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Before operating this product, please read the instructions carefully and save this manual for future use.

Please also read the operating instructions of peripheral equipment.

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First, please read the “Safety Precautions”.

English version is the original instructions.

2011

Operating Instructions

Model No.

YC-300BZ3YHD

Fully digital and inverter controlled TIG welding

OMCTT5621E18

DC TIG Welding Power Source

Содержание YC-300BZ3YHD

Страница 1: ...re 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 YC 300BZ3YHD Fully digital and inverter controlled TIG welding OMCTT5621E18 DC TIG Welding Power Source ...

Страница 2: ...or the use of it the cause of which is other than the foregoing but is also not attrib utable to PSFS Any claim of a third party that this Product infringes the intellec tual property rights of such third party that are directly or indi rectly caused by User s use of this Product and relate to the method of production ANY LOST PROFITS OR SPECIAL INDIRECT INCIDEN TAL OR CONSEQUENTIAL DAMAGES IN CON...

Страница 3: ...compatible this may require additional protection measures h The time of day that welding or other activities are to be carried out 3 The user shall be observe to reduce emission distur bance as below a Welding equipment should be connected to mains supply according to the manufacture s recommen dations b Welding equipment should be routinely maintained according to the manufacture s recommendatio...

Страница 4: ...ищує 0 1wt ваги речовини або в концентрації до 1000 частин на мільйон 2 кадмій Cd не перевищує 0 01wt ваги речовини або в концентрації до 100 частин на мільйон 3 ртуть Hg не перевищує 0 1wt ваги речовини або в концентрації до 1000 частин на мільйон 4 шестивалентний хром Cr6 не перевищує 0 1wt ваги речовини або в концентрації до 1000 частин на мільйон 5 полібромбіфеноли PBB не перевищує 0 1 ваги ре...

Страница 5: ...ing 29 7 1Preparation 29 7 1 1Use of protective equipment 29 7 1 2Pre operation check 29 7 1 3Turning ON power 29 7 1 4Adjusting gas flow rate 29 7 2Termination processing steps after welding operation 30 7 2 1Shutting off gas 30 7 2 2Shutting off power 30 7 2 3Precautions for use of water cooling torch in winter season 30 8 Settings 31 8 1DETAIL settings 31 8 1 1Factory settings 31 8 1 2How to ch...

Страница 6: ...ed area or above floor level check related national state and local codes and regulations for any special treatment and comply with it if any Electromagnetic disturbance 1 Pacemaker wearers should consult their doctor before going near arc welding Magnetic fields can affect pacemakers 2 Peripheral electronics or safety device may cause electromagnetic disturbance Ground all of such devices without...

Страница 7: ...ations and wear ear protection such as ear plug or hear muff 2 The larger the welding current is the larger the noise becomes Gas cylinder and gas flow regulator 1 The gas cylinder must be handled properly according to the applicable law and in house standards 2 Use the gas flow regulator that is supplied or recom mended by our company 3 Read the instruction manual of the gas regulator prior to us...

Страница 8: ...0 500Hz In increments of 10Hz Pulse width 5 95 Arc spot time s 0 1 5 Increment 0 1s Control system IGBT inverter method Crater control system Selectable from 3 modes of crater controls ON OFF or Repeat High frequency wave generating equipment High frequency arc start type Communication function RS 232C RS 422 Memory function 64ch storage and reproduction Robot interface function Enables communicat...

Страница 9: ...utput other than rated value is used TIG welding Stick welding 2 3 Dimensions Do not use this product at any usage rate over the rated duty cycle Allowable duty cycle Rated output current Actual output current Rated duty cycle x 2 50 100 4 190 245 300 0 100 60 Rated duty cycle 40 Output current A Duty cycle 50 100 4 160 204 250 0 100 60 Rated duty cycle 40 Output current A Duty cycle For your refe...

Страница 10: ...n the horizontal position in the proper posi tion Indoors not subject to direct sunlight or rain with less moisture and dust in industrial environment area Ambient temperature 10 C to 40 C Maintain an appropriate distance of 20 cm or more from any wall or other devices Maintain an appropriate distance of 30 cm or more between power sources installed side by side Install this product in the horizon...

Страница 11: ...2 Connect it to the output cable of the base metal if neces sary 3 Do not put the cooling water system on top of the welding power unit 4 Welding torch and fingertip joint Make sure to use the Panasonic genuine products only Or the connection part may be burnt due to poor contact 5 The gas hose lead out point of the air cooling TIG welding torch is different from that of the water cooling TIG weld...

