Operating Instructions AC Arc Welding Power Source Model No YC-300WP ● 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.： YC-300WP5□□□ Panasonic Welding Systems (Tangshan) Co., Ltd TSM89578-09 Notice：Machine Export to Europe This product does not meet the requirements specified in the EC Directives which are the EU safety ordinance Please bear in mind that this product may not be brought as is into the EU The same restriction also applies to any country which has signed the EEA accord 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 CONTENTS Safety Ⅰ Caution for use Rating -2 Preliminary Arrangements For Operation -3 Connections -4 Operation -6 Movement Operation Condition 10 Check Points For Abnormal Operation 13 Maintenance And Inspection -15 Jig Terminal And Sample Applications -17 Circuit Diagram -19 Parts List 20 Outline Drawing -22 1.Safety Safety Precaution Read this manual carefully to use the machine properly The cautions mentioned in this manual are important to operate the machine properly and prevent hazardous situation and damage to you and other personnel This manual is also structured on the premise that any personnel who handle industrial robots must complete the appropriate training programs, which can be a requirement of related regulations and standards Some safety precautions are emphasized using the following symbols for extra caution Warnings, Cautions, Mandatory Actions and Prohibitions listed in this manual must be followed without fail If directions are not followed carefully, potentials for personal injury not only to the operator(s), but also other personnel and potential for property damage to the equipment 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 ● Improper operation of the machine may lead to various levels of hazardous conditions This document classifies all of these hazardous conditions into three levels, namely Danger, Warning or Caution, and indicates these levels by using symbols The warning symbols and signal phrases are also used on the warning labels attached on the machine Warning symbol Signal phrase Description Danger When you see this symbol it means that a hazardous accident including death or serious personal injury is imminent, if directions are not followed carefully Warning When you see this symbol it means that the potential for a hazardous accident including death or serious personal injury is high, if directions are not followed carefully When you see this symbol it means that the potential for hazardous accident including medium-level or light personal injury and/or the potential for Caution property damage to the equipment are high if, directions are not followed carefully The above warning symbols are commonly used “Serious personal injury” refers to loss of eyesight, burns (high-temperature and low-temperature burn), electrical shock, bone fractures and gas poisoning, as well as those that leave after-effects, which require hospitalization or necessitate medical treatment for an extended period of time “Medium-level and light personal injury” refers to burns, electrical shock and injuries which not require hospitalization or necessitate medical treatment for an extended period of time “Property damage” refers to extensive damage to the surrounding items and equipment ● Furthermore, the mandatory items or actions that must be performed and those that are prohibited are indicated as follows Warning symbol Signal phrase Description Mandatory Action Action which MUST be performed without fail, such as grounding Prohibition Action which MUST NOT be performed The above warning symbols are commonly used Ⅰ 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 Failure to so can result in serious injury or even death Work of driving source at the input side, selecting work site, handling, storage and piping of high pressure gas, storage of welded products and also disposal of waste should be performed according to the operating instruction and national, state and local codes and