Panasonic YC-300BP2YAF User manual

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.”
2011
Operating Instructions
Model No. YC-300BP2YAF
Fully digital controlled power source
OMCTT5639E09
Inverter TIG welding power source

Introduction
OMCTT5639E09
2
Signal Words and Safety Symbols
Disclaimer
Panasonic Smart Factory Solutions Co., Ltd. (hereinafter
called “PSFS”) and its affiliates (including any subcontrac-
tor, 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 installation, 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 indi-
rectly the result of any malfunction or defect of one or more
related parts or products that are not supplied by PSFS. 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 PSFS.
• 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 attrib-
utable to PSFS.
• Any claim of a third party that this Product infringes the intellec-
tual property rights of such third party that are directly or indi-
rectly caused by User’s use of this Product and relate to the
method of production.
ANY LOST PROFITS OR SPECIAL, INDIRECT, INCIDEN-
TAL OR CONSEQUENTIAL DAMAGES IN CONNECTION
WITH OR ARISING FROM ANY MALFUNCTION,
DEFECT OR OTHER PROBLEM OF THIS PRODUCT.
Signal Words Safety Symbols (Examples)
Indicates an imminently hazardous situ-
ation which, if not avoided, will result in
death or serious injury.
Indicates a prohibited
action.
Indicates a potentially hazardous situa-
tion which, if not avoided, could result in
death or serious injury.
Indicates a
mandatory action.
Indicates a potentially hazardous situa-
tion which, if not avoided, could result in
minor injury or property damage.
Indicates a
hazard alert.
DANGER
WARNING
CAUTION
This operating instructions manual is based on the information as of November, 2020.
The information in this operating instructions manual is subject to change without notice.
English version is the original instructions.
Introduction
• This product is useful up to 400Hz in AC TIG frequency.
• It is easy to use even with multiple functions incorpo-
rated.
(a) “Simple touch panel”
(b) “Digital display”
(c) “LCD display screen”
• As it is fully digitalized, it has the excellent reproducibility
of welding conditions.
• It can store and reproduce up to 50 different welding con-
ditions in total.
• Using an external connecting unit (option) enables it to
call its stored conditions more easily.
• An IT system can also be introduced into your welding
site by enhancing communication facilities.
(a) It can be connected to the controller “G2” of our
industrial robot “Panasonic robots VR2 series”.
(b) It can also be connected to other various open
networks*.
*: Networks constructed by using standard proto-
cols, such as TCP/IP, etc.
• Compact and lightweight / mass: 51kg (69% of our con-
ventional machine)
Caution for your safety
Read and understand this manual before installing, operat-
ing or servicing this product.
This equipment and instructions are for use only by per-
sons trained and experienced in the safety operation of
welding equipment. Do not allow untrained persons to
install, operate, or maintain this equipment.
The wiring and grounding should be done by educated
and/or skilled person.

OMCTT5639E09 3
Cautions about electromagnetic disturbance
(1) Extra precaution may be required when welding power
source is used in a domestic establishment.
(2) 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 indus-
trial 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 environ-
ment; 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.
(3) The user shall be observe to reduce emission distur-
bance as below.
(a) Welding equipment should be connected to mains
supply according to the manufacture's recommen-
dations.
(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 component 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 allevi-
ate problems of interference. Screening of entire
welding installation may be considered for special
applications.
(4) The user should take the responsibility with respect to
interference from welding.

