Inverter Controlled Mig Welding-Machine YD-400GT3 Operating Manual

Operating Instructions
Inverter controlled GMAW DC Power Source
Model No. YD-400GT3YUD
Fully digital and inverter controlled GMAW
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”.
OMDT6399E00
0811
Features
♦Features
• High Duty Cycle; 400A output with 60% duty cycle • Encoder-equipped motor; that provides stable
Using at 310A (output) allows 100% duty cycle. and high-precision wire feed performance.
• 1.4 mm (diameter) mild sold wire, and Pulsed MAG • 9-channel memory; that allows you to store and
welding is available. reproduce up to nine welding conditions.
• Analog operation with slim digital display and • Upgraded mobility, toughness and dust-proof-
volume type remote controller; that enhances ness.
user-friendliness.
♦Applicable welding methods

（1）CO2 welding
（2）MAG welding
（3）Stainless steel MIG welding
（4）Pulsed MAG welding
♦Warning symbols for safe usage

Each symbol describes things to be observed to prevent you and other personnel from hazardous conditions or damage to property..
• Each symbol below describes things to be observed • The following symbols indicates things to be
to prevent you and other personnel from hazardous observed.
conditions or damage to property.
A hazardous situations including death or
Danger Things that MUST NOT be performed.
serious personal injury is imminent.
The potential for a hazardous accident includ-

Warning Things that MUST be performed.
ing death or serious personal injury is high.
The potential for hazardous accident including

Caution light personal injury and/or the potential for Things attention must be paid to.
property damage are high.
• The description of this manual is based on the contents as of November, 2008.

• The contents of this manual are subject to change without further notice.
2 OMDT6399E00
♦Table of Contents welding operation)................................... 26
7.2.1 Shutting off gas......................................... 26
7.2.2 Shutting off power- ................................... 26
7.3 Settings ................................................... 26
Features ..................................................2 7.3.1 “F.ADJ” for setting and checking set values.
..................................................................... 26
7.3.2 “CALL” and “RECORD” welding conditions28
1. Safety precautions .............................4
7.4 Wire inching ............................................ 29
7.5 Checking shield gas ............................... 29
2. Rated Specifications ..........................6 7.6 Welding operation .................................. 30
2.1 Standard accessories...............................7 7.6.1 “NO CRATER” .......................................... 31
2.2 Duty cycle ..................................................8 7.6.2 “CRATER” ................................................ 31
2.3 Dimensions................................................8 7.6.3 “INI & CRATER” and “INI & CRATER (no
crater pulse)”................................................ 32
7.6.4 “Crater repeat” operation .......................... 33
3. Installation...........................................9
3.1 Installation site..........................................9 8. Maintenance and inspection........... 34
3.2 Power supply equipment .........................9
8.1 Daily check.............................................. 34
3.3 Transportation.........................................10
8.1.1 Welding machine (This product)............... 35
8.1.2 Cables and hoses..................................... 35
4. Names and functions .......................11 8.2 Periodic check ........................................ 36
4.1 Front panel ..............................................11 8.2.1 Check items.............................................. 36
4.1.1 Power switch: ........................................... 11 8.3 Precautions for withstand voltage test and
4.1.2 Connection of the front panel ................... 11 insulation resistance measurement ...... 37
4.1.3 Operation panel ........................................ 12
4.2 Rear panel................................................15 9. Troubleshooting .............................. 38
4.3 <Switches on PC Board..........................16
4.3.1 Slide switch (SW1) ................................... 16
9.1 When indicators blink irregularly.......... 38
4.3.2 DIP switches (DSW1) ............................... 16 9.2 Error indication....................................... 38
4.4 Remote controller (YD-40GTR1) ............17 9.2.1 If the 7-segment displays do not function
correctly ....................................................... 40
9.3 Troubleshooting table............................ 41
5. Configuration ....................................18
5.1 What’s needed for welding operation ...18 10. Circuit diagram .............................. 42
5.1.1 CO2/MAG welding.................................... 18
5.1.2 Hard aluminum welding ............................ 19
5.2 Connection cable (optional unit) ...........20 11. Repair parts list.............................. 44
6. Connection........................................21 12. Appendix ........................................ 46

6.1 Connecting output cables......................21 12.1 MAGwelding conditions table ............. 46
6.2 Connecting base metal voltage detection 12.1.1 CO2 welding conditions table: Solid wire
wire............................................................22 (Reference).................................................. 46
12.1.2 CO2 welding conditions table: Flux cored wire
6.3 Connecting input cable and ground wire22
(Reference).................................................. 48
6.4 Connecting jig terminals ........................23 12.1.3 MAG welding conditions table: Solid wire
6.4.1 JIg terminal board..................................... 23 (Reference).................................................. 49
12.2 Pulsed MAG welding conditions table
7. Operation...........................................25 (Reference)............................................... 50
7.1 Preparation ..............................................25 12.3 MIG welding conditions table: Stainless
7.1.1 Use of protective equipment..................... 25 steel (Reference)...................................... 51
7.1.2 Pre-operation check ................................. 25 12.4 Pulsed MIG welding conditions table:
7.1.3 Turning on power ..................................... 25 Stainless steel (Reference)..................... 52
7.2 Termination processing (steps after 12.4.1 Welding conditions memorandum .......... 53
OMDT6399E00 3
Safety precautions
1. Safety precautions
WARNINGS
Welding power source （10）In case of AC arc welding in a confined area or above
Observe the following instructions to prevent the floor level, check related national, state and local codes
hazard. and regulations for any special treatment and comply with
it if any.
（1） Never use the welding power source for other than Ventilation and protective equipment
welding purpose. (e.g. Never attempt to use the welding
power source for pipe thawing.) Oxygen deficit, fume and gas generated
（2） It is very important to comply with all instructions, safety during welding can be hazardous.
warnings, cautions and notes mentioned. Failure to do so
can result in serious injury or even death.
（1） When conducting welding in the bottom of the tank, boiler
（3） Work of driving source at the input side, selecting work
or hold as well as legally-defined sites, use a local
site, handling, storage and piping of high pressure gas,
exhauster specified by the applicable laws and
storage of welded products and also disposal of waste
regulations (occupational safety and health regulation,
should be performed according to the operating
rules on preventing suffocation or etc.) or wear protective
instruction and national, state and local codes and
breathing gear.
regulations.
（2） To prevent dust injury or poisoning by the fume generated
（4） Prevent any unauthorized personnel to enter in and
during welding, use a local exhauster specified by the
around the welding work area.
applicable law (occupational safety and health regulation,
（5） Pacemaker wearers should consult their doctor before rules on preventing injury by inhaled dust or etc.), or wear
going near arc welding. Magnetic fields can affect protective breathing gear.
pacemakers.
（3） When conducting welding in a confined area, make sure
（6） Only educated and/or skilled persons who well to provide sufficient ventilation or wear protective
understand this welding power source should install, breathing gear and have a trained supervisor observe the
operate, maintain and repair the unit. workers.
（7） Only educated and/or skilled persons who well
（4） Do not conduct welding at a site where degreasing,
understand the operating instruction of the unit and are
cleaning or spraying is performed. Conducting welding
capable of safe handling should perform operation of the
unit. near the area where any of these types of work is
performed can generate toxic gases.
Against electric shock
（5） When welding a coated steel plate, provide sufficient
Observe the following instructions to prevent ventilation or wear protective breathing gear. (Welding of
the hazard. coated steel plates generates toxic fume and gas.)
Against fire, explosion or blowout
（1） Grounding of the case of the welding power and base
metal or a jig electrically connected to the base metal Observe the following cautions to prevent
must be performed by educated and/or skilled persons. fires explosion or blowout.
（2） Before installation or maintenance work, turn off power at
the power box, wait it for at least five minutes to discharge （1） Remove any combustible materials at and near the work
capacitors. Significant voltage may exist on capacitors site to prevent them from being exposed to the spatter. If
after turning off power at the power box so it is imperative they cannot be relocated, cover them with a fireproofing
to check to make sure that no charged voltage present at cover.
capacitors before touching any parts. （2） Do not conduct welding near combustible gases.
（3） Do not use undersized, worn, damaged or bare wired （3） Do not bring the hot base metal near combustible
cables. materials immediately after welding.
（4） Connect cables completely and insulate connection parts. （4） When welding a ceiling, floor or wall, remove all
（5） Keep all cases, panels and covers securely in place. flammables including ones located in hidden places.
（6） Do not handle the welding power source with torn or wet （5） Properly connect cables and insulate connected parts.
gloves. Improper cable connections or touching of cables to any
（7） Wear safety harness in case of working above floor level. electric current passage of the base metal, such as steel
（8） Turn off all equipment when not in use. beam, can cause fire.
（9） Perform periodic checks without fail and repair or replace （6） Connect the base metal cable at a section closest to the
any damaged parts before using the power source. welding part.
（7） Do not weld a sealed tank or a pipe that contains a gas.
（8） Keep a fire extinguisher near the welding site for an
emergency.
4 OMDT6399E00
Safety precautions
CAUTIONS
Installing shielding (curtain etc.) Welding wire

Arc flash, flying spatter, slugs, and noise
generated during welding can damage your Welding wire, especially wire tip part can
eyes, skin and hearing. cause injury.
（1） Install a protective curtain around the welding manipulator （1） Do not perform inching operation or pull the torch switch
site to prevent the arc flash from entering the eyes of
with your eyes, face or body close to the end of the
people in the surrounding area.
welding torch - wire extends out from the end of the
（2） When welding or monitoring welding, wear safety glasses welding torch and may stick into the eye, face or body.
with sufficient light blocking performance or use a
（2） In case of using a torch cable with the resin liner,
protective mask designed for welding operation.
straighten the torch cable and reduce the preset feed
（3） When welding or monitoring welding wear protective amount (current) to a half or less before applying the wire
closes designed for welding operation, such as leather inching.
gloves, leg cover and leather apron, and also wear long-
（3） Make sure to replace any damaged liner or cable with a
sleeve shirts.
new one as use of damaged liner/cable may cause gas
（4） Be sure to wear noise-proof protective equipment if the leak or insulation deterioration.
noise level is high. Against insulation deterioration
Gas cylinder and gas flow regulator
Insulation deterioration can cause fire of
Overturn of gas cylinder and blowout of welding power source.
gas flow regulator can cause injury.
（1） Keep enough distance from welding power source when

