see this symbol it means that a hazardous accident including death or serious personal injury is imminent if directions are not followed carefully Warning When you see this symbol it means that the potential for a hazardous accident including death or serious personal injury is high i...

Page 5: ...to overheat Use of filter voids warranty Never use the welding power source for other than welding purpose e g Never attempt to use the welding power source for pipe thawing Against electric shock Touching any live electrical parts can cause fatal electric shocks or severe burns Never touch live electrical parts Grounding of the case of the welding power and base metal or a jig electrically connec...

Page 6: ...osion or blowout Observe the following cautions to prevent fires explosion or blowout Remove any combustible materials at and near the work site to prevent them from being exposed to the spatter If they cannot be relocated cover them with a fireproofing cover Do not conduct welding near combustible gases Do not bring the hot base metal near combustible materials immediately after welding When weld...

Page 7: ...ans feed roller of the wire feeder or hand finger s hair or part of your clothes may be caught by the parts resulting in injury Keep all covers panels and cases closed when using the product Maintenance work and repair should be perform only by educated and or skilled persons who thoroughly understand welding machines While performing maintenance or repair work provide fence or the like around the...

Page 8: ... and receivers c Computer and other control equipment d Safety critical equipment e g guarding of industrial equipment e The health of the people around e g the use of the pacemaker and hearing aids f Equipment used for calibration or measurement g The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may requ...

Page 9: ... ambient air a during welding 10 to 40 deg C b after transport and storage 20 to 55 deg C Humid a up to 50 at 40deg C b up to 90 at 20deg C Altitude above sea level up to 1000 m Power Source Facility Power source YD 500KR2 YD 500KR2HD0 YD 500KR2HU0 3 Phase 220V 3 Phase 380V Frequency 50 60 Hz Switch able on the printed circuit board Facility capacity Commercial power source 40 kVA Engine generator...

Page 10: ...elding source and is provided with compensating winding Wiring on the input side Attach a switch with fuse of specified capacity or no fuse Breaker or leakage breaker to the switch box for each welding source When using the no fuse breaker or leakage breaker select those for the welding machine or motor or transformer This machine has input power frequency select switch Please confirm the correct ...

Page 11: ...nits are to be prepared by the customer The non crosshatched units may be altered according to a customer s request or separately arranged Switch box 3 phase rated Input Voltage Gas Regulator Grounding Input Cable Heater Cable Gas Hose Gas Bomb Grounding Wire Feed Control Cable Output Cable Base Metal Cable Welding Wire Wire Feeder Grounding ...

Page 12: ...nce on the cable or bring it into contact with a weld Zone Tighten securely a cable joint This machine has input power frequency select switch Please confirm the correct position of the switch Refer to pages 27 28 and 30 When a frequency changes depending on where you use the welding source switch to an adequate frequency Welding Torch Base Metal Safety Warning Loose the left and right screws to r...

Page 13: ...he terminal cover Remove two bolts from the terminal cover Connect the other end of the base metal cable to the base metal Minus terminal Plus terminal Base Metal Cable Using an accessory bolt connect the base metal cable to the minus terminal Using an accessory bolt connect the output cable coming from the wire feeder to the plus terminal Tape around any exposed conductive sections which may come...

Page 14: ...r and welding torch read their respective instruction manual Turn off the POWER switch Align the guide Guide Align a guide insert and fix with a ring screw Ring Screw Wire Feeder Output cable connect to the plus terminal of the welding power source Gas hose Connect to the gas regulator Connect a gas hose to a gas outlet fitting Gas outlet fitting Welding Torch Locking Bolt CC Fixture Confirm that ...

Page 15: ...e aware of the following In case of CO2 welding use carbon dioxide gas with moisture content of 0 005 or less or welding carbon dioxide gas For a mixed gas in case of MAG welding use MAG welding gas argon gas with 5 to 20 carbon dioxide gas When mixing two kinds of gas carbon dioxide gas and argon gas for use use a gas mixer In order to avoid irregular mixture Argon gas to be mixed should be high ...