regulations Prevent any unauthorized personnel to enter in and around the welding work area Pacemaker wearers should consult their doctor before going near arc welding Magnetic fields can affect pacemakers Only educated and/or skilled persons who well understand this welding power source should install, operate, maintain and repair the unit Never use filtering devices to cover vents of power source warranty Filters will restrict airflow and can cause unit to overheat Use of filter voids Never use the welding power source for other than welding purpose (e.g Never attempt to use the welding power source for pipe thawing.) Against electric shock Touching any live electrical parts can cause fatal electric shocks or severe burns Never touch live electrical parts Grounding of the case of the welding power and base metal or a jig electrically connected to the base metal must be performed by educated and/or skilled persons Before installation or maintenance work, turn off power at the power box, wait it for at least five minutes to discharge capacitors Significant voltage may exist on capacitors after turning off power at the power box so it is imperative to check to make sure that no charged voltage present at capacitors before touching any parts Do not use undersized, worn, damaged or bare wired cables Connect cables completely and insulate connection parts Keep all cases, panels and covers securely in place Do not handle the welding power source with torn or wet gloves Wear safety harness in case of working above floor level Perform periodic checks without fail and repair or replace any damaged parts before using the power source Turn off all equipment when not in use In case of AC arc welding in a confined area or above floor level, check related national, state and local codes and regulations for any special treatment and comply with it if any Ventilation and protective equipment 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 When conducting welding in the bottom of the tank, boiler or hold, make sure to provide sufficient ventilation or wear protective breathing gear Gas heavier than air generated during welding, such as carbon dioxide gas or argon gas settles in the bottom if conducted in such area When conducting welding in a confined area, make sure to provide sufficient ventilation or wear protective breathing gear and have a trained supervisor observe the workers Do not conduct welding at a site where degreasing, cleaning or spraying is performed these types of work is performed can generate toxic gases Conducting welding near the area where any of When welding a coated steel plate, provide sufficient ventilation or wear protective breathing gear coated steel plates generates toxic fume and gas.) Ⅱ (Welding of Against fire, explosion or blowout Observe the following cautions to prevent fires explosion or blowout Remove any combustible materials at and near the work site to prevent them from being exposed to the spatter relocated, cover them with a fireproofing cover If they cannot be Do not conduct welding near combustible gases Do not bring the hot base metal near combustible materials immediately after welding When welding a ceiling, floor or wall, remove all flammables including ones located in hidden places Properly connect cables and insulate connected parts metal, such as steel beam, can cause fire Improper cable connections or touching of cables to any current path of the base Connect the base metal cable at a section closest to the welding part Do not weld a sealed tank or a pip that contains a gas Keep a fire extinguisher near the welding site for an emergency CAUTIONS Installing shielding (curtain etc.) Arc flash, flying spatter, slugs, and noise generated during welding can damage your eyes, skin and hearing Install a protective curtain around the welding manipulator site to prevent the arc flash from entering the eyes of people in the surrounding area When welding or monitoring welding, wear safety glasses with sufficient light