（1） The gas cylinder must be handled properly according to
performing welding or grinding work so as to prevent such
the applicable law and in-house standards.
spatters or iron particles from getting into the power
（2） Use the gas flow regulator that is supplied or source.
recommended by our company.
（2） Perform check and maintenance work periodically so as
（3） Read the instruction manual of the gas regulator prior to to prevent insulation deterioration due to accumulated
using it, observe the cautions in the manual dust or dirt.
（4） Secure the gas cylinder to a dedicated gas cylinder stand. （3） When spatters or iron particles get into the welding power
（5） Do not expose the gas cylinder to high temperature. source, turn off the power switches of the welding power
（6） When opening the valve of the gas cylinder, do not bring source and power distribution box, and then blow out.
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
Rotating parts can cause injury.
（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 resulting in injury.
（2） Keep all covers, panels and cases closed when using the
product.
（3） Maintenance work and repair should be perform only by
educated and/or skilled persons who thoroughly
understand welding machines. While performing
maintenance or repair work, provide fence or the like
around the welding machine so that unauthorized person
can not come close carelessly.
OMDT6399E00 5
Rated Specifications
2.Rated Specifications
Rated input voltage V 380/415 VAC (Allowable fluctuation range: 345 to 455 V)
Rated frequency Hz 50/60 Hz (Common)
Number of Phase 3-phase
kVA 20.5
Rated input
kW 19
Maximum non-load voltage V 66 (DC)
Rated output current A 400 (DC)
Rated output voltage V 38 (DC)
Output current adjustable range A 30 - 400
Output voltage adjustable range V 12 - 38
Rated duty cycle % 60
Power control method - IGBT inverter type
Memory - 9 ch, reproducible storages
Applicable welding method - CO2, MAG/Stainless steel MIG / Pulsed MAG
Waveform control method - Digital control: -7 (small) to +7 (large) (Standard: 0)
Main welding,
Main welding - Crater (“Crater repeat” is available),
Sequence -
Initial - Main welding - Crater (“Crater repeat” is available),
Initial - Main welding - Crater (No crater pulse) (“Crater repeat” is available)
CO2 (100%),
MAG (80% argon and 20% CO2)
Applicable shielding gas - Stainless steel MIG (98% argon and 2% oxygen)
Aluminum MIG (100% argon)
<Note> See also table on the next page for applicable combination.
Applicable wire size (diameter) mm 0.9, 1.0, 1.2, 1.4, 1.6 (hard aluminum)
Mild steel (MS)
Flux cored mild steel (MS_FCW)
Applicable wire material (Note) - Stainless steel
Flux cored stainless steel (SUS FCW)
Hard aluminum
Gas purge time - 1 second - 1 minute / continuous
Pre-flow time s 0.0 - 5.00 (Increment of 0.1) continuous
Post-flow time s 0.0 - 5.00 (Increment of 0.1) continuous
Input power terminal - Terminal block (for 3-phase, M5 bolting)
Output terminal - Copper terminal with M8 bolting
Dimension (Width x Depth x Height) mm 380 x 540* x 675 (*: Input power terminal cover is not included.)
Mass kg 61
(Note): For the details, refer to section “Applicable arc characteristics table on the inside front cover.
6 OMDT6399E00
Combination of “Welding method”, “Shield gas”, “Wire diameter”, and “Applicable wire material”.
Wire Welding
Wire type Shield gas Pulse Wire diameter (mm)
material method
No 0.9 1.0 1.2 1.4 -
CO2 CO2 (100%)
Yes - - - - -
Sold wire
No 0.9 1.0 1.2 1.4 -
MAG Argon (80%) + CO2 (20%)
Yes 0.9 1.0 1.2 1.4 -
Mild steel
No 1.2 1.4 -
CO2 CO2 (100%)
Flux cored Yes - - - - -
wire No - - 1.2 - -
MAG Argon (80%) + CO2 (20%)
Yes - - - - -
No 0.9 1.0 1.2 - -
MIG Argon (98%) + O2 (2%)
Yes 0.9 1.0 1.2 - -
Stainlss No 0.9 - 1.2 - -
Solid wire CO2 CO2 (100%)
steel Yes - - - - -
No - - 1.2 - -
MAG Argon (80%) + CO2 (20%)
Yes - - - -
No 1.2 - 1.6
Hard alumium MIG Argon (100%)
Yes 1.2 - 1.6
2.1 Standard accessories

Name Product number Q’ty Remarks
Glass tube fuse XBA2E80NR5 1 For Motor on the front panel (8A)
Nut XNGZ8SWFJ 2 For output terminal (M8)
Washer XWE8X22FJ 2
Bolt XVGZ8 + F20FJ 2
Binding band ALT150M 1 For binding lead-in wires over the boot of grommet
OMDT6399E00 7
2.2 Duty cycle

• The rated duty cycle for this product is 60%.
“The duty cycle is 60% at the rated output” means that
for 60 percent of the ten minute period (6 minutes), the Duty cycle (%)
100% (309.8 A or less)
power source can maintain operation at 40 degrees-C 100
ambient temperature conditions with the rated output
current without overheating. The remaining four 60% (Rate)
minutes must be operated at no-load to allow proper 60
cooling. Applicable range
• When using the product in combination with other
devices, such as the welding torch, etc., use it at the
lowest rated duty cycle among those devices 0 30 100 200 310 400
Output current (A)
<Note>
Using a product at a duty cycle over the rated duty
cycle may cause the increase of equipment * When an output other than rated value is used.
temperature over the permissible maximum, and result Rated 2
in the deterioration or burnout of the equipment. Allowable output current Rated
duty cycle (%) = Actual x duty cycle (%)
• IGBT, DCL and some diodes of this unit are protected output current
with “Thermal protector”. The error “Err 3: Abnormal
rise in temperature” occurs when the temperature of
those units exceeds the allowable temperature.
For your reference:
Duty cycle: The 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, however, it means when driving it at
the rated number of revolution.
2.3 Dimensions
380 540
33 642
675
73
324 379
35
(Unit: mm)
8 OMDT6399E00
Installation
3.Installation
3.1 Installation site
In order to prevent possible human injury at installation or
CAUTION transportation, make sure to wear protective equipment, such as
gloves, safety shoes, long sleeve shirt, etc. properly.
In case that the product gets wet with rain or water spray:
Make sure that persons who well understand this product should check the inside of the product and wipe up water
if any. Such water entered inside the product may cause the product to malfunction.
（1）Locate indoors only, where the floor is capable of

supporting the weight of the product.
（2）Avoid exposure to the direct sun light or the rain or
water spray.
<Note>
If exposed to the rain or water spray, or dew
condensation occurred, dry the product before using it.
（3）Range of temperature of the ambient air:
40°C
（a）During welding:10 to +40 deg-C,
-10°C
（b）After transport and storage:-20 to +55 deg-C
30cm or more
（4）Humid: 20cm or more
（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.
<Note>
When the product is installed on a slope, make sure to
scotch the caster. Or the product may move Note
unexpectedly. When the product is installed on the floor where it is too
low to operate, customers are required to prepare a table
（8）Avoid wind to the arc (provide windshields.)
to mount it. (And, in that case, provide such a table with a
（9）Free from abnormal amounts of dust, acid, corrosive flange, etc. so that the product does not slip down from
gases or substances etc. other than those generated the table.)
by the welding process (Especially, avoid where the
metallic substance may get into the power source.)
3.2 Power supply equipment

Observe the following to prevent burnout, destruction of parts and unstable
CAUTION arc.
Input protective devices Type and capacity to be applied should conform to all national
(Breaker, fuse etc.) and local codes.
Cable cross section area Type and size of cables to be applied should conform to all
for input cable and ground wire national and local codes.
OMDT6399E00 9
Installation
3.3 Transportation
Do not lift the product on your own.
As this product is heavy, it is dangerous to lift it on your own. Involve plural
number of persons with its lifting.
• Transport it either by pushing on the floor or by lifting it

with crane or forklift.
• A crane or forklift shall be operated by a qualified

person.
• With crane, make sure to use the provided two

eyebolts and hook the shackle to the eyebolts. And
make sure no person is near or under the hanging
product during transportation.
Double
Keep the balanced of the product during wired.
transportation.
About eyebolts
Eyebolts are important safety parts. When
they are lost or broken, purchase
Panasonic genuine eyebolts for your
safety.
• With folklift, no personnel should hold or support the

product
• Avoid any impact to the product during transportation

and unloading procedure.
• Do not leave the product on a slope. Topple or trundle

(as the product is provided with casters) may result.
• If jostling, do not make a sharp turn. Floor and/or

castes may be damaged.
10 OMDT6399E00
Names and functions
4.Names and functions

4.1 Front panel
When the power switch is turned off automatically, do not reclosing it.
CAUTION Consult with sales distributor of Panasonic representatives..
4.1.1 Power switch:

（1）Turns ON/OFF power to the product.
（2）Press it over the cover. Power switch
（3）The lever position when tripped (i.e. the switch is
turned off automatically due to over-current) is the
same as the off position.
（4）When the power is turned on,
• The cooling fan at the rear side rotates,
• Then the “7-segment displays” on the panel show
the software version information for about four
seconds,
• And then the indicator lamps on the front panel show
the settings when the power was turned on last time.
(Exception: the FUNCTION always shows “WELD”.)
（5）When activating a power generator, turn off the
power switch.
4.1.2 Connection of the front panel

1) How to open the terminal cover
Loosen the bolt (M6) and flip-open (in the direction of the
arrow) the cover at the bottom of the panel. Flip up
Cover fixing bolt (M6)
2) Terminal names
No. Name Description Output terminal name plate
It is used when an behind the terminal cover
(1)
Base metal (-) voltage detection extension cable is
terminal
used.(M6)
(2)
Base on the base metal Base metal side cable
side (-) connecting terminal
At CO2/MAG welding:
(3)
Output CO2/MAG
terminal Power cable from the wire
Torch feeder connecting terminal.
(OUTPUT) side (+)
TORCH Pulsed At pulsed MAG welding:
(4) MAG Power cable from the wire
(PULSE) feeder connecting terminal.
Feeder connector Connector to connect

(5) control cable from the
(FEEDER) wire feeder. (16P) (1) (2) (3) (4) (5)
<Note> • Do not connect (3) and (4) at the same time.

• Nuts, washers and bolts for (2) and (3) ( or (4)) are provided.
OMDT6399E00 11
Names and functions
4.1.3 Operation panel
(1) (2) (5)
(14)
(3) (6)
(15)
(8) (9) (10) (11)
(12) (13)
(4) (7)
(16)
Note
• As for the button (8) in the above figure, only “WELD” and “F. ADJ” are available at shipment. To
add “CALL” and “RECORD”, it is necessary to change DIP switch settings.
• About pulsed welding settings, use the remote controller (“WELD PROCESS” switch.)
If the use of remote controller is set to invalid, it is automatically set to pulsed welding.
• Please also read sections “9. Operation” and “11. Troubleshooting.”
（1）OVER TEMP. indicator lamp to be stored blinks.