Страница 12: ...10 Base metal 5 Fingertip joint Accessory 11 Base metal cable 2 6 Fingertip joint 1 1Prepare the fingertip joint CWC00180 to connect to the cable from the electrode holder 2Connect it to the output cable of the base metal if necessary Notice About stick welding In case of stick welding operatin please check ans operate in the follwoing order 1 Refer to section 9 3 STICK welding operation on page 4...

Страница 13: ... 8 m YT 30TSW1TAH 8 m TIG welding torch Non fingertip joint Torch connection adapter Product number Replacement cable clamp Control cable assembly YT 08TS1 YT 088T YT 12TS1 YT 12TP1 YT 128T P YT 15TS1 YT 15TP1 YT 158T P YX 151AJ1J1 TJM00046 TWX00018 YT 20TS1 YT 208T YX 201AJ1 TJM00038 TWX00018 YT 20TSW1 YT 30TSW1 YT 30TPW1 YT 208TW YT 208TPW YT 308TW YT 308TPW YX 301A J1 TJM00041 TWX00018 Replacem...

Страница 14: ...0 YN 10C2S YN 10L2S 1 0 150 YN 16C2S YN 16L2S 1 6 150 YN 20C2S YN 20L2S 2 0 150 YN 24C2S YN 24L2S 2 4 150 YN 30L2S 3 0 150 YN 32C2S YN 32L2S 3 2 150 YN 40C2S YN 40L2S 4 0 150 YN 48C2S YN 48L2S 4 8 150 Long nozzle Nozzle for gas lens GL Note Torch cap S Arc spot nozzle Good for welding of deep section Good for welding of those that require high shielding perfor mance such as titanium and spe cial a...

Страница 15: ...mp attached to the welding machine side of the special torch Remove the rubber cover of the replacement cable clamp and the screw appears Remove that screw and the replacement cable clamp comes off Note The torch connection side of the extension cable employs a screw connection As the special torch with the replacement cable clamp removed also employs a screw connection it can be connected with th...

Страница 16: ...l cable assembly TWX00018 0 3 m 1 pc 8 Terminal adapter CWC00180 0 3 m 1 pc Extension cable TWU20133 1 Gas hose YX 503TKC 15 24 m 1 pc 2 Current cable YSH7 5 x 1B Orange 15 m 1 pc 3 Relay fitting 38 mm2 15 m 1 pc 4 Return water hose TJM20106 1 pc Optional items for connecting extension cables MUST items 7 Control cable assembly TWX00018 0 3 m 1 pc 8 Terminal adapter CWC00180 0 3 m 1 pc Welding YC ...

Страница 17: ...on cable TUWU30134 1 Gas hose YX 503TKC 15 24 m 1 pc 2 Current cable YSH7 5 x 1B Orange 15 m 1 pc 3 Relay fitting 38 mm 2 15 m 1 pc 4 Return water hose TJM30106 1 pc 5 Supply water hose 6 x 1B Blue rubber hose 15 m 1 pc 6 Gas hose 6 x 1B Blue rubber hose 15 m 1 pc Optional items for connecting extension cables MUST items 7 Control cable assembly TWX00018 0 3 m 1 pc 8 Terminal adapter CWC00180 0 3 ...

Страница 18: ...t in the welding power source is applied 2 To have a current value displayed when adjusting each current switch the LCD display to the screen of each current item Then the current value of each item appears on the set value display Details See chapter 6 Name and function of each part and chapter 9 Operation It is also possible to make the adjustment of each current without switching the LCD displa...

Страница 19: ...ntly during the pulse welding etc Indicates an Err error mark in case of a trouble 3 4 5 6 1 10 9 8 2 7 4 Set value display Indicates the set values 1 of current A time S frequency Hz pulse width etc The unit display lamp changes according to the type of indicated set values i e A is lit for current dis play Depending on the DETAIL settings it indicates the Output voltage Indicates an Err error nu...

Страница 20: ...ding mode If the display lamp is flashing a set value can be changed even during the welding operation When there is no need to do so press the jog dial and the display lamp is turned on Then it becomes impossible to change the set value by means of the jog dial Therefore it serves the prevention of an operation error 17 16 15 14 13 12 18 11 10 9 8 7 11 PULSE The button is effective when PULSE 9 i...