OMCTT5639E09
4
About “Turkish RoHS Regulation”
About “Ukrainian RoHS Regulation”
EEE Complies with Directive of Turkey.
English Declaration of Conformity
with the requirements of Technical Regulation on the Restriction Of the use of certain Hazardous
Substances in Electrical and Electronic Equipment
(adopted by Order №1057 of Cabinet of Ministers of Ukraine)
The Product is in conformity with the requirements of Technical Regulation on the Restriction Of the
use of certain Hazardous Substances in electrical and electronic equipment (TR on RoHS).
The content of hazardous substance with the exemption
of the applications listed in the Annex №2 of TR on RoHS:
1. Lead (Pb) - not over 0,1wt % or 1000wt ppm;
2. Cadmium (Cd) - not over 0,01wt % or 100wt ppm;
3. Mercury (Hg) - not over 0,1wt % or 1000wt ppm;
4. Hexavalent chromium (Cr6+) - not over 0,1wt % or 1000wt ppm;
5. Polybrominated biphenyls (PBBs) - not over 0,1wt % or 1000wt ppm;
6. Polybrominated diphenyl ethers (PBDEs) - not over 0,1wt % or 1000wt ppm.
Ukrainian Декларація про Відповідність
Вимогам Технічного Регламенту Обмеження Використання деяких Небезпечних Речовин в
електричному та електронному обладнанні
(затвердженого Постановою №1057 Кабінету Міністрів України)
Виріб відповідає вимогам Технічного Регламенту Обмеження Використання деяких
Небезпечних Речовин в електричному та електронному обладнанні (ТР ОВНР).
Вміст небезпечних речовин у випадках, не обумовлених в Додатку №2 ТР ОВНР, :
1. свинець(Pb) – не перевищує 0,1wt % ваги речовини або в концентрації до 1000 частин
на мільйон;
2. кадмій (Cd)– не перевищує 0,01wt % ваги речовини або в концентрації до 100 частин на
мільйон;
3. ртуть(Hg) – не перевищує 0,1wt % ваги речовини або в концентрації до 1000 частин на
мільйон;
4. шестивалентний хром (Cr6+ ) – не перевищує 0,1wt % ваги речовини або в концентрації
до 1000 частин на мільйон;
5. полібромбіфеноли (PBB) – не перевищує 0,1% ваги речовини або в концентрації до
1000 частин на мільйон;
6. полібромдефенілові ефіри (PBDE) – не перевищує 0,1wt % ваги речовини або в
концентрації до 1000 частин на мільйон.
Russian Декларация о Соответствии
Требованиям Технического Регламента об Ограничении Использования некоторых Вредных
Веществ в электрическом и электронном оборудовании
(утверждённого Постановлением №1057 Кабинета Министров Украины)
Изделие соответствует требованиям Технического Регламента об Ограничении
Использования некоторых Вредных Веществ в электрическом и электронном оборудовании
(ТР ОИВВ).
Содержание вредных веществ в случаях, не предусмотренных Дополнением №2 ТР ОИВВ:
1. свинец (Pb) – не превышает 0,1wt % веса вещества или в концентрации до 1000
миллионных частей;
2. кадмий (Cd) – не превышает 0,01wt % веса вещества или в концентрации до 100
миллионных частей;
3. ртуть (Hg) – не превышает 0,1wt % веса вещества или в концентрации до 1000
миллионных частей;
4. шестивалентный хром (Cr6+)– не превышает 0,1wt % веса вещества или в
концентрации до 1000 миллионных частей;
5. полибромбифенолы (PBB) – не превышает 0,1wt % веса вещества или в концентрации
до 1000 миллионных частей;
6. полибромдифеноловые эфиры (PBDE) – не превышает 0,1wt % веса вещества или в
концентрации до 1000 миллионных частей.

OMCTT5639E09 5
Table of Contents
Introduction ............................................2
1. About safety........................................6
1.1 Safety precautions....................................6
2. Rated Specifications ..........................8
2.1 Standard accessories...............................9
2.2 Duty cycle ..................................................9
2.2.1 Dimensions ..................................................10
3. Installation.........................................11
3.1 Installation siter ......................................11
3.2 Power supply equipment .......................11
3.3 Transportation.........................................12
3.4 Configuration ..........................................13
3.4.1 When using the special air-cooling torch .....13
3.4.2 When using the special water-cooling torch 13
3.5 Peripheral equipment (Optional items).14
3.5.1 TIG Welding torch........................................14
3.5.2 Ground ring assembly (CWX00560)............ 15
3.5.4 Argon gas regulator (YX-251A) ...................17
3.5.5 Cooling water unit and cooling water...........17
3.5.6 Potentiometer-type remote control unit (YC-
30BPR1,YC-30BMR1) ................................. 17
3.5.7 External equipment connection unit (YX-CB009)
.....................................................................17
4. Names and Functions ......................18
4.1 Front panel ..............................................18
4.1.1 Data display/setting section and welding condi-
tions selecting section..................................18
4.1.2 Welding conditions setting buttons section.. 19
4.1.3 Switches and rear side ................................20
4.2 Welding methods and output waveform
...................................................................21
4.3 Welding conditions.................................22
4.3.1 Welding condition setting table ....................22
4.3.2 About welding conditions .............................22
5. Connection........................................25
5.1 Connecting output cables......................25
5.1.1 About output cables (Below figures are images)
.....................................................................25
5.2 Input and ground (PE) cable connection
...................................................................26
5.3 Connecting gas regulator ......................27
5.3.1 Connecting procedures................................27
5.4 Connecting with jig(s) ............................28
5.4.1 Applications .................................................28
5.4.2 Position of jig terminal.................................. 28
5.4.3 Cautions at wiring ........................................28
5.4.4 Functions of jig terminal............................... 29
5.5 Connecting with Robot...........................29
5.5.1 Applications .................................................29
5.5.2 Connection................................................... 29
5.5.3 Cautions at connecting cables.....................29
5.6 Connecting with external device connect-
ing unit......................................................30
5.6.1 Applications..................................................30
5.6.2 Connection...................................................30
6. Operation.......................................... 31
6.1 Preparation steps ...................................31
6.1.1 Use of protective equipment ........................31
6.1.2 Confirmation of completed connection.........31
6.1.3 Turning ON power........................................31
6.1.4 Adjusting gas flow rate.................................31
6.2 Steps after welding operation ...............32
6.2.1 Shutting off Gas ...........................................32
6.2.2 Shutting off power........................................32
6.2.3 Precautions for winter season (when using the
water-cooling torch) .....................................32
6.3 Settings ...................................................33
6.3.1 Factory settings............................................33
6.3.2 How to change settings................................34
6.3.3 How to restore the original factory setting of this
product.........................................................34
6.3.4 Memory deletion ..........................................35
6.3.5 Memory lock.................................................36
6.3.6 Setting and checking welding conditions .....36
6.3.7 Storing welding conditions ...........................37
6.3.8 Reproducing welding conditions ..................38
6.4 Welding operation ..................................39
6.4.1 “No Crater”...................................................39
6.4.2 ”Crater”.........................................................39
6.4.3 “Crater repeat” .............................................40
6.4.4 “SPOT”.........................................................40
7. Maintenance and inspection........... 41
7.1 Daily check..............................................41
7.2 Periodic check ........................................42
7.2.1 Check guideline ...........................................43
7.2.2 [Time period for which customers-set conditions
can be maintained] ......................................43
7.3 Precautions in performing withstand volt-
age test and insulation resistance measure-
ment .......................................................... 44
7.3.1 Test preparation...........................................44
7.3.2 After the test completes ...............................45
8. Troubleshooting .............................. 46
8.1 Error codes and messages....................46
8.2 Troubleshooting table............................48
9. Parts list............................................ 49
10. Circuit diagram .............................. 53
10.1 Enlarged (left half) ................................54
10.2 Enlarged (right half) .............................55
11. Appendix ........................................ 56
11.1 Welding conditions table .....................56
11.1.1 TIG welding conditions table (Reference)..56
11.1.2 Tungsten welding rod.................................58
11.1.3 TIG welding shield gas...............................58
11.1.4 Filler wire....................................................58
11.2 Welding conditions memorandum......59
11.3 Program list...........................................60
12. Information on Disposal................ 61

