THYRISTOR CONTROLLED DC ARC WELDER

CLEAN ARC

YD-630SS3

INSTRUCTION MANUAL

Thank you for your purchase of Panasonic welding power

source, Please read this manual carefully and use
according to the adequate method.

TANGSHAN MATSUSHITA INDUSTRIAL EQUIPMENT CO., LTD.

TSM89730
 Notice：Machine Export to Europe

This product does not meet the requirements specified in

the EC Directives which are the EU safety ordinance. Please
bear in mind that this product may not be brought as is into
the EU. The same restriction also applies to any country which
has signed the EEA accord.

Please be absolutely sure to consult with us before

attempting to relocate or resell this product to or in any EU
member state or any other country which has signed the EEA
accord.

1995-1-1
Tangshan Matsushita Industrial Equipment Co., Ltd.
 CONTENTS

R a t i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

Preparation------------------------------------2

C o n n e c t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

O p e r a t i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Welding condition---------------------------6

T r o u b l e s h o o t i n g - - - - - - - - - - - - - - - - - - - - - - - 8

Maintenance and inspection------------------9

Part list-----------------------------------10

O u t s i d e d r a w i n g - - - - - - - - - - - - - - - - - - - - - - 1 1

Circuit diagram--------------------------------12
 RATING
Table 1
Type
YD-630SS3HNE
Item
Rated Input Voltage V 480
Allowable Range Of
% ±10%
Voltage Regulation
Phase 3 Phase
Rated Frequency Hz 60
kVA 44.3
Rated Input
kW 34
Rated Duty Cycle 60%
Rated No-Load Voltage V 81
Sticking
100～630
Rated Output welding
A
Current
Gouging 150～630
Sticking
24～44
Rated Output welding
V
Voltage
Gouging 24～44
Weight kg 225
Dimensions (W×D×H) mm 496×690×920

ACCESSORIES
Table 2
Type Code No.
Item YD-630SS3HNE
Glass tube fuse 61NR030H (3A) l
Bolt M10×30 2
Washer 10 2
Spring Washer 10 2
Nut M10 2
Instruction Manual TSM89730 1

1
 PREPARATION

(1) Capacity of Power Source Facility And Connection Cables Table 3

Power Source
YD-630SS3HNE
Item
Power Source Voltage 3 Phase 480V±10%
Capacity Over 50kVA
Capacity of
Fuse 100A
Distribution Box
Input Cable Over 22mm2
Output Cable Over 95mm2
* Use a generator provided with compensating winding for thyristor equipment of
3 to 5 times of the welding power source capacity when using engine generators.

Note )
• Always turn “OFF” the distribution box switch when connecting wires.
• Provide a distribution box for each welder using those fuses and breakers
specified.
(2) Place of installation
Install the welder in an environment as described below.
• Indoors free from moisture, dust or dirt.
• In a place not exposed to direct sunlight or rainfall.
• In a place where ambient temperature is between 0～40℃
• In a place 20cm or more apart from the wall.
• In a place where the welder will not subject to any abnormal vibration or
impact.
• In a place free from vaporous oil or harmful corrosive gas

2
 CONNECTIONS (YD-630SS3HNE)
The following shows the standard composition of a welder. Perform connections in
accordance with the connection diagram illustrated below.

„ Hand welding

Front side Rear side

Grounding

Grounding YD-630SS3HNE
Fig. 1

Connect the holder and base metal cable according to the proper polarity of the
welding rod used.
Tape the part where the current passes through after connection so that it is not
exposed.
Table 4
Symbol Designation
1 Holder
2 Base Metal
3 Base Metal Cable
4 Output Terminal(Base Metal Side)
5 Output Terminal(Holder Side)
6 Distribution Box
7 Input Cable
8 Plug Socket For Remote Controller
9 Remote Controller
10 Output terminal (Gouging)
Prepare item separately
3
 CONNECTIONS (YD-630SS3HNE)

„ Gouging
The crosshatched units are to be prepared by the customer.

Distribution Box

Input Cable

Air Compressor

Grounding
(Over 22mm2)

Gas Hose
Base Metal Cable

Base Metal

Grounding
(Over 22mm2) Gouging Holder

4
 OPERATION (YD-630SS3HNE)

„ Power Source Panel

Welding conditions are set by the operation panel located on the front face of the
power source.

STICK POWER
POWER
(3A)

WARN.

WELDING CUR. GOUGING

PANEL

REMOTE
ARC FORCE CURRENT CONTROL MODE

Welding Operation
Power Source: Switch to “on” will light up the pilot lamp and turn the cooling
fan.
Selection: Switch the penal remote control selector switch according to the
work method.
Set the panel remote control selector switch to “panel” when
regulating the welding current by the welding current regulator
the main welder assembly.
Set the panel remote control selector switch to “remote” when
using a remote controller (option) and by connecting the remote
controller plug socket will allow it to become operable.

Welding Current Regulation: Regulate the welding current with the welding current
regulator or the remote controller according to the welding
method, type of welding rod, type of weldment or sheet thickness.

