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Panasonic YD-350GL4 Operating Instructions Manual

Digital igbt controlled mig / mag arc welding power source
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MIG/MAG Arc Welding Power Source
Thank you for your purchase of Panasonic welding power source.
Before operating this product, please read the instructions carefully and save this manual for future use.
ＹＤ－３５０ＧＬ４ＨＧＮ、ＹＤ－５００ＧＬ４ＨＧＮ
SPEC. No:
Digital IGBT Controlled

Operating Instructions

ＹＤ－３５０ＧＬ４
Model No.
ＹＤ－５００ＧＬ４
TSM50447-04

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Summary of Contents for Panasonic YD-350GL4

  • Page 1: Operating Instructions

    MIG/MAG Arc Welding Power Source Operating Instructions ＹＤ－３５０ＧＬ４ Model No. ＹＤ－５００ＧＬ４ Thank you for your purchase of Panasonic welding power source. Before operating this product, please read the instructions carefully and save this manual for future use. ＹＤ－３５０ＧＬ４ＨＧＮ、ＹＤ－５００ＧＬ４ＨＧＮ SPEC. No: TSM50447-04...
  • Page 2 ■ Caution for your safety Read and understand this manual before installing, This equipment and instructions are for use only by operating or servicing this product. persons trained and experienced in the safety operation of welding equipment. Do not allow The wiring and grounding should be done by untrained persons to install, operate, or maintain this educated and/or skilled person.
  • Page 3 ■ Features ● LED digital display and soft-touch buttons for easy and convenient operation ● The wire feeder equipped with encoder provides stable and high-precision wire feeding control. ● The welding parameters can be recorded & called. ● The enhanced mobility, robust structure and dust tightness ■...

  • Page 4: Table Of Contents

    Table of Contents 1. About safety ........1 8. Settings ...........21 1.1 Safety precautions ........1 8.1 FUNCTION settings ......21 1.2 Safety instructions that must be observe 1 8.1.1 “F. ADJ” ..........21 8.1.2 “CALL” and “RECORD” ......25 8.2 CHANGE settings .......26 2. Rated Specifications ......4 ８．３　Ｔｈｅ　ｗｅｌｄｉｎｇ　ｍａｃｈｉｎｅ　ｆａｃｔｏｒｙ　ｄｅｆａｕｌｔｓ...

  • Page 5: About Safety

    About safety 1. About safety 1.1 Safety precautions Read this manual carefully to use the machine properly. Caution, and indicates these levels by using symbols. The cautions mentioned in this manual and on the Those Dangers, Warnings, Cautions as well as product are important to operate the machine properly Mandatory Actions and Prohibitions mentioned must be and prevent hazardous situation and damage to you and followed without fail.
  • Page 6 About safety Do not use undersized, worn, damaged or bare Do not bring the hot base metal near combustible （ ） （ ） wired cables. materials immediately after welding. Connect cables completely and insulate connection When welding a ceiling, floor or wall, remove all （...
  • Page 7 About safety of the welding torch - wire extends out from the end When the gas cylinder is not used, be sure to install （ ） of the welding torch and may stick into the eye, face a protective cap. or body.

  • Page 8: Rated Specifications

    Rated Specifications ⒉ Rated Specifications 2.1.1 Rated specifications for YD-350GL4HGN/YD-500GL4HGN Contents Item Unit YD-350GL4HGN YD-500GL4HGN Control method digital IGBT control Rated input· 380 VAC (Allowable fluctuation range:304 to 437V) 380 VAC (Allowable fluctuation range:304V to 437V) Number of phases Input power frequency 50/60 Rated input capacity kVA/kW...

  • Page 9: Duty Cycle

    Rated duty cycle: means the rate of use when loading the rated output current intermittently at the rated input voltage of the rated frequency. Regarding the engine-driven welding power unit, however, it means when driving it at the rated number of revolution. 2.1.3 Dimensions for YD-350GL4 机型 YD-350GL4HG...

  • Page 10: Rated Specifications For 500Gl4

    Rated Specifications 2.2.2 Duty cycle for YD-500GL4 The rated duty cycle for this product is 60%. ● “The duty cycle is 60% at the rated output” means that for 60 percent of the ten minute period (6 minutes), the Duty cycle (%) 100% (387A or less) power source can maintain operation with an output of 500A without overheating.

  • Page 11: Installation

    Installation 3. Installation 3.1 Transportation When hanging this product for transportation, hang it at two eyebolts. Do not lift the product on your own. ● As this product is heavy, it is dangerous to lift it on your own. Involve plural number of persons with its lifting.