About safety
OMCTT5639E09
6
1. About safety
Safety symbols
1.1 Safety precautions
Welding power source
(1) Never use the welding power source for other than
welding purpose. (e.g. Never attempt to use the weld-
ing 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
instruction and national, state and local codes and reg-
ulations.
(4) Prevent any unauthorized personnel to enter in and
around the welding work area.
(5) Only educated and/or skilled persons who well under-
stand this welding power source should install, operate,
maintain and repair the unit.
(6) 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.
Against electric shock
(1) 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.
(2) Before installation or maintenance work, turn off power
at the power box, wait it for at least five minutes to dis-
charge 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.
(3) Do not use undersized, worn, damaged or bare wired
cables.
(4) Connect cables completely and insulate connection
parts.
(5) Keep all cases, panels and covers securely in place.
(6) Do not handle the welding power source with torn or
wet gloves.
(7) Wear safety harness in case of working above floor
level.
(8) Perform periodic checks without fail and repair or
replace any damaged parts before using the power
source.
(9) Turn off all equipment when not in use.
(10) 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.
Electromagnetic disturbance
(1) Pacemaker wearers should consult their doctor before
going near arc welding. Magnetic fields can affect
pacemakers.
(2) Peripheral electronics or safety device may cause elec-
tromagnetic disturbance. Ground all of such devices
without fail. Provide an electromagnetic shielding if
necessary.
(3) Weld cable should be as short as possible and also lay
it as near to the floor or ground as possible if not on.
(4) Never provide grounding of base metal and welding
machine in common.
(5) Do not operate the torch switch if not necessary.
Ventilation and protective equipment
(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 protec-
tive breathing gear.
(2) To prevent dust injury or poisoning by the fume gener-
ated during welding, use a local exhauster specified by
the applicable law (occupational safety and health reg-
ulation, rules on preventing injury by inhaled dust or
etc.), or wear protective breathing gear.
If a protective breathing gear is used, it is recom-
mended to use one with an electric fan with high pro-
tection performance.
(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 per-
formed 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.)
WARNINGS
Observe the following instructions to prevent
the hazard.
Observe the following instructions to prevent
the hazard.
Observe the following instructions to prevent
the electromagnetic disturbance due to weld
current or high frequency at arc start.
Oxygen deficit, fume and gas generated
during welding can be hazardous.

About safety
OMCTT5639E09 7
Against fire, 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.
Do not place the welding power source near combusti-
ble gases, otherwise, such gases may catch fire from a
spark of electricity inside the welding power source as
it is electric equipment.
(3) Do not bring the hot base metal near combustible
materials immediately after welding.
(4) When welding a ceiling, floor or wall, remove all flam-
mables including ones located in hidden places.
(5) Wire the cables correctly and connect them tightly.
Insulate the connected parts surely so that no exposed
conductive part touches the cases or housings. (Poor
cable connection or incomplete current path on the
base metal side, such as steel, if any, can cause fire
due to the heat generated by energization.)
(6) Connect the base metal cable as close to the welding
position as possible. (If not, unexpected current path
may be created, which can cause fire due to the heat
generated by energization.)
.
Installing shielding (curtain etc.)
(1) Install a protective curtain around the welding manipu-
lator 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 performance or
use a protective mask designed for welding operation.
(3) 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.
(4) Be sure to wear noise-proof protective equipment if the
noise level is high.
Gas cylinder and gas flow regulator
(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, 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.
Rotating parts
(1) 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 result-
ing 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 main-
tenance or repair work, provide fence or the like around
the welding machine so that unauthorized person can
not come close carelessly.
Welding wire
(1) Wire extends out from the end of the welding torch and
may stick into the eye, face or body.
(2) 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
(1) Keep enough distance from welding power source
when performing welding or grinding work so as to pre-
vent such 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 accumu-
lated dust or dirt.
(3) When spatters or iron particles get into the welding
power source, turn off the power switches of the weld-
ing power source and power distribution box, and then
blow out.
Observe the following cautions to prevent
fires explosion or blowout.
CAUTIONS
Arc flash, flying spatter, slugs, and noise
generated during welding can damage your
eyes, skin and hearing.
Overturn of gas cylinder and blowout of
gas flow regulator can cause injury.
Rotating parts can cause injury.
Welding wire, especially wire tip part can
cause injury.
Insulation deterioration can cause fire of
welding power source.

