Table of Contents
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Fully digital and inverter controlled TIG welding
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.
First, please read the "Safety Precautions".
English version is the original instructions.
Operating Instructions
DC TIG Welding Power Source
YC-300BZ3YHD
Model No.
OMCTT5621E18
2011
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Table of Contents
Troubleshooting
Related Manuals for Panasonic YC-300BZ3YHD
Summary of Contents for Panasonic YC-300BZ3YHD
- Page 1 Operating Instructions DC TIG Welding Power Source YC-300BZ3YHD Model No. Fully digital and inverter controlled TIG welding 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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Page 2: Features
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
Table of Contents Features..........7.1.3Turning ON power........7.1.4Adjusting gas flow rate........ 1.Safety precautions ......7.2Termination processing (steps after welding operation)........2.Rated Specifications ......7.2.1Shutting off gas ........... 7.2.2Shutting off power ........2.1Standard accessories......7.2.3Precautions for use of water-cooling torch in 2.2Duty cycle .......... -
Page 6: Safety Precautions
Safety precautions 1. Safety precautions WARNING Welding power source (9) In case of AC arc welding in a confined area or above floor level, check related national, state and local Observe the following instructions codes and regulations for any special treatment and comply with it if any. - Page 7 Safety precautions WARNING Against fire, explosion or blowout (5) Wire the cables correctly and connect them tightly. Insulate the connected parts surely so that no exposed Observe the following cautions to conductive part touches the cases or housings. (Poor prevent fires explosion or blow- cable connection or incomplete current path on the base metal side, such as steel, if any, can cause fire out.
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Page 8: Rated Specifications
Rated Specifications 2. Rated Specifications Rated input voltage Number of Phase Rated frequency 50/60 Hz (Common) Rated input 10.5 kVA (9.5 kW) Efficiency Idle state power consumption TIG, SPOT DC 300 Rated output current STICK DC 250 TIG, SPOT DC 22 Rated output voltage STICK... -
Page 9: Duty Cycle
Rated Specifications 2.2 Duty cycle Do not use this product at any usage rate over the rated duty cycle. The rated duty cycle for this product is 100%. TIG welding “The duty cycle is 100% at the rated output” means that Duty cycle (%) (100%) the power source can maintain operation continuously... -
Page 10: Installation
Installation 3. Installation 3.1 Installation siter CAUTION This product is designed for indoor use only. Do not install it in any places subject to rain or water spray. CAUTION 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 troubles like equip- ment burnout, etc. -
Page 11: Configuration
Base metal cable Input power cable Welding torch and fingertip joint Make sure to use the Panasonic genuine products only. Distribution box Or the connection part may be burnt due to poor contact. Note The gas hose lead-out point of the air-cooling TIG welding About “Base metal cable”... -
Page 12: Stick Welding
(optional items), with separate sales. (See section “Peripheral equipment”). Note (1) Fingertip joint Make sure to use the Panasonic genuine products only. Or the connection part may be burnt due to poor contact. (2) Base metal cable To prevent overheat of the cable and provide with... -
Page 13: Peripheral Equipment (Optional Items)
Configuration 4.3 Peripheral equipment (Optional items) 4.3.1 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 14 Configuration 3) Tungsten electrode for TIG welding *: YWCe-2: Tungsten with 2%Cerium trioxide Dia. Length YWCe-2 YWLa-2 YWLa-2: Tungsten with 2% Lanthanum trioxide (mm) (mm) YN-05C2S YN-05L2S YN-10C2S YN-10L2S YN-16C2S YN-16L2S YN-20C2S YN-20L2S YN-24C2S YN-24L2S YN-30L2S Note YN-32C2S YN-32L2S See also section “Appendix: Tungsten electrode”. YN-40C2S YN-40L2S YN-48C2S...