Arc Force Control: Arc force control function is to increase the short circuit
current value by properly adjusting arc force current, in order
to increase penetration and prevent from stick adhesion, hence
enhancing arc penetration for welding various kinds of work
pieces. For conventional welding, it’s unnecessary to use this
function as stick adhesion rarely happens. Attention must be
given to the fact, however, that arc force current has to be
properly applied whenever necessary otherwise excessive spatter
will occur.

5
 WELDING CONDITION

Please refer to the following:

1.Diameter of stick: stick diameter is usually subject to work piece thickness,
as referred to by table 5. For the first layer of multi-layer welding with groove
or for welding in non-horizontal position, thinner stick should be adopted. For
welding important structure, stick diameter shall be decide according to the
relations between welding current and stick diameter as shown in table 6.

Table 5 Stick Diameter Selection

Thickness(mm) ≤4 4～12 ＞12
Stick No larger than thickness of work
3.2～4 ≥4
diameter(mm) piece

Table 6 Relation Between Welding Current And Stick Diameter

Stick
diameter 1.6 2.0 2.5 3.2 4.0 5.0 6.0
(mm)
Welding
100～ 160～ 200～ 260～
current 25～40 40～65 50～80
130 210 270 300
(A)

2.Welding current: welding current is the primary technical parameter in manual

arc welding. When current is too high, the end of stick will become heating, the
coating will be ineffective or peeled off and welding pool protection becomes
weak, thus leading to gas hole. Furthermore, such welding defects as undercut
and burn-through will occur as a result. When current is too low, such defects
as non-penetration, non-fusion, gas hole and slag inclusion will emerge,
resulting in a crippled productivity. Therefore, priority should be given to
ensuring welding quality by selecting appropriate current, while keeping an eye
on adopting higher current for a high productivity.
Welding current can be primarily selected according to the diameter of the stick
to be used, referring to [Table 5] . Furthermore, thickness of work piece, joint
type, welding position, welding circumstance, temperature, chemical composition
of base metal and stick should be taken into account. When work pieces are thick
and ambient temperature is low, current should be set lower in order to easily
control the formation of weld. When welding stainless steel, lower current should
be used for minimizing the extent of intercrystalline corrosion.

After selection of current, test welding must be done to verify weld and defects
before current is finally determined. For such important structures as pressure
vessel and boiler with special requirement of welding, welding technical
specifications including current won't be finalized unless it passes appraisal.

6
 [Table 7] Relation Between Gouging Current and Carbon Dia.

Carbon Specification
Model Current (A)
type (mm)
B504 ∅4×355 150～250
B505 ∅5×355 150～250
B506 ∅6×355 200～300
B507 ∅7×355 300～400
B508 ∅8×355 300～400
Cylinder
B509 ∅9×355 350～450
B510 ∅10×355 350～450
B512 ∅12×355 400～500
B514 ∅14×355 500～600
B516 ∅16×355 500～650
B5510 5×10×355 320～380
B5512 5×12×355 320～380
B5515 5×15×355 350～450
B5518 Rectangle 5×18×355 350～450
B5520 5×20×355 350～450
B5525 5×25×355 450～550
B5620 6×20×355 450～550
Note) This table is just for reference.

3.Gouging carbon and current must be selected according to the specific technical
requirements. The relationship of the carbon and current can be reference to
table[7] above. After selection of the carbon and current, test gouging must be
done to verify and detect before carbon and current are finally determined. For
those important structure as pressure vessel and boiler with special requirements,
gouging technical specifications including carbon and current won’t be finalized
unless they passes appraisal.

7
 TROUBLE SHOOTING

There's no no-load voltage------------Cause power source switch is damaged.

------------Incorrect setting of the control selector
switch
------------Failure of PCB
Difficult to start arc, arc is interrupted
------------Incomplete connection of torch cable
------------Incomplete connection of base metal cable
------------- Work piece has too much greasy dirt
Can't regulate output current
------------Incorrect setting of the control selector
switch
------------Poor contact of welding current regulator
------------Failure of PCB
Arc is unstable excessive spatter occurs
------------Stick is rusty or wet, work piece is
improperly treated .
------------Main thyristor is damaged.
------------Arc force current is excessive.
Abnormal pilot lamp turns on
------------Operating in excess of rated duty cycle
------------Main thyristor is damaged.
------------ Failure of main circuit.

8
 MAINTENANCE AND INSPECTION

Due attention should be paid to periodical maintenance and inspection far safe
operation of the welding machine.
Before checking interior and exterior terminal of the welding machine, be sure to
turn the switch box at the primary side (or NFB).

„ Daily precautions
(1) Check for abnormal vibration, beat or smell.
(2) Check for abnormal heating at the cable connections.
(3) Ensure that the welding machine cooling.-fan rotates smooth1y with power ON.
(4) Check the-switch for abnormal operation.
(5) Check for poor cable connection and insulation.
(6) Check the cable for any possible disconnection.

