Table of Contents
Advertisement
Thyristor Controlled 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. First of all, please read "Safety precautions" or "Safety
manual".
● SPEC. No.：YD-500KR2HD0、YD-500KR2HU0
Panasonic Welding Systems (Tangshan) Co., Ltd.
Operating Instructions
Model No.
YD-500KR
TSM50262-02
Advertisement
Table of Contents
Related Manuals for Panasonic YD-500KR
Summary of Contents for Panasonic YD-500KR
- Page 1 YD-500KR Model No. ● 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. First of all, please read “Safety precautions” or “Safety manual”.
- Page 2 Features Non-remote control cable design Convincing high 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 Glass tube fuse (3 A) 61NR030H...
-
Page 3: Table Of Contents
C0NTENTS SAFETY AND IMPORTANT ITEMS ..........................2 1.Safety ................................. 2 2.Important Safety Items ......................... 3 INSTALLATION PLACE AND POWER SOURCE FACILITY ..................7 OVERALL CONNECTION DIAGRAM OF EQUIPMENT ....................9 CONNECTION ................................10 Welding Source Switch Box ........................10 Welding Power Source and Output Side ....................11 Welding Power Source and Wire Feeder .................... -
Page 4: Safety And Important Items
It is also important to ensure that equipment functions correctly at all times. Panasonic robots are designed and manufactured on the premise that contents of this manual are conformed to by users. Personnel who use any other manuals must read and understand the contents of this manual first. -
Page 5: Important Safety Items
2.Important Safety Items The following instructions must be followed carefully in case of working near the robot performing arc welding operation. WARNINGS Welding power source Observe the following instructions to prevent the hazard. This welding power source is designed and manufactured giving due consideration to safety of the product, however, it is very important to comply with all instructions, safety warnings, cautions and notes mentioned in this operating instruction. - Page 6 Oxygen deficit, fume and gas generated during welding can be hazardous. To prevent gas poisoning and suffocation by the gas generated during welding, use a local exhauster specified by the applicable law, or wear protective breathing gear. To prevent dust injury or poisoning by the fume generated during welding, use a local exhauster specified by the applicable law, or wear protective breathing gear.
- Page 7 leg cover and leather apron, and also wear long-sleeve shirts. Be sure to wear noise-proof protective equipment if the noise level is high. Gas cylinder and gas flow regulator Overturn of gas cylinder and blowout of gas flow regulator can cause injury.
- Page 8 When spatters or iron particles get into the welding power source, turn off the power switches of the welding power source and power distribution box, and then blow out. .Notice: In order to get better performance and provide proper maintenance, please follow the below instructions: 1 If welding machine is placed on a slope, a countermeasure should be taken to keep it from falling on one side.
-
Page 9: Installation Place And Power Source Facility
INSTALLATION PLACE AND POWER SOURCE FACILITY Avoid the direct sunshine and rain, and install in an indoor Do not install in a place where a metallic foreign place with less humidity and dust. substance may enter inside the welding source. (Indoor ambient temperature -10 to 40℃) Install the welding source 20cm or more away from the wall: Install in a place where welding arc is not exposed to the... - Page 10 Caution For safe use and operation, observe the following. Otherwise, the parts may he broken, arc may become unstable, or devices may be burnt out. Fluctuation of the supply voltage An allowable range is a rated input voltage±10%. When using the engine generator: use the generator which has a capacity twice larger than the rated input of the welding source and is provided with compensating winding.
-
Page 11: Overall Connection Diagram Of Equipment
OVERALL CONNECTION DIAGRAM OF EQUIPMENT The following figure shows a connection diagram for our standard component units. The crosshatched units 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) Gas Regulator... -
Page 12: Connection
CONNECTION Welding Source Switch Box Safety Warning Be sure to observe the following in order to avoid a burn or an accident resulting in injury or death. Prior to connection work, be sure to turn off the switch of the switch box and make sure or safety. -
Page 13: Welding Power Source And Output Side
CONNECTION (CONTINUED) Welding Power Source and Output Side ①Turn off the power switch. ③Open upward the terminal cover located at the lower part of the operation.(after completing connections, connect the wire feed control cable to the plug socket shown on the next page and Terminal cover put back the terminal cover) ④Using an accessory... -
Page 14: Welding Power Source And Wire Feeder
CONNECTION (CONTINUED) Welding Power Source and Wire Feeder Caution Be sure to use this power source in combined with a specified feeder. Welding is not allowed with a non-specified power source or when combined with a non-specified wire feeder. Erroneous use may damage the equipment. ①... -
Page 15: Connecting The Gas Regulator
CONNECTION (CONTINUED) Connecting the Gas Regulator Warning for Safety This is a high-pressure gas device. Erroneous handling could endanger your safety such as being directly struck by a gas bomb due to a high-pressure gas. Prior to connecting it, be sure to read its instruction manual. -
Page 16: Component Unit And Their Functions
COMPONENT UNIT AND THEIR FUNCTIONS Welding Power Source(Operation Panel) Ammeter Wire Diameter Selector Switch Select a desired wire diameter according to Indicates a welding current your need. value. Note) The figure shows the switch for the Refer to n0te) at the lower YD-200KR2 and YD-350KR2. - Page 17 FEEL SAFE TO USE IT. Welding power source Crater Voltage Control Crater Current Control When “CRATER ON” is selected with the crater selector When “CRATER ON” is selected with switch, you can control a crater welding voltage. Note) the crater selector switch, you can When SIMPLE UNIFIED is selected (refer to pages 30 and control a crater welding current 49), this serves as a crater voltage fine control.