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Page 15: 2Extension Cable (Available On Request)
Configuration 4.3.2 Extension cable (available on request) Use an extension cable when the welding torch cable is When connecting the special torch to an extension not long enough. (It is connected between the welding cable, remove the replacement cable clamp attached to torch and this product.) the welding machine side of the special torch. - Page 16 Configuration <Examples of extension cable connection> 1) Connecting to torch; YT-15TS1C (150A, air cooled, 8m) Replace the fitting MT25C2 at the welding torch side with this relay fitting. Welding power source YC-300BZ3YAA Extension cable (TWU15127) 1. Gas hose ........YX-503TKC(15)24 m ....1 pc. 2.
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Page 17: 3Argon Gas Regulator (Yx-251A)
Configuration 3) Connecting to torch; YT-30TSW1C1 (300A, water cooled, 8m) Connect to JIG terminal “WATER” circuit Replace the fitting at the welding torch side MT25C2 with this relay fitting. Welding power source YC-300BZ3YAA Water- coolant Nipples (2 pcs.) (Supplied with YX-09KDC1) ... -
Page 18: 5Cooling Water
* Please contact Panasonic representatives for more • After connecting the remote controller to the weld- information, such as detail specifications. ing power source, the power source recognizes the remote controller in about two seconds. -
Page 19: Names And Functions
5. Names and Functions CAUTION About power switch: When the power switch is turned off automatically, do not turn it on again. (Consult Panasonic representatives.) When activating a power generator, turn off the power switch. 5.1 Front panel For details of functions, see section “Welding conditions”... -
Page 20: 2Welding Conditions Setting Buttons Section
Names and Functions *1:See section “Settings” for how to display welding volt- “FUNCTION” selection button age. Select an operation “mode”. In the case of a welding voltage, indicates the welding WELD: To set welding conditions (using buttons 7 to 9) and conduct welding operation. voltage (between output terminals of this product) during REPLAY: To reproduce stored welding conditions. -
Page 21: 3Switches And Rear Side
Names and Functions 5.1.3 Switches and rear side WARNING When removing or replacing a fuse: To prevent an accident caused by an electric shock, make sure to turn the power switch off before such removal or replacement Front panel Rear panel REMOTE CONTROLLER outlet: Gas inlet: (Screw size: 9/16-18UNF) Connect the plug of the remote controller (sepa-... -
Page 22: 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 national and local codes. -
Page 23: Connecting Output Cables For Stick Welding
Connection 6.2 Connecting output cables for STICK welding • Connect the cables in the order shown in the following • The polarity relation between the welding rod holder and table referring the figure on the right. base material is electrode plus (DCEN) unless otherwise instructed by the applied electrode. -
Page 24: Connecting Gas Regulator
Connection 6.4 Connecting gas regulator 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 ... -
Page 25: Connecting With Jig(S)
Connection 6.5 Connecting with jig(s) 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 part of the case with your hand to discharge static electricity ... - Page 26 Connection • Wiring procedures (1) Connect the wires to the jig terminals Route it so that the end part of the wire can be placed on the binding band holder. (2) Pass the binding band through the binding band <View from A> holder, and then connect the signal wires.
- Page 27 Connection Jig terminal block Jumper Terminal Terminal # Functions Note name • Output current (Initial current, welding current Contact capacity (Resistive load): including pulse current and base current, and cra- DC: 24V, 1A ter current) flows between those terminals. AC: 125V, 0.3A •...