Rated Specifications
OMCTT5639E09
8
2. Rated Specifications
Note
• As arc is stable in the low current range, select an appro-
priate welding condition.
• In the case of AC TIG or MIX TIG, when AC frequency is
increased, the rated output current may not be available
due to the voltage drop caused by the impedance (AC
resistance) of the output-side cable. However, this is not
the error of this product.
Rated input voltage V 200
Number of Phase 3
Rated frequency Hz 50/60
Rated input 11kVA, 8.8kW
Efficiency % 73
Idle state power consumption W 62
Rated output current A DC 300, AC 300
Rated output voltage V DC 22, AC 22
Duty cycle % 40
Output, initial and cra-
ter current(See Note)
DC TIG A 4 - 300
AC TIG
Standard A 10 - 300
Hard A 20 - 300
Soft A 10 - 200
MIX TIG A 10 - 300
Maximum non-load voltage V DC 65
Up slope time s 0 - 10 (Increment: 0.1)
Down slope time s 0 - 10 (Increment: 0.1s)
Pre-flow time s 0 - 10 (Increment: 0.1s)
Post-flow time s 0 - 30 (Increment: 0.1s)
(AC TIG) AC frequency Hz 50 - 400 (STD: 70) (50 - 200Hz: In increments of 1Hz)
(200 - 400Hz: In increments of 10Hz)
(MIX TIG) MIX frequency Hz 0.5 - 10 (STD: 1.0)(In increment of 0.1Hz.)
(MIX TIG) DC ratio % 10 - 90 (STD: 30)(In increments of 5%)
Pulse frequency Hz 0.8 - 500
(0.8 - 9.9Hz: In increments of 0.1Hz)
(10 - 99Hz: In increments of 1Hz)
(100 - 500Hz: In increments of 10Hz)
Pulse width % 5 - 95
AC balance adjustable welding method ACTIG, MIXTIG
AC balance % EP 10 - 50 (Standard: 30)(Increment: 1% )
Arc spot time s 0.1 - 5(Increment: 0.1 s)
Control system IGBT inverter method
Crater control system Selectable from crater control “ON”. “OFF” or “Repeat”
High-frequency-wave generating equipment High frequency arc start type
Communication function RS-232C, RS-422
Memory function 50ch storage and reproduction
Robot interface function Enables communication with Panasonic robot controllers.
Cooling system Forced air-cooling
Type of insulation Class H
Dimension (Width: W x Depth: D x Height: H) mm 380 x 510 x 656
Mass kg 59
Protection grade IP21S
Classification for RF emission tests Class A
List of equivalent -

Rated Specifications
OMCTT5639E09 9
2.1 Standard accessories
2.2 Duty cycle
• The rated duty cycle for this product is 40%.
• Using this product at any usage rate over the rated rate
of use may cause the increase of equipment temperature
over the permissible maximum, and result in the deterio-
ration or burnout of the equipment.
• Set the output current (A) at the pulse welding to an
average value between the pulse current and the weld-
ing current.
• When using the product in combination with other
devices, such as the welding torch, etc., use it at the low-
est rated rate of use in those devices
• “The duty cycle is 40% at the rated output” means for 40
percent of the ten-minute period (4 minutes), the power
source can maintain operation with the rated welding
output without overheating. The remaining six minutes
must be operated at no-load to allow proper cooling.
Calculation formula:
(4 minutes/10 minutes) x 100% = 40%
• When using any output current different from the rated
output current, obtain the permissible rate of use from
the following calculation formula.
• (The rated output current of this product: 300 A)
• Allowable duty cycle (%) =
( )2XRated duty cycle (%)
Name Part number Q’ty Remarks
Glass tube fuse (3A) BET3.15A 1 Rear fuse (Fu1): Rush-resistant
Gas hose CWG30101 1 TBV6X11, 3 m
Fingertip joint MET00001 1 For output (base material side) cables: Plug side
Hose band WHB12 1 For gas regulator
Do not use this product at any usage rate over the rated duty cycle.
Output current (A)
Rated duty cycle (%)
（１００％）
（６０％）
４０％ (Rated
duty cycle)
５０
１００
０
６０
１９０
３００
２４５
For your reference
Duty cycle: he percentage ratio of loading time to full
time. A cycle of the full time shall be 10 minutes.
Rated duty cycle: means the rate of use when loading
the rated output current intermittently at the rated input
voltage of the rated frequency.
Regarding the engine-driven welding power unit, how-
ever, it means when driving it at the rated number of
revolution.
Rated output current
Actual output current