  • Page 12: Configuration

    Configuration 4. Configuration 4.1 what’s needed Welding power source: YD-350GM3 (this product) ● item remarks Equipment available as peripher (separate sales) ● base metal 35 mm 70 mm item remarks ⑤ welding higher higher cable welding grounding 6 mm 10 mm ① power YD-350GL4HGN YD-500GL4HGN...

  • Page 13: Connecting Cable

    Configuration 4.2 Connecting cable CAUTION Caution against getting the cable wet. Power cable Avoid the connecting cable to get wet. Connecting cable If there is a chance of getting the cable exposed to rain or water splay, make sure to protect the connection with waterproof cover. Water seeping into the machine may degrade the insulation between ter- minals, which may cause an error or damage this product or wire feeder.

  • Page 14: Names And Functions

    About power switch: When the power switch is turned off automatically, do not turn it on again. ● CAUTION (Consult with sales distributor of Panasonic representatives.) When activating a power generator, turn off the power switch. ● Power ● The connection and disconnection operation of the...
  • Page 15 Names and functions ⑤ ④ ⑧ ⑥ ⑦ ④ power source input terminal (It is attached with the protective cover ) ●After connecting the power source input cables, please be sure to well install power source input protective cover. ⑤ ⑤...

  • Page 16: Front Panel

    Names and functions 5.2 Front panel ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ name description ● When abnormal rise in important components temperature occurs, temperature temperature abnomal alarm is sent, this lamp blinks and the welding ○...
  • Page 17 Names and functions name description ● When Mode selection key ○ is set to “ Weld ”, (refer to description in ○ )・ when key ○ selects different options, please adjust corrosponding set value according different items. ・During welding, “ Welding ” current can be adjusted. However “ initial ” and “...
  • Page 18 Names and functions name description ● When Mode selection key ○ is set to“ Weld ”, (please refer to the description in ○ 6 ) ・ When key ○ 6 selects different options, please adjust corrosponding set value according different items. ・...
  • Page 19 Names and functions name description ● select welding wire diameter to be used ○ wire diameter ・OP1 reserved for special design. ● welding method select. please prepare gas according to the requirement listed below: ・CO2: CO2 gas 100% ○ ・MAG: Ar gas 80%＋CO2 gas 20% ・MIG: Ar gas 98%＋O2 gas 2% or Ar gas 97.5%＋CO2 gas 2.5% ・OP1, OP2, OP3 and OP4 are reserved for special design.

  • Page 20: Connection

    Connection 6. Connection The installation shall be done by qualified installation personnel and should conform to all national and ● local codes. Important Type and capacity of protection devices, such as breaker and fuse, to be applied should conform to all ●...

  • Page 21: Connecting Torch Cable

    Connection 6.1.2 Connecting torch cable Connect torch cable from the wire feeder to the torch ter- minal (+) with the attached M10 bolt. Torch After connection, insulate the cable connections with terminal (+) insulation tape. Connect torch cable 6.1.3 Connecting feeder cable Put in the plug of the feeder cable from the wire feeder to the feeder connector.

  • Page 22: Connecting Grounding Wire

    Connection ６．１４ Connecting grounding wire Water supply pipes, building iron frames, etc. do not serve as sufficient ground. CAUTION Do not connect any grounding wire to them. Ground terminal M8 bolt 10 mm or more. Grounding wire Customer preparation Ground * Grounding work should be performed by qualified elec- tricians.

  • Page 23: Connecting Jig(S)

    Connection 6.2 Connecting jig(s) When touching a printed circuit board, observe the following item to prevent electrostatic destruction of the printed circuit board. Before starting an operation, for example, touch any metal part of the case with your hand to discharge static electricity. There are two types of jig terminals (Jig terminals 1 and 2) Jig terminal 1 （...

  • Page 24: Preparation And Termination Processings

    Preparation and termination processings 7. Preparation and termination processings 7.1 Preparation 7.1.1 Use of protective equipment To protect you and other people from gases, fumes and lack of oxygen that may WARNING be generated during the welding operation, make sure to prepare ventilation facilities and use protective equipment, etc.

  • Page 25: Settings

    Settings 8. Settings 8.1 FUNCTION settings 8.1.1 “F. ADJ” The following table shows the pages and parameters for fine adjustment/settings using the “F. ADJ”. (1)Use the Mode selection key ○ to select F. Adj. (During welding, it can NOT be selected.) It shows P00 in ○ and 00 in ○...
  • Page 26 Settings Menu contents Set range Increment Default Note Fine adjustment of output voltage during burn-back time. (The setting reflects on the FTT Voltage -50～50 wire burning at arc end.) Increase the set value for stronger wire burning. 【Pulse-OFF】The time of the main welding voltage to the back burning voltage, BURNBACK -50～50...
  • Page 27 Settings ※4 P26（Robot connection mode）: When P26 is set to [1], it indicates that it is compatible with other social robots (only analog interfaces can be used with other robots). (Refer to Section 10.2 for details). The spare output port is used as the sticky wire detection output port.
  • Page 28 Settings 【INIT·CRATER】 Menu contents Set range Increment Default Note CRATER 1: enabled, 0: disabled. 0 or 1 （ REPEAT Chapter 8） CRATER The setting of the value of the time of REPEAT 0 s～5 s closing arc repeating. TIME NOT 0: The arc current is [Welding current] * [Setting value] %;...

