Panasonic YD-200KR User manual

● 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-500KR2HJG
Panasonic Welding Systems (Tangshan) Co., Ltd.
Model No. YD-200KR
YD-350KR
YD-500KR
Operating Instructions
Thyristor Controlled MIG/MAG Arc Welding Power Source
TSM80227-05

１
C0NTENTS
PREPARATIONS
INSTALLATION FLACE AND POWER FACILITY ………………………………………………………………… 1
OVERALL CONNECTION DIAGRAM OF EQUIPMENT ………………………………………………………………3
CONNECT10N ……………………………………………………………………………………… 4
W el d i n g P ow e r S o u r ce a nd Sw i t c h B ox ………………………………………………4
Welding Power Source and Output S ide ………………………………………………5
Welding Power Source and Wire Feeder ………………………………………………6
C o n n e c t i n g t h e G a s R e g u l a t o r ………………………………………………7
COMPONENT UNITS AND THEIR FUNCTIONS ………………………………………………………8
Welding Power Source(Operation Panel) ……………………………………………8
Remote Controller ………………………………………………………………………10
BASICS
CHECKS AND PREPARATIONS FRIOR TO OPERATION………………………………………………11
Wearing the Safety Protective Gear………………………………………………………11
Adjusting the Gas Flow Rate ………………………………………………………1 2
Attaching the Welding Wire………………………………………………………1 3
Feeding the Wire by Inching Operation…………………………………………………14
WELDING BY MAN U AL OPE RA T ION ……………………………………………………………… 15
Welding with Crater Control Enabled………………………………………………………15
Welding with Crater Control Disabled………………………………………………………16
DUTY CYCLE……………………………………………………………………………………………… 17
APPLICATIONS
EXTENDED FUNCTIONS… … … … … … … … … … … … … … … … … … … … … … … … 1 8
C o n n e c t i n g t h e E x t e n s i o n C a b l e … … … … … … … … … … … … … … … … 1 8
S w i t c h e s a n d C o n t r o l s o n t h e P r i n t e d C i r c u i t B o a r d ……………………1 9
Setting the Selector Swi tches On the Printed Cir cuit Board… …… … …… 20
A d j u s t i n g t h e C o n t r o l s o n t h e P r i n t e d C i r c u i t B o a r d ……………………2 3
Switching the DC Reactor Tap ……………………………………………2 3
FOR YOUR INFORMATION
DAILY INSPECTION ………………………………………………………………2 4
W e l di n g P o w e r S o u rc e ………………………………………………………………2 4
C a b l e s ………………………………………………………………………2 5
PERIODIC INSPECTION ………………………………………………………………………2 6
INITIAL TROUBLE DIAGN0SIS………………………………………………………………………28
O T H E R T R O U B L E A N D E R R O R S … … … … … … … … … … … … … … … … … … … … … … … … 3 0
Trouble Shooting ………………………………………………………3 3
A F T E R - S A L E S E R V I C E ………………………………………………………………………3 4
P A R T S L A Y O U T D R A W I N G ………………………………………………………………………3 5
PARTS LIST………………………………………………………………………3 7
C I R C U I T D I A G R A M … … … … … … … … … … … … … … … … … … … … … … … … 4 0
O U T S I D E D R A W I N G … … … … … … … … … … … … … … … … … … … … … … … … 4 2
GLOSSARY… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 4 3
EXAMFLE OF WELDLLG COHOIT10NS………………………………………………………4 5
R A T I N G S A N D S P E C I F I C A T I O N S ………………………………………………………4 6

２
WARNINGS AND CAUTIONS FOR SAFETY
For your safety, be sure to observe the following.
■！Warning! In Order to Avoid Serious Accident Result in Injury or Death
Carry Out Grounding Work:
In order to prevent you from getting an electric shock, carry out grounding work provided
by the law.
Wear The Proper Work Uniform and Safety Protective Gear:
In order to prevent inflammation of your eye or skin burn, wear a proper protective gear.
Carry out Ventilation:
In order to prevent gas-poisoning or suffocation (welding fume and carbon monoxide are
harmful to the human body), install a local exhauster, etc. or use an effective inhaler.
■！Caution ！In Order to Prevent Burn-Out of Equipment or Fire
Prevent a Fire or Burn-out of the Equipment due to Overheat:
Install a welding power unit 20 cm or more away from the wall and 50 cm or more from an
inflammable substance.
Prevent a Fire or Burn-out of the Equipment due to Spark:
See to it that spark(spatter, flash) will never reach an Inflammable substance or fall
on the equipment and enter inside through an air Inlet or opening.
Prevent an Injury to Your Body or Damage on the Equipment due to a Fall or Overturn:
When installing the equipment on the trestle, secure safety by preventing its dislocation
or fixing it with anchor bolts. (Be sure to prevent a gas bomb from turning over)
Be Sure to Read the Instruction Manuals:
In addition to the instruction manual for this machine, be sure to read those for the wire
feeder, we1ding torch, and gas regulator for proper use.