Rated Specifications
OMCTT5639E09
10
2.2.1 Dimensions

Installation
OMCTT5639E09 11
3. Installation
3.1 Installation siter
3.2 Power supply equipment
Note
• This Class A equipment is not intended for use in resi-
dential locations where the electrical power is provided
by the public low-voltage supply system. There can be
potential difficulties in ensuring electromagnetic compati-
bility in those locations, due to conducted as well as radi-
ated radio-frequency disturbances.
• This equipment does not comply with IEC 61000-3-12. If
it is connected to a public low voltage system, it is the
responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network
operator, that the equipment may be connected.
CAUTION This product is designed for indoor use only.
Do not install it in any places subject to rain or water spray.
CAUTION
Do not use this product in a vertical position (i.e.: with its control panel side up).
Using it in the vertical position may reduce its cooling effect, and cause any
troubles like equipment burnout, etc. Therefore, make sure to use it in the
horizontal position (in the proper position).
(1) Locate indoors only in industrial environment area.
(2) Avoid exposure to the direct sun light or the rain or water
spray.
(3) 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
(4) Humid:
(a) up to 50% at 40deg-C,
(b) up to 90% at 20deg-C
(5) Altitude above sea level: up to 1000 m.
(6) Installing distance to maintain adequate airflow:
(a) 20 cm or more from any wall,
(b) 30 cm or more between power sources installed side-
by-side.
(7) Base of the welding power source inclined:max. 10deg.
(8) Avoid wind to the arc (provide windshields.)
(9) Free from abnormal amounts of dust, acid, corrosive
gases or substances etc. other than those generated by
the welding process (Especially, avoid where the metallic
substance may get into the power source.)
Note
When the product, which is installed on the floor, is too
low to operate, customers are required to prepare a
table to mount it. (And, in that case, provide such a table
with a flange, etc. so that the product does not slip down from
the table.)
20cm 30cm or more
CAUTION Observe the following to prevent burnout, destruction of parts and
unstable arc.
Input voltage 200 VAC
Input current 32 A
Input protective devices
(Breaker, fuse etc.)
Type and capacity to be applied should conform to all national and
local codes.
Cable cross section area
for input cable and ground wire
Type and size of cables to be applied should conform to all national
and local codes.

Installation
OMCTT5639E09
12
3.3 Transportation
Do not use the handles to hang the product.
• Hanging with the handles, which is unstable, may cause an accident.
• When hanging this product by using a crane, etc., make sure to use the
eyebolts.
Do not lift the product on your own.
• As this product is so heavy (mass: 51kg), it is dangerous to lift it on your own.
• Involve plural number of persons with its lifting.
• When putting this product down, do not cause a shock to it.
When hanging it for transportation When pushing it for transportation
Make sure to hang it at 2
points.
As this product is
provided with
wheels (not uni-
versal wheels.) in
the front and rear
of its bottom, you
can push it for its
transportation.

Installation
OMCTT5639E09 13
3.4 Configuration
• Customers are required to prepare the items other than
marked as “This product” or “Accessory”.
• The items marked with “*” are available as peripheral
equipment (optional items), with separate sales. (See
section “Peripheral equipment”).
• Cable for the base metal side:
To prevent overheat of the cable and provide with proper
welding, prepare a cable which is a welding cable or
cabtire cable (excluding the class-1 cabtire cable and vinyl
cabtire cable) of 38mm2 or more.
3.4.1 When using the special air-cooling
torch
3.4.2 When using the special water-cooling
torch
No. Item Remarks No. Item Remarks
(Common) (For water-cooling torch)
1 Welding power source This product 13 Supply water hose Accessory of
cooling water
unit.
2 Argon gas regulator 14 Return water hose
3 Argon gas 15 Flow-rate switch cable
4 Gas hose Accessory 16 Cooling water unit and cooling
water*4
5 Grounding wire
6Gas hose*1 *1 The gas hose lead-out point of the air-cooling TIG welding
torch is different from that of the water-cooling TIG
welding torch.
*2 In the case of arc spot welding, use the special arc spot
nozzle.
*3 Connect it to the output cable of the base metal.
*4 Do not put the cooling water system on top of the welding
power unit.
7a Air-cooling TIG welding torch*2
7b Water-cooling TIG welding torch*2
8 Base metal
9 Remote controller
10 Fingertip joint*3 Accessory
11 Input power cable
12 Distribution box
123
4
5
6
7a
8
9
10
11
12
5
123
4
5
6
7b
8
9
10
11
12
5