  • Page 29: Call" And "Record

    Settings 8.1.2 “CALL” and “RECORD” Reminder ●“Call” is a function to use stored welding conditions and “Record” is to store the well-tuned welding conditions. Record/Call operation is applicable to the set values of current ・ voltage, spot welding time, arc characteristics, penetration control, welding control, pulse ON/OFF, material, wire diameter, gas and F.

  • Page 30: Change Settings

    Settings settings ＣＨＡＮＧＥ 8.2  Four types of welding operation are available by Note ● setting “CHANGE button on the front panel; “NO For detail operation procedures of each welding CRATER”, “CRATER”, “INI.&CRATER” and “ARC operation, please refer to section “Operation”. SPOT”.

  • Page 31: Welding Wire Inching

    0.9 mm Use of a wire in small diameter may cause unstable wire feeding. In case of using such wires, please feed the wire at low speed or contact Panasonic representatives. Press the “INCHING” (8) button on the operation panel to feed the wire manually.

  • Page 32: Operation

    Operation 9. Operation Depending on the CHANGE button settings and the use of “Crater repeat”, torch operation varies as follows. Note After turning on the torch switch, if the voltage detect is not executed, the welder goes in an error state (Err6: Arc start error) and turns off the output automatically.

  • Page 33: Crater

    Operation 9.3 “CRATER” Operation: Turn the torch switch on and off twice. Torch: ON Torch: OFF Torch: ON Torch: OFF ① ① ① ① ② ② ② ② ③ ③ ③ ③ ④ ④ ④ ④ → → → Arc ON Arc continues Change arc type Arc OFF...

  • Page 34: Ini. &Crater

    Operation 9.4 “INI. &CRATER” Operation: Turn the torch switch on and off twice. OFF to switch to main welding. Then turn it ON again to (Turn the torch switch ON to start initial welding and turn it start crater operation.) Torch: ON Torch: OFF Torch: ON Torch: OFF...

  • Page 35: Crater Repeat" Operation

    Operation 9.5 “Crater repeat” operation To repeat crater operation turn ON the torch switch within Note a preset time (Trep)* after turning off the previous crater If the torch switch is not turned on within the preset time, operation. (In this manner, it is possible to repeat the cra- the function is cancelled.

  • Page 36: Arc Spot

    Operation 9.6 “ARC SPOT” Press (turn on) and hold down the torch switch until the Note welding arc is turned off automatically. If the torch switch is released while generating the welding arc (before Tspt ends), the welding arc is turned off immediately.

  • Page 37: Maintenance And Inspection

    ● ● make the most of the performance of this product and genuine parts for Panasonic welding machine to keep to secure the safety of daily operations. its performance and functions Check the items indicated in the following table, and ●...

  • Page 38: Other Devices

    Maintenance and inspection 10.1.3 Other devices Check item Check point Remarks Welding torch, Wire feeder, Follow the operating instructions of the individual devices. Remote controller, Gas regulator If joint is fastened securely. If there is any defect, additional In case a hose band is used,if there is any loose attachment. Gas hose fastening, hose replacement, etc.

  • Page 39: Periodic Check

    Maintenance and inspection 10.2 Periodic check • To secure physical safety, make sure that a qualified person or a person who is familiar with the welding machine takes care of a regular check. WARNING • As for the inside check, make sure to conduct it at least 5 minutes after turning the power off in consideration of electric discharge from a capacitor.

  • Page 40: Precautions For Withstand Voltage Test And Insulation Resistance Measurement

    Panasonic representatives, or educated and/ Prepare jumper cables (cross section 1.25 mm2 ● or skilled persons who well undersand and/or who are approx.) with a clip to short-circuit each device.

  • Page 41: Troubleshooting

    Troubleshooting 11. Troubleshooting Touching the current-carrying parts may cause a fatal electric shock or burn injury. WARNING To prevent a physical accident, such as an electric shock, burn injury, etc., make sure to observe the followings. To ensure safety, troubleshooting work shall be done by qualified personnel. ●...
  • Page 42 Troubleshooting Error type Group Probable causes and remedy The input voltage exceeds allowable range (higher than primary AC 437V). ● After input voltage returns within the allowable range, over-voltage then turn power switch back ON again. The input voltage is lower than allowable range (lower than AC 304V) or input power source phase failure happens.