-
Page 18: Remote Controller
FEEL SAFE TO USE IT. REMOTE CONTROLLER The remote controller is fixed to the wire feeder. Scale Plate Pressing this switch feeds the welding wire. Both sides of the plate is used properly, Although a feed rate can he adjusted with the depending type setting;... -
Page 19: Checks And Prefarations Prior To Operation
CHECKS AND PREFARATIONS PRIOR TO OPERATION Wearing the Safety Protective Gear Safety Protective Gear Wear leather gloves and safety shoes, and protect the eyes and exposed parts of your body. Prepare a protective welding mask with light-shielding filter plate. ... -
Page 20: Adjusting The Gas Flow Rate
CHECKS AND PREFARATIONS PRIOR TO OPERATION Adjusting the Gas Flow Rate ③Set the GAS SUPPLY switch to CHECK. ④Set the GAS SUPPLY switch to WELD. Turn on the switch Switch Box the switch box. Welding Power Source ②Turn on the POWER switch ④Open the main valve of the gas bomb. -
Page 21: Attaching The Welding Wire
CHECKS AND PREFARATIONS PRIOR TO OPERATION Attaching the welding wire ⑩Put back a pressure arm and pressure nut in that order. Attach a feed roller in direction which allows you to see the same numeral as the wire diameter used. -
Page 22: Feeding The Wire By Inching Operation
CHECKS AND PREFARATIONS PRIOR TO OPERATION Feeding the Wire by Inching Operation Hold Down the inching switch to feed the wire and release it when the wire comes out of the tip of the welding torch about 15 to 20 mm. Caution Feed a fine-diameter wire (0.9) slowly because it buckles easily. -
Page 23: Welding By Manual Operation
WELDING BY MANUAL OPERATION 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 start/stop operation. -
Page 24: Welding With Crater Control Disabled (Torch Switch Synchronous Operation)
WELDING BY MANUAL OFERATION Welding with crater control disabled (torch switch synchronous operation) This welding is mainly used for tack welding,, repeated short welding or thin-plate welding. 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. -
Page 25: Duty Cycle
DUTY CYCLE 60%(387 A or less) Rating YD-500KR (Service Range) 60 100 Welding Current (A) A rated duty cycle 50% means to use the rated welding current for 5 minutes out of 10 minutes and suspend operation for remaining 5 minutes. -
Page 26: Extended Functions
EXTENDED FUNCTIONS The extended functions refer to the altered and expended forms or various basic functions and performances set and specified upon shipment, including the basic welding control sequence described so far. Connecting the Extension Cable (Extension Cable is Optional) If an extension cable is connected between the plus(+)-side output terminal of the welding power unit and the output cable of the wire feeder, the scope of welding work can be expanded. -
Page 27: Switch And Controls On The Printed Circuit Board
EXTENDED FUNCTIONS Switch and Controls on the Printed Circuit Board Tips When the front panel is removed, you can find various switches (connectors) and controls 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. -
Page 28: Setting The Selector Switch On The Printed Circuit Board
EXTENDED FUNCTIONS Layout of Switches and Controls on Printed Circuit Board Changeover Caution: To change over the setting of the SW11,and from the SW8 and vice SW6 to versa.change an inserted position of a white connector. Setting the Selector Switch on the Printed Circuit Board. ... - Page 29 EXTENDED FUNCTIONS Self-hold Crater Operation with Initial Condition Function(SW6 Selected) This is the same as “general self-hold crater operation” described in [BASICS] in that it is a welding control sequence which assumes twice on/off operation of the torch switch to be one cycle. What differs from “general self-hold crater operation”...
- Page 30 EXTENDED FUNCTIONS APPLICATIONS Selector Switch 10 (SIMPLE UNIFIED/INDIVIDUAL) --- Set to INDIVIDUAL upon shipment INDIVIDUAL --- This mode sets both welding current and voltage to INDIVIDUAL. SIMPLE UNIFIED --- When a welding current is selected with the output regulator on the remote controller, the SIMPLE UNIFIED mode takes place ,where an almost corresponding welding voltage is automatically set.