Installation
OMCTT5639E09
14
3.5 Peripheral equipment (Optional items)
3.5.1 TIG Welding torch
(1) Special torch (Fingertip joint)
(2) Type-1.8 TIG welding torch
You are required to purchase the torch connection
adapter separately.
(3) When using any TIG welding torch other than those
described in the above items (1) and (2):
You are required to purchase the terminal adapter
(CWC00180: See the figure shown below) and the
control cable assembly (TWX00018: See the upper
right figure) separately. (Quantity: one each)
Air-cooling 200A torch Water-cooling 300A torch
YT-20TS1TAG (4 m) YT-30TSW1TAG (4 m)
YT-20TS1TAH (8 m) YT-30TSW1TAH (8 m)
TIG welding torch
(Non-fingertip joint)
Torch connection adapter
Product number Descriptions (See also Fig.1)
YT-08TS1, YT-088T
YT-12TS1, TP1, YT-128T(P)
YT-15TS1, TP1, YT-158T(P)
YX-151AJ1J1 [Replacement cable clamp]TJM00046
[Control cable assembly]TWX00018
YT-20TS1, YT-208T YX-201AJ1 [Replacement cable clamp]TJM00038
[Control cable assembly]TWX00018
YT-20TSW1
YT-30TSW1,TPW1
YT-208TW,TPW
YT-308TW,TPW
YX-301A J1 [Replacement cable clamp]TJM00041
[Control cable assembly]TWX00018
<Fig. 1 Replacement cable clamp> <Fig.2 Control cable assembly (TWX00018)>
Remove the torch cable clamp, and connect it to the torch
side as shown in the above figure. (The welder
side uses a
fingertip joint, and the torch side uses a screw-type clamp.)
Welder side
Toc h si d e
Welder side
Tor c h si de
(To gas outlet clamp）
(To output terminal)
Shown below is the case of the air-cooling torch.
(As for the water-cooling torch, a hose and clamp for
return water shall be used, and connected to the
cooling-water equipment.)
<Fig.3> Terminal adaptor (CWC0018)
300
Cabtire cable: 38 mm
2
Torch side:
Crimp terminal
(For Ｍ8, (φ8.4), Width: 22 mm)
A
fter its connection to the torch,
make sure to insulate it by tape,
etc.
Welder side:
Fingertip joint
(P3550-2)

Installation
OMCTT5639E09 15
3.5.2 Ground ring assembly (CWX00560)
In case of an insufficient arc start, you can install this
ground ring to improve it.
(For details, see the instruction manual supplied with the
ground ring assembly.)
3.5.3.Extension cable (Made to order)
Use an extension cable when the welding torch
cable is not long enough. (It is connected between
the welding torch and this product.)
* It is not possible to connect extension cables
each other because of their structure. (Use one
extension cable only.
To use an extension cable, you are required to
purchase the terminal adapter (CWC00180) and
the control cable assembly (TWX00018) sepa-
rately. (Quantity: one each) (See Fig.2, Fig.3)
When connecting the special torch to an extension
cable, remove the replacement cable clamp
(Fig.1) attached to the welding machine side of the
special torch. (Remove the rubber cover of the
replacement cable clamp, and the screw appears.
Remove that screw, and the replacement cable
clamp comes off.)
How to install the ground ring assembly
As for its initial installation, consult with our CS
center.
(An installation error may cause damage to the
torch, or make it impossible to improve an insuf-
ficient arc start.)
(Resistor)
(Lead wire)
Welding torch
nozzle
Ground ring ass’y
(CWX00560)
Connect either to welder
case or base metal.
Note
As the output terminal of this product employs a fingertip joint, the extension cable, which employs a bolt-fixing termi-
nal, cannot be connected to this product without using a terminal adapter.
Also, as the torch switch outlet of the extension cable is different in type from the outlet of this product, it cannot be
connected to this product without using a control cable assembly.
Note
The torch connection side of the extension cable employs a screw connection. As the special torch with the replace-
ment cable clamp removed also employs a screw connection, it can be connected with the extension cable
Applicable torches
Extension cable length
5 m 10 m 15 m
Air-
cooling
YT-15TS1
YT-15TS1C1 TWU15125 TWU15126 TWU15127
YT-20TS1TAG*1
YT-20TS1TAH*1
YT-20TS1
YT-20TS1C1
YT-208T
YT-208TC1
TWU20131 TWU20132 TWU20133
Water-
cooling
YT-30TSW1TAG*1
YT-30TSW1TAH*1
YT-30TSW1
YT-30TSW1C1
YT-208TW
YT-208TWC1
YT-308TW
YT-308TWC1
TWU30132 TWU30133 TWU30134*2
*1: Special torch
*2: Refer to the “Example of extension cable connection” on the next page.

