Panasonic YC-300WY User manual

Operating Instructions
IGBT controlled AC/DC TIG arc welding power source
Model No. : YC-300/500WY
YC-500WX
● 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-300WY4HJE、YC-500WY4HJE、YC-500WX4HJE
.
Panasonic Welding Systems (Tangshan) Co., Ltd.
TSM81248-03

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 EEAaccord.
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 EEAaccord.

CONTENTS
S a f e t y -------------------------------------Ⅰ
I m p o r t a n t S a f e t y I t e m s - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ⅱ
R a t i n g A n d S p e ci f i c a t i o n s - - - - - - - - - - - - - - - - - - - - - 1
Preparation-------------------------------------3
F u n c t i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
C o n n e c t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
M e t h o d O f O p e r a t i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
M a i n t e n a n c e A n d I n s p e c t i o n - - - - - - - - - - - - - - - - - - - 17
P r e c a u t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
C o n n e c t i o n W i t h O t h e r E q u i p m e n t - - - - - - - - - - - - - - - - 23
T r o u b l e s h o o t i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
C i r c u i t d i a g r a m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
P a r t s L i s t - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
P a r t s L a y o u t D r a w i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
O u t l i n e D r a w i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
C h a r a c t e r i s t i c s O f I n d i v i d u a l W e l d i n g M e t h o d s - - - - -31

I
Safety
Warning symbols for safe usage
Each symbol describes things to be observed to prevent you and other personnel from hazardous
conditions or damage to property.
●The followings explains harzardous conditions
or damages that are classi-fied into the
following three levels.
●The following symbols indicates things to be
observed.
Things that MUST NOT be
performed.
A hazardous situations including death or serious
personal injury is imminent.
Things that MUST be performed.
The potential for a hazardous accident including
death or serious personal injury is high.
Things attention must be paid to.
The potential for hazardous accident including light
personal injury and/or the potential for property
damage are high.
◆Disclaimer：
Panasonic Welding Systems（Tangshan）Co., Ltd., (hereinafter called “PWST”) and its affiliates (including
any subcontractor, sales company or agent) shall not assume or undertake any responsibility or liability of
the followings:
•Any problem arising out of, or directly or indirectly attributable to,the failure of user to carry out those
normal maintenance, normal adjustment and periodical check of this product.
•Any problem arising out of any force majeure, including but not limited to, act of god.
•Any malfunction or defect of this product that is directly or indirectly the result of any malfunction or
defect of one or more related parts or products that are not supplied by PWST. Or any problem arising
out of, or directly or indirectly attributable to, the combination of this product with any other product,
equipment, devices or software that is not supplied by PWST.
•Any problem arising out of, or directly or indirectly attributable to,user’s failure to strictly carry out or follow
all of the conditions and instructions contained in this instruction manual, or user’s misusage, mishandle,
operational miss or abnormal operation.
•Any problem arising out of this product or the use of it, the cause of which is other than the foregoing but
is also not attributable to PWST.
•Any claim of a third party that this product infringes the intellectual property rights of such third party that
are directly or indirectly caused by user’s use of this product and relate to the method of production.
●The description of this manual is based on the contents as of July, 2019.
●The contents of this manual are subject to change without further notice.
●English version is the original instructions.