-
Page 31: Adjusting The Controls On The Printed Circuit Board
EXTENDED FUNCTIONS Adjusting the Controls on the Printed Circuit Board The following control functions are incorporated In this machine in order to improve weld ability. They will work regardless of the settlings/operations of various switches on the welding power unit operation panel. The incorporated control functions can he adjusted with the controls on the printed circuit board. -
Page 32: Daily Inspection
(consumable) parts of the welding torch and wire feeder, and clean or replace 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. -
Page 33: Cables
DAILY INSPECTION Cables Block Inspection Point Remarks Torch cable Causes a wire feed failure Too much bent of the torch cable Causes winking of arc due to scooping wire feed or unstable arc generation Stretch out the torch cable as straight possible when... -
Page 34: Periodic Inspection
These lives depend on the machine operating condition at customer's site and cannot be precisely stated. In periodic inspection, assume that they are a kind of consumable parts. For replacement parts, be sure to use those purely designed for the PANASONIC welding machines in order to maintain performance and functionality. - Page 35 PERIODIC INSPECTION Removal of the Top Plate and Side Plate. ①Remove of the top plate. (4 bolts) ②Remove the side plates. (9 bolts each on the left and right) Tips Cautions for Dielectric Strength Test and Insulation Resistance Test Since this machine uses many semiconductors, including thyristors, an imprudent dielectric strength test or insulation resistance measurement could lead to a trouble of the equipment.
-
Page 36: Initial Trouble Diagnosis
INITIAL TROUBLE DIAGNOSIS Even if you have a trouble such as being unable to weld, unstable arc, bad welding result, do not jump to the hasty conclusion that the welding machine is out of order. Even if the welding machine has nothing wrong, the above-mentioned errors may occur because or something far from a trouble, for example, blown or loosened fuse, unset or erroneously set switches, almost disconnected cable, cracked gas hose. - Page 37 INITIAL TROUBLE DIAGNOSIS Error Block and check item Adaptability of the feed Roller and SUS tube wire Diameter Crack, choked groove, or tipping of Wire feeder the feed roller ○ ○ ○ ○ ○ Excessive/insufficient clamping of the pressure rod ...
-
Page 38: Other Trouble And Erroes
OTHER TROUBLE AND ERROES When you have a trouble or error other than those mentioned in INITIAL TROUSLE DIAGNOSIS, determine which one of the following categories it belongs to. Following a relevant flow chart, make an appropriate check. When the WARN. indicator lamp goes on When the POWER switch ... - Page 39 OTHER TROUBLE AND ERROES When the power switch of the welding machine is turned on, but the POWER indicator lamp does not go on 3-phase rated voltage being applied to Is the switch of the the input end of the switch box turned on ? welding power unit ? Is the switch of the...
- Page 40 OTHER TROUBLE AND ERROES When output suddenly stops during welding(while arc is being produced) wire Has the chip melted Is the Warn. Indicator turning on the torch and stuck to the wire? lamp [22] turned on? switch? Is the feed roller of wire feeder damaged?
- Page 41 OTHER TROUBLE AND ERROES Trouble shooting Warning for safety Prior to troubleshooting, be sure to turn off the switch box and welding machine and make sure of safety. Otherwise, it may lead to a serious accident affecting safety or the human body, such as electric shock or burn.
-
Page 42: After-Sale Service
AFTER-SALE SERVICE When asking for repair For welding errors, check by yourself, following the Initial diagnoses List on pages 37 and 38. When you need a repair, please contact our dealer where you purchased the equipment, or our branch office. ... -
Page 43: Apart Layout Drawing
APART LAYOUT DRAWING The part specifications shown in figure is required to refer the attached parts list. Front Right Side Rear Left Side ○ YD-500KR2... - Page 44 PARTS LIST ( The No. of the table shows the location number of Parts Layout Drawing) (Spec. No.YD-500KR2) No. Symbol Name Q’ty Remarks YD-500KR2HD0 YD-500KR2HU0 Mtr(Tr1) Main transformer TSM94842 TSM94849 UTU19690 TSMU0171 Control transformer TSMLU014 Reactor ass’y TSM94291 SCR1-6 Thyristor PWB150AA30 Resistor RX274H30WR5K...
- Page 45 CIRCUITDIAGRAM...
-
Page 46: Outside Drawing
OUTSIDE DRAWING YD-500KR2... -
Page 47: Glosary
GLOSARY What is Crater Except welding with a very low current, there generally occurs a concave at the end of welding. This concave is referred to as a crater; it reminds you of a crater on the moon surface. Welding arc The crater results from a push-down force by arc Welding bead... - Page 48 GLOSARY What is Simple Unification Adjustment? Selection of the welding current with the output regulator on the remote controller. "Simple unification" adjustment refers to adjustment which automatically selects the welding voltage almost commensurate with that welding current. What is Wire Slowdown Speed? In order to obtain a secure arc start.
-
Page 49: Example Of Welding Conditions
EXAMPLE OF WELDING CONDITIONS welding conditions list(Reference) The following list gives you reference values of standard welding conditions. In actual welding work, it is necessary to alter them in compliance with a shape of weld assembly and welding posture to obtain appropriate conditions. Plate Wire Route Gap... -
Page 50: Ratings And Specifications
RATINGS AND SPECIFICATIONS YD-500KR2HD0 YD-500KR2HU0 Power source 3-Phase 220 V 3-Phase 380 V Frequency 50/60Hz (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 Solid wire (mild steel) Applicable wire dia. - Page 51 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：Tangshan New & Hi-Tech Development Zone, Hebei, China Post Code：063020 Tel：（0315）3206017 3206066 Fax：（0315）3206070 3206018...