Installation
OMCTT5639E09
16
<Example of extension cable connection>

Installation
OMCTT5639E09 17
3.5.4 Argon gas regulator (YX-251A)
The maximum flow rate is 25L/min.
3.5.5 Cooling water unit and cooling water
(1) Cooling water unit (with built-in flow-rate switch)
(2) Cooling water
Use our genuine cooling-water (Pana-coolant K),
which keeps its quality for a long time.
Product number: CWU00098
(Service temperature: -20 to +90 deg-C)
3.5.6 Potentiometer-type remote control unit (YC-30BPR1,YC-30BMR1)
(1) The remote control unit enables you to set the pres-
ence, absence or repeat of the crater control and the
presence or absence of the pulse control, and to adjust
the initial current, welding current, crater current and
pulse current (Only YC-30BPR1) at a distance. (Cable
length: 5 m)
YC-30BPR1
YC-30BMR1
* After connection of the remote control unit, such
setting and adjustment can be done via the remote con-
trol unit only.
(2) To have a current value displayed when adjusting each
current, switch the LCD display to the screen of each
current item. Then, the current value of each item
appears on the set-value display.
* Details: See chapter 6 (Name and function of each
part) and chapter 9 (Operation).
* It is also possible to make the adjustment of each
current without switching the LCD display to the screen
of each current item. (In that case, however, no current
value appears on the set-value display.)
(3) As the analog input is employed for the input of current
values from the remote control unit, current values
appearing on the set-value display may vary by about
plus or minus 1A. (It becomes stable if you change the
position of a potentiometer slightly.)
3.5.7 External equipment connection unit (YX-CB009)
• This connection unit enables this welding power source
to change over the pages of stored welding conditions by
connecting with external equipment (sequencer).
• The sequencer is not included in this welding power unit
and the attachment unit.
• When using this connection unit: See”Connection: Con-
necting to external equipment connection unit”
Note Cooling water unit (Product number: YX-09KGC1)
• No flow-rate switch is incorporated in this welding power unit.
• When using a water-cooling torch, use the cooling-water system with a flow-rate switch incorporated to prevent the
torch from burnout.
• Connect the cable of the flow-rate switch to the “water circulation path” terminal of the jig terminal block within this
welding power unit.
Note TIG welding remote control unit
The conventional YC-301URTRK1 cannot be used. (Due to the difference in connectors and signal lines)
Note
Observe the followings to prevent troubles caused by the incorporation of high frequency waves.
• Keep the signal line connected to the external-equipment attachment unit away from the welding arc area, welding
torch, base-material-side cable, base-material grounding wire, power input line, grounding wire, etc.
• The length of wiring shall be 10m or shorter.
• Make sure to connect the grounding wire of this welding power unit to the ground.

Names and Functions
OMCTT5639E09
18
4. Names and Functions
4.1 Front panel
4.1.1 Data display/setting section and welding conditions selecting section
For details of functions, see “Welding conditions” in this
chapter.”
*1: In the case of a welding voltage, indicates the welding
voltage (between output terminals of this product) during
the welding operation rather than the set value.
*2: See section “Operation” for how to display welding volt-
age.
1
Digital ammeter
• Indicates welding current values during the weld-
ing. (Displays an average current value mea-
sured during the period of 0.4 second in
amperes.)
Due to a rounding error, a resulting value may
vary within the range of plus or minus 1A.
As this ammeter is designed to display an aver-
age current value measured during the period of
0.4 second, it may not be able to follow the varia-
tion of current quickly enough when the current
changes frequently during the pulse welding, etc.
• Indicates an “Err” (error) mark in case of a trou-
ble.
2
Set-value display
• Indicates the set values*1 of current (A), time (S),
frequency (Hz), pulse width (%), AC balance (%),
DC ratio (%), welding voltage (V)*2, etc.
• The unit display lamp changes according to the
type of indicated set values.
• Indicates an “Err” (error) number in case of a
trouble.
3
LCD display
• This is the information display area.
• Indicates condition-setting items in letters.
• Indicates error contents in letters in case of a
trouble.
12 3 4
5789
6
4
Jog dial
• This is a dial to carry out the function of a potenti-
ometer (setup of current and time).
For example, to set welding current to 125A, turn
the dial to the right (increase) or to the left
(decrease) until such a value is indicated (on the
set-value display).
Note: Turning the jog dial without discretion may
result in the change of a set value for the item
currently indicated on the LCD display.
• Use the press button function of the jog dial in the
following situation.
In the reproduction, storage or details mode (See
item 9 in the right column.)
5
“Weld conditions” selection button
Selects a required welding method (DC TIG, AC
TIG or MIX TIG).
6
“Crater control” selection button
Regarding the selected welding method, selects
the “absence, presence or repeat” of the crater
control, as well as the “spot” (arc spot welding).
The arc spot welding can be done only in the case
of “DC TIG” and “AC TIG” welding.
7
“Pulse” selection button
Regarding the selected welding method, selects
the absence or presence” of pulses.
8
“AC waveform” selection button
In case the AC welding method is selected, selects
an AC waveform (standard, hard or soft).
9
“Mote” selection button
Selects an operation “mode” of this product (weld-
ing, reproduction, storage, or details).
Welding: Can be used to set welding conditions
and conduct a welding operation.
Reproduction: Can be used to reproduce stored
welding conditions.
Storage: Can be used to store the present welding
condition.
Details: Can be used to change the factory-set
mode of this product.