３
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 1 , 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.
ACCESSORIES
We1ding power source
Name
Code No.
Q’ty
Glass tube fuse (1A)
61NR010H
1
Glass tube fuse (3A)
61NR030H
1
Glass tube fuse (8A)
61NR080H
1

１
INSTALLATION PLACE AND POWER SOURCE FACILITY
Installation Place
Power Source Facility
Power source
YD-200KR2
YD-200KR2HD□
YD-200KR2HG/N□
YD-200KR2HK□
YD-200KR2HJ□
3-Phase 220V
3-Phase 380V
3-Phase 440V
3-Phase 415V
Frequency
50/60Hz (Switchable on the printed circuit board)
Facility
capacity
Commercial power
source
10kVA
Engine generator
Twice large than 7.6 kVA with compensating winding.
Primary line current
Approx. 20A
Approx. 11.5A
Approx. 10A
Approx. 10.6A
Cable
sectional
area
Welding source
input side
8mm2or more
5.5mm2or more
5.5mm2or more
5.5mm2or more
Welding source
output side
38mm2or more
Power source
YD-350KR2
YD-350KR2HD□
YD-350KR2HG/N□
YD-350KR2HK□
YD-350KR2HJ□
3-Phase 220V
3-Phase 380V
3-Phase 440V
3-Phase 415V
Frequency
50/60Hz (Switchable on the printed circuit board)
Facility
capacity
Commercial power
source
20kVA
Engine generator
Twice large than 18.1 kVA with compensating winding.
Primary line current
Approx. 47.5A
Approx. 27.5A
Approx. 23A
Approx. 25.2A
Cable
sectional
area
Welding source
input side
14mm2or more
8mm2or more
8mm2or more
8mm2or more
Welding source
output side
38mm2or more
PREPARATIONS
Avoid the direct sunshine and rain, and install in
an indoor place with less humidity and dust.
(Indoor ambient temperature -10 to 40℃)
Install the welding source 20cm or more away from the
wall: when installing two or more units, they should
be separated 30 cm or more from each other.
Do not install in a place where a metallic foreign
substance may enter inside the welding source.
Install in a place where welding arc is not exposed
to the wind. (Set up a screen. etc. to prevent the
wind.)

２
Power source
YD-500KR2
YD-500KR2HD□
YD-500KR2HG/N□
YD-500KR2HK□
YD-500KR2HJ□
3-Phase 220V
3-Phase 380V
3-Phase 440V
3-Phase 415V
Frequency
50/60Hz (Switchable on the printed circuit board)
Facility
capacity
Commercial power
source
40kVA
Engine generator
Twice large than 31.9 kVA with compensating winding.
Primary line current
Approx. 83.7A
Approx. 48.3A
Approx. 41.9A
Approx. 44.4A
Cable
sectional
area
Welding source
input side
22mm2or more
14mm2or more
14mm2or more
14mm2or more
Welding source
output side
38mm2or more
When using at a construction site or in a humid place or on an iron plate or steel frame, a
leakage breaker should be also installer.
…………………………………………………………………………………………………………………
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.
Wiring on the input side: Attach a switch with fuse of specified capacity or no-fuse
Breaker (or leakage breaker) to the switch box for each
welding source.
When using the no-fuse breaker or leakage breaker, select those for the welding machine
or motor or transformer.
This machine has input power frequency select switch. Please confirm the correct position
of the switch. (Refer to Pages 22,23 and 25 )
This machine should be used in combination with the specified wire feeder.
Caution

３
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.
PREPARATIONS
Welding Torch
Switch box
(3-phase rated)
Input Voltage)
Gas Regulator
Grounding
Input Cable
Heater Cable
Gas Hose
Gas Bomb
Grounding
Wire Feed Control Cable
Output Cable
Base Metal Cable
Base Metal
Welding Wire
Wire Feeder
Grounding