When abnormal rise in important components If it is after selecting a channel and then pressing
temperature occurs, this lamp goes on and the (8), it shows “rEC” and starts recording “no/YES”
welding operation stops. Welding operation cannot operation.
be re-started unless this lamp is turned off. （e）When a self-diagnosable error occurs, the
（2）7-segment display characters “Err” blink.
* The corresponding error code is displayed on
（a）When the “FUNCTION” (8) is set to “WELD”:
the 7-segment display (5).
In standby state, it shows the current value of the
current type specified by (3) （3）INITIAL/MAIN/CRATER select buttons
In welding state, it shows the measured current Select a button to set or check corresponding current
value. and voltage. (*Buttons related to the control method
specified by (12) are selectable.)
（b）When the “FUNCTION” (8) is set to “F. ADJ”:
Welding current of the selected item is displayed on
It shows the page number.
the 7-segment display (2). See description of the
* The measured value on that page is displayed
button (6) for indication of the welding voltage.
on the 7-segment display (5).)
* Please note rotating the jog-dial (4) after
（c）When the “FUNCTION” (8) is set to “CALL”: selecting a button changes the set value.
If it is before selecting a channel with the jog-dial
（4）Jog-dial
(7) or if the jog-dial (7) is in the “OFF” position, it
shows “---”. （a）When the “FUNCTION” (8) is set to “WELD”:
* The current welding condition is applied. Rotate the jog dial to set the current value of the
If it is after selecting a channel, the current value current type specified by (3).
of the selected channel blinks. It is possible to set current value while welding.
* The selected welding condition is applied. * When the remote controller is used, use the
remote controller to set the current value.
（d）When the “FUNCTION” (8) is set to “RECORD”:
If it is before selecting a channel with the jog-dial （b）When the “FUNCTION” (8) is set to “F. ADJ”:
(7) or if the jog-dial (7) is in the “OFF” position, it Rotate the jog dial to specify a page.
shows “---”. （c）When the “FUNCTION” (8) is set to “CALL” or
If it is after selecting a channel, the current value “RECORD”, it is nonfunctional.
12 OMDT6399E00
Names and functions
（5）7-segment display • W A V E F O R M
Current waveform
CONTROL:
（a）When the “FUNCTION” (8) is set to “WELD”: Waveform
It is to adjust the slope control
In standby state, it shows the data specified by of the wave control part
(6). (Rang: -7 to +7).
In welding state, it shows the measured voltage From zero (0); standard
value. value, adjust to (+) side
（b）When the “FUNCTION” (8) is set to “F. ADJ”: to increase di/dt of the
Short-circuit Arc
part. (i.e., for sharper
It shows the set value of the page shown in the 7-
slope as the current
segment display (2)
increment rate per time increases.)
（c）When the “FUNCTION” (8) is set to “CALL”: Adjustment Changes
If it is before selecting a channel or if the jog-dial 0 - (Standard)\
(7) is in the “OFF” position, it shows “oFF”.
• Softer arc-feeling
* Current welding condition is applied. To “-” side
• Reduce spatter
If it is after selecting a channel, it shows the
voltage value of the selected channel and the • Harder arc-feeling
selected channel alternately. To “+” side • More stable arc in high speed
welding
* The selected welding condition is applied.
（d）When the “FUNCTION” (8) is set to “RECORD”:
（7）Jog dial
If it is before selecting a channel or if the jog-dial
(7) is in the “OFF” position, it shows “oFF”. （a）When the “FUNCTION” (8) is set to “WELD”,
* Current welding condition is applied. rotate the jog dial to set value for the item
If it is after selecting a channel, it shows the selected in (6).
voltage value to be stored and the specified If “VOLT” is specified by (6) and “INDIVIDUAL” is
channel number alternately. specified by (13), rotate the jog dial to set each
voltage.
（e）When a self-diagnosable error occurs, the
If “VOLT” is specified by (6) and “UNITARY” is
corresponding error code blinks.
specified by (13), rotate the jog dial to adjust the
The characters “Err” is displayed on the 7-
voltage for unitary settings between -9.8V and
segment display (2).
+9.8V.
（6）PULSE CHAR/VOLT/WAVEFORM CONTROL * When the remote controller is used, use the
select button remote controller to set those settings.
Select a button to set or check corresponding data. * It is possible to set current value while welding.
The data of the selected item is displayed on the 7-
（b）When the “FUNCTION” (8) is set to “F. ADJ”:
segment display (5).
Set the data of the page shown in the 7-segment
* Please note that rotating the jog-dial (7) after
display (2)
selecting a button changes the set value.
（c）When the “FUNCTION” (8) is set to “CALL”:
• PULSE CHAR.:
Select the channel to replay.
Setting range: -15 to +15 (“0”:
* Only stored channels are selectable.
standard value), Increment of 1,
(Factory settings at shipemtn: （d）When the “FUNCTION” (8) is set to “RECORD”:
“0”.) Specify a channel to record, and then select either
It is for fine adjustment of arc Yes (to record) or No (not to record).
(-) ←→ (+)
form at pulsed welding. Increase
the set value for harder arc. （8）FUNCTION button
• VOLT: • WELD: Select this and set welding conditions using
It is to display set voltage specified by (3). If (13) is (2) to (7) and gas and wire check using (9) to (13) to
set to “UNITARY”, then voltage and “Fine execute welding operation.
adjustment ±9.8V” are displayed alternately by • F. ADJ: Select this for setting or fine adjustment of
pressing this button. welding parameters, and also for welding operation.
• CALL: Select this to weld using the stored welding
conditions.
• RECORD: Select this to store the current welding
conditions.
OMDT6399E00 13
Names and functions
（9）MATERIAL button • INDIVIDUAL: Welding voltage needs to be set

Select a wire material to be applied for welding. individually.
* FCW stands for flux cored wire. （14）GAS CHECK:
* AL ALLOY: Hard aluminum It is to check shield gas and adjust flow rate.
（10）WIRE DIA button • Normally, the indicator lamp is off.
Select a wire diameter to be applied for welding. The lamp is on while checking gas.
（11）GAS button • Gas check is available when the welder is in standby
Select a welding method. Applied gas type is state.
determined depending on the selection as follows. • To perform the gas check, press this button once (or
you can keep pressing it), then the gas valve of the
• CO2: 100%CO2 gas wire feeder is turned ON and then turned OFF in 60
• Ar MIX: 80% Argon gas and 20 % CO2 seconds.
• Ar: Argon gas with 2% O2. Press this button once again to terminate the gas
check immediately.
（12）CONTROL button
Select a welding sequence. （15）INCHING button
Use this button to feed the wire manually. The wire
• NO CRATER: Main welding only. is fed forward while this button is pressed.
• CRATER: Welding using main welding and crater.
• Normally, the indicator lamp is off.
• INI.&CRATER: Welding using initial welding, main The lamp is on while feeding the wire.
welding and crater.
• Inching is available when the welder is in standby
• INI.&CRATER (No crater pulse): Welding using initial state.
welding, main welding and crater. In pulsed welding,
pulsed is not applied to “Crater welding”. • Current set value for the main welding is used to
determine the wire inching speed.
（13）UNITARY/INDIVIDUAL:
（16）MOTOR (8A) fuse
Select a welding voltage setting type.
It is a protective fuse for wire feeder motor.
• UNITARY: Welding voltage is set based on the * Make sure to turn off the power switch prior to
welding current set value automatically. replacing or checking the fuse.
(Welding voltage can be adjusted using the jog dial
(7).
<Note>
• When the remote controller is used: • About distane between the chip and base metal.
While operating the remove controller, the set values is The output value of the welding current to the set value
displayed. The display will be switched to the is set according to the distance between the chip and
measured value in two seconds or so after stopping base metal (se the following table).
the operation of the remote controller stops .
operations.Then twe seconds or so appears
Wire diameter (mm) Welding current set value 50A 100A 150A 200A 250A 300A
0.9 12 12 12 15 - -
Chip - Base metal
1.0 / 1.2 12 15 15 18 22 -
distance (mm)
1.4 - - - 18 22 27
14 OMDT6399E00
Names and functions
4.2 Rear panel

No. Name Description (1) (2) (3)
(1) Input power terminal Connect input power cable and then place the
cover back in position without faile.
(2) Ground terminal Provide grounding that comform to all national
and local codes.
(3) Wiring port lit the grommet membrace and insert a wire from
(For jig terminal) this port to connect to the internal jig terminals.
(4) Cooling fan air intake See the “Caution about cooling fan air intake
vent vent” below.
When the power is turned on, the fan rotates. If
the no-welding operation lasts more than seven
minutes, it automatically stops to save electricity
until the welding operation starts for the next
time.
(4)
♦Remarks about cooling fan air intake vent

• Do not install the product in the following conditions, or
spatters may enter from the air intake vent, which may
damage the internal equipment or cause a fire.
（a）Near the workpieces.
（b）Facing the rear side (especially cooling fan
air intake vent part) toward the workpieces.
In case it is not possible to avoid installing the product

in the above conditions, put the fan cover unit;
DKU00806 (optional part) over the vent part as per the
figure on the right.
Please note the fan cover unit does not provide any Fan cover unit mounting bolts
guarantees to avoid spatters or fume from entering into (M5, 4 pcs).
the product completely. Clean the inside of the product (Attached at shipment)
at periodic check without fail.
Fan cover unit (Optional part

DKU00806
(Sold separately)
OMDT6399E00 15
Names and functions
4.3 <Switches on PC Board

Touching any current-carrying parts may cause a fatal electric shock or
burn injury.
WARNING To prevent a fatal accident, such as an electric shock, burn injury, etc., make sure to
observe the followings.
• For safety reasons, provide base material with grounding work. Wiring and grounding work should
be done by qualified electricians.
• Prior to working on the P.C. Board, make sure to turn off the power switches of the product and
peripherals and also the distribution box. And allow at least five minutes for capacitor discharge.
To prevent the electrostatic destruction of semiconductor parts and the

CAUTION printed circuit board, observe the following.
Allow static electricity to escape by, for example, touching the metal parts of the case with your
hand before touching the equipment, the conductor of wire and/or the printed circuit board.
4.3.1 Slide switch (SW1)

When the “Base metal voltage detection terminal” is used,
switch this slide switch (SW1) to “EXT” side. Slide switch DIP switch
* Default setting: “NORM” side. (SW1) (DSW1)
4.3.2 DIP switches (DSW1)

Use this switch for advanced functions.
* Default setting: OFF position for all switches.
Control board: YEP10070
DSW1 Description ON OFF Remarks

1 For special specifications - - Keep it in the OFF position.
2 Crater repeat Yes No Yes: To use this function.
A function to keep the leg length constant at any leg
3 (*1) Leg length control Yes No
length.
4 (*2) Remote control No Yes Yes: To use the remote controller.*
5 CALL/Record Yes No Yes: To use these functions
6 Burnback 2 No Yes A function to prevent the wire stick at weld end.
Reference volt. for welding
7 (*3) A/V adjust.
10V input 15V input It is for command from an external device, such as
the remote controller determining the
Reference volt. for welding corresponding input voltage for the max. output.
8 (*3) A/V adjust.
12V input 15V input
(*1): This switch is effective on ly when the pulse setting is OFF.

(*2)
: When this switch is set to OFF, the remote controller is used to set the main welding current and voltage, and also
pulse.
(*3): Do not set the switches (7) and (8) to the ON side at the same time. Or the both functions is ignored.
16 OMDT6399E00
Names and functions
4.4 Remote controller (YD-40GTR1)

* The remote controller is separately sold.ely.
(2) (1) (3)
WELD Specify “PULSED” or “NO PULSE”

(1)
PROCESS welding.
• Specify welding current.

WELDING
(2) • While wire inching operation, use it
CUR.ADJ
to adjust wire feed speed.
In Unitary setting: Cable

Adjust welding voltage with the (2m)
VOLT FINE range ±9.8V.
(3)
ADJ.
In Individual setting:
Specify welding voltage.
(4)
• Perform wire inching operation.
Note
(4) INCHING • Use (2) welding cur. adjust volume Scales on the remote controller are reference only.
to adjust wire feed speed. It may vary with applied types of connecting cable,wire
extrusion, torch angle, wire type and gas type.
OMDT6399E00 17
Configuration
5.Configuration
Note Handling of wire feeder and welding torch
• Please use this welding power source together with specified wire feeder. If a welding power source other than the
specified one is used, it is not possible to perform welding operation. Besides, it may damage the equipment.
• As for handling of wire feeder and welding torch, please read individual operating instructions.
Note Applied gas quality (that affects welding result.)