Страница 21: ... plug turn clockwise until the con nector is fastened 4 GAS OUTLET Screw size 9 16 18UNF For TIG or SPOT welding Connect the joint of the gas hose from the welding torch 5 terminal for torch Fingertip joint For TIG or SPOT welding Connect the fingertip joint of the TIG torch cable After inserting the plug turn clockwise until the con nector is fastened 6 Gas inlet Screw size 9 16 18UNF Connect the...

Страница 22: ... injury and so on To prevent physical accidents like an electric shock burn injury and so on make sure to observe the followings Make sure to turn off the switches of this product and the distribution box before starting connections Do not perform any connection work with moistened hands Make sure to insulate all bare current carrying parts like joints and so on by tape etc Do not strain cables or...

Страница 23: ...d of the input power cable to the load side terminal of the switch of the distribution box 3 Provide the grounding terminal of the distribution box For reference Input power cable size 5 5 mm2 or more Name Connect to Power source side 1 Welding rod holder cable terminal for base metal 2 Base metal cable Attach the fingertip joint terminal for torch 3 Remote controller Optional unit REMOTE CONTROLL...

Страница 24: ...his product Screw size U9 16 Thread 18 WARNING This is a high pressure gas apparatus Its mishandling may cause a physical accident such as the direct hit of parts due to the high pressure gas Make sure to read the instruction manual of the gas regulator carefully before connection Note About shield gas Use the high purity welding argon gas JISK1105 99 9 or more in purity as a TIG welding shield ga...

Страница 25: ...e grommet Observe the following instructions Route the wires not to touch to any other parts or board inside the welding power source Bind the binding band holder and the grommet with the attached binding band When touching a printed circuit board observe the following item to prevent elec trostatic destruction of the printed circuit board Before starting an operation for example touch any metal p...

Страница 26: ... Terminal Terminal name Functions Note I N P U T 1 Emergency stop Remove the jumper between the terminals 1 and 2 before connection Open between those terminals and the welding power supply comes to an emergency stop To restart close those terminal and then turn on power switch again Open 15 VDC Close 3mA DC approx 2 Water circuit Remove the jumper between the terminals 2 and 3 before connection O...

Страница 27: ...ith the current detection Contact capacity Resistive load DC 24V 1A AC 125V 0 3A Never operate over the capacity 5 6 Pulse detect Output current Initial current welding current including pulse current and base current and cra ter current flows between those terminals The terminals are connected with normally open contact at the photo MOS relay on the PC board The terminals are closed in synchroniz...

Страница 28: ...nal of the jig terminal block See section Connecting with jigs Connect the Over 200 V harness of the optional unit YX CB009 to MCB 6P side of the 200 V harness and other side connector 3P goes to the 200 V connector See figure on the right To enable this function set the DIP switch DSW 2 10 to the ON side Note Keep the DSW2 10 in the OFF position if this function is not used Note Keep the signal l...

Страница 29: ...o protect you and other people from arc light flying spat ters slag and arc noises generated by welding use pro tective equipment Wear leather 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 fil ter plate appropriate to the applied welding current 1 Turn on the switch of the distribution box ...

Страница 30: ... box 7 2 3 Precautions for use of water cooling torch in winter season In case the special cooling water Pana coolant K is not used do not forget to take freeze proofing measures after every welding operation to prevent possible breakage of the water coolant or welding torch caused by freezing For example Take the cooling water out of the water circulat ing path including the flow rate switch Impo...

Страница 31: ...his settings the gas after flow operates as usual to cool down the work and the electrode after stopping the output To reset release the short circuit between the electrode and base metal If the torch switch is in the OFF position the power source recov ers automatically after gas after flow operation Disp Hold Time O 0 0 S to 10 0 S This is the time period to keep the display of an average curren...

Страница 32: ...ay Operation Remarks 1 Set FUNCTION button to DETAIL First V Disp Status is displayed on the LCD 2 Press the JOG dial until the set item you would like to change is displayed 3 Turn the JOG dial until the required set item appears Turn the JOG dial either clockwise or counter clockwise The Set value display indicates set content if that is value or on off 4 Press the JOG dial The present set conte...

Страница 33: ... you are confused during the operation turn the power off and redo the operations from item 1 again Operation Set value display LCD 1 Hold down the JOG dial and while holding it down turn on the POWRE switch Then indication changes to 2 Press the JOG dial to determine the choice When you turn the JOG dial without pressing down the screen displays the next set item In that case turn it further unti...