Page 16: ...e diameter choices of 1 2 l 4 and 1 6 Fuse A power fuse for the control circuit is Fuse A feeder motor fuse Voltmeter Indicates a welding voltage value Crater Selector Switch POWER Switch Wire Selector Switch Selects whether to enable crater control Refer to pages 23 24 and 48 enable ON disable OFF Select either the flux cored wire in conformity with your wire Turns on off this equipment Note Occa...

Page 17: ...age may not be an optimum condition depending on a welding posture wire brand and length of an extension cable If this is the case the crater voltage can be finely adjusted lower by turning this control to the left and higher by turning to the right Gas Supply Switch Warn Indicator Lamp Power Indicator Lamp Prior to welding use this switch to adjust a gas flow rate in advance Set it to the CHECK s...

Page 18: ...n Scale Plate Fixing Bolt Capable of adjusting a welding current value Note When SIMPLE UNIFIED is selected the welding voltage is internally processed so that it automatically assumes an appropriate value with respect to a set current value This is called simple unification Welding Current Control Capable of adjusting a welding voltage Note When SIMPLE UNIFIED is selected refer to page 30 It work...

Page 19: ...riate measure for ventilation in order not to inhale toxic gases Carbon monoxide Ozone Nitrogen oxide etc or metallic fume Confirmation of Complete Connection Make sure again that the entire equipment is connected as shown in OVERALL CONNECTION DIAGRAM refer to Page 8 In case of gas shielded arc welding CO2 welding or MAG welding alter the light shielding degree of the light shielding filter plate...

Page 20: ...e switch box Turn on the POWER switch Welding Power Source Flow Meter Gas Regulator Primary Pressure Gauge Open the main valve of the gas bomb Prior to opening it make sure that a flow rate control knob is turned to the SHUT side Turn the flow rate control knob gradually toward OPEN so that a flow meter indicates a required value Flow Rate Control Knob Gas Bomb Earthing Terminal ...

Page 21: ...diameter used The figure above shows an example of attaching l 2 of the 0 9 1 2 feed roller Put back a pressure arm and pressure nut in that order Pressure Nut Shaft down Lift up Pressure Arm Loosen a lock nut an d co rr e ct io n adjusting bolt in that order Wire Correction Roller Lock nut CC Fixture Wire Stopper Hole Feed Roller Knob Screw Wire Correction Roller ...

Page 22: ...ould be taken when adjusting the wire pressurization force For your safety be sure to turn off the switch of the switch box located on the input side of the welding power source switch with fuse or no fuse breaker or leakage breaker and POWER switch of the welding power source At the time of inching do not peep through a tip hole to check if the wire is being fed It is very dangerous because the w...

Page 23: ... crater treatment If arc discontinues for 0 5 second or more during welding however self hold will be cancelled The following two kinds of welding are allowed by operating the CRATER ON OFF selector switch on the operation panel and the torch switch Be sure to read Duty cycle on Page 22 and observe a duty cycle in using the equipment Using only this switch allows you to start stop operation CRATER...

Page 24: ...ing Operation Procedure Set the CRATER ON OFF selector switch to OFF and turn on off the torch switch Synchronized with it welding arc starts or stops Operation Timing Chart Welding Arc Start Welding Arc Stop Torch Switch ON Torch Switch OFF Torch Switch Gas Supply Wire Feed Welding Voltage Welding Current Welding Condition Adjustment Tpf Gas preflow time Arc start timing Arc stop timing ...

Page 25: ... equipment may be deteriorated or burnt out The figure above shows the relations between the welding current and duty cycle for the 500KR2 welding current value and use the equipment within that range When using in combination with other device such as welding torch etc use at the lowest duty cycle reactor of each device NOTE SCR IPL are protected with Thermal protector Welding Current A Duty cycl...

Page 26: ...rop due to an electric resistance or the connected extension cable or how it is led about Undesirable effects are magnified as the extension cable becomes 1onger or its sectional area becomes smaller Therefore erroneous selection of the extension cable used may degrade a welding result Upon using the extension cable bear the following in mind Relations between the extended distance and cable s sec...

Page 27: ... on the printed circuit board as well which are available for extending many different functions Caution After switching work is completed be sure to put back the front panel as it was If this is neglected dust may accumulate inside any destroy the electric circuit of the printed circuit board Change over the switches on the printed circuit board Put back the front panel with 4 bolts 1 Turn off th...