Names and Functions
OMCTT5639E09 19
4.1.2 Welding conditions setting buttons section
*1: It can be used when the “welding method” is set to “DC
TIG” or “AC TIG”, the “pulse” is set to “presence”, and the
“crater control” is set to a mode other than the “spot”.
For details of the function of each button, see section
“Welding conditions” or “Operation”.
When the “mode” selection is set to “welding”, the display
lamp of the welding-condition setting button section turns on
according to the set details of the welding-condition select-
ing section In other words, the display lamp for sections, to
which welding conditions are required to be set, is turned
on.]
The display lamp indicated above (indicated within __) nor-
mally remains turned on. When pressing a button corre-
sponding to the display lamp, which is turned on, that
display lamp starts flashing, the LCD display indicates the
name of that item, and the set-value display indicates a set
current value. (By turning the jog dial at this point, the set
value can be changed.)
Note
Do not turn the jog dial without discretion. (Doing so may
result in the change of the present set value.)
The above operation also applies to the welding mode. (If
the display lamp is flashing, a set value can be changed
even during the welding operation. When there is no need to
do so, press the jog dial, and the display lamp is turned on.
Then, it becomes impossible to change the set value by
means of the jog dial. Therefore, it serves the prevention of
an operation error.)
10 11 12
13
14 15 16
17 18 19
20
21
10
Pre-flow: Sets the time required until the output
voltage is turned on (i.e. arc start) after the torch
switch is turned on.
Make sure to set it so that the shield gas covers the
welding area before the start of arc.
11
Initial current: Sets the current required for start-
ing the welding.
The initial current can be used only when the “cra-
ter control” is set to “presence” or “repeat”.
12
Up-slope: Sets the time required to increase the
welding current gradually to the set value after the
initial current.
The up-slope can be used only when the “crater
control” is set to “presence” or “repeat”.
13 Welding current: Sets the welding current.
14
Down-slope / spot time
Down-slope: Sets the time required for decreasing
the welding current gradually and having the crater
current started after the self-holding is turned off.
The down-slope can be used only when the “crater
control” is set to “presence” or “repeat.
Spot time: Sets the spot time of arc spot welding,
only when the “crater control” is set to the “spot”
mode.
15
Crater current: Sets the crater current.
The up-slope can be used only when the “crater
control” is set to “presence” or “repeat”.
16
Post-flow: Sets the time period for the shield gas
to keep flowing for a certain period of time after the
output voltage is turned off (i.e. arc stop).
17 Pulse current*1: Sets the pulse current.
18 Pulse frequency*1: Sets the pulse frequency (0.8
to 500Hz).
19 Pulse width: Pulse width*1: Sets the pulse width.
20
AC TIG (AC BALANCE / AC frequency): Sets the
AC balance* or AC frequency* (50 to 400Hz) when
the “welding method” is set to “AC TIG” or “MIX
TIG”. (To select the AC balance or AC frequency,
press this “AC TIG” button once or twice until the
applicable display lamp start flashing.)
21
MIX TIG (MIX frequency / DC ratio): Sets the MIX
frequency or DC ratio* when the “welding method”
is set to “MIX TIG”. (To select the MIX frequency or
DC ratio, press this “MIG TIG” button once or twice
until the applicable display lamp start flashing.)

Names and Functions
OMCTT5639E09
20
4.1.3 Switches and rear side
DANGER When removing or replacing a fuse:
To prevent an accident caused by an electric shock, make sure to
turn the power switch off before such removal or replacement
CAUTION
About power switch:
• When the power switch is turned off automatically, do not turn it on again. (Consult
with sales distributor of Panasonic representatives.)
• When activating a power generator, turn off the power switch.
1
2
345
76
Front panel
89
10
11
12
13
Rear panel
1
“Power” switch (NFB)
Turns the power supply on and off.
Turn it on and off from outside of the case.
The lever position at the time of tripping (means
that the switch is turned off automatically due to
over-current) is same as the off position.
2
Gas supply switch
Normally set it to the “welding” side. When
checking the gas flow rate, set it to the “inspec-
tion” side.
3Gas outlet joint
4Negative (-) terminal (fingertip joint)
5(+) Terminal (fingertip joint)
6Torch switch outlet
7
Outlet for remote control unit
Insert the plug of a remote control unit (optional
item), and it is securely fixed.
8
Input power cables (with PE): The PE cable is
connected to the PE terminal in the power distri-
bution box.
9Wiring port (with grommet)
for the communication connector
10 Wiring port (with grommet) for the jig terminal
11
3A power fuse (FU1)
This is a fuse for the control power circuit.
This fuse is resistant to rush current.
12
Cooling fan air-outlet: This is the cooling fan air-
outlet to cool this product.
Do not leave any obstacles near this outlet.
13
Gas inlet joint (Screw size: U9 / 16 Thread 18):
Connect the welding shield gas from the gas reg-
ulator securely.
Any gas incorporation may affect the result of
welding.