blocking performance or use a protective mask designed for welding operation When welding or monitoring welding wear protective closes designed for welding operation, such as leather gloves, 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 The gas cylinder must be handled properly according to the applicable law and in-house standards Use the gas flow regulator that is supplied or recommended by our company Read the instruction manual of the gas regulator prior to using it, observe the cautions in the manual Secure the gas cylinder to a dedicated gas cylinder stand Do not expose the gas cylinder to high temperature When opening the valve of the gas cylinder, not bring your face close to the discharge outlet When the gas cylinder is not used, be sure to install a protective cap Do not hang the welding torch on the gas cylinder, or touch the gas cylinder with the electrode Rotating parts Rotating parts can cause injury Keep away from rotating parts such as cooling fans, feed roller of the wire feeder, or hand, finger(s) hair or part of your clothes may be caught by the parts resulting in injury Keep all covers, panels and cases closed when using the product Maintenance work and repair should be perform only by educated and/or skilled persons who thoroughly understand welding machines While performing maintenance or repair work, provide fence or the like around the welding machine so that unauthorized person can not come close carelessly Ⅲ5 Welding wire Welding wire, especially wire tip part can cause injury Wire extends out from the end of the welding torch and may stick into the eye, face or body Do not perform inching operation or pull the torch switch with your eyes, face or body close to the end of the welding torch - wire may stick into your eye, face or body Against insulation deterioration Insulation deterioration can cause fire of welding power source Keep enough distance from welding power source when performing welding or grinding work so as to prevent such spatters or iron particles from getting into the power source Perform check and maintenance work periodically so as to prevent insulation deterioration due to accumulated dust or dirt 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: If welding machine is placed on a slope, a countermeasure should be taken to keep it from falling on one side The degree of protection is IP21S, appropriate coverage is required in case of rain When using forklift, please fork welding machine at the side with “Fork” mark to avoid falling When using hoisting machine, please fasten cordage in the rings on the top of welding machine and make the angle Φ across the cordage and perpendicular shown in the drawing not more than 15 degrees ■ Cautions about electromagnetic disturbance ● Extra precaution may be required when welding power source is used in a domestic establishment ● Before installing welding equipment ,the user shall make an assessment of potential Electromagnetic problems in the surrounding area as below a) Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; b) Radio and television transmitters and receivers; c) Computer and other control equipment; d) Safety critical equipment, e.g guarding of industrial equipment; e) The health of the people around , e.g the use of the pacemaker and hearing aids; f) Equipment used for calibration or measurement; g) The immunity of other equipment in the environment; the user shall ensure that other equipment being used in the environment is compatible; this may require additional protection measures; h) The time of day that welding or other activities are to be carried out ● The user shall be observe to reduce emission disturbance as below a) Welding equipment should be connected to mains supply according to the manufacture’s recommendations b) Welding equipment should be routinely maintained according to the manufacture’s recommendations c) The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level d) Confirm to connection of all metallic components