Page 28: ... of outputting the same conditions as the crater welding conditions as initial welding conditions Prerequisite The CRATER ON OFF selector switch should be set to ON The relations with the crosshatched new control sequence operation and welding torch switch operation in the table below are described in the timing chart on the next page Setting of CRATER ON OFF Switch Selector Switch 8 6 on PCB Cont...

Page 29: ...lding condition Operation Timing chart Tpf Gas preflow time Arc start timing Arc stop timing An initial condition welding period refers to a period between arc generation by Initial torch switch on and first torch switch off A regular welding period refers to a period between first torch switch off and next torch switch on A crater welding period refers to a period between 2nd torch switch on and ...

Page 30: ...ng to INDIVIDUAL allows optional setting of the welding voltage to widen an adjustment width Selector Switch 11 FTT Control Enable Disable Set to DISABLE upon shipment DISABLE Does not provide FTT control ENABLE Provides FTT control Refer to page 49 enable ON disable OFF Selector Switch 12 60 Hz 50 Hz 60Hz Select 60 Hz when using in a 60 Hz district 50Hz Select 50 Hz when using in a 50 Hz district...

Page 31: ...value decrease Increase Adjustment position Preflow time Adjusts the Preflow time VR11 Preflow time Decrease Increase 0 05 s 0 6 s Adjustment position Afterflow time Adjusts the Afterflow time VR12 Afterflow time Decrease Increase 0 35 s 0 9 s Adjustment position Exterior ammeter Adjustment Adjusts the Exterior ammeter VR15 Decrease Increase Center position Already adjusted Do not touch VR3 VR4 VR...

Page 32: ...the parts as required For replacement parts be sure to use those purely designed for the PANASONIC welding machines in order to maintain performance and functionality Welding power source Block Inspection point Remarks Operation panel Sense of operating changing over the switches loose mounting Secure lighting up off of the POWER indicator lamp Cooling fan Smooth rotating sound and Generation of c...

Page 33: ...nd stable arc carry out inspection in an appropriate method suitable to your work site Roughly and simply in daily inspection Elaborately in details in periodic inspection Input cable Whether the input and output terminals of the input protective device of the switch box are tight Whether the fuse holder is clamped tight Whether the input terminal of the welding power source is clamped tight Wheth...

Page 34: ... the welding power source Using moisture free compressed air dry air blow off dust accumulated in the welding power source Removal of the top plate and side plates is shown on the following page Inspection of overall Welding Power Source and its Surroundings Centering around checks for odor discoloration trace of heat generation Loosened internal connections and retightening check the items which ...

Page 35: ...tor to short circuit them 3 Remove two output cables connected to two output terminals Tie the two output terminals with a conductor to short circuit them 4 Using conductors tie between the anode and cathode of the thyristors SCR1 SCR6 to short circuit them The conductors used in and should have a sectional area of about 1 25 mm 2 5 Remove the case grounding terminal wire number 9 The 500KR2 has t...

Page 36: ...lanks below that phenomenon For the fuses the operation panel has a power fuse and the printed circuit board has a motor fuse and gas valve fuse respectively Welding Error Initial Diagnoses List Error Block and check item Switch box input protective device Turning on the switch securely Blown fuse Loose connection Input cable Cable being almost cut Loose connection Trace of overheat Switches on th...

Page 37: ...ing torch power cable and torch switch contro1 cable Snapping of the cable bending fatigue Trace of a drop of a heavy substance Surface condition of the base metal and wire projection length Distance between the chip and base metal Oil contamination rust painting film Too much wire projection Output cable Insufficient sectional of area of cable Loose connection of the or output cable Improper powe...

Page 38: ... inside the welding power unit When you restart welding be sure to lower the welding conditions shorten the welding time or lower the output current When the Warn indicator lamp goes on repeatedly stop using the machine It would lower insulation of internal parts or shorten their lives resulting in a trouble or burn out or the equipment never use the machine in a manner which may turn on the Warn ...