• As for mixed gas for MAG welding, use argon gas with 5 to 20% of ,CO2.
• In case of using a mixture of two types of gases (CO2 and argon), use gas mixer.
At that time, argo should be high purity argon gas for welding (Purity: 99.9%)
5.1 What’s needed for welding operation

5.1.1 CO2/MAG welding
Model number/ (10)

No. Necessary equipment
Remarks DC welding power source
(YD-400GT3YUA)
(1) Wire feeder YW-40DG1
YW-50DG1
(2) Power cable (1.8 m) Factory connected
one end with wire (11)
(3) Feeder cable (1.8 m)
feeder.
(4) Gas hose (4.8 m)
(5) Remote controller YD-40GTR1
(Cable: 2 m) (7)
(12)
(6) Welding torch YT-35CSG4
YT-50CSG4
(7) Gas regulator YX-25AD1 (14)
(8) Gas cylinder (Shield gas) -
(9) Base metal side cable -
(9) (2) (3)
(10) Line disconnect device - (4)
(8)
Example of
(11) Input power cable 2
14 mm or more connecting to
CO2/MAG
(12) Ground wire 14 mm2 or more output terminal (15)
(13) Ground wire 2 (1)
14 mm or more Base metal
(14) Ground wire 1.25 mm2 or more
(13) (5)
(15) Wire -
* For details of specification, rates of the above (6)

equipment, please contact Panasonic representatives.)
18 OMDT6399E00
Configuration
5.1.2 Hard aluminum welding
Model number/ (10)

No. Necessary equipment
Remarks DC welding power source
(YD-400GT3YUD)
(1) Wire feeder YW-40DG1TAK
(2) Power cable (1.8 m) Factory connected
(3) Feeder cable (1.8 m) one end with wire
feeder. (11)
(4) Gas hose (4.8 m)
(5) Remote controller YD-40GTR1
(Cable: 2 m)
(6) Welding torch YT-20MD1TAB (12) (7)
YT-30MFA1TAB
(7) Gas regulator YX-25AD1
(14)
(8) Gas cylinder (Shield gas) -
(9) Base metal side cable -
(10) Line disconnect device - (9) (2) (3)
(4)
(11) Input power cable 14 mm2 or more Example of
connecting to
(12) Ground wire 14 mm2 or more pulsed MAG (8)
output terminal
(13) Ground wire 14 mm2 or more
(15)
(14) Ground wire 1.25 mm2 or more Base metal
(1)
(15) Wire -
(13) (5)
* For details of specification, rates of the above

equipment, please contact Panasonic representatives.)
(6)
OMDT6399E00 19
Configuration
5.2 Connection cable (optional unit)
CAUTION Avoid the connection cable to get wet.
If exposure to rain or water splay is expected, make

sure to protect the connection with waterproof cover.
Output cable
Water seeping into the machine may degrade the
insulation between terminals, which may cause an
error, such as output cannot be turned off, or welding
Waterproof cover
power source failure.
or
Waterproof outlet
Wire feed control cable
Note Cautions about using connection cable
• Keep the connection cable as short as and as thick as possible. Avoid connecting an unnecessarily long connection
cable.
• Keep the connection cable straight. Using the connection cable winded may cause the arc unstable.
• Using a connection cable between positive side output

terminal of the welding power source and wire feeder
<Connection cable: model number and specifications>
expands welding operation range.
* Normally it is necessary to extend the base metal Model number Size Length Remark
cable at the same time. YV-610GR1A 10 m -
• Applying a proper connection cable is important. YV-610GR3A01 10 m For aluminum
60 mm2
Electric resistance and lay out conditions of the exten- YV-615GR1A 15 m -
sion cable can negatively effect on welding operation, YV-620GR1A 20 m -
such as voltage drop.
YV-810GR1A 10 m -
The longer the extension cable is, and/or the smaller
the cable cross section is, the greater the negative YV-815GR1A 80 mm2 15 m -
effect becomes. YV-820GR1A 20 m -
* Refer to the following table for details of the connec- * For model numbers other than the above, please
tion cables. consult Panasonic representatives.
* Each connection cable unit comes with power cable
Note (1 pc.), control cable (1 pc.), and gas hose (1 pc.).
• For cable smaller than 80 mm2, it is necessary to
reduce the output current or duty cycle below its rated
value.
• It is necessary to cover the wire feeder with waterproof
cover or so to protect from water.
• Do not extend the connection cable with an extension
cable.
20 OMDT6399E00
Connection
6.Connection
Prior to connection work, shut off the line disconnect device and ensure
safety.
Touching current carrying parts may cause a fatal accident like an electric
WARNING shock, burn injury and so on.
After completion of connection work, position removed panels back in place
without fail.
In order to prevent possible human injury at installation or transportation,

CAUTION make sure to wear protective equipment, such as gloves, safety shoes, long
sleeve shirt, etc. properly.
CAUTION Make sure to connect the cable completely.
• Connection work should be performed by personnel with experience of electric work who well understand elec-
tricity. If no such person is available, please consult Panasonic representatives.
• Grounding work should be performed by qualified electricians.
• To ensure safety operation, connect output cables before connecting input cables.
• Use a cable with the specified cable size or larger one.
6.1 Connecting output cables

（1）Base metal cable
Connect the base metal cable to the “(-) base metal
terminal” with the attached M8 bolt.
（2）Power cable
Connect the power cable drawn from the wire feeder
to the (+) torch terminal with the attached M8 bolt.
* Select the terminal either “CO2/MAG” or “PULSED
MAG” depending on the applied welding method.
DO NOT connect both terminals with the power (-) Feeder
cables. Base metal connector
terminal
（3）Feeder cable
(+) Torch
Plug in the plug of the feeder cable drawn from the CO2/MAG PULSED MAG
wire feeder to the “Feeder connector”. terminal terminal
• About base metal cable (Customer preparation)

Indication of selecting base metal cable and power cable
• After connection, insulate the cable connections with
insulation tape. Cable cross Allowable current / Duty cycle
• Use a cable for welding or a specified tough rubber section (10-minute cycle)
sheath cable (excluding vinyl type) whose cross section 60mm2 400A / 50% 350A / 65% 300A / 89%
should be equal to or larger than that of the applied con-
necting cable. 80mm2 400A / 95% 389A or less / 100%
• Determine the cable length based on the applied con- 100mm2 400A or less / 100%
necting cable. Do not use unnecessarily long cable.
• Make sure to attach the proper clamp terminal.
OMDT6399E00 21
Connection
6.2 Connecting base metal voltage detection wire

Connect the base metal voltage detection wire (-) to this
terminal and the base metal when the arc stability cannot
be obtained (shows sudden increase in spatters) even
though the connecting cable (optional) is correctly applied.
Before touching a printed cir-

cuit board, touch any metal part
of the case with your hand to
discharge static electricity. Or
electrostatic destruction of the
printed circuit board may be the
result. (-) Base metal
voltage detection terminal
Once this terminal is used, switch the slide switch (SW1)
on the PC. Board; YEP10070 to “EXT” side. (It is factory
set to “NORM” side.)
For details, see section “Slide switch (SW1).)
6.3 Connecting input cable and ground wire
Prior to connecting input side cables, make sure to shut off the line discon-
WARNING nect device (use provision) and ensure safety.
（1）Ground wire:
Ground terminal
• Ground wire is customer provision. Cross section of the (M6 bolt)
wire should be 14mm2 or more. Terminal cover
• Ground work should be performed by qualified
electricians.
• DO NOT connect the ground wire to water supply
pipes, building iron frames, etc., as they do not serve as
sufficient ground.
Input terminal
Connect one end to the “Ground” terminal (M6 bolt) board
located at hte rear panel. Ground wire
(Customer
provision)
Line disconnect
（2）Input cable: device
1
• Provide one line disconnect device for one welding
power source.
• DO NOT use wrench. Connect mannually at the
specified clamping torque of 2.45 to 3.4 N•m.
（a）Shut off ht line disconnect device. Input power

cable
（b）Remove the terminal cover.
（c）Connect one end of the input cable to the input.
No specific phase connecting order.
（d）Put the terminal cover back in place.
（e）Connect the other end of the input cable to the (-)
(minus) terminal of the line disconnecting device.
22 OMDT6399E00
Connection
6.4 Connecting jig terminals
Prior to connection work, turn off power switch of the line disconnect device
and other related equipment, and let stand it for about five minutes for
capacitor discharge.
WARNING Do not conduct connecting work with wet hands.
Insulate any exposed lead wires, such as cable connections, with insulation
tape or so.
There are two types of jig terminals (Jig terminals 1 and 2)

(1) Jig terminal 1
To send out a command for the emergency stop and Wiring port
temporary stopping from a jig or another device.
To send out the current detection signal to a jig or
another device.
Top view (without top panel)
Location: On the P.C. Board inside the product.
(Front)
(2) Jig terminal 2
To install an external voltmeter or ammeter.
Location: On the chassis inside the product.
Note
• Keep the communication cables away from the welding
arc area, the welding torch, the base-material-side cable,
etc. to prevent troubles caused by incorporation of the
high frequency wave. And keep the wiring length within
10m.
• Lead wires from the wiring port. (Make a cut in the grom-
met wall to insert wires.)
As to signal wires from another device: (Rear)
make sure to tie the lead-in wires in a bundle with a
binding band (15 cm) over the boot of the grommet Jig terminal 1 Jig terminal 2
to prevent dust to get in (On the P.C. Board) (On the chassis)
6.4.1 JIg terminal board
Jig terminal 1 Jig terminal 2
CUR.DETECT STOP2 STOP1 EMERGENCYSTOP GAS PURGE VOLTMETER AMMETER

DC60V DC60V DC24V DC24V DC24V CONTACT CAPACITY DC60mV
0.6A 0.6A 10mA 10mA 10mA DC30V OVER1A DC600A
OMDT6399E00 23
Connection
1) Jig terminal 1
Name Function
When these terminals are opened, the product comes to • To these terminals, make
an emergency stop. At that time, the welding output, gas sure to connect a no-voltage
Emergency supply and wire feed are also stopped. contact signal or an open-
stop collector transistor signal.
To release the emergency stop,
(Connecting a signal with
turn OFF power switch, and close the terminals, and
voltage may cause a circuit
then turn power switch back ON again.
burnout to this product.)
• When these terminals are opened, the product comes to • Between these terminals,
a stopped state.
At that time, welding output, gas supply, wire feed are the voltage of 24VDC is
Stop 1 also stopped. Gas purge, wire jogging and wire retract applied when the circuit is
INPUT
are also stopped. open, and the current of
To release “Stop 1” state, DC 10mA is generated
• Connect a signal for reduced-gas-level detection, etc. when the circuit is closed.
• To release the stopped state, close these terminals. [Connect a signal not
To release “Stop 2” state, likely to cause any
• In case that a water cooled torch is used, connect a sig- damage or contact failure
Stop 2 nal for reduced-water-level detection, etc.
under this voltage or
• To release the stopped state, close these terminals.
current to these
terminals.]
Between these terminals, the normally-open contact of a • Do not exceed the following
photo MOS relay is connected, and it is closed while contact ratings.
welding current flows. Load voltage: 60 VDC
Current Load current: 0.6 ADC
To release
detection • AC (alternating current) is
Use it when there is a jig whose operation should
be synchronized with the flow of the welding not applicable.
OUTPUT current.
Between these terminals, the normally-open contact of a
photo MOS relay is connected.
To release
User output
This is provided for special use.
(As to the product with standard specification,
nothing is output.
2) Jig terminal 2
• Connect those terminals to use a DC ammeter to display the output current.
• Use a DC ammeter with an external shunt resister(600A/60mA) that can display up to 600A. (This
AMMETER product has a built-in shunt resistor.)
• In order to prevent any indication error, make sure that the applied connecting cable to the ammeter
has correct section area and length specified by its manufacturer.
• Connect those terminals to use a DC voltmeter to display the output voltage.
VOLTMETER
• Make sure to use a DC voltmeter that can display 100 VDC or more.
• Close these terminals with a push-button switch* or the like to operate the gas supply solenoid valve
GAS PURGE of the wire feeder.
* Be sure to use a no-voltage contact type push-button switch with 30 VDC 1A in capacity.
24 OMDT6399E00
Operation
7.Operation
Arc welding operation should be performed by qualified of the welding machine and who understands the opera-
personnel who has knowledge and skill for safe handling tion instructions well.
7.1 Preparation
7.1.1 Use of protective equipment
In order to prevent fire, explosion or blowout, ensure the safety of the opera-
CAUTION tion area and its vicinity prior to operation.
（1）Avoid spatter to hit any flammable material by removing away from the vicinity or cover it with fireproof mate-
rial.
（2）Do not perform welding operation near the flammable gas.
（3）Do not bring the base metal immediately after welding operation (which is still hot) near the flammable mate-
rial.
（4）Prior to perform welding of ceiling, floor or wall, remove flammable materials that lie behind the scenes.
（5）Cables should be connected and insulated completely.
（6）Connect the base metal cable as close as where welding operation is conducted.
（7）Do not perform welding operation to gas pipe with gas inside or a sealed tank or pipe.
（8）Prepare a fire extinguisher near the welding area for in case.
Spatters in welding operation or iron powder in grinding operation may

CAUTION cause fire if it is entered inside of the welding power source. In order to pre-
vent file, make sure to observe the following instructions.
（1）Perform welding or grinding operation away from welding power source so as to prevent spatters or iron pow-
der to be entered inside the power source.
（2）Perform periodic cleaning of inside the power source without fail to prevent insulation aging.
（3）In case spatters or iron powder entered the inside of the power source, turn off powers to the welding power
source and line disconnect device, and then blow them off with hair dryer or the like.
To protect you and other people from arc light,

CAUTION flying spatters, slag, and arc noises generated
by welding, use protective equipment.
• Wear leather gloves and safety shoes to protect the exposed
parts of your eyes and skin.
• Prepare light-shielding glasses or a welding face-shield with a
light-shielding filter plate appropriate to the applied welding
current.
7.1.2 Pre-operation check

• Check if all connections are correct and complete.
• Check if settings of the switches on the P.C. Board are
correct
• Check if wire is set to the wire feeder.
7.1.3 Turning on power

(1) Turn of the power to the distribution box.
(2) Turn on the POWER switch of this product.
OMDT6399E00 25
Operation
7.2 Termination processing (steps after welding operation)

7.2.1 Shutting off gas
(1) Close the main valve of the gas bottle.
(2) Perform the “gas purge” to take the residual pressure
out of the pipe.
7.2.2 Shutting off power-

After completion of welding operation, let stand the machine for at least five minutes before turning
Important
off the power. This is to allow the inside of the product to cool down.
(1) Turn off “POWER” switch.