４
CONNECTION
Welding Source Switch Box
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.
Do not touch with a wet hand.
Electrical connection work and grounding work should be carried out by a qualified .
In order to prevent a fire or burn-out of the device due to overheat of the cable or to prevent
generation of unstable arc。
Use the cable of the specified thickness or more. (Refer to page 5)
Do not place a heavy substance on the cable or bring it into contact with a weld Zone.
Tighten securely a cable joint.
This machine has input power frequency select switch. Please confirm the correct
position of the switch. (Refer to pages 22,23 and 25.)
When a frequency changes depending on where you use the welding source, switch to an
adequate frequency.
PREPARATIONS
Safety Warning
① Loose the left and right
screws to remove the cover.
⑤Connect input cables(3 of them) to
the switch with fuse or no-fuse
breaker (or leakage breaker).
② Connect the input
cables (3 of them) to
the input terminals.
3-phase rated
input voltage
③Tape around any exposed
conductive sections which
may come into contact with
other parts
Welding Power Source
Switch
Box
Cover
Input Terminal
⑥Ground with cable
④Attach the cover
Caution

５
CONNECTION (CONTINUED)
Welding Power Source and Output Side
PREPARATIONS
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
put back the terminal cover)
②Remove two bolts from
the terminal cover.
⑦Connect the other end
of the base metal cable
to the base metal.
Minus
terminal
Plus
terminal
Base Metal
Cable
④Using an accessory
bolt, connect the
base metal cable to
the minus(-)
terminal.
⑤ Using an accessory
bolt, connect the output
cable coming from the
wire feeder to the
plus(+) terminal.
⑥ Tape around any exposed
conductive sections which may
come into contact with other
parts.
⑧Ground the base metal
Installing
tape
Terminal cover

６
CONNECTION (CONTINUED)
Welding Power Source and Wire Feeder
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.
PREPARATIONS
Caution
For handling of the wire feeder and welding torch, read their respective instruction
manual.
① Turn off the POWER
switch.
Align
the guide
Guide
②Align a guide, insert,
and fix with a ring screw.
Ring Screw
Wire Feeder
Output cable (connect to the
plus terminal of the welding
power source)
Gas hose
(Connect to the
gas regulator)
⑤Connect a gas
hose to a gas
outlet fitting.
Gas outlet
fitting
Welding Torch
Locking Bolt
CC Fixture
Confirm that
it does not
come off,and
fix
④Align a guide, Insert,
and fix with a ring screw.
③Insert into a CC
fixture to
connect.
Tips

７
CONNECTION (CONTINUED)
Connecting the Gas Regulator
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.
There is a plug socket for the gas regulator on the upper rear side of the welding power unit.
Be aware of the following:
A pin layout of the plug socket is when you face the rear side of the welding unit.
The pins 2 and 3 have been short-circuited inside the welding power unit upon shipment.
As the heater power for the gas regulator, 100 V AC is applied to between the pins 1
and 3.
When obtaining the heater power from other than the exclusive plug socket of the welding
power unit, you will need a power source of 100 V AC, 2 A or more.
A quality of the gas used has a direct effect on welding. be aware of the following:
In case of CO2welding, use carbon dioxide gas with moisture content of 0.005% or less,
or "welding" carbon dioxide gas.
For a mixed gas in case of MAG welding, use MAG welding gas (argon gas with 5 to 20%
carbon dioxide gas).
When mixing two kinds of gas(carbon dioxide gas and argon gas) for use, use a gas mixer.
(In order to avoid irregular mixture)
Argon gas to be mixed should be high-purity welding argon gas(purity of 99.9% or higher)
PREPARATIONS
Warning for Safety
1Attach the gas regulator to the gas
bomb with a lock nut and tighten it
fully with a monkey wrench, etc.
Connecting to the Plug socket for Gas
Regulator
Caution
Caution
Lock Nut
Gas Bomb
Gas Regulator
This is a power plug socket for
a heater to prevent freezing of
the gas regulator when welding
with carbon dioxide gas.
Never use it for other than the
heater power for the carbon
dioxide gas regulator.
④Be sure to ground
with a cable.
②Connect the gas hose to the gas
hose joint. (Fix it firmly with
an
accessory hose band)
Plug Socket for Gas Regulator
③Connect the heater cable to the plug socket.