II
Safety precautions
welding power source
Observe the following instructions to
prevent the hazard.
(1)Never use the welding power source for other than
welding purpose. (e.g. Never attempt to use the welding
power source for pipe thawing.)
(2)It is very important to comply with all instructions,
safety warnings, cautions and notes mentioned. Failure
to do so can result in serious injury or even death.
(3)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
instructions and national, state and local codes and
regulations.
(4)Prevent any unauthorized personnel to enter in and
around the welding work area.
(5)Pacemaker wearers should consult their doctor before
going near arc welding. Magnetic fields can affect
pacemakers.
(6)Only educated and/or skilled persons who well
understand this welding power source should install,
operate, maintain and repair the unit.
(7)Only educated and/or skilled persons who well
understand the operating instructions of the unit and are
capable of safe handling should perform operation of the
unit.
Against electric shock
Observe the following instructions to
prevent the hazard.
(1)Do not touch live parts.
(2)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.
(3)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.
(4)Do not use undersized, worn, damaged or bare wired
cables.
(5)Connect cables firm and insulate connection parts.
(6)Keep all cases, panels and covers securely in place.
(7)Do not handle the welding power source with torn or
wet gloves.
(8)Wear safety harness in case of working above floor
level.
(9)Turn off all equipment when not in use.
(10)Perform periodic checks without fail and repair or
replace any damaged parts before using the power
source.
Ventilation and protective equipment
Oxygen deficit, fume and gas generated
during welding can be hazardous.
(1)When conducting welding in the bottom of the tank,
boiler or hold as well as legally-defined sites, use a local
exhauster specified by the applicable laws and
regulations (occupational safety and health regulation,
rules on preventing suffocation or etc.) or wear
protective breathing gear.
(2)To prevent dust injury or poisoning by the fume
generated during welding, use a local exhauster specified
by the applicable law (occupational safety and health
regulation, rules on preventing injury by inhaled dust or
etc.), or wear protective breathing gear.
(3)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.
(4)Do not conduct welding at a site where degreasing,
cleaning or spraying is performed. Conducting welding
near the area where any of these types of work is
performed can generate toxic gases.
(5)When welding a coated steel plate, provide sufficient
ventilation or wear protective breathing gear. (Welding
of coated steel plates generates toxic fume and gas.)
Against fire, explosion or blowout
Observe the following cautions to
prevent fires explosion or blowout.
(1)Remove any combustible materials at and near the
work site to prevent them from being exposed to the
spatter. If they cannot be relocated, cover them with a
fireproofing cover.
(2)Do not conduct welding near combustible gases.
(3)Do not bring the hot base metal near combustible
materials immediately after welding.
(4)When welding a ceiling, floor or wall, remove all
flammables including ones located in hidden places.
(5)Properly connect cables and insulate connected
parts. Improper cable connections or touching of
cables to any electric current passage of the base
metal, such as steel beam, can cause fire.
(6)Connect the base metal cable at a section closest to
the welding part.
(7)Do not weld a sealed tank or a pipe that contains a
gas.
(8)Keep a fire extinguisher near the welding site for an
emergency.

III
Installing shielding (curtain etc.)
Arc flash, flying spatter, slugs, and
noise generated during welding can
damage your eyes, skin and hearing.
(1)Install a protective curtain around the welding
manipulator site to prevent the arc flash from
entering the eyes of people in the surrounding area.
(2)When welding or monitoring welding, wear safety
glasses with sufficient light blocking structure or
use a protective mask designed for welding
operation.
(3)When welding or monitoring welding wear protective
clothing designed for welding operation, such as
leather gloves, leg cover and leather apron, and also
wear long-sleeve shirts.
(4)Be sure to wear noise-proof protective equipment if
the noise level is high.
(5)The larger the welding current is, or in case of AC
TIG or MIXTIG welding, the larger the AC frequency
is, the larger the arc sound becomes.
Gas cylinder and gas flow regulator
Overturn of gas cylinder and
blowout of gas flow regulator can
cause injury.
(1)The gas cylinder must be handled properly according
to the applicable law and in-house standards.
(2)Use the gas flow regulator that is supplied or recom-
mended by our company.
(3)Read the instruction manual of the gas regulator prior
to using it, and observe the cautions in the manual.
(4)Secure the gas cylinder to a dedicated gas cylinder
stand.
(5)Do not expose the gas cylinder to high temperature.
(6)When opening the valve of the gas cylinder, do not
bring your face close to the discharge outlet.
(7)When the gas cylinder is not used, be sure to install a
protective cap.
(8)Do not hang the welding torch on the gas cylinder, or
touch the gas cylinder with the electrode.
(9)Do not attempt to disassemble or repair the gas
regulator. Such works require special knowledge.
Rotating parts
Rotating parts can cause injury.
(1)Keep away from rotating parts such as cooling fans，
and 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.
(2)Keep all covers, panels and cases closed when
using the product.
(3)Maintenance work and repair should be perform only
by educated and/or skilled persons who thoroughly
understand welding machines. While
performing maintenance work or repair work, provide
fence or the like around the welding machine so that
unauthorized person can not come close carelessly.
Welding wire
Welding wire, especially wire tip part
can cause injury.
(1)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 extends out from the end
of the welding torch and may stick into the eye,
face or body.
(2)In case of using a torch cable with the resin liner,
straighten the torch cable and reduce the preset feed
amount (current) to a half or less before applying
the wire inching.
(3)Performing wire inching while torch cable has been
bent extremely can cause the wire to pierce the
resin liner and cable. Make sure to replace any
damaged liner or cable with a new one, or damaged
liner/wire can cause gas leak or dielectric
degradation.
. Against insulation deterioration
Insulation deterioration can cause fire
of welding power source.
(1)Keep enough distance from welding power source
when performing welding or grinding work so as to
prevent spatters or iron particles from getting
into the power source.
(2)Perform check and maintenance work periodically
so as to prevent insulation deterioration due to
accumulated dust or dirt.
(3)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.
(4)Make sure to replace any damaged liner or cable
with a new one as use of damaged liner/cable may
cause gas leak or dielectric degradation.
(5)In order to avoid dust and dirt to be collected inside
of the power source, make sure not to leave the
panel and bolts (including eyebolts) open and
removed.