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Page 28: Connecting With Robot
Connection 6.6 Connecting with Robot Use it in case of perform welding operation using our industrial robot “VR-2 series” by connecting to a G2 con- Note troller. Keep the signal lines from a jig and/or a robot away from (For details, see manuals of individual products.) the welding arc area, the welding torch, the base-mate- rial-side cable, etc. -
Page 29: Preparation And Termination Processing
Preparation and termination processing 7. Preparation and termination processing 7.1 Preparation 7.1.1 Use of protective equipment WARNING To protect you and other people from gases, fumes and lack of oxygen that may be generated during the welding operation, make sure to prepare ventilation facilities and use protective equipment, etc. -
Page 30: Termination Processing (Steps After Welding Operation)
Preparation and termination processing 7.2 Termination processing (steps after welding operation) 7.2.1 Shutting off gas (1) Close the main valve of the gas bottle. (2) Perform the “gas purge” to take the residual pressure out of the pipe. 7.2.2 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 31: Settings
Settings 8. Settings 8.1 DETAIL settings 8.1.1 Factory settings The following table shows the functions and default setting of each set item. Default Set item Choice Description setting V Disp Status It is not possible to display output voltage. The welding current screen and the output voltage screen appear on the LCD display alternately every time the “WELD. -
Page 32: 2How To Check Settings
Settings 8.1.2 How to check settings (1) Set the “FUNCTION” button on the front panel to Set-value “DETAIL”. display Then “V Disp Status” is display on the LDC. (2) Press the JOG dial until the set item you would like to check is displayed. -
Page 33: 4How To Restore The Original Factory Settings Of This Product
Settings 8.1.4 How to restore the original factory settings of this product • The following table shows how to restore the original fac- write them in the “Welding conditions memorandum” in tory-setting. (Underlined bold character in the “LCD” col- Appendix. umn indicates the cursor position.) •... -
Page 34: 5Memory Deletion
Settings 8.1.5 Memory deletion If you would like to delete any welding conditions that you programmed, follow the below steps. Operation Set-value display LCD display Hold down the JOG dial, and while holding it down, Rescue Menu turn on the “POWRE” switch. YC-300B Series Then indication changes to 1 Set Defaults? -
Page 35: 6Memory Lock
Settings 8.1.6 Memory lock If it is not desired for anybody other than the administrator to conduct the storing operation, lock the stored memory in the following manner. Operation Set-value display LCD display Hold down the JOG dial, and while holding it down, Rescue Menu turn on the “POWRE”... -
Page 36: Welding Conditions
Settings 8.2 Welding conditions 8.2.1 Settings and checking After trial of welding, if you want to have higher welding quality and performance, try to change the factory-set con- dition to suit such a welding condition as desired. <Use the “Welding condition memorandum” (Appendix) to keep a note of the result after chang.>... -
Page 37: 2Welding Condition Setting Table
Settings 8.2.2 Welding condition setting table Items marked with in the following table are applicable if the PULSE selection button is set to “ON”. Pre-flow Initial Welding Down Spot Crater Post-flow Pulse Pulse Pulse Mode Crater time current slope current slope... -
Page 38: 4Storing Welding Conditions
Settings 8.2.4 Storing welding conditions • Up to 64 welding conditions (P01 to P64) set by custom- Note ers can be stored. When the memory locking is on, no information can be Just reproduce your stored welding condition, and you stored. -
Page 39: Operation
Operation 9. Operation 9.1 TIG Welding operation WARNING Pressing the torch switch by mistake may cause an electric shock. When inspecting or replacing any torch parts, make sure to turn the power switch off in advance. <Regarding the following diagrams> The ON/OFF operation of the torch switch enables you •... - Page 40 Operation 2) “Crater: ON” welding operation This welding mode is used to fill in the crater of beads With the “Crater” switch set to “ON”, perform welding by generated on the terminal end of welding of intermedi- repeating the ON/OFF cycle of the torch switch twice. ate plates and thick plates.
- Page 41 Operation 3) “Crater: REPEAT” welding operation Unlike the aforementioned Crater “ON” welding, the same pletion of Crater welding, and it is repeated from then on. welding cycle is started from the beginning again on com- (Raise the torch to stop the welding.) (1) Torch: ON (2) Torch: OFF (3) Torch: ON...