８
COMPONENT UNIT AND THEIR FUNCTIONS
Welding Power Source(Operation Panel)
PREPARATIONS
Ammeter
Wire Diameter Selector Switch
Indicates a welding current
value.
Refer to n0te) at the lower
right on this page.
Select a desired wire diameter according to
your need.
Note) The figure shows the switch for the
YD-200KR2 and YD-350KR2.
The YD-500KR2 has wire diameter
choices of 1.2, l.4, and 1.6.
Fuse
A power fuse for the
control circuit is
Fuse
A feeder motor
fuse
Voltmeter
Indicates a
welding voltage
value
Crater Selector Switch
POWER Switch
Wire Selector Switch
Selects whether to enable crater
control.
(Refer to pages 18, 19, and 43)
enable : ON disable: OFF
Select either the flux
cored wire in conformity
with your wire.
Turns on/off this equipment.
Note)
Occasionally the power switch
operation make small flickering
of the ammeter.
But the machine does not output
any current from the terminal.

９
FEEL SAFE TO USE IT.
Welding power source
PREPARATIONS
Crater Current Control
When “CRATER ON”is selected with
the crater selector switch, you can
control a crater welding current
value.
Crater Voltage Control
When “CRATER ON”is selected with the crater selector
switch, you can control a crater welding voltage. Note)
When SIMPLE UNIFIED is selected (refer to pages 25 and
44), this serves as a crater voltage fine control.
A unified crater voltage may not be an optimum
condition, depending on a welding posture, wire brand,
and length of an extension cable. If this is the case,
the crater voltage can be finely adjusted "lower" by
turning this control to the left, and "higher" by
turning to the right.
Gas Supply Switch
Warn. Indicator Lamp
Power Indicator Lamp
Prior to welding, use this
switch to adjust a gas flow
rate in advance. Set it to
the “CHECK”side.
(Refer to page 15)
When a warn. occurs, this
lamp goes on. It informs
you of an warn inside the
welding power source.
(Refer to page 34)
This lamp indicates a
power-on/-off state.
Turning on the POWER switch
Illuminates a green lamp.

１０
FEEL SAFE TO USE IT.
REMOTE CONTROLLER
The remote controller is fixed to the wire feeder.
PREPARATIONS
Scale Plate
Both sides of the plate is used properly,
depending on a type of setting;
INDIVIDUAL or SIMPLE UNIFIED.
When SIMPLE UNIFIED is selected (select
on the printed circuit board: refer to
Page 25),reverse the scale plate for use.
Welding Current Control
Pressing this switch feeds the welding wire.
Although a feed rate can he adjusted with the
adjacent welding current control, select a
low speed because the wire tends to buckle as
its diameter decreases.
The wire can be only fed out.
(It cannot be wound in. )
Scale Plate Fixing Bolt
Capable of adjusting a welding
current value.
Note) When SIMPLE UNIFIED is
selected, the welding voltage is
internally processed so that it
automatically assumes an
appropriate value with respect to
a set current value. This is
called simple unification)
Welding Current Control
Capable of adjusting a welding voltage.
Note) When SIMPLE UNIFIED is selected (refer to page
25). It works as a fine control for the simple unified
welding voltage. With this control being at a
standard position, the welding voltage may not be an
optimum condition, depending on a welding posture,
wire brand, and length of the extension cable, wire
projection length. If this is the case, the welding
voltage can be finely adjusted "lower" by turning
this control to the left, and “higher”by turning to
the right.

１１
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.
Take an appropriate measure for ventilation in order not to inhale toxic gases (Carbon
monoxide. Ozone. Nitrogen oxide, etc.) or metallic fume.
Confirmation of Complete Connection
Make sure again that the entire equipment is connected as shown in OVERALL CONNECTION
DIAGRAM (refer to Page 6).
In case of gas shielded arc welding (CO2welding or MAG welding), alter the light-shielding
degree of the light-shielding filter plate to be used, according to the upper limit value of
the service welding current.
BASICS