in the welding installation and adjacent to it should be considered for safety e) The work-piece should be connected to earth for electric safety f) Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of entire welding installation may be considered for special applications The user should take the responsibility with respect to interference from welding Ⅳ CAUTION FOR USE Cooling Water In case of a water-cooled torch Use with cooling-water flow of more than 0.7L/min.Water Caution pressure at the torch entrance is 0.1~0.3MPa for 4m cable torch 0.15~0.3MPa for 8m cable torch Insufficient water flow can cause burn out of the torch ● Never use a water-cooled torch for air cooling ● Never use the Water leaked torch to prevent electrical shocks Cable Hose Caution Do not bring the hose cable on the hat base metal immediately after welding, load the heavy material on the cable hose, and bend it by force, It can cause burn out of the welding torch Welding Operation and Exchange of Parts Caution Observe the following cautions to prevent burns i ● Do not touch directly the nozzle, electrode and torch body where the temperature rise ● When welding, wear protective gear such as protective leather gloves designed for welding operation ● After turn off the power supply, exchange the torch parts when temperature is lower Caution For safety and good welding, exchange any damaged parts for new ● Be sure to use the parts marked “Panasonic” Caution Wear protective glasses to protect the eyes when grinding electrode ● Follow the standard for safety when using the grinding machine Rating YC-300WP5 HDF、HDM YC-300WP5 HGH、HGM YC-300WP5 HJE V 220 380 415 V 220±10% 380±10% 415±10% Item Type Rated Input Voltage Allowable fluctuation No of Phase Rated Frequency Rated input Rated Duty Cycle D.C No-Load Voltage A.C No-Load Voltage D.C Output Current D.C Output Volt.(TIG) D.C Output Volt.(STICK) A.C Output Current A.C Output Volt.(TIG) A.C Output Volt.(STICK) Pre-flow Post-flow Arc spot timer Up slope timer Down slope timer Pulse frequency Pulse current Crater control system Cleaning width adjuster Weight Hz KVA KW % Single phase 50/60 26 17 40 V 70 V 76 A 5~315 V 10.2~22.6 V 20~32.6 A 20~315 V 10.8~22.6 V 20.8~32.6 S S S S S Hz A 0.3 5~25 0.5~5 0.1~6 0.2~10 0.5~10 50~315 Tree mode(ON,OFF REPEAT) A.C.TIG only kg 193 Remote controller YC-304URW Preliminary Arrangements for Operation Prepare and check the following (1) Capacity of Power Source Facility And Connection Cables (Table3) Model Item Supply voltage Capacity of Distribution Box Input Cable Output Cable z z z Commercial source YC-300WP5HDF、 HDM YC-300WP5HGH、 HGM YC-300WP5HJE 220±10% 380±10% 415±10% power Primary line current Min.36kVA 118A Min.25mm2 68A Min.16mm2 Min.60mm2 63A Min.16mm2 Since a sudden inflow of current to a machine may cause maloperation to a breaker, the use of a breaker for welding or motor is recommended When using an engine generator, use a generator with thyristor equipment compensating lead wire 3to5 times greater than the welding power source capacity Ensure than the commercial frequency to be used coincides with the applicable frequency for welding power To this, identify the applicable frequency for welding power with a specification tag attached to front welding power supply (2) TIG welding torch Always prepare (Panasonic) TIG welding torch (3) Argon gas Always prepare welding argon gas with purity 99.9% (4) Gas flow rate regulator Always prepare (Panasonic) gas regulator YX-251A (5) Cooling water equipment When using a water-cooled TIG welding torch, prepare city water or cooling water unit (YX-09KB) z Installation Place Be sure to locate the machine in the following surroundings: — Indoor, free from moisture and dust — Place under ambient temperature to +40℃ — Place not subjected to abnormal vibration or shock — Place not exposed to direct sunlight or rainfall — Place 20cm or more apart from the wall surface — Place free from oil steam or detrimental corrosive gas Ib Iw Ic IB IP Initial current