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Page 42: Spot Welding Operation
Operation 9.2 SPOT welding operation Note There is no pulse function in the case of the Spot weld- When the torch switch is turned off during the arc spot ing. time, the welding operation is terminated immediately. Even with the torch switch turned on, welding terminates when the arc spot time has elapsed. -
Page 43: Maintenance And Inspection
The daily check is important to make the most of the For replacement of parts, make sure to use our genuine performance of this product and to secure the safety of parts for Panasonic welding machine to keep its perfor- daily operations. mance and functions ... -
Page 44: 2Cables And Hoses
Maintenance and inspection 10.1.2 Cables and hoses Check item Check point Remarks Of this product To prevent a physical accident If the grounding wires are removed or Grounding wires Of the base metal caused by electric leakage, make fastened securely. sure to check it. -
Page 45: 1Check 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 46: Precautions For Withstand Voltage Test And Insulation Resistance Measurement
Executing withstand voltage test or insulation resistance measurement casually may cause serious phys- ical injury or mechanical failure. In case of necessity, con- tact our sales distributors or Panasonic representatives. Attention of sales distributors / Panasonic representatives Prior to conducting withstand voltage test and insulation resistance test, prepare the followings and also connect ground wire (cross section: about 1.25 mm... -
Page 47: Troubleshooting
CAUTION When the power switch is turned off automatically, contact sales distributor or Panasonic rep- resentatives without 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). - Page 48 E r r Curr.DetectError It may be failure of this product. Please contact sales distributor or Panasonic representative. E r r WaterCircuitErr A “WaterCircuitErr” signal was input from external equipment, such as cooling-water equipment, etc. connected to the jig terminal.
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Page 49: 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. Front panel display is not turned on Error condition Neither high frequency wave nor arc is generated. ... -
Page 50: Parts List
Parts list 12. Parts list OMCTT5621E18... - Page 51 Parts list Mark Rescription Part number Q’ty Note Internal code Receptacle YCA5 For remote NR2012RF Receptacle CN70AJ2P For torch switch CN70AJ2P C1,C2 Capacitor YCA23 RWE45LGSN102 Capacitor YCA12 SS351206PPQ1 C3,C4 Capacitor CEX00002 CEX00002 C5,C6 Capacitor CEX00105 CEX00105 YCA6 TN300A4VB15A Diode YCAD102 DF75LB160F D2,D3 Diode...
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Page 52: Circuit Diagram
Circuit diagram 13. Circuit diagram OMCTT5621E18... - Page 53 Circuit diagram OMCTT5621E18...
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Page 54: Appendix
Appendix 14. Appendix 14.1 TIG Welding conditions table - (Reference) The list of TIG welding conditions (stainless steel) In actual welding operations, work out an appropriate shown in this chapter is a reference value as a guideline condition in consideration of the shape of substances to for standard welding conditions. -
Page 55: Tungsten Welding Rod
Appendix 14.2 Tungsten welding rod 1) The following table shows tungsten electrode types commonly used for TIG welding. Tungsten electrode type Symbol Applicable TIG welding method Pure tungsten AC TIG Tungsten with 2 % Cerium trioxide YWCe-2 DC TIG, AC TIG Tungsten with 2 % Lanthanum trioxide YWLa-2 DC TIG... -
Page 56: Welding Conditions Memorandum
Appendix 14.5 Welding conditions memorandum It is recommended to keep a note of the user-created weld- Those custom welding conditions in this unit by allocating a ing conditions for your convenience. channel number to each of them. * Put the data on the below “Program list” once stored. Program number Material to be welded Remarks... -
Page 57: Program List
Appendix 14.6 Program list Program Prepared Prepared Material to be welded Remarks number OMCTT5621E18... -
Page 58: Information On Disposal
Information on Disposal 15. Information on Disposal Information on Disposal for Users of Waste Electrical & Electronic Equipment (private households) This symbol on the products and/or accompanying documents means that used electri- cal 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 59 OMCTT5621E18...
- Page 60 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 2006 OMCTT5621E18...