(2) Turn off the power to the distribution box.
7.3 Settings
7.3.1 “F.ADJ” for setting and checking set values.
1) Setting items
With “FUNCTION” button, select “F.ADJ” (fine adjust-
ment) to check and change the set values of the following
welding related parameters. It is possible to check and
change set value during welding operation.
Default
Page Parameter Set range Increment Description
settings
P00 Slowdown -50 to +50 1 0 Fine adjustment of the slowdown speed.
Parameter to improve arc start by adjusting voltage that
P01 Hot voltage -50 to +50 1 0
is ignited at arc start instantaneously.
Parameter for the wire flare-up amount. The set values
P02 FTT voltage -50 to +50 1 0 Adjust the output voltage during the relate to the
burnback time. wire burning at
P03 Burnback time -50 to +50 1 0 Fine adjustment of the burnback time. arc end.
P04 Penetration -7 to +7 1 0 Fine adjustment of the penetration
Parameter to set the duration of time from starting of gas
P05 Pre-flow time 0.0 to 5.0 0.1 s 0.2
supply by turning on the torch switch to the arc start.
Parameter to set the duration of time from the arc end to
P06 Post-flow time 0.0 to 5.0 0.1 s 0.5
stopping of gas supply by turning off the torch switch.
Pulse peak cur- Fine adjustment of pulse peak current.
P07 -50 to +50 1 0
rent 1 data = 2 A
Fine adjustment of pulse base current.
P08 Base current -50 to +50 1 0
1 data = 1 A
Fine adjustment of pulse rise.
P09 Pulse rise -7 to +7 1 0
To “+” direction to 1 to sharper slope.
Fine adjustment of pulse fall.
P10 Pulse fall -7 to +7 1 0
To “+” direction to 1 to sharper slope.
Fine adjustment of wire feed rate.
P11 Feed rate -50 to +50 1 0
1 data = about 0.5 r/min
Fine adjustment of wire burning at arc start in pulsed
Pulse start volt-
P12 -50 to +50 1 0 welding operation.
age
To “+” direction to increase wire burning.
26 OMDT6399E00
Operation
• Supplements
• P00: Slowdown (P04)
To obtain solid arc start, the wire feed speed • To increase penetration
immediately after turning on the torch switch should be • Effect: Ensure penetration.
set lower than that of usual welding operation.
• P03: Burnback time To “-” side
It is the duration of time to keep supplying output Large
Wire penetration
voltage after turning off the torch switch in order to burn
off the wire extruding from the end of the torch tip. Bead
(Front)
• P04: Penetration
See the figure on the right. * This adjustment is not for • To reduce penetration
pulsed welding • Effect: Prevent burn through
Vertical up welding
To “+” side
• P07 to P10: Pulse peak current, Base current, Pulse rise Small
and Pulse fall Wire penetration
Change the pulse waveform to change arc softness Bead
(width). (Front)
Please note, significant change in pulse waveform may (P07 - P10)
disable drop transition, which causes generation of P07
spatter.
<A setting example> (See figure on the right)
• Increase in peak current (P07) gives concentrated
P09 - P10
arc, but more chances of bead burning.
• Increase in base current (P08) gives soft arc (wider) + + P08
but longer arc length.
• Smoothen the rise (P09) and fall (P10) slope gives
soft arc (wider) but less chances of drop transition. (P12)
V +
• P12: Pulse start voltage
See the figure on the right. -
At arc start t
2) Procedure
Procedure Panel indication

1.With (8), select “F.ADJ”. (2) shows “P00”.
(2) (5)
(5) shows “00”.
2.With (4), specify page you want (2) shows specified page number.
to work on. (5) shows set value of the page. (8)
<Note> From here on, do not move the volume (7). Or set value (5)
will be changed. (4) (7)
3.Use dial (7) to change the set (5) shows set value of the new
value of the selected page. page.
4.To end the operation of this page, select an item other than “F.ADJ”
with (8). If the set value has been change in procedure 3, the value
will be updated with the new one.
5.To set/check another page, repeat the procedure 1.
OMDT6399E00 27
Operation
7.3.2 “CALL” and “RECORD” welding conditions

• Those items are factory disabled at shipment. To
enable the items, switch the Dipswitch (DSW1) No.5. (2) (5)
• The items are to call a welding conditions to apply for

welding operation, and to store the current welding
conditions. (8)
• The welding conditions include Pulse characteristics,

Wave control, Fine adjustment, Materials, Wire (4) (7)
diameter, Welding method, Control method and
Unitary/Individual as well as welding current and
welding voltage.
1) Procedures: CALL (2) (5)
1.With the “FUNCTION”button (8), select “CALL”.

(“---” appears on (2) and “OFF” on (5).)
2.With Jog-dial (7), select a channel* you want to adjust

or check. (* CH1 to CH9 with welding conditions having .
stored are selectable.)
• “Channel #” and “Voltage set value” alternately appear

on (5).
3.To exit from “CALL”, change the selection of the “FUNCTION”. (Select a function other than “CALL”.)
2) Procedures: RECORD
1.With the “FUNCTION”button (8), select “CALL”.
(“---” appears on (2) and “OFF” on (5).)
2.With Jog-dial (7), select a channel you want to adjust or

check. .
• “Channel #” and “Voltage set value” alternately appear

on (5).
3.Press (8).
• Press (8) again to return to welding operation without
recording the current welding conditions.
4.To record the current welding conditions, rotate the jog-
dial (7) to display “YES” on (5).
*It is possible to quit the operation without recording
data by displaying “no” again and press (8).
5.Press (8) to start recording the current welding
conditions.
• Indications on (2) and (5) go on and off repeatedly
while recording.
<Note>
While recording, do not turn off the power switch or do not operate other buttons. Or data may not be recorded correctly.
28 OMDT6399E00
Operation
7.4 Wire inching

Wire extends out from the end of the welding torch and may stick into the
CAUTION eye, face or body, which can cause injury.
Do not perform wire 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.
Applying high-speed wire inching with the torch cable bent may cause the
CAUTION wire to run through the resin liner and the cable.
In case of using a torch cable with the resin liner, straighten the torch cable and reduce the feed amount (current) to a
half or less before performing the wire inching. Please replace any damaged liner or cable with a new one as use of
them may cause gas leak or insulation deterioration.
In case of using a welding wire with a

Attention
small diameter (0.8 mm2 or 0.9 mm2)
Use of a wire in small diameter may cause unstable wire
feeding. In case of using such wires, please feed the (15)
wire at low speed or contact Panasonic representatives.
Press the “INCHING” (15) button on the operation panel to

feed the wire manually. The wire is fed forward while this
button is pressed. And the lamp is on while feeding the
wire.
7.5 Checking shield gas

Improper handling may cause personal injury due to high pressure gas.
CAUTION Prior to checking, read the operating instructions of the applied gas regulator.
Also read and understand safety precautions.
• Checking procedure
(1) Check and make sure that the Flow adjustment knob is
place in the “SHUT” position. Gas cylinder
(2) Turn on the gas cylinder main valve. main valve
(3) Press the “GAS CHECK” (14) button.
(4) Turn the flow adjustment knob gradually in the “open” Flow adjustment knob
direction until the flow rate becomes appropriate.
Gas cylinder
OMDT6399E00 29
Operation
7.6 Welding operation

Depending on the CONTROL button settings and the use
of “Crater repeat”, torch operation varies as follows.
Note
After turning on the torch switch, if the voltage detect is not
executed, the welder goes in an error state (Err6: Arc start
error) and turns off the output automatically.
(12)
Welding method Description Note

NO CRATER An welding operation using “main welding” only. This method is suitable for
(No initial welding or crater.) • Tack welding,
• Repetition of short welding,
• Thin plate welding.
CRATER An welding operation using “crater”* after “main This method is suitable for medium thick plate
welding”. welding.
(No initial welding.)
*Crater is a built-up welding that can fill the
crater part at the end of a welding section.
INI. &CRATER An welding operation using “initial welding”** ** Initial welding is a welding useful for sta-
before “main welding” and “crater” after “main ble arc start.
welding”.
In pulsed welding, pulse is applied to all initial,

main and crater welding operation.
INI. &CRATER An welding operation using “initial welding”**
(No crater pulse) before “main welding” and “crater” after “main
welding”.
In pulsed welding, pulse is applied to initial and

main welding operation, but not to crater welding
operation.
CRATER REPEAT It is a function that allows repetitive crater To use “crater repeat” it is necessary to set
operation if the torch switch is turned ON within a DIP switch (DSW1 No.2)
preset time (Trep) (about two seconds) after
turning off the previous crater operation. It is applicable only when DIP switch (DSW1
In this manner, it is possible to repeat the crater No.2) is set to ON side.
operation again and again.)
If the torch switch is not turned on within the
preset time, the function is cancelled.
30 OMDT6399E00
Operation
7.6.1 “NO CRATER”

Operation: Turn the torch switch on and off to start and
stop welding arc respectively.
(1) Torch: ON (2) Torch: OFF
Arc ON Arc OFF
ON OFF Tpf: Gas pre-flow time

☆ :Arc start
Torch switch
Tpf
★:Arc end
Taf
ON
OFF
Gas supply
Wire slow down
Wire feed Burn-back time
Weld voltage
Weld current
Main welding
Weld conditions
7.6.2 “CRATER”
Operation: Turn the torch switch on and off twice.
(1) Torch: ON (2) Torch: OFF (3) Torch: ON (4) Torch: OFF
→ → →
Arc ON Arc continues Change arc type Arc OFF

(Self-hold**) (Arc for crater)
ON OFF ON OFF
Tpf: Gas pre-flow time
Torch switch Tpf
(Self hold**) Taf ☆ :Arc start
ON OFF ★:Arc end
Gas supply
Wire slow down
Wire feed
Burn-back time
Weld voltage
Weld current
Main welding Crater
Weld conditions
OMDT6399E00 31
Operation
7.6.3 “INI & CRATER” and “INI & CRATER (no crater pulse)”
Operation: Turn the torch switch on and off twice. OFF to switch to main welding. Then turn it ON again to
(Turn the torch switch ON to start initial welding and turn it start crater operation.)
.
→ → →
Arc ON Change arc type Change arc type Arc OFF

(For initial welding) (For main welding) (For crater)
(Self-hold)
ON OFF ON OFF
Torch switch Tpf: Gas pre-flow time

