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Operating Instructions
Inverter TIG welding power source
YC-300BP2YAF
Model No.
Fully digital controlled power source
Before operating this product, please read the instructions carefully and save this manual for future use.
First of all, please read "Safety precautions" or "Safety manual."
OMCTT5639E09
2011
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Table of Contents
Troubleshooting
Related Manuals for Panasonic YC-300BP2YAF
Summary of Contents for Panasonic YC-300BP2YAF
- Page 1 Operating Instructions Inverter TIG welding power source YC-300BP2YAF Model No. Fully digital controlled power source Before operating this product, please read the instructions carefully and save this manual for future use. First of all, please read “Safety precautions” or “Safety manual.”...
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Page 2: Introduction
Disclaimer Panasonic Smart Factory Solutions Co., Ltd. (hereinafter • Any problem arising out of, or directly or indirectly attributable to, user’s failure to strictly carry out or follow all of the conditions called “PSFS”) and its affiliates (including any subcontrac- and instructions contained in this instruction manual, or user’s... - Page 3 Cautions about electromagnetic disturbance (1) Extra precaution may be required when welding power (3) The user shall be observe to reduce emission distur- source is used in a domestic establishment. bance as below. (a) Welding equipment should be connected to mains (2) Before installing welding equipment, the user shall make an assessment of potential Electromagnetic supply according to the manufacture's recommen-...
- Page 4 About “Turkish RoHS Regulation” EEE Complies with Directive of Turkey. About “Ukrainian RoHS Regulation” English Declaration of Conformity with the requirements of Technical Regulation on the Restriction Of the use of certain Hazardous Substances in Electrical and Electronic Equipment (adopted by Order №1057 of Cabinet of Ministers of Ukraine) The Product is in conformity with the requirements of Technical Regulation on the Restriction Of the use of certain Hazardous Substances in electrical and electronic equipment (TR on RoHS).
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Page 5: Table Of Contents
5.6.1 Applications..........30 Table of Contents 5.6.2 Connection........... 30 6. Operation.......... 31 Introduction ..........2 6.1 Preparation steps ........31 6.1.1 Use of protective equipment ......31 1. About safety........6 6.1.2 Confirmation of completed connection..31 1.1 Safety precautions........6 6.1.3 Turning ON power........31 6.1.4 Adjusting gas flow rate......... -
Page 6: About Safety
About safety 1. About safety Safety symbols 1.1 Safety precautions (9) Turn off all equipment when not in use. (10) In case of AC arc welding in a confined area or above WARNINGS floor level, check related national, state and local codes and regulations for any special treatment and comply with it if any. - Page 7 About safety Against fire, explosion or blowout (3) Read the instruction manual of the gas regulator prior to using it, observe the cautions in the manual Observe the following cautions to prevent (4) Secure the gas cylinder to a dedicated gas cylinder fires explosion or blowout.
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Page 8: Rated Specifications
High frequency arc start type Communication function RS-232C, RS-422 Memory function 50ch storage and reproduction Robot interface function Enables communication with Panasonic robot controllers. Cooling system Forced air-cooling Type of insulation Class H Dimension (Width: W x Depth: D x Height: H) -
Page 9: Standard Accessories
Rated Specifications 2.1 Standard accessories Name Part number Q’ty Remarks Glass tube fuse (3A) BET3.15A Rear fuse (Fu1): Rush-resistant Gas hose CWG30101 TBV6X11, 3 m Fingertip joint MET00001 For output (base material side) cables: Plug side Hose band WHB12 For gas regulator 2.2 Duty cycle Do not use this product at any usage rate over the rated duty cycle. -
Page 10: Dimensions
Rated Specifications 2.2.1 Dimensions OMCTT5639E09... -
Page 11: Installation
Installation 3. Installation 3.1 Installation siter This product is designed for indoor use only. CAUTION Do not install it in any places subject to rain or water spray. Do not use this product in a vertical position (i.e.: with its control panel side up). Using it in the vertical position may reduce its cooling effect, and cause any CAUTION troubles like equipment burnout, etc. -
Page 12: Transportation
Installation 3.3 Transportation Do not use the handles to hang the product. • Hanging with the handles, which is unstable, may cause an accident. • When hanging this product by using a crane, etc., make sure to use the eyebolts. Do not lift the product on your own. -
Page 13: Configuration
Installation 3.4 Configuration • Customers are required to prepare the items other than • Cable for the base metal side: marked as “This product” or “Accessory”. To prevent overheat of the cable and provide with proper welding, prepare a cable which is a welding cable or •... -
Page 14: Peripheral Equipment (Optional Items)
Installation 3.5 Peripheral equipment (Optional items) 3.5.1 TIG Welding torch (1) Special torch (Fingertip joint) Air-cooling 200A torch Water-cooling 300A torch YT-20TS1TAG (4 m) YT-30TSW1TAG (4 m) YT-20TS1TAH (8 m) YT-30TSW1TAH (8 m) (2) Type-1.8 TIG welding torch You are required to purchase the torch connection adapter separately. -
Page 15: Ground Ring Assembly (Cwx00560)
Installation 3.5.2 Ground ring assembly (CWX00560) In case of an insufficient arc start, you can install this (For details, see the instruction manual supplied with the ground ring to improve it. ground ring assembly.) How to install the ground ring assembly Welding torch (Lead wire) As for its initial installation, consult with our CS... - Page 16 Installation <Example of extension cable connection> OMCTT5639E09...