Welding current Crater current Base current Pulse current STICK WELDING Power source switch Magnetic switch Welding current Fig.5 Operation Condition Prior to operation, refer to the following For tungsten electrode, see Table below [Table 6] Welding current (A) A C D C S P D C R P YWP YWTh2 YWP ·YWTh2 YWP ·YWTh2 0.5 5～15 5～20 5～20 1.0 10～30 10～40 15～80 1.6 20～100 20～100 70～150 10～20 2.4 60～130 60～180 150～250 15～30 3.2 100～160 120～240 250～400 25～40 4.0 130～240 160～380 400～500 40～55 4.8 170～300 180～360 500～800 55～80 YWP···Pure Tungsten YWTh2···2% Thoriated Tungsten ● Shielding gas for TIG welding For shielding gas for TIG welding, use welding argon gas Intrusion of impurities such as oxygen, moisture and nitrogen into argon gas may worsen shielding performance and downgrade the quality at the weld zone Size (mmф) ● Filler wire For the filler wire, material is determined by the base metal, and thickness is determined by the welding current value In general, the same quality material as base metal is used, and in special cases such that different types of metal is welded, for example, it is important to select a proper material according to applications Hints on Filler Wire Diameter Selection [Table 7] Filler wire dia (mm) ～1.0 ～1.6 1.0～2.4 1.6～3.0 2.4～4.5 4.5～6.0 Welding current (A) 10～20 20～50 50～100 100～200 200～300 300～500 10 Inert Gas Arc welding condition for Stainless Steel(D.C.S.P.) Base Metal mm 0.5 Weld form Butt lap Fillet T.type 1.0 Butt lap Fillet T.type 1.5 Butt lap Fillet T.type 2.5 Butt lap Fillet T.type 3.0 Butt lap Fillet T.type 4.5 Butt lap Fillet T.type 6.0 Butt lap Fillet T.type 12.0 Butt lap Fillet Welding current（A） Flat position 10～15 10～15 10～20 15～20 30～40 40～50 45～60 50～60 60～100 60～100 60～80 70～80 100～120 110～130 100～120 110～130 120～140 130～150 120～140 130～150 200～250 225～275 200～250 225～275 275～（350） 300～（375） 275～（350） 300～（375） （350～450） （375～475） （375～475） Vertical position 10～15 10～15 10～20 15～20 30～40 40～50 45～55 50～60 60～80 70～100 60～70 70～90 90～110 100～120 90～110 100～120 110～130 120～140 110～130 115～135 150～200 175～225 150～200 175～225 200～250 225～250 200～250 225～275 225～275 230～280 230～280 Overhead position 10～15 10～15 10～20 10～20 30～40 40～50 45～60 50～60 60～70 80～90 60～70 70～90 90～110 100～120 90～110 100～120 105～185 120～140 115～135 120～140 155～200 175～225 150～200 175～225 200～250 225～275 200～255 225～275 225～275 230～280 235～280 11 Welding speed cm/min 40 20 40 35 [Table 8] Filler Argon Metal wire gas mm ～1.0 ～1.0 l/min 4 4 15～40 15～30 20～40 10～35 15～80 15～80 20～40 10～20 20～80 20～80 28～30 15～25 30 25 30 25 1.0～1.6 1.0～1.6 1.0～1.6 1.0～1.6 ～1.6 ～1.6 ～1.6 ～1.6 1.5～2.5 1.5～2.5 1.5～2.5 1.5～2.5 2.5 2.5 2.5 2.5 5 5 25 20 25 20 3.0 3.0 3.0 3.0 6 25 20 25 20 4.5 4.5 4.5 4.5 6 6 15 15 15 6.0 6.0 6.0 7 5 5 5 5 5 5 Inert Gas Arc welding condition for Aluminum(A.C.) Base Metal mm 0.5 Weld form Butt lap Fillet T.type 1.2 Butt lap Fillet T.type 1.6 Butt lap Fillet T.type 3.0 Butt lap Fillet T.type 4.5 Butt lap Fillet T.type 6.0 Butt lap Fillet T.type 9.5 Butt lap Fillet T.type 12.0 Butt lap Fillet T.type Welding current（A） Flat position 20～40 20～50 20～40 20～40 30～60 30～60 30～60 30～75 60～80 60～80 60～80 70～80 125～145 140～160 125～145 140～160 190～220 210～240 190～220 210～240 260～300 290～340 280～320 280～320 330～380 350～400 350～400 330～380 400～450 400～450 420～470 400～450 Vertical position 10～20 10～20 10～20 10～20 20～30 20～30 20～30 24～35 40～60 40～60 50～70 60～70 115～135 120～145 115～135 115～135 190～220 190～220 180～210 190～220 220～260 220～260 220～260 220～260 250～300 250～300 250～300 250～300 290～300 290～300 290～300 290～300 Overhead position 10～20 10～20 10～20 10～20 20～30 20～30 20～30 25～35 40～60 40～60 40～60 60～70 120～140 130～160 130～150 140～160 180～210 180～210 180～210 180～210 210～225 210～225 210～225 210～225 250～300 250～300 250～300 250～300 250～300 275～325 265～325 275～325 12 Welding speed [Table 9] Filler Argon Metal wire gas cm/min mm l/min 20～40 15～40 20～40 5～15 15～40 15～40 15～40 15～30 15～40 15～30 30 15～25 30 25 30 25 ～1.2 ～1.2 ～1.2 1.0～1.2 ～1.6 ～1.6 ～1.6 ～1.6 ～1.6 ～1.6 ～1.6 ～1.6 2.5～2.5 ～2.5 ～2.5 1.5～2.5 3.0 3.0 3.0 3.0 5 5 28 28 28 15 25 20 25 20 13 13 13 13 8 8 3.0～4.5 3.0～4.5 3.0～4.5 3.0～4.5 4.5～6.0 4.5～6.0 4.5～6.0 4.5～6.0 4.5～6.0 4.5～6.0 4.5～6.0 4.5～6.0 6 6 7 7 8 8 10 10 10 10 12 12 12 12 14 14 14 14 15 15 15 15 Check Points for Abnormal Operation ■ No arc occurs No high - frequency Current is generated H F fuse (5A) blown Spark-gap spacing too large or short circuited Torch cable disconnected Welding method selector switch is set to “STICK” High - frequency Current is generated, While no arc occurs Failure in connecting base metal side cable or poor connection Torch cable and base metal side cable disconnect Tungsten electrode-base metal distance too long Supply voltage excessively low (U1±10%V is proper) ■ Unstable arc Arc is hard to start Arc is intermittently cut off Tungsten electrode is too thick for the current value Pure tungsten electrode is in use (Thoriated tungsten electrode should be used) Shielding gas flow rate is too excessive Shielding gas other than pure argon gas is used Poor connection of base metal side cable (Connect one base metal side cable to one machine securely) 13 ■ Poor supply of shielding gas No shielding gas flows Shielding gas keeps flowing Gas hose bent midway Dust clogged in the torch No gas valve is actuated Gas leaks from the gas hose joint Gas valve malfunction ■ Arc stops automatically “WARN.” Lamp is lighting Cooling water runs short Mtr Or Dcl is too hot 14 Maintenance and Inspection Due attention should be paid to periodical maintenance and inspection for safe operation of the welding machine Before checking interior and exterior terminals of the welding machine, be sure to turn the switch box at the primary side (or NEF) ■ Daily precautions (1) Check for abnormal vibration, beat or smell (2) Check for abnormal heating at the cable connections (3) Ensure that the welding machine cooling fan rotates smoothly with power ON (4) Check the switch for abnormal operation (5) Check for poor cable connection and insulation (6) Check the cable for any possible disconnection ■ 3-to-6-mouth inspection (1) Checking electrical connection sections Ensure that tightening screw at the input and output side cable connections of welding machine are not loose, rust does not worsen the electric contact, and check for any problem in insulation (2) Grounding line Ensure that the welding machine case is completely grounded (3) Removing dust inside the welding machine Dust deposited on the thyristor cooling plate reduces heat dissipation effect, which in turn adversely affects the thyristor If dust is accumulated between windings of the transformer, for example, insulation may deteriorate accordingly; therefore, remove the side and top plates of the welding machine at least once per months, and blow compressed air with less moisture against each section for cleaning ■ Adjusting high-frequency current Do not touch the spark gap in normal cases (the distance between spark gap is adjusted for 0.8mm) When the electrode is significantly non-uniform and contaminated on the surface, always clean the surface, and then adjust the interelectorde gap for 0.3 to 0.4mm (To this, use a thickness gauge.) ■ Operating precautions (1) Power switch operation If power switch is turned OFF immediately after the welding work is completed, the cooling fan will stop and the temperature of transformer, ect Will remain high; thereby expediting the deterioration of transformer, etc and reducing the life span; therefore, remember to attempt to turn power switch OFF or minutes after completion of the operation, not immediately 15 (2) (3) Service factor Be sure to use the machine so that the preset service factor is not exceeded Over-service factor may cause burning to the welding machine in the worst case, and even when it does not lead to burning trouble, reduced service life may result; therefore, be sure to follow the service factor appropriate to the welding current The rated service factor 40% means