„ 3- to-6 month inspection

(1) Checking electrical connection sections
Ensure that tightening screws at the input and output side cable connections
of welding machine are not loose, rust does not worse in the electric contact,
and check for any problem in insulation.
(2) Grounding line
Ensure that the welding machine case is completely grounded.
(3) Removing dust inside the welding machine
Dust deposited on the thyristor cooling plate reduces heat dissipation effect,
which in turn adverse1y affects the thyristor.
If dust is accumulated between windings of the transformer, for example,
insulation may deteriorate accordingly; therefore, remove the side and top
plates of the welding machine at least once per 6 months, and blow .compressed
air with less moisture against each section for cleaning.
„ Operating precautions
(1) Power switch operation.
If power switch is turned OFF .immediately after the weld work is completed.
The cooling fan will stop. And the temperature of transformer, etc. Will remain
high; thereby expediting the deterioration of transformer, etc. and reducing
the life span; therefore, remember to attempt to turn power switch OFF 2 or3
minutes after completion of the operation , not immediately.
(2) Service factor
Be sure to use the machine so that the preset service factor is not exceeded.
Over-service factor may cause burning to the welding machine in the worst case
and even when it does not lead to burning trouble, reduced service life will
result; therefore, be sure to follow the service factor appropriate to the
welding current.
The rated service factor 60% means that if the welding machine works for 6
minutes at the rated output current m(for example, 630A output current with
the 630A machine) in a cycle of 10 minutes, it must suspend operation for
4minutes.
(3) Precautions after maintenance and inspection
When removing a top board, side board and rear board for maintenance and
inspection, do not fail to reinstall them just as they were.

9
 PART LIST
Code
Mark Name Q’ty
YD-630SS3HNE
TR1 Main Transformer 1 set TSM96107
TR2 Control transformer 1 set ——
1 for
TR3,4 Transformer TSM13154
each
IPL Interphase reactor 1 TSM03720
1 TSM04219
DCL DC reactor
1 TSM04220
1 for
SCR1,2 Thyristor TM150SA-6
each
Remote controller plug
CO1 1 MT25B4-01
socket
SH Shunt 1 F700
FAN Cooing fan 1 SF-200-25-4D
1 for
ZNR1～3 Surge absorber DNR20D112
each
ZNR4 Surge absorber 1 DNR20D112
C.P Ceramipek 1 DSA362MA05
FU1 Power source fuse 1 61NR030H
MS Magnet switch 1 PT403011LS
SW1 Power source switch 1 ASS33HTK368
Welding method selector
S2 1 AJ461103
switch
PL1 Power source pilot lamp 1 DB40BG
PL2 Alarm pilot 1 DB40BY
A Ampere meter 1 KFM7BDC700AK
1 for
C1,C2 Condenser ECQE10473KV
each
R1 Resistance 1 SFW40A161J

VR1 Welding current Resistance 1 RV24YN20SB14

Arc force current

VR2 1 RV24YN20SA24
resistance
S1 Stick-gouging switch 1 DS850A00B
Phase control print
1 TSM9497
substrate
Main control substrate 1 TSM9158
Low voltage protective
1 TSM9474
print substrate
Protective print substrate 1 TSM9500

10
1 Out put terminal case 5 Power fuse 9 Control mode switch 13 Stick-Gouging Switch
2 Welding current regulator 6 Power pilot lamp 10 Input terminal case
3 Arc force regulator 7 Power Warn lamp 11 Cable clamp
4 Ampere meter 8 Power source switch 12 Case grounding

690
496
680
487

630

860

920
OUTSIDE DRAWING (YD-630SS3HNE)

11
 CP ZNR4
TR1 SH DCL1 DCL2 27
SCR1
24 25 26
+
ZNR3 20 C1
ZNR1 ZNR2 28 R1
1
C2
2 23
L1(IPL)
22 －
3
MS
TH1
TSM94740
MS2MS1 L +24L +15H G
21
PL2
SW1 SCR2
103 102 101
PL1
TR3 TR4

12
7 73 8 65 76 43 44 76 77 49 48 49 92 93 Stick
手 工焊
4 6 24 S1
9 25 94
14
65 15 气 刨
Gouging
MS 10 73
11 20V
FU1 28 16 76 95
76 相位控 制
Phase 电路
control circuit 17 Control circuit
76 控 制 电路 0V
12 76 TR4

MS
77 ZUEP07014 13
5 TSM9497□ 18 TSM91580
TSM9158□
58
19 96 20V
20V
FAN 87
4
TR3
6
88 40 41 42 45 46
7 0V

S2
59 41 59 VR2
60 电弧推 力
direction
Gazing 插座 向视
Arc force current
61 62
VR1 regulator
60 Welding
焊接 电流current
远 控 插座
Remote controller socket

CIRCUIT
总 电路图 DIAGRAM
Tangshan Matsushita Industrial Equipment Co . , Ltd.
Add : Tangshan New & Hi-Tech Development Zone.
Post code :063020
Tel : (0315) 3206060 3206066
Fax : (0315) 3206070 3206018