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Page 17: Argon Gas Regulator (Yx-251A)
Installation 3.5.4 Argon gas regulator (YX-251A) The maximum flow rate is 25L/min. 3.5.5 Cooling water unit and cooling water (1) Cooling water unit (with built-in flow-rate switch) Note Cooling water unit (Product number: YX-09KGC1) • No flow-rate switch is incorporated in this welding power unit. •... -
Page 18: Names And Functions
Names and Functions 4. Names and Functions 4.1 Front panel 4.1.1 Data display/setting section and welding conditions selecting section For details of functions, see “Welding conditions” in this Jog dial chapter.” • This is a dial to carry out the function of a potenti- ometer (setup of current and time). -
Page 19: Welding Conditions Setting Buttons Section
Names and Functions 4.1.2 Welding conditions setting buttons section For details of the function of each button, see section When the “mode” selection is set to “welding”, the display “Welding conditions” or “Operation”. lamp of the welding-condition setting button section turns on according to the set details of the welding-condition select- ing section In other words, the display lamp for sections, to 17 18 19... -
Page 20: Switches And Rear Side
About power switch: • When the power switch is turned off automatically, do not turn it on again. (Consult CAUTION with sales distributor of Panasonic representatives.) • When activating a power generator, turn off the power switch. Front panel Rear panel “Power”... -
Page 21: Welding Methods And Output Waveform
Names and Functions 4.2 Welding methods and output waveform Note The “applicable material” section of the following table lists the general material. In the case of special metal, etc., welding results may be different from your requirement. Output waveform Welding method Main materials Features (Image) -
Page 22: Welding Conditions
Names and Functions Output waveform Welding method Main materials Features (Image) • Due to the difference in heat input between AC and DC, neatly wave-patterned bead appearance is obtained. • With DC TIG and AC TIG mixed together, good weld penetration can be achieved. •... - Page 23 Names and Functions Pulse frequency Applicable to the pulse “present” mode in AC or DC Pulse current welding. Welding current It means the number of repeat times per second of the combined waveforms of pulse current and welding current (as shown in the following diagram as (1Hz)). ...
- Page 24 Names and Functions MIX frequency Applicable to the MIX TIG welding. It means the number of repeat times per second of the waveform shown as (1Hz) in the right diagram. (1Hz) MIX frequency DC ratio Means the MIX (DC) ratio and is applicable to the MIX TIG welding.