at the rated output current (for example, 300A output current with the 300A machine) in a cycle of 10 minutes, it must suspend operation for minutes Precautions after maintenance and inspection When removing a top board, side board and rear board for maintenance and inspection, not fail to reinstall them just as they were ■ Precautions for flow switch Water pressure: This machine uses a flow rated switch to prevent the water-cooled torch from burning For the flow rate switch, since the water amount becomes small in a low water pressure place, “WARN.” indicator lamp lights up, and it ceases to operate In this case, be sure to take in water from a high water pressure place or locate a water tank Also, always keep the water pressure at 1.2kgf/cm2 and water quantity at 0.7L/min or more ★ When using the water tank: Replace cooling water with a new one or times per months Deposited fur may cause the pump motor to cease to rotate, and the water line of torch and flow rate switch may become clogged accordingly When using non-freezing fluid: For non-freezing fluid, always use glycols If this antifreeze mixing ratio is increased, cooling water viscosity becomes higher, thus making it hard to let cooling water flow, and the flow rate switch may become inoperative Therefore, it is recommended that this antifreeze mixing ratio should not exceed 20% ■ Caution in dielectric strength testing and insulation measurement since a thyristor, IC, and many other semi-conductor parts are used in this machine, often dielectric strength test and insulation measurement will cause mechanical troubles The flowing points must be observed when performing these tests with the company’s standard Short-circuit the anode and the cathode in thyristor SCR1 and SCR2 Disconnect the grounding in the welding power source Short-circuit the electromagnetic contactor Short-circuit two of the input terminals Short-circuit two of output terminals 16 Jig Terminal and Sample Applications ● This machine is provided with signal terminals convenient for use with a jip within pc board box of welding power supply as shown in blow ● Connection with TIG-MATE (YJ-1051T) control cable Connect TIG-MATE (YJ-1051T) control cable to the jig terminal board of the welding power supply Front pamel pc board box Jig terminal 75 99 60 61 66 67 60 61 66 67 E 39 From TIG-MATE Notes 1) 60 61 are a pulse detecting contact, and 66 67 are a current detecting contact 2) E is used for grounding: use a terminal board mounting screw to connect in to the welding power case 17 3) 39 is used, for example, when a robot is used: it is not used in normal case 4) Contacts 60 61, and 66 67 may be replaced 5) When emergency stop signals 75 99 are used, always remove the short-circuiting wire 6) The current capacity (resistance load) of current detecting relay and pulse detecting relay contacts is 24V DC 5A, 24V DC 2A: Always use the machine at a lower current than the above 18 MTr SCR1 G1 A1 K1 A2 K2 K1 ZNR1 C1 INPUT MS2 63 23 18 #2 ZNR3 R1 TO C11 31 SCR3 S1 202 201 G1 30 R2 115 121 DC 115 122 SCR4 341 223 20 206 A1 G1 K1 G1 K1 K1 A3 G2 SCR2 ZNR2 G1 K1 A3 G2 C3 19 G1 A1 K1 A2 K2 K1 41 108 64 MS1 TIG 19 19 FU2 51 42 Tr1S Tr1S C A 20V 20V 100 19 TSM9451□ DC 20V AC DC AC 153 157 33 200 57 82 81 34 43 ② ① VR6 ③ S4 GAS CHECK 87 23 25 22 35 86 SOL CR8 83 TSMP461□ 303 304 99 OFF TSM9427□ TH ① ② 156 ② 27 29 ② 26 ① ① VR1 100 ③ ① VR2 ③ 28 CR5 CR9 ② 104 203 204 61 75 120 58 59 101 102 105 106 99 S3 S5 OFF ON OFF SPOT WATER ③ VRA 155 47 73 ON ON ② ① 56 48 76 62 302 100 ③ VRC ① 62 301 ③ VR8 83 66 67 60 98 CR8 75 Tr1S ② VR4 44 46 55 80 PL2 ③ ② 21 (15)(38) （6）20（ 13） （41）9 10 54 75 37 201 123 141 206 213 341 53 ① 74 WELD REMOTE TSM9451□ 100 FAN 57 S6 52 R6 36 C5 R8 65 TSM9447□ 117 141 108 114 POWER PL1 154 20V C5 SH 257 #2 TSM9451□ TORCH 18 SG C4 12 TS MS2 R5 C11 DCL STICK C10 80 C10 16 DC 254 R7 TSM9448□ 17 ZNR5 C9 C.C 241 117 21 22 G1 K1 A3 G2 TR1 R3 40 FU1 C12 11 AC 200V R4 19 100 93 19 19 114 OUT(BASE) 100 AC TUF1 0V SH DCL 115 MS1 PULSE 