Page 39: ...he switch box turned on Is the switch of the switch box turned on Is the switch of the switch box turned on The printed circuit board is defective YES NO NO NO NO YES YES DC24V YES Is the electromagnetic contactor turned on The electromagnetic contactor is defective Is the output cable properly connected and the cable condition normal When the torch switch is turned on is the wire fed Is the outpu...

Page 40: ...make a check NO NO When output cannot be adjusted When the torch switch is turned on does the voltmeter s needle swing Check the wire feeder for its connection Is it not snapped Is SIMPLE UNIFIED INDIVIDUAL properly selected Ask our office for examination repair When the torch switch is turned on does the voltmeter s needle swing Is the welding condition appropriated When it gets stuck to the chip...

Page 41: ...he human body such as electric shock or burn Caution After finding out a cause by following the flow chart take a remedy according to the relevant category below When the fuse is gone After eliminating a cause overload or short circuit replace the fuse with a specified one referring to the Parts List When the fuse goes again after turning on the power turn off the power and ask our office for exam...

Page 42: ...you need a repair please contact our dealer where you purchased the equipment or our branch office When you ask for a repair let us know the following Your address name and phone number Machine type in terms of spec number Manufacture year and number inscribed on the name plate stuck to the welding power source Details of the trouble or error ...

Page 43: ...41 APART LAYOUT DRAWING The part specifications shown in figure is required to refer the attached parts list 25 Front Right Side Rear Left Side YD 500KR2 ...

Page 44: ...VK 1 13 CT Cur transformer HC SL400V4B15 1 14 SW1 Switch LAY39 20X K2X 1 Power 15 SW2 Switch SLE6A2 1 Gas 16 SW3 Switch SLE6A2 1 Crater 17 SW4 Switch SLE6A2 1 Wire material 18 SW5 Switch ADS850CF1A02 1 Wire dia 19 VRAC Crater cur Adjustor TV18Y20FB502FNCB 1 20 VRVC Crater vol Adjustor TV18Y20FB502FNCB 1 21 LED1 Pilot lamp Green DB40NBG 1 Power 22 LED2 Pilot lamp Red DB40NBY 1 Warn 23 Fu1 Fuse 61NR...

Page 45: ...CIRCUITDIAGRAM ...

Page 46: ...44 OUTSIDE DRAWING W D H YD 500KR2 436 675 762 ...

Page 47: ...ler welding About 60 to 70 of the welding current so far regular welding current is a setting yardstick of the crater filler welding current Crater filler welding is generally referred to as crater welding There is a control sequence which allows you to switch the regular welding current so far to the lower crater welding current by operating the switch of the welding torch just before the end of ...

Page 48: ...ends to project from the tip of the welding torch This causes the wire to get stuck to a weld assembly or worsens an arc start for next welding thus leading to an inconvenience To eliminate this inconvenience an output voltage is generated for a very short time to burn up surplus wire even after the torch switch is turned off This processing time is called a burn back time its time width differs d...

Page 49: ...5 2 3 1 0 1 2 0 5 1 0 120 130 19 5 20 45 50 10 10 15 3 2 1 0 1 2 1 0 1 2 140 150 20 21 45 50 10 15 10 15 4 5 1 0 1 2 1 0 1 2 170 185 22 23 45 50 15 15 6 0 Front 1 2 1 2 1 5 230 260 24 26 45 50 15 15 20 Back 1 2 1 2 1 5 230 260 24 26 45 50 15 15 20 9 0 Front 1 2 1 2 1 5 320 340 32 34 45 50 15 15 20 Back 1 2 1 2 1 5 320 340 32 34 45 50 15 15 20 0 8 0 8 0 9 0 89 16 5 120 10 15 1 0 0 8 0 9 0 100 17 12...

Page 50: ...z Switchable on the printed circuit board Rated input 31 9 kVA 28 1 kW Rated output current DC 60 500 A Rated output volt DC 16 45 V Applicable wire dia for unitary control Solid wire mild steel 1 2 1 4 1 6mm flux cored mild steel 1 2 1 4 1 6mm Rated duty cycle 60 Outside dimension W D H 436 675 762mm Mass 158 kg ...

Page 51: ...y 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 and then assign the o...

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