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Page 25: Connection
Connection 5. Connection The installation shall be done by qualified installation personnel and should conform to all national Important and local codes. Touching current carrying parts may cause a fatal accident like an electric DANGER shock, burn injury and so on. To prevent physical accidents like an electric shock, burn injury and so on, make sure to observe the followings. -
Page 26: Input And Ground (Pe) Cable Connection
Connection 5.2 Input and ground (PE) cable connection The frame of this power source must be grounded to protect operat- WARNING ing technician from potentially deadly electrical shock. Never pull or apply undue force on primary cable once it has been WARNING installed. -
Page 27: Connecting Gas Regulator
Connection 5.3 Connecting gas regulator 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. DANGER Make sure to read the instruction manual of the gas regulator carefully before connection. -
Page 28: Connecting With Jig(S)
Connection 5.4 Connecting with 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 5.4.1 Applications •... -
Page 29: Functions Of Jig Terminal
Connection 5.4.4 Functions of jig terminal Terminal names Function • When the circuit is opened between these terminals, the operation of this product is sus- pended.(Such suspension results in the stoppage of the welding output, gas supply and gas WATER inspection.) •... -
Page 30: Connecting With External Device Connecting Unit
Connection 5.6 Connecting with external device connecting unit 5.6.1 Applications To switch the pages of stored welding conditions by connect- Note ing external equipment (sequencer) to the product. For preventing troubles caused by incorporation of the (For details, see manual of the external device connecting high frequency wave, see “Installation: Peripheral equip- unit.) ment”. -
Page 31: Operation
Operation 6. Operation 6.1 Preparation steps 6.1.1 Use of protective equipment To protect you and other people from gases, fumes and lack of oxygen that may DANGER be generated during the welding operation, make sure to prepare ventilation facil- ities and use protective equipment, etc. •... -
Page 32: Steps After Welding Operation
Operation 6.2 Steps after welding operation 6.2.1 Shutting off Gas Close the main valve of the gas bottle first of all, and then take the residual pressure out of the pipe through the gas checking process. 6.2.2 Shutting off power To allow the inside of this product to cool down, turn the power off at least 5 minutes after the com- Important pletion of welding operations. -
Page 33: Settings
Operation 6.3 Settings 6.3.1 Factory settings Default Set item Choice Description setting Any output voltage (values measured between output termi- ○ nals) cannot be indicated on the set-value display.\ The welding current screen and the output voltage screen appear on the LCD display alternately every time when press- ing the “welding current”... -
Page 34: How To Change Settings
Operation 6.3.2 How to change settings • Change these welding conditions as desired before use. • As for welding condition not in store, the setting of the product returns to the original factory-set welding condi- • As for any important welding conditions, store them in tions when the factory setting is restored,. -
Page 35: Memory Deletion
Operation 6.3.4 Memory deletion While this product is capable of storing up to 50 different welding conditions that you programmed, follow the follow- welding conditions (P01 to P50), if you want to delete any ing steps. Operation Set-value display LCD display Rescue Menu •... -
Page 36: Memory Lock
Operation 6.3.5 Memory lock While this product is capable of storing up to 50 welding other than the administrator to conduct the storing opera- conditions (P01 to P50), if it is not desired for anybody tion, lock the stored memory in the following manner. Operation Set-value display LCD display... -
Page 37: Storing Welding Conditions
Operation • Set (or check) the welding condition data. Indication lamp starts flashing, the name Press a button, which is desired of that item appears on the LCD display, to be set and confirmed, related and the present set value is indicated on JOG dial to an indication lamp turned on the set-value display. -
Page 38: Reproducing Welding Conditions
Operation 6.3.8 Reproducing welding conditions • Welding can be done by reproduction of any desired condition selected from the stored welding conditions. • A reproduced welding condition can be changed as desired. (Once changed, it turns to be different from the original condition any more.) •... -
Page 39: Welding Operation
Operation 6.4 Welding operation • Pressing the torch switch by mistake may cause an electric shock. • When inspecting or replacing any torch parts, make sure to turn the power DANGER switch off in advance. • The on/off operation of the torch switch enables you to <Regarding the following diagrams>... -
Page 40: Crater Repeat
Operation 6.4.3 “Crater repeat” The following shows in case of “Standard” (end welding Weld end method depends on the setting of the operation by lifting up the torch.) factory setting item “Crater End Type.” ＯＮ ＯＮ ＯＮ Torch switch ＯＦＦ... -
Page 41: Maintenance And Inspection
• The daily check is important to make the most of the per- • For replacement of parts, make sure to use our genuine formance of this product and to secure the safety of daily parts for Panasonic welding machine to keep its perfor- operations. mance and functions •... -
Page 42: Periodic Check
Maintenance and inspection Check item Check point Remarks If it is fastened securely. If there is any defect, addi- Joint In case a hose band is used, if Hoses tional fastening, hose replace- there is any loose attachment. ment, etc. are required. Overall Wear or damage. -
Page 43: Check Guideline
• In case of a regular check, perform their inspection and maintenance on the basis that the cooling fan and the electrolytic capacitor are a kind of consumables. • When replacing them, make sure to use genuine parts for Panasonic welding machine to maintain the performance and functions of the product. -
Page 44: Precautions In Performing Withstand Voltage Test And Insulation Resistance Measurement
Maintenance and inspection 7.3 Precautions in performing withstand voltage test and insulation resistance measurement Do not perform the withstand voltage test and the • Prepare jumper cables (cross section 1.25 mm approx.) with a clip to short-circuit each device. insulation resistance measurement carelessly, or failures (The figure on the following page shows the locations of may be caused as the unit is equipped with semiconductor the device to be short-circuited. -
Page 45: After The Test Completes
Maintenance and inspection 7.3.2 After the test completes • Reconnect the ground cables and connectors on the PC If power is ON without removing board as they were. WARNING the jumper bar for test, devices • Return the dust cover, top panel, right panel, and left may be damaged or burnt out. -
Page 46: Troubleshooting
It may be failure of this product. E r r Sec. OverCurrent Please contact sales distributor or Panasonic representative. The temperature inside this product has been increased. • Do not turn the power off until the temperature inside this product is reduced. - Page 47 It may be failure of this product. E r r Curr.DetectError Please contact sales distributor or Panasonic representative. A “WaterCircuitErr” signal was input from external equipment, such as cooling-water equipment, etc. connected to the jig terminal. • When the input of the “WaterCircuitErr” signal is stopped, the error indication disappears automatically.