Страница 34: ...l 4 Press the JOG dial Note The screen on the right appears on the digital ammeter 5 Turn the JOG dial to select a program number you want to delete Stored program numbers appear in series When selecting P01 6 Press the JOG dial 7 Turn the JOG dial and have YES displayed 8 Press the JOG dial To continue to delete the memories of other pro gram numbers Go to no 4 9 On completion of the desired dele...

Страница 35: ...old down the JOG dial and while holding it down turn on the POWRE switch Then indication changes to 2 Turn the JOG dial until the screen on the right appears 3 Press the JOG dial 4 Turn the JOG dial and have YES displayed 5 Press the JOG dial 6 Turn the JOG dial and have YES displayed 7 Turn off the power to complete the operation Rescue Menu YC 300B Series 1 Set Defaults No 3 Lock Memory No 3 Loc...

Страница 36: ... OFF of pulsed welding When TIG is selected in the step 2 5 Set or check the welding condition data Note Avoid careless turning of the jog dial The current set value is modified You can press any button from the buttons corresponding to lighting indicator lamps Press the button you want to set check The indicator lamp corre sponding the button starts blinking and the name of the item is dis played...

Страница 37: ...switch operation Output current Shield gas OFF ON OFF ON Pulse Welding Initial current current current Pre flow Up slope Down slope Post flow Pulse frequency Applicable if the PULSE selection button is set to ON in TIG MODE It means the number of repeat times per second of the com bined waveforms of pulse current and welding current as shown in the following diagram as T 1Hz Pulse width Applicable...

Страница 38: ...al and select a program number to be stored Numbers starting with P01 are indicated in order Numbers already stored flash New storage Select a solidly lit no flash number When solidly lit P02 is selected Press the JOG dial then the FUNCTION button automatically returns to WELD Overwriting Select a number you want to overwrite the number flashes Note The screen on the right appears on the digital a...

Страница 39: ...repe tition of short welding and thin plate welding Turn the torch switch on and off with the Crater switch set to OFF and welding arc starts and stops in syn chronization with such switch operations There is no self hold initial current and crater current WARNING Pressing the torch switch by mistake may cause an electric shock When inspecting or replacing any torch parts make sure to turn the pow...

Страница 40: ... of self maintenance exists The crater current and the initial current are also available 1 Torch ON 2 Torch OFF 3 Torch ON 4 Torch OFF Arc ON Self hold ON Crater arc ON Arc OFF Torch switch Output current Shield gas ＯＦＦＯＮＯＦＦＯＮ Pulse current Welding current Pre flow Up slope Down slope Post flow Crater current About Self hold Self hold is reset if the arc cut occurs more than 0 5 second To stop...

Страница 41: ...ater welding and it is repeated from then on Raise the torch to stop the welding 1 Torch ON 2 Torch OFF 3 Torch ON To stop welding raise the torch until arc is cut Arc ON Self hold ON Crater arc ON Torch switch Output current Shield gas ＯＮＯＦＦＯＮＯＮＯＦＦＡ Pulse current Welding current Initial current Pre flow Up slope Down slope Up slope Crater current Repeating section A 1 2 3 2 3 ...

Страница 42: ... may be difficult to perform the welding depending on the type of electrodes ex low hydrogen type electrode etc and or welding methods Therefore it is recommended to perform a weld ing test in advance Torch switch Output current Shield gas ＯＮＯＦＦ Pre flow Post flow No self hold Arc spot time CAUTION To prevent an electric shock touching any live parts of the electrode holder may cause a fatal elec...

Страница 43: ...a daily check However any external check made without touching current carrying parts or their surrounding area is excluded Check item Check point Remarks Front Control or display devices Breakage or loose attachment Operation or indication error If there is any defect an inside check additional fastening parts replacement etc are required Fingertip joint Connector and gas outlet joint Breakage or...

Страница 44: ... hose band is used if there is any loose attachment If there is any defect additional fastening hose replacement etc are required Hose band if used Wear or damage If any heavy items not placed on the cable WARNING Touching any current carrying parts may cause a fatal electric shock or burn injury To secure physical safety only educated and or skilled persons who well understand the welding power s...