Tpf (Self hold) Taf
ON OFF ☆ :Arc start
Gas supply ★:Arc end
Wire slow down
Wire feed
Burn-back time
Weld voltage
Weld current
Initial Main
welding welding Crater
Weld conditions
32 OMDT6399E00
Operation
7.6.4 “Crater repeat” operation

To repeat crater operation turn ON the torch switch within a Note
preset time (Trep)* after turning off the previous crater If the torch switch is not turned on within the preset time,
operation. (In this manner, it is possible to repeat the crater the function is cancelled.
operation again and again.)
*: Trep: About 2 seconds
→ → → →
Arc ON Arc continues Change arc type Arc OFF

(Self-hold) (Arc for crater)
(Crater repeat)
Torch: ON within Trep time Torch: OFF
→ Repeat (3) and (4) to →

repeat crater welding.
→
Change arc type Arc OFF
(Arc for crater)
• To stop welding, raise the torch until arc is cut.
Previous
crater operation Taf: Gas after-flow time
Crater repeat
Torch switch OFF ON OFF Trep: Crater repetition time
☆ :Arc start
Trep ★:Arc end
Trep
Taf Taf
Gas supply
OFF ON
Wire slow down
Wire feed
Burn-back
Weld voltage
time
Burn-back
Weld current time
Crater Crater
Weld conditions
OMDT6399E00 33
Maintenance and inspection
8. Maintenance and inspection

• Executing the maintenance and inspection work of spec- • For replacement of parts, make sure to use our genuine
ified contents and at specified frequency is very impor- parts for Panasonic welding machine to keep its perfor-
tant to make the most of the performance of this product mance and functions
and to secure the safety of daily operations.
Make sure to turn off the power switch and the switch of the line disconnect device
before maintenance and inspection work.
WARNING Make sure to put the parts removed during maintenance and inspection work, such as
panels, back in place after completion of the work.
8.1 Daily check

• Perform the daily check without fail. It is important to • In the daily check, mainly check if the (consumable) parts
make the most of the performance of this product and to are worn, deformed or clogged consumable parts of the
secure the safety of daily operations. welding torch and wire feeder. Refer to the following
table, and clean and replace the parts when necessary.
34 OMDT6399E00
8.1.1 Welding machine (This product)

Check item Check points
• If equipment is damaged.
• If all the attachments work loose.
Front panel
• If indicator lamps goes ON/OFF correctly and clearly.
• If 7-segment display indicates items correctly.
• If the input power terminal cover is attached.
• If the input power terminal cover work loose.
Rear panel • If the cooling fan guard work loose.
• If the cooling fan rotate smooth or sounds normal.
• If cool fan sucks cool air.
Peripherals • Check the case, such as the top panel, and eyebolts if they work loose.
• Check appearance if any trace of heat generation, such as decoloration.
Overall • After turning on the power switch and during welding operation, check if any abnormal vibra-
tion, noise or odor are observed.
8.1.2 Cables and hoses

Check item Check points
• If the ground wire for this product is connected completely.
Ground wire • If the ground wire for base metal is connected completely.
• If the ground wire for gas regulator is connected completely.
• If cable coating is worn or damaged.
• If any heavy item(s) are placed on the cable.
Input cable • If connections are tightly connected.
(Especially load side terminal of the line disconnect device, or input power terminal of this
product.)
• If cable coating is worn or damaged.
Base metal cable • If current-carrying part of the cable (other than connection part) is exposed.
Power cable • If any heavy item(s) are placed on the cable.
• If connections are tightly connected.
• If the connector is completely inserted.
Feeder cable • If cable coating is worn or damaged.
• If any heavy item(s) are placed on the cable.
• If the hose band at the connection part is tightly attached.
Gas hose
• If the hose is worn or damaged.
OMDT6399E00 35
8.2 Periodic check
Crack of the resin parts across the ages and inadvertent handling of the prod-
CAUTION uct may cause personal injury. Properly wear the protective equipment, such
as protective gloves.
• To secure physical safety, make sure that a qualified person or a person who is familiar with the welding machine
takes care of a regular check.
• Prior to connection work, turn off power switch of the line disconnect device and other related equipment, and let
stand it for about five minutes for capacitor discharge.
• In case it is necessary to remove the case for inspection or repair work, provide measures, such as fences around
welding power source, to prevent any person to come close to the welding power source unnecessarily.
• Daily checks are not enough to keep the proper perfor- of sucking dusts or dirt into the power source, perform
mance of this product for a long time. the periodic check roughly every 3 months.
• In the periodic check, check the product thoroughly • While details for checking are shown below table, con-
including checking and cleaning of the inside of this sider any additional check items according to your condi-
product. tions of use.
• Conduct the periodic check every 6 months normally.
If the work environment is rather dusty including fine dust
and oily dust, or the work environment has more chance
Ground yourself such as touching metallic part of the case before

Note handling the P.C. Board to protect P.C. Board from electrostatic
discharge damage
Clean with soft cloth using only water or diluted neutral cleansers. Do not use
Note organic solvents (i.e. benzene, toluene, gasoline, etc.) to clean the power source
and its housing. These solvents will damage the plastic molded parts.
8.2.1 Check items
Check item Guideline
Removal of inside • Remove the top panel before cleaning.

dust • Blow off internally-accumulated dirt and dust by compressed dry air (no moisture included).
• Remove the top panel before cleaning.
• Check the following points and points that are not covered by daily check intensively.
Overall check （a）Odor, discoloration and trace of heat generation.
（b）Loose connections
（c）Over-fastening
• For ground wire, input cable, base metal cable, power cable and feeder cable, check points
Cables
that are not covered by daily check intensively.
Hoses • For hoses, check points that are not covered by daily check intensively.
• Cooling fan and electrolytic capacitor have certain electrical and mechanical service life
For example, when the product is used at rated specifications, the service life of the cooling
fan is about 10,000 hours and that of the electrolytic capacitor is 8,000 hours. However they
varies with usage.
Consumable
• Those cooling fan and electrolytic capacitor are consumable components. Handle them as
consumable for inspection and maintenance.
• For replacement of parts, make sure to use our genuine parts for Panasonic welding machine
to keep its performance and functions
36 OMDT6399E00
8.3 Precautions for withstand voltage test and insulation resistance measurement
This product uses semiconductor components such as ical injury or mechanical failure. In case of necessity, con-
transistor. Executing withstand voltage test or insulation tact our sales distributors or Panasonic representatives.
resistance measurement casually may cause serious phys-
♦Attention of sales distributors / Panasonic representatives

Prior to conducting withstand voltage test and insulation
resistance test, prepare the followings and also connect
ground wire (cross section: about 1.25 mm2).
Area Operation
Input power cable Draw out the input power cable from the power box, and short the connecting terminals of the
cable.
Output terminal of Disconnect the cables connected to the output terminal except one for welding main circuit, and
welding power source then short-circuit the output terminals with conductor cable.
Connecting connector Disconnect all connecting cables and signal wires for external devices from jig terminal, welding
torch, wire feeder connector, communication connector and so on.
Ground wire for case Disconnect all ground wires inside of the case connected to the case.
Main circuit Short-circuit between the emitter and collector of the main transistor IGBT, and between anode
and cathode of the secondary diode with conductor cable.
Control circuit Disconnect all connectors connected to the P.C. Board.
After completion of the test(s) and prior to re-installing the case or cover, do the followings without fail.
• Remove all conductor cables for short-circuit.
• Reconnect all cables, connectors and ground wires that have been disconnected before the tests to
Note
the original condition.
Make sure to conduct the above. If the power has been turned on without removing the conductor
cables for the test, the equipment may be burnt.
OMDT6399E00 37
Troubleshooting
9. Troubleshooting
Prior to any troubleshooting work, make sure to turn off power switch of line discon-
WARNING nect device, and confirm safety.
Touching the current-carrying parts may cause a fatal electric shock or burn injury.
Crack of the resin parts across the ages and inadvertent handling of the prod-
CAUTION uct may cause personal injury. Properly wear the protective equipment, such
as protective gloves.
• To secure physical safety, make sure that a qualified per- • Prior to connection work, turn off power switch of the line
son or a person who is familiar with the welding machine disconnect device and other related equipment, and let
takes care of a regular check. stand it for about five minutes for capacitor discharge.
9.1 When indicators blink irregularly

In case any one of three input phases is removed, the
seven-segment displays (2 and 5) on the operation panel
blink irregularly. (2) (5)
Check the connection of the input power system.
9.2 Error indication

When a self-diagnosable error occurs, “Err” (for error) and
an “error code” blink at intervals of 0.5 second. (and each
time, on for 1 second.) 7-segment display (2) 7-segment display (5)
See the following table for details of the error codes.
(Note) About “Group” in the table S
It is not necessary to turn power switch off and A V
A back ON again The displays are automatically
turned off when the cause is removed.
It is necessary to turn power switch OFF and back
B ON again. Even though the cause is removed, the
lamp blinks until the power switch is turned OFF.
(2) (5) Error type Group Probable causes and remedy

Received the emergency stop signal from an external equipment
connected to the jig terminal.
Err 1 Emergency Stop B <Remedy>
Turn power switch OFF, remove the cause and then turn power
switch ON again.
Over current (Sec- Over-current due to short-circuit in the secondary circuit or so on.
Err 2 A
ondary side) Turn torch switch OFF and remove the cause of the over current.
Rise in temperature inside this welding power source.
<Remedy>
Keep the input power in no load state and wait for a while. The
Abnormal rise in error code indication automatically turned of when the power
Err 3 A
temperature source is cooled down.
Check and remove causes of over-heat.
• Over duty cycle,
• Air flow blocking at ventilation and cooling fan windows
38 OMDT6399E00
Troubleshooting

The input voltage exceeds the allowable upper limit.
Over voltage <Remedy>
Err 4 B
(Primary side) Turn power switch OFF and set the input voltage to the rated
value+10 % or less, and then turn power switch back ON again.
The input voltage is below the allowable lower limit.
Low voltage <Remedy>
Err 5 B
(Primary side) Turn power switch OFF and set the input voltage to the rated value
-10 % or more, and then turn power switch back ON again.
No voltage is detected when the torch switch is turned on.
<Note>
When the “Arc Start” error occurs, the welding current output,
motor of the wire feeder and shielding gas flow are stopped auto-
matically.
<Remedy>
Turn power switch OFF and then check the followings to remove
Err 6 Arc Start error B the cause(s).
• In case of using the base metal voltage detection wire;
Check if the detection wire is disconnected or severed.
Check if the slide switch “SW1” on the P.C. Board is set to “EXT”
side.
Check if the fuse for the detection wire in the wire feeder is
blown.
• Otherwise, refer to the “Troubleshooting table”.
The torch switch was turned on before turning on the power switch.
Err 7 Torch switch error A <Remedy>
Turn torch switch OFF.
Output current or voltage is detected when the power switch is
turned on.
<Remedy>
Current detection Turn power switch OFF and then check the followings to remove
Err 8 B
error the cause(s).
• This product is defective.
• Check if the current or voltage is applied to the secondary side of
this product from an external device.
Received “Stop 1” signal from an external equipment.
Stop 1
Err 10 A <Remedy>
(External device)
Remove the cause on the external equipment side.
Received “Stop 2” signal from an external equipment.
Stop 2
Err 11 A <Remedy>
(External device)
Remove the cause on the external equipment side.
• The following errors are to conduct self-diagnosis of the software.