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Page 48: Troubleshooting Table
Troubleshooting 8.2 Troubleshooting table * In the case of welding errors without any error (Err) indication, refer to the following table to search for their causes. Front panel display is not turned on Error Neither high frequency wave nor arc is gener- condition ated. -
Page 49: Parts List
Parts list 9. Parts list OMCTT5639E09... - Page 50 Parts list Mark Parts number Description Q’ty Note Internal code CTU00039 Main transformer CTU00039 UTU19750 Control transformer UTU19751 CLU00031 CLU00031 CLU00041 DC reactor CLU00041 CLU00042 Coupling coil CLU00042 UTU20880 Control transformer UTU20880 YCAD39 IGBT CM100DUS12 Q1-4 Q5-6 YZA/EEA003 IGBT CM300DU12F YCA16 Diode DF75LB160...
- Page 51 Parts list Mark Parts number Description Q’ty Note Internal code YCA4 Output terminal D1XBE50 CN70AJ2P ReceptacIe Torch switch CN70AJ2P YCA5 Receptacle Remo-con NR2012RF YCAD44 DC power supply LDA50F24-1 YCAD45 DC power supply LDA60F2-1 ZUEP1398 PC Board Main control ZUEP1398 ZUEP1395 PC Board Operation ZUEP1395...
- Page 52 OMCTT5639E09...
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Page 53: Circuit Diagram
Circuit diagram 10. Circuit diagram OMCTT5639E09... -
Page 54: Enlarged (Left Half)
Circuit diagram 10.1 Enlarged (left half) NF8 MCB OMCTT5639E09... -
Page 55: Enlarged (Right Half)
Circuit diagram 10.2 Enlarged (right half) OMCTT5639E09... -
Page 56: Appendix
Appendix 11. Appendix 11.1 Welding conditions table 11.1.1 TIG welding conditions table (Reference) The list of TIG welding conditions shown in this In actual welding operations, work out an appropri- chapter is a reference value as a guideline for ate condition in consideration of the shape of sub- standard welding conditions. - Page 57 Appendix TIG welding conditions table: Aluminum (AC, MIX) Thickness of Welding FIller wire Gas flow Welding current (A) base metal speed size (Dia.) rate Joint Downward Vertical Upward cm/min L/min Butt 20 - 40 10 - 20 10 - 20 20 - 40 - 1.2 20 - 50...
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Page 58: Tungsten Welding Rod
Appendix 11.1.2 Tungsten welding rod As for the selection of tungsten welding rod diame- ters, refer to the following table. Welding current (A) Welding rod size Electrode minus (-) Electrode plus (Dia.) (DCEN) (+)(DCEP) YWTh-2 (mm ) YWTh-2 YWTh-2 5 - 15 5 - 20 5 - 20... -
Page 59: Welding Conditions Memorandum
Appendix 11.2 Welding conditions memorandum In case the monitoring software is not used, it is recom- Register your conditions in the program number mended to keep a note of your selected welding condi- list on the next page. tions* for your convenience. (*: It is preferable to store such ... -
Page 60: Program List
Appendix 11.3 Program list Program Prepared Prepared Material to be welded Remarks number OMCTT5639E09... -
Page 61: Information On Disposal
Information on Disposal 12.Information on Disposal on on Disposal for Users of Waste Electrical & Electronic Equipment Informati (private households) This symbol on the products and/or accompanying documents means that used electrical and electronic products should not be mixed with general household waste. Please dispose of this item only in designated national waste electronic collection schemes, and not in the ordinary dust bin. - Page 62 OMCTT5639E09...
- Page 63 OMCTT5639E09...
- Page 64 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 2007 OMCTT5639E09...