IV
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.
2 The degree of protection is IP21S, appropriate coverage is required in case of rain.
3 When using forklift, please fork welding machine at the side with “Fork” mark to avoid falling.
4 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 than15 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.

YC-500WY4
YC-500WX4
415

Item
Type YC-300WY 4
Rated input voltage V415
Phase
Three phase
Input voltage fluctuation tolerance
Rated input voltage ±10％
Rated frequency Hz 50/60 (in common.)
Rated input
kVA
kW
10.5
9.5
No load voltage DC STICK V
voltage reducing "ON" : 14
voltage reducig "OFF" : 63
TIG A 4~300 D.C. output current
STICK A4~250
MIX TIG A 1 10-300
A.C. STD. TIG A 10~300
A.C. HARD TIG A 20~300
A.C. output current
A.C. SOFT TIG A 10~200
TIG V 10.2~22
Rated D.C output
voltage
STICK V 20~30
MIX TIG V 10.4~21
A.C. STD. TIG V 10.8~22
A.C. HARD TIG V 10.8~22
Rated A.C. output
voltage
A.C. SOFT TIG V 10.4~18
A.C. STD.MIX.INITIAL.CRATER current A 10~300
D.C. INITIAL.CRATER current A 4~300
A.C. SOFT.INITIAL.CRATER current A 10~200
A.C. HARD.INITIAL.CRATER current A 20~300
Rated duty cycle %4 40
Gas preflow time s0.3
Gas postflow time s 2~20
Upslope time s 0 or 0.1~5 N.B 1)
Downs lope time s 0 or 0.2~10 N.B 1)
MIDDLE PULSE Hz 10~500 Pulse frequency
LOW PULSE Hz 0.5~25
Pulse width % 15~85
Cleaning width
A.C. STD. TIG, MIX TIG, A.C.
SOFT TIG, A.C. HARD TIG
MIX TIG frequency Hz 0.5—10
Crater control process "ON" "OFF" "REPEAT"
Outside dimension mm 380（W）×530（D）×730（H）
Mass kg74

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－2－

PREPARATION
(1) Capacity of power supply facility and connecting cable
Item Model YC-300/500WY4 /500WX4
Supply voltage V415
Phases Three-phase
Faci1ity kVA 40 or more
Primary 1ine current A approx.36.5
Input cable mm2 14 or more
Output cable mm2 60 or more
N.B.
• Turn off the switch of the switch box when connection cable.
• Provide a switch box for every welder and use a specified fuse.
• Power supply cable should be 14mm
2
or more in sectional area if its length is more than
10m.
• If an engine generator is used, it should be provided with an inverter of capacity from
three to five times of that of the welder with compensating winding for thyristor equipment.
(2) Required equipments and materials
Prepare the following equipments and materials to perform welding work.
[TIG welding]
TIG welding torch (purchased separately)
Argon gas for welding (purity over 99.9%) (purchased separately)
Argon gas regulator (purchased separately)
Base metal side cable (purchased separately)
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