Страница 45: ...eat generation Loose connections Additional fastening Cables and hoses Regarding the grounding wire for this product base material etc input and output cables cables for the torch switch remote control unit etc and hoses for gases and for water supply and drainage when using the water cooling torch check those items that are not covered by the daily check See page 12 1 intensively Inspection and m...

Страница 46: ...r welding main circuit and then short circuit the output terminals with conductor cable Connecting connector Disconnect all connecting cables and signal wires for external devices from jig terminal welding torch wire feeder connector communication connector and so on Ground wire for case Disconnect all ground wires inside of the case connected to the case Main circuit Short circuit between the emi...

Страница 47: ...hout turning it on again The power switch uses a non fuse circuit breaker If over current occurs for some reasons the power is turned off automatically tripping Do not turn it on again It is ous to turn the power on again without removing the cause of such over current Notice Do not turn the power on with the top panel and or side panel of this product removed The electromagnetic force may cause t...

Страница 48: ...signal is stopped the error indication disappears automatically Check for the clogging of cooling water equipment the concentration of coolant solution the bending of supply and return hoses for the torch cable etc to secure the flow rate of cooling water E r r 19 Electrode Short The electrode and the base metal are short circuited during welding or at arc start If the torch switch is OFF then the...

Страница 49: ...S switch is placed to Purge O Gas cylinder and Gas regulator Main cock is not open Gas nearly runs short Insufficient flow rate O O O O O Excessive flow rate O O Gas hose From gas cylin der to torch Loose connections Hose is damaged O O Torch cable Torch is bent at acute angle Coating is damaged Sign of insulation deterioration O O O Torch switch is not ON O Around the torch body Insufficient fast...

Страница 50: ...Parts list OMCTT5621E18 50 12 Parts list ...

Страница 51: ...L30A480V C 17 P2 PC board ZUEP1370 1 ZUEP1370 19 Q1 Q2 IGBT YMAD125 2 CM100DY24NFF 20 R1 R2 Resistor CEX00101 2 CEX00101 21 R3 R6 Resistor MFS40A100KN 4 MFS40A100KN 22 R7C7 R8C8 Snaber CEX00084 2 CEX00084 23 SW1 Knob CHT00004 1 CHT00004 24 SW1 Encoder YCA11 1 Jog dial RE21BARE100 25 SW2 Switch SLE6A2 1 GAS CHECK SLE6A2 26 TH Thermal switch 0HD85B02 1 0HD85B02 27 SOL Gas valve CEX00092 1 CEX00092 2...

Страница 52: ...Circuit diagram OMCTT5621E18 52 13 Circuit diagram ...

Страница 53: ...Circuit diagram OMCTT5621E18 53 ...

Страница 54: ... 50 40 50 15 30 1 2 5 Fillet 45 55 45 55 45 55 20 40 1 2 5 1 5 Butt 60 100 60 80 60 70 15 30 1 6 5 Lap 60 100 80 100 80 90 15 30 1 6 5 Fillet 60 80 60 70 60 70 20 40 1 6 5 T shape 70 90 70 90 70 90 10 20 1 6 5 2 5 Butt 100 120 90 110 90 110 20 30 1 6 7 Lap 110 130 100 120 100 120 20 30 1 6 7 Fillet 100 120 90 110 90 110 25 30 1 6 7 T shape 110 130 100 120 100 120 15 25 1 6 7 3 0 Butt 120 140 110 1...

Страница 55: ...s used in general In special cases including the welding of different metal etc select material depend ing on your purposes As for the diameter of filler wire an appropriate thick ness is decided depending on the welding current in general Guideline for selecting filler wire diameter Tungsten electrode type Symbol Applicable TIG welding method Pure tungsten YWP AC TIG Tungsten with 2 Cerium trioxi...

Страница 56: ...method Crater Pulse TIG OFF OFF SPOT ON ON STICK Repeat Column with thick frame for Pulse ON NA Method Crater Pre flow time Initial current Up slope Welding current Down slope Spot time Cra ter time Post flow time Pulse cur rent Pulse frequency Pulse width DC TIG OFF ON Repeat SPOT STICK Factory setting item Default settings Set contents MEMO V Disp Status OFF OFF ON Hot Cur Level Standard Low Sta...

Страница 57: ...621E18 57 14 6 Program list Program number Material to be welded Remarks Prepared on Prepared by P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30 ...

Страница 58: ...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 Union If you wish to discard...

Страница 59: ...OMCTT5621E18 59 ...

Страница 60: ...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 OMCTT5621E18 2006 ...

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