１２
CHECKS AND PREFARATIONS PRIOR TO OPERATION
Adjusting the Gas Flow Rate
Switch Box
③Set the GAS SUPPLY
switch to CHECK.
④Set the GAS SUPPLY
switch to WELD.
1Turn on the switch
of
the switch box.
②Turn on the POWER
switch
Welding Power Source
Flow Meter
Gas Regulator
Primary
Pressure Gauge
④Open the main valve of the gas bomb. (Prior to
opening it, make sure that a flow rate control
knob is turned to the SHUT side)
⑤Turn the flow rate control knob
gradually toward OPEN so that a flow
meter indicates a required value.
Flow Rate Control Knob
Gas Bomb
Earthing
Terminal
BASICS

１３
CHECKS AND PREFARATIONS PRIOR TO OPERATION
Attaching the welding wire
Attach a feed roller in
the direction which
allows you to see the
same numeral as the wire
diameter used. (The
figure above shows an
example of attaching
“l.2”of the 0.9/1.2
feed roller)
⑩Put back a pressure arm and pressure nut in
that order.
Pressure
Nut
②Shaft
down
③Lift up.
Pressure
Arm
④Loosen a lock nut
a n d c o r r e c t i o n
adjusting bolt in
that orde r .
(Not required for
the 200KR2/350KR2)
1Make sure that the
m o u n t e d f e e d
roller conforms to
a diameter of the
w e l d i n g w i r e .
Wire
Correction
Roller
Lock nut
Correction Adjusting Bolt
CC Fixture
Wire Stopper
Hole
Feed Roller
Knob Screw
Spool Clamping Washer
Wire
Correction Roller
⑤ Loosen a knob screw to remove a spool clamping
washer.
⑥Attach the welding wire to the spool fitting. (In the
clockwise direction of the wire spool)
⑦Put back the spool clamping washer and tighten the
knob screw.
⑧Remove a wire stopper from the outer edge of the wire
spool.
(Be careful of the wire jumping up of getting loose)
(11)Turn the pressure nut to make a pressurization
force
commensurate with a diameter of the welding wire.
⑨Pull out the welding wire. Insert it
into the CC fixture, putting it
through the correction rollers
(Wire guide for the 200KR2/350KR2)
BASICS

１４
CHECKS AND PREFARATIONS PRIOR TO OPERATION
Feeding the Wire by Inching Operation
Inching Switch
Regardless of a kind of the wire, select the feed roller according to the wire diameter. When
the flux contained wire is used, it is necessary to adjust the wire pressurization force slightly
weaker than the solid wire. There are many kinds of flux contained wire and may require
delicately different pressurization forces, depending on their brands or manufacturing methods.
Care should be taken when adjusting the wire pressurization force.
For your safety. be sure to turn "off" the switch of the switch box located on the input
side of the welding power source (switch with fuse or no-fuse breaker or leakage breaker)
and POWER switch of the welding power source.
At the time of inching, do not peep through a tip hole to check if the wire is being fed.
It is very dangerous because the wire may fly out and stick into your face or eye.
BASICS
1Hold 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.
Tip
Warning for safety

１５
WELDING BY MANUAL OPERATION
Welding Crater Control Enable (Self-holding Crater Operation)
Welding with crater control enabled is used for welding a medium-thickness plate in order to
fill up a bead concave at the end of welding.
enable : ON disable : OFF
Operation Procedure
Set the CRATER “ON/OFF”Selector switch to CRATER “ON”and turn on/off the torch switch
twice to perform welding.
Again Operation Timing Chart
Thus, operating the torch switch allows self-hold of switch operation and lowers the welding
current at the end of welding to enable crater treatment.
If arc discontinues for 0.5 second or more during welding, however, self-hold will be cancelled.
BASICS
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 20, and observe a duty cycle in using the equipment.
Using only this switch
allows you to
start/stop operation.
CRATER
ON/OFF
Selector Switch
Welding Arc Start
Welding Arc
Maintained
(Self-Hold)
Changed to
Crater Welding
Arc
Welding Arc Stop
Torch Switch ON
Torch
Switch OFF
Torch Switch
ON Again
Torch Switch
OFF
Torch Switch
Gas Supply
Wire Feed
Welding Voltage
Welding Current
Welding Condition Adjustment
Tpf = Gas preflow time
☆ = Arc start timing
★ = Arc stop timing

１６
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.
Operation Timing Chart
BASICS
Welding Arc Start
Welding Arc Stop
Torch Switch ON
Torch Switch OFF
Torch Switch
Gas Supply
Wire Feed
Welding Voltage
Welding Current
Welding Condition Adjustment
Tpf = Gas preflow time
☆ = Arc start timing
★ = Arc stop timing