Panasonic YD-500KR 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-500KR2HD0、YD-500KR2HU0
Panasonic Welding Systems (Tangshan) Co., Ltd.
Model No. YD-500KR
Operating Instructions
Thyristor Controlled MIG/MAG Arc Welding Power Source
TSM50262-02

Features
Non-remote control cable design
Convincing high reliability
Good welding performance
With individual and Simple Unitary mode
Various kinds of user-friendly design
ACCESSORIES
We1ding power source
Name
Code No.
Q’ty
Glass tube fuse (1 A)
61NR010H
1
Glass tube fuse (3 A)
61NR030H
1
Glass tube fuse (8 A)
61NR080H
1

1
C0NTENTS
SAFETY AND IMPORTANT ITEMS............................................................................................................................ 2
1.Safety.........................................................................................................................................................2
2.Important Safety Items.........................................................................................................................3
INSTALLATION PLACE AND POWER SOURCE FACILITY........................................................................................7
OVERALL CONNECTION DIAGRAM OF EQUIPMENT..................................................................................................9
CONNECTION...........................................................................................................................................................10
Welding Source Switch Box.....................................................................................................................10
Welding Power Source and Output Side.............................................................................................. 11
Welding Power Source and Wire Feeder.............................................................................................. 12
Connecting the Gas Regulator...............................................................................................................13
COMPONENT UNIT AND THEIR FUNCTIONS.......................................................................................................... 14
Welding Power Source(Operation Panel)............................................................................................ 14
REMOTE CONTROLLER.....................................................................................................................................16
CHECKS AND PREFARATIONS PRIOR TO OPERATION..........................................................................................17
Wearing the Safety Protective Gear.................................................................................................. 17
Adjusting the Gas Flow Rate.................................................................................................................18
Attaching the welding wire...................................................................................................................19
Feeding the Wire by Inching Operation............................................................................................ 20
WELDING BY MANUAL OPERATION........................................................................................................................ 21
Welding Crater Control Enable (Self-holding Crater Operation)............................................21
Welding with crater control disabled (torch switch synchronous operation)
.................................. 22
DUTY CYCLE...........................................................................................................................................................23
EXTENDED FUNCTIONS...........................................................................................................................................24
Connecting the Extension Cable (Extension Cable is Optional)
.......................................................... 24
Switch and Controls on the Printed Circuit Board...................................................................... 25
Setting the Selector Switch on the Printed Circuit Board.
................................................................26
Adjusting the Controls on the Printed Circuit Board
.......................................................................... 29
Switching the DC Reactor Tap
.................................................................................................................... 29
DAILY INSPECTION...............................................................................................................................................30
Welding power source...............................................................................................................................30
Cables........................................................................................................................................................... 31
PERIODIC INSPECTION........................................................................................................................................ 32
INITIAL TROUBLE DIAGNOSIS............................................................................................................................ 34
OTHER TROUBLE AND ERROES.............................................................................................................................. 36
AFTER-SALE SERVICE...........................................................................................................................................40
APART LAYOUT DRAWING...................................................................................................................................... 41
OUTSIDE DRAWING.................................................................................................................................................44
GLOSARY.................................................................................................................................................................45
EXAMPLE OF WELDING CONDITIONS.................................................................................................................... 47
RATINGS AND SPECIFICATIONS.......................................................................................................................... 48

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SAFETY AND IMPORTANT ITEMS
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.
Caution
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 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 do 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.

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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 do 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. Filters will restrict airflow and can cause unit to overheat.
Use of filter voids warranty.
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

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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. Conducting welding near the
area where any of these types of work is performed can generate toxic gases.
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.
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.
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. Improper cable connections or touching of cables to any
current path of the base metal, such as steel beam, can cause fire.
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,

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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, do 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.
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.

6
When spatters or iron particles get into the welding power source, turn off the power switches of the welding power
source and power distribution box, and then blow out.
.Notice: In order to get better performance and provide proper maintenance,
please follow the below instructions:
1 If welding machine is placed on a slope, a countermeasure should be taken to
keep it from falling on one side.
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 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.

7
INSTALLATION PLACE AND POWER SOURCE FACILITY
Avoid the direct sunshine and rain, and install in an indoor
place with less humidity and dust.
(Indoor ambient temperature -10 to 40℃)
Do not install in a place where a metallic foreign
substance may enter inside the welding source.
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.
Install in a place where welding arc is not exposed to the
wind. (Set up a screen. etc. to prevent the wind.)
Range of temperature of the ambient air:
（a）during welding:-10 to 40 deg-C,
（b）after transport and storage:-20 to 55 deg-C
Humid:
（a）up to 50% at 40deg-C,
（b）up to 90% at 20deg-C
Altitude above sea level: up to 1000 m.
Power Source Facility
Power source
YD-500KR2
YD-500KR2HD0
YD-500KR2HU0
3-Phase 220V
3-Phase 380V
Frequency
50/60 Hz (Switch able on the printed circuit board)
Facility
capacity
Commercial power
source
40 kVA
Engine generator
Twice large than 31.9 kVA with compensating winding.
Primary line current
Approx. 83.7 A
Approx. 48.3 A
Cable
sectional
area
Welding source
input side
22 mm2or more
14 mm2or more
Welding source
output side
38 mm2or 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.
…………………………………………………………………………………………………………………

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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 27,28 and 30)
This machine should be used in combination with the specified wire feeder.
Caution