37 50 S2 AC 70 S7 91 92 71 68 69 150 85 89 88 103 90 ③ ② VR5 ③ VR3 ① S9 50HZ 60HZ 153 ② S8 DC TIG MANUAL OFF ON REPEAT ③ VR7 ① CIRCUIT DIAGRAM 19 257 Cleaning Width TORCH CO1 Current Detecting Pulse Detecting Emergency Stop 156 254 155 REMOTE CO2 PARTS LIST YC-300WP5 DV No Name of parts TYPE,RATING QT SCR1,3 Thyristor ST280S04P0V SCR2,4 Thyristor PDT2008 MS1、2 Electromagetic contactor PT323010LS A Ampere meter KFM7BDC400AK SH SHUNT F400A TR2 Hi Freq transformer TSM04069 C.C Coupling coil CLU30148 To Output terminal TSM15748 FAN Cooling SF-200-25-4D SOL Gas valve J540-716G SG Spark gap TSM94163 Tg Jig terminal T51B6PR Co1 Plug socket MT25B2PM Co2 Plug socket MT25B4-01 FS Flow switch XYK-0.06/0.03 CT Current transformer ZCT4 ZNR1 Surge absorber DNR10D102 ZNR2,3 Surge absorber DNR20D112 ZNR1,2,3 Surge absorber DNR10D471(YC-300WP5HD□) G1 Spark gap DSA362MA05 Fu1 Power source 61NR010H Fu2 High frequency 61NR050H S1 Power switch AJ461003F S8 Crater AJ461203F S9 Power frequency selector switch SDS201N5B PL1 Pilot lamp (Power source) DB40NBG PL2 Pilot lamp (Warning) DB40NBY C1 Capacitor ECQE12104KF C3 Capacitor CBB61-7uF-200V C4 Capacitor XS17A506FP4 C5 Capacitor ITY8611 C10 Capacitor ECQM1104KZ C11 Capacitor ECQE6474KF fan selector fuse fuse switch 20 26 PARTS LIST YC-300WP5 DV No Name of parts TYPE,RATING QT R1,2 Resistor RXGB120W100J R3 Resistor SFW30A501 R4 Resistor SFW10A100 R5 Resistor RX27-4V10W10K-J R6 Resistor MOG2ANJ103 R8 Resistor SFW40A100 VR7 Cleaning width adjuster RV24YN20FB14 (10KΩ) VR8 Initial current adjuster RV24YN20FB53 Welding current adjuster RV24YN20FB53 Crater current adjuster RV24YN20FB53 P.C board TSM9427 VR1~VR6 P.C board TSM9450 S2~S7 Switch P C board TSM9447 P.C board TSM9449 P.C board TSM9448 P.C board TSM9451□ P.C board TSMP461 REMARK: POWER SOURCE MODEL YC-300WP5HDF MAIN TRANS D.C reactor CONTROL TRANS ZNR ASS’Y TSM92805 TSMLU106 TSM92807 TSM06511 YC-300WP5HDM TSM92805 TSMLU106 TSM92807 TSM06511 YC-300WP5HGH TSM92961 TSMLU106 TSM92037 TSM00348-04 YC-300WP5HGM TSMTU092 TSMLU067 TSM92037 TSM00348-04 YC-300WP5HJE TSM94591 TSMLU106 TSM92037 TSM00348-04 27 21 No Description Gas outlet Remote controller socket Output terminal(Base metal) Output terminal(Torch) Remote controller socket Water outlet No 10 11 Description Cable inlet for JIG terminal Input cable Water inlet Grounding 465 446 617 607 ⑤ ⑨ ⑥ ⑩ ① 11 ⑦ ② ③ ④ YC-300WP5HGE 外形图 OUTLINE DRAWING 2228 796 846 ⑧ 【The standard of the product】 This product is designed and manufactured according to GB15579.1-2004 This product may not conform to the local laws and standards of other countries Please be absolutely sure to consult with us before attempting to relocate or resell this product to other countries 【ATTENTION: The disposal of the product】 In case of disposal of the product, please sign the assignment agreement on disposal treatment with the authorized organization and then assign the organization to dispose the product 【NOTICE：Machine export to Europe】 This product does not meet the requirements specified in the EC Machinery Directive which is the EU safety ordinance that will be enforced starting on January , 1995 Please bear in mind that this product may not be brought as is into the EU after January 1, 1995 The same restriction also applies to any country which has signed the EEA accord 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 May,2011 Printed in China 29 ... electrode ● Follow the standard for safety when using the grinding machine Rating YC- 300WP5 HDF、HDM YC- 300WP5 HGH、HGM YC- 300WP5 HJE V 220 380 415 V 220±10% 380±10% 415±10% Item Type Rated Input Voltage... Capacity of Distribution Box Input Cable Output Cable z z z Commercial source YC- 300WP5HDF、 HDM YC- 300WP5HGH、 HGM YC- 300WP5HJE 220±10% 380±10% 415±10% power Primary line current Min.36kVA 118A... REMARK: POWER SOURCE MODEL YC- 300WP5HDF MAIN TRANS D.C reactor CONTROL TRANS ZNR ASS’Y TSM92805 TSMLU106 TSM92807 TSM06511 YC- 300WP5HDM TSM92805 TSMLU106 TSM92807 TSM06511 YC- 300WP5HGH TSM92961 TSMLU106