  • Page 43: Troubleshooting Table

    Troubleshooting １１．２ Troubleshooting table * In the case of welding errors without any error (Err) indication, refer to the following table to search for their causes.. Blowholes Error ● condition Welded tip ● Wire runs into the base metal ● Bead turns black.

  • Page 44: Parts List

    Parts list 12. Parts list 12.1 Parts list for 350GL4 The digital S/N is in accordance with the same on parts configuration diagram. Front view Rear view ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Top view ○...
  • Page 45 Parts list Right view ○ ○ ○ ○ ○ ○ ○ ○ ○ Left view ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 46 Parts list •YD-350GL 4 The No. column and digital S/N are in accordance with the same on parts configuration diagram. Quant Symbol Part Name Part Number Remarks Main Transformer TSMTU211 FCH Unit TSMLU223 Inductor TSMLU183 Ring Inductor TSMLU184 Q1～Q4 IGBT 2MBI100TA065 ～...
  • Page 47 Parts list •YD-350GL4 Quantit Symbol Part Name Part Number Remarks TSM20368-01 Input Cord Bracket 1 each TSM20369-01 Rubber Cover SG30T Grounding Bolt Knob TSMH0062 Power Source Switch AR22PR-230B Output Protective Cover TSMK6122-01 16 Cored Socket WS28K16Z-1.6 Output Terminal TSM15748 Control Transformer TSMU0949-口口...
  • Page 48 Parts list 12.2 Parts list for 500GL4 The digital S/N is in accordance with the same on the parts list. Rear view Front view ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Top view ○...
  • Page 49 Parts list Right view ○ ○ ○ ○ ○ ○ ○ ○ ○ Left view ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
  • Page 50 Parts list •YD-500GL4 The No. column digital S/N is in accordance with the same on parts configuration diagram. Symbol Part Name Part Number Quant Remarks Main Transformer TSMTU213 FCH Unit TSMLU223 Inductor TSMLU187 Ring Inductor TSMLU188 Q1～Q4 IGBT 2MBI100TA065 R302～R305 Cement Resistor RX274H40W5R0JW Rectifier Bridge...
  • Page 51 Parts list •YD-500GL4 Symbol Part Name Part Number Quan Remarks tity TSM20368-01 1 each Input Cord Bracket TSM20369-01 Rubber Cover SG30T Grounding Bolt Knob TSMH0062 Power Source Switch AR22PR-230B Output Protective Cover TSMK6122-01 16 Cored Socket WS28K16Z-1.6 Output Terminal TSM15748 Control Transformer TSMU0949-口口...

  • Page 52: Circuit Diagram

    Circuit diagram 13. Circuit diagram 13.1 Circuit diagram for 350GL 4...

  • Page 53: Circuit Diagram For 500Gl4

    Circuit diagram 13.1 Circuit diagram for 500GL 4...

  • Page 54: Appendix

    Appendix 14. Appendix Followings are rough indications of standard welding it is necessary to set values in consideration of shape of conditions as reference data. In actual welding operation, the workpiece, welding position and so on. welding conditions table: Solid wire (Reference) 14.1 CO Wire Tip-to-work...
  • Page 55 Appendix Wire Tip-to-work Fillet Welding Thickness Position length diameter Current Voltage Speed distance Gas flow (Horizontal position) (mm) (mm) (cm/min) (mm) (L/min) （ ） ① ② 2.5-3 0.8, 0.9 70-80 17-18 50-60 10-15 ① (At low-speed) 3-3.5 0.9, 1.0 85-90 19-19 50-60 10-15...

  • Page 56: Mag Welding Conditions Table: Solid Wire (Reference)

    Appendix welding conditions table: Solid wire (Reference) 14.2  * MAG gas: 80% argon and 20% CO Wire Tip-to-work Butt Joint Welding Thickness Route gap G diameter Current Voltage Speed distance Gas flow (Square groove joint) (mm) (cm/min) (mm) (L/min) （ ）...

  • Page 57: Welding Conditions Memorandum

    Appendix 14.4 Welding conditions memorandum It is recommended to keep a note of the user-created Those custom welding conditions in this unit by allocating welding conditions for your convenience. a channel number to each of them. * Put the data on the below “Channel list” once stored. <Make a copy of the following table for each welding condition.>...
  • Page 58 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. Panasonic Welding Systems (Tangshan) Co., Ltd. Add：No.9 Qingnan Road, New & Hi-Tech Development Zone, Tangshan,Hebei, China Post Code：063020...

This manual is also suitable for:

Yd-500gl4

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