Memory error 1 occurred.
Turn power switch OFF and back ON again, and then check the
Err 41 Memory error 1 B data in the memory including welding conditions, FUNCTION
(including “F. ADJ” settings) and so on. (If data is lost, set all data
once again.)
Err 42 Memory error 2 B
Turn power switch OFF and back ON again
OMDT6399E00 39
Troubleshooting

System error 1 occurred.
Err 50 System error 1 B
Note
If the error recurs frequently, contact sales distributors or Panasonic representatives.
9.2.1 If the 7-segment displays do not function correctly

If the indications on the 7-segment displays are not proper
although the power switch is on, the data in the memory
may be damaged.
In such case, you can restore the data in the memory to the
initial settings at shipment by following the below proce-
dures.
(2) (5)
Procedure:
(1) Turn power switch OFF.
(2) While holding down “INITIAL” and “CRATER” buttons
(3), turn power switch ON.
Then the displays (2 and 5) indicate
S
A V for six seconds. The data is
reset to the initial settings at shipment while the indica-
tions are on.
Do not turn off the power switch while resetting data
(while the above indications are on. Or data won’t be
reset to the initial settings at shipment. In such case, re-
do the operation from the beginning.
(3) Once the indications are turned off, turn power switch
OFF and back on again.
(4) Re-do all the settings including welding conditions, “F.
ADJ” settings), settings using (8) to (13) buttons and
so on.
40 OMDT6399E00
Troubleshooting
9.3 Troubleshooting table

* In the case of welding errors without any error (Err) indication, refer to the following table to search for their causes.
Error • Blowholes
conditions
• Welded tip
• Wire runs into the base metal
• Bead turns black.
• Unstable arc start
• Poor arc start
• No wire feeding
• No gas supply
• No arc
Check item Probable causes
Input cable • Cable is disconnected or severed.
O O O
• Loose connections.
This product • Switch is not ON.
O O O
• Tripping of circuit breaker.
Gas cylinder • Main cock is not open.
Gas regulator • Gas nearly runs short.
O O O
• Insufficient flow rate setting.
• Loose connections.
Gas hose • Loose connections
O O
• Hose is damaged.
Wire feeder • Size of the wire for feed roller/SUS tube is wrong.
• Crack, clogging or breakage at the feed roller.
O O O O O
• Insufficient fastening of pressure rod.
• Accumulation of wire powder at SUS tube inlet.
Torch cable • Cables (for power and torch switch) are severed.
• Loose connection to the wire feeder. O O O O O
• Traces of dropping impact
• Torch cable is bent at an acute angle or coiled. O O O O
Welding torch • Tip/liner is worn, clogged, distorted or has wire with
wrong wire size. O O O O
• Torch cable is bent at an acute angle or coiled.
• Tip/nozzle/insulation tube: Loose connection
• Loose connection of the torch body to the connector O O
fittings.
Base metal cables • Cross section area is too small.
• Loose connection. O O O
• Poorly energized base metal.
Welding conditions • Improper welding conditions, such as welding cur-
rent/voltage, torch angle, welding speed, wire exten-
O O O O O
sion length.
• Wrong wavelength control.
Base metal surface • Attachment of oil, dirt, rust or painting film.
O O O O O
and wire extension
OMDT6399E00 41
Circuit diagram
10.Circuit diagram
YEP10070-□□
External Extended
relay VR Binary data input
42 OMDT6399E00
Circuit diagram
Gas purge
Check
Write
YEP10070-□□ Write
Write
Special
Communication connector S/A board
OMDT6399E00 43
Repair parts list
11.Repair parts list

Model
Modelnumber: YD-400GT3YUA
YD-400GT3YUD
number:
44 OMDT6399E00
Repair parts list
№ Mark Description Part number Q’ty Note Internal code

1 CO1 Receptacle YMAD41 1 JMR2516F
2 Output terminal KET09001 3 -
3 NFB Switch YZA/ESB001 1 1DA3-60-415A
Fuse holder YZA51 1 FHS07F
4 Fu1
Fuse XBA2E80NR5 1 8A for motor -
5 FAN1,FAN2 Cooling fan 9WG1224J103 2 -
6 MTr Main transformer DTU00235 1 -
7 L2 DCL DLU00157 1 -
8 L1 DCH DLU00072 1 -
9 CT CT YCA6 1 TN300A4VB15A
10 D1 Diode DF100LB160F 1 Primary diode -
11 D2,D3,D4,D5 Diode YCAD99 2 Secondary diode FRS300BA50F
12 Q1,Q2 IGBT SKM150GB128D 2 -
13 C1,C2 Capacitor YMAD88 2 ECST401LGC23
14 THP1 Thermal switch YPAD44 1 0HD3-80B02
15 R2 ～ R7 Resistor SFW40A5R0AP 6 -
16 SH Shunt resistor YMAD33 1 HY600A
17 TM2 Terminal T375-16B 1 -
18 R8,R9 Resistor SFW20A5R0AP 2 -
19 Sheet DHS00016 1 -
20 Knob YDB2 2 K2056S
21 Terminal assembly DET00023 1 -
22 Terminal cover DEK00050 1 -
23 TM Terminal YMAD98 1 W123B6P
24 P.C.B PC board YEP10070 1 Control board -
25 P.C.B PC board ZUEP1425_A1 1 Governor board -
26 P.C.B PC board ZUEP1426_A1 1 DC power board -
27 P.C.B PC board ZUEP1431 1 Operation board -
28 P.C.B PC board ZUEP1363_A1 2 Drive board -
29 THP2 Thermal switch SB604A3H 1 -
30 R10,R11 Resistor YMAD67 2 SFW40E201
31 L3 Reactor DLU00155 1 -
32 P.C.B PC board ZUEP08533T4 2 -
33 C12S Capacitor YMAD86 1 Start unit ESME101LGB47
34 SCR SCR PK25F40 1 Start unit -
35 R11S,R12S Resistor SFW20E391 2 Start unit -
36 R13S Resistor SFW20E4R7 1 Start unit -
37 R14S Resistor SFW20E300 1 Start unit -
38 Tr2 Control transformer UTU21900 1
39 Tr3 Control transformer UTU21910 1
- Eye bolt XVN8FJ 2 -
OMDT6399E00 45
Appendix
12.Appendix
Followings are rough indications of standard welding it is necessary to set values in consideration of shape of
conditions as reference data. In actual welding operation, the workpiece, welding position and so on.
12.1 MAGwelding conditions table

12.1.1 CO2 welding conditions table: Solid wire (Reference)
Tip-to-
Butt Joint Welding Thickne Wire Speed work Gas
(Square groove joint) ss Route gap diameter Current Voltage (cm/ distance flow
(mm) G(mm) (mm) (A) (V) min) (mm) (L/min)
0.8 0 0.8, 0.9 60-70 16-16.5 50-60 10 10
(At low-speed) 1.0 0 0.8, 0.9 75-85 17-17.5 50-60 10 10-15
1.2 0 0.8, 0.9 80-90 17-18 50-60 10 10-15
1.6 0 0.8, 0.9 95-105 18-19 45-50 10 10-15
2.0 0-0.5 1.0, 1.2 110-120 19-19.5 45-50 10 10-15
2.3 0.5-1.0 1.0, 1.2 120-130 19.5-20 45-50 10 10-15
3.2 1.0-1.2 1.0, 1.2 140-150 20-21 45-50 10-15 10-15
4.5 1.0-1.2 1.0, 1.2 170-185 22-23 40-50 15 15
Front 1.2-1.5 1.2 230-260 24-26 40-50 15 15-20
6
Back 1.2-1.5 1.2 230-260 24-26 40-50 15 15-20
Front 1.2-1.5 1.2 320-340 32-34 40-50 15 15-20
9
Back 1.2-1.5 1.2 320-340 32-34 40-50 15 15-20
Wire Tip-to- Gas Coppe

Butt Joint Welding
Thickne Route diamet Speed work flow r
(Square groove
ss gap er Current Voltage (cm/ distance (L/ backin
joint)
(mm) G(mm) (mm) (A) (V) min) (mm) min) g
0.6 0 0.6 40 16 60 10 15-20
(With backing) 0 0.6 40 16.5 45 10 15-20
0.8
0 0.8 80-90 18-19 45-50 10 15-20
1.0 0 0.9 50 18 45 15 15-20
*1
0 0.8 60 18 45 15 15-20
1.2
0-0.5 0.9 90-120 19-20 45-50 10 15-20
0 0.9 95-105 18-19 45-50 10 15-20
1.6
0-0.5 1.2 120-140 19-20 40-50 10 15-20
0-0.8 0.9 100-140 19-21 35-45 10 15-20
2.3
0-1.2 1.2 130-150 19-21 35-45 10 15-20
*2
3.2 0-1.5 1.2 130-180 20-23 30-35 10-15 15-20
4.5 1-2 1.2 150-200 21-24 40-45 10-15 15-20
0-0.8 1.2 280-330 28-36 35-45 15-20 15-20
6
0-0.8 1.6 380-420 37-38 40-45 15-20 15-20 *3
9 0-0.8 1.2 320-340 32-34 45-50 15-20 15-20
*1: Thickness: 3.2-6 mm
*2: Thickness: 6-8 mm, Groove depth: 1-2 mm, Groove width: 5-6 mm
*3: Thickness: 12 mm or more, Groove depth: 3-4 mm, Groove width: 6-8 mm
46 OMDT6399E00
Appendix
Positi Tip-to-
T-Joint (Fillet) on
(Horizontal Thickne Leg Wire Speed work Gas
ss length diameter Current Voltage ①/ (cm/ distance flow
position)
(mm) (mm) (mm) (A) (V) ② min) (mm) (L/min)
1.0 2.5-3 0.8, 0.9 70-80 17-18 ① 50-60 10 10-15
(At low-speed)
1.2 3-3.5 0.9, 1.0 85-90 19-19 ① 50-60 10 10-15
1.6 3-3.5 1.0, 1.2 100-110 18-19.5 ① 50-60 10 10-15
45 2.0 3-3.5 1.0, 1.2 115-125 19.5-20 50-60 10 10-15
①
2.3 3-3.5 1.0, 1.2 130-140 19.5-21 ① 50-60 10 10-15
3.2 3.5-4 1.0, 1.2 150-170 21-22 ① 45-50 15 15-20
4.5 4.5-5 1.0, 1.2 180-200 23-24 ① 40-45 15 15-20
1.0-2.0
6 5-5.5 1.2 230-260 25-27 ① 40-45 20 15-20
8, 9 6-7 1.2, 1.6 270-380 29-35 ② 40-45 25 20-25
12 7-8 1.2, 1.6 300-380 32-35 ② 35-40 25 20-25
Lap Joint (Fillet) Tip-to-

(Horizontal Thickne Wire Positio Speed work
position) ss diameter Current Voltage n (cm/ distance Gas flow
(Thin plate) (mm) (mm) (A) (V) ①/② min) (mm) (L/min)
(At low-speed) 0.8 0.8, 0.9 60-70 16-17 ① 40-45 10 10-15
1.2 0.8, 0.9 80-90 18-19 ② 45-50 10 10-15
1.6 0.8, 0.9 90-110 19-20 ② 45-50 10 10-15
0.8, 0.9 100-130 20-21 ③ 45-50 10 10-15
2.3
1.0, 1.2 120-150 20-21 ③ 45-50 10 10-15
3.2 1.0, 1.2 150-180 20-22 ③ 35-55 10-15 10-15
4.5 1.2 200-250 24-26 ③ 40-50 10-15 10-15
Corner Joint Tip-to-

(Fillet) Thicknes Wire work
(Horizontal position) s diameter Current Voltage Speed distance Gas flow
(Thin plate) (mm) (mm) (A) (V) (cm/min) (mm) (L/min)
(At low-speed) 1.6 0.8, 0.9 65-75 16-17 40-45 10 10-15
2.3 0.8, 0.9 80-100 19-20 40-45 10 10-15
3.2 1.0, 1.2 130-150 20-22 35-40 10-15 10-15
4.5 1.0, 1.2 150-180 21-23 30-35 10-15 10-15
OMDT6399E00 47
Appendix
Tip-to-
Fillet Welding Thicknes Leg Wire work
(Flat position) s length diameter Current Voltage Speed distance Gas flow
(mm) (mm) (mm) (A) (V) (cm/min.) (mm) (L/min)
1.0 3 0.9 60-65 16-17 30 10 10-15
1.2 3-3.5 0.9 70-80 17-18 40-50 10 10-15
1.6 3.5-4 0.9 90-130 19-20 40-50 10 10-15
2.3 4-4.5 1.2 120-160 20-21 40-45 10 10-20
3.2 4-5 1.2 150-200 21-25 35-45 10-15 10-20
4.5 6-6.5 1.2 270-300 28-30 40-45 15-20 10-20
4-4.5 1.2 300-330 30-35 60-70 15-20 10-20
6 6-7 1.2 300-350 30-36 40-45 15-20 10-20
6 1.6 380-400 37-38 45-50 15-20 10-20
6 1.2 300-350 30-36 40-45 15-20 10-20
8
8-9 1.6 430-480 38-42 40-45 15-20 10-20
10 1.6 430-480 38-42 30-40 15-20 10-20
12
12-13 1.6 450-480 38-42 25-30 20-25 10-20
12.1.2 CO2 welding conditions table: Flux cored wire (Reference)

Wire Leg
Metallic diameter length Current Voltage Speed
(mm) (mm) Path (A) (V) (cm/min.) Weaving
6 1 270 28 42 No
9 1 270 28 24 Yes
1.2 1 280 29 34 No
12 2 280 29 36 No
3 280 28 45 No
9 1 330 31 28 Yes
1 330 31 40 No
1.4
12 2 330 31 42 No
3 330 30 50 No
Wire Leg
Titania diameter length Current Voltage Speed
9 1 270 28 25 No
1.2 1 300 31 35 No
12
2 300 31 29 Yes
48 OMDT6399E00
Appendix
Wire Leg
Titania diameter length Current Voltage Speed
4 / 220 27 70 -
1.2 6 / 270 29 50 -
8 / 300 30 35 -
4 - 260 28 70 -
1.4 6 - 320 31 50 -
Fillet welding
8 - 350 33 35 -
4 - 180 22 50 -
Fillet welding
1.2 6 - 200 23 50 -
(Vertical position)
8 - 220 23 45 -
12.1.3 MAG welding conditions table: Solid wire (Reference)

* MAG gas: 80% argon and 20% CO2
Tip-to-
Butt Joint Welding Thickne Wire Speed work Gas
(Square groove joint) ss Route gap diameter Current Voltage (cm/ distance flow
(mm) G(mm) (mm) (A) (V) min) (mm) (L/min)
0.4 0 0.4 20 15 40 10 10
(At low-speed) 0.6 0 0.4, 0.6 25 15 30 10 10
0.8 0 0.6, 0.8 30-40 15 40-55 10 10
1.2 0 0.8, 0.9 60-70 15-16 30-50 10 10-15
1.6 0 0.8, 0.9 100-110 16-17 40-60 10 10-15
3.2 1.0-1.5 0.8, 1.2 120-140 16-17 25-30 15 10-15
4.0 1.5-2.0 1.0, 1.2 150-160 17-18 20-30 15 10-15
Fillet Welding Tip-to-

(Horizontal Thick- Leg Wire Positio Speed work Gas
position) ness length diameter Current Voltage n (cm/ distance flow
(At low-speed) (mm) (mm) (mm) (A) (V) ①/② min) (mm) (L/min)
0.6 2 0.4, 0.6 70-80 17-18 ① 50-60 10 10-15
45
1.0 2-2.5 0.6, 0.8 85-90 19-19 ① 50-60 10 10-15
1.6 3 0.6, 0.8 100-110 18-19.5 ① 50-60 10 10-15
2.4 3.5 0.8-1.0 115-125 19.5-20 ① 50-60 10 10-15
1.0-2.0 3.2 4 0.8-1.2 130-140 19.5-21 50-60 10 10-15
①
OMDT6399E00 49
Appendix
12.2 Pulsed MAG welding conditions table (Reference)

1) Butt welding (Downside/ Single and double sides)
Thick Wire Route gap
Current Voltage Speed
ness Welding position diameter G
Path Weaving
(mm) (mm) (mm) (A) (V) (cm/min)
3.2 1.2 1.0 1 140 25 50 Yes
Top1 100-130 21-24 25

6.0 1.2 1.5
Top2 150 26 25
Top 170 26 30
6.0 1.2 0
Bottom 180 27 30
Top 270 30 30
9.0 1.2 0
Bottom 290 31 30
Top 1 100-130 21-24 25
12.0 1.2 1.5 Top 2 200-240 26-28 25
Top 3 200-240 26-28 25
Top 280 31 40
12.0 1.2 0
Bottom 330 34 40
Top 1 100-130 21-24 25

19.0 1.2 1.5 Top 2 280-320 29-32 25
Top 3 280-320 29-32 25
Top 1 300 32 45
Top 2 300 32 45
19.0 1.2 0
Bottom 1 340 33 45
Bottom 2 280 31 45
Top 1 300 32 45
Top 2 320 33 45
Top 3 320 33 45
25.0 1.2 0
Bottom 1 340 33 45
Bottom 2 320 33 45
Bottom 3 320 33 45
50 OMDT6399E00
Appendix
2) Fillet welding (Horizontal)

Leg
Thickness Wire diameter Current Voltage Speed
length Welding position Path
(mm) (mm) (mm) (A) (V) (cm/min)
3.2 3-4 1.2 1 150 27 60
4.5 5 30-40° 1.2 1 170 27 40
6.0 6 Target 1.2 1 200 28 40
Angle
10°
30-40°
8.0 7 1.2 1 250 30 35
1mm (2-3mm)
1 180-200 26-27 45
12.0 10 1.2 2 180-200 26-28 45
3 180-200 26-28 45
3
1 220-230 26-28 45
1 2
16.0 12 1.2 2 220-230 26-28 45
3 210-230 26-28 45
12.3 MIG welding conditions table: Stainless steel (Reference)

1) Wire diameter: 1.00 mm
Thickness Route Tip-to-work
Current Voltage Speed Gas flow
Joint type Thickness gap distance
(mm) (mm) (A) (V) (cm/min) (mm) (L/min)
Butt joint 1.6 80-100 16-18
0 50 13 13
(I-shape) 2.0 90-110 16-18
Corner or T- 1.6 80-100 16-18
0 40 10 10
Joint 2.0 100-120 16-18

Route Tip-to-work
Thickness Current Voltage Speed Gas flow
Joint type gap distance
(mm) (mm) (A) (V) ( ㎝ /min) (mm) (L/min)
3.2 150-170 18-19
50 15 15
Butt joint 4.5 220-240 22-25
0
(I-shape) 6.0 280-300 28-30
40 20 20
9.0 280-330 28-32
2.3 140-170 18-20
50 15 15
Corner or T- 3.2 180-220 21-24
0
Joint 4.5 220-240 22-25
40 20 20
6.0 250-300 25-30
OMDT6399E00 51
Appendix

Route Tip-to-work
(mm) (mm) (A) (V) ( ㎝ /min) (mm) (L/min)
Butt joint 8.0 280-330 27-31
0 40 20 20
(I-shape) 10.0 350-400 34-38
8.0 280-330 26-30
Corner or T-
9.0 0 300-340 28-33 40 20 20
Joint
10.0 330-370 30-34
12.4 Pulsed MIG welding conditions table: Stainless steel (Reference)

1) Wire diameter: 1.00mm
Route Tip-to-work
Butt joint 1.6 80-100 19-21
0 40 13 13
(I-shape) 2.0 90-110 19-21
Corner or T- 1.6 80-100 16-18
0 40 10 10
Joint 2.0 100-120 16-18

Route Tip-to-work
2.3 130-150 24-25 50 13 13
3.2 160-200 23-26
Butt joint 40 15 15
4.5 0 200-240 24-28
(I-shape)
6.0 270-300 28-31
40 20 20
9.0 300-350 30-34
2.3 130-150 24-25
40 13 13
3.2 160-200 23-26
Corner or T-
4.5 0 200-240 24-28 50 15 15
Joint
6.0 270-300 28-31
50 20 20
9.0 280-320 28-32

Route Tip-to-work
Butt joint 8.0 300-350 29-34
0 40 20 20
(I-shape) 10.0 330-380 30-36
Corner or T- 8.0 280-320 27-31
0 50 20 20
Joint 10.0 320-360 29-33
52 OMDT6399E00
Appendix
12.4.1 Welding conditions memorandum

It is recommended to keep a note of the user-created * Put the data on the below “Channel list” once stored.
welding conditions for your convenience.
Those custom welding conditions in this unit by allocating
a channel number to each of them.
<Make a copy of the following table for each welding condition.>
Channel (CH) number Material to be welded Remarks Prepared on Prepared by
● Welding conditions UNITARY / INDIVIDUAL
WAVEFORM
INITIAL WELD CRATER SPOT TIME
CONTROL
Welding current (A) (A) (A)
(s)
Welding voltage (±) (V) (±) (V) (±) (V)
● F. ADJ settings (FUNCTION) ● MATERIAL/WIRE DIA/GAS settings

Item Contents Item Contents
P00 Slowdown MS-SOLID
MS-FCW
P01 Hot voltage MATERIAL SUS-SOLID
P02 FTT voltage SUS-FCW
AL ALLOY
P03 Burnback time
1.2 mm
P04 Penetration 1.0 mm
WIRE DIA
P05 Preflow time 0.9 mm
0.8 mm
P06 Afterflow time
CO2
GAS Ar MIX
● DIP switch (DSW1) settings Ar
C.REP (Crater repeat) ON OFF
ARC.CTL (Leg length control) ON OFF ● CONTROL settings
Item Contents
P.BBK (Burnback 2) ON OFF
NO CRATER
CRATER
CONTROL
INI.&CRATER
ARC SPOT
■ Channel list
Channel (CH) number Material to be welded Remarks Prepared on Prepared by
1
2
3
4
5
6
7
8
9
OMDT6399E00 53

Inverter Controlled Mig Welding-Machine YD-400GT3 Operating Manual

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Inverter Controlled Mig Welding-Machine YD-400GT3 Operating Manual

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Operating Instructions

Inverter controlled GMAW DC Power Source

Model No. YD-400GT3YUD

Fully digital and inverter controlled GMAW

♦Applicable welding methods

♦Warning symbols for safe usage

The potential for a hazardous accident includ-

The potential for hazardous accident including

• The description of this manual is based on the contents as of November, 2008.

6. Connection........................................21 12. Appendix ........................................ 46

Installing shielding (curtain etc.) Welding wire

（1） Keep enough distance from welding power source when

Rotating parts can cause injury.

2.1 Standard accessories

2.2 Duty cycle

（1）Locate indoors only, where the floor is capable of

3.2 Power supply equipment

• Transport it either by pushing on the floor or by lifting it

• A crane or forklift shall be operated by a qualified

• With crane, make sure to use the provided two

• With folklift, no personnel should hold or support the

• Avoid any impact to the product during transportation

• Do not leave the product on a slope. Topple or trundle

• If jostling, do not make a sharp turn. Floor and/or

4.Names and functions

4.1.1 Power switch:

4.1.2 Connection of the front panel

Cover fixing bolt (M6)

Feeder connector Connector to connect

<Note> • Do not connect (3) and (4) at the same time.

4.1.3 Operation panel

(1) (2) (5)

（1）OVER TEMP. indicator lamp to be stored blinks.

（9）MATERIAL button • INDIVIDUAL: Welding voltage needs to be set

4.2 Rear panel

♦Remarks about cooling fan air intake vent

In case it is not possible to avoid installing the product

Fan cover unit (Optional part

4.3 <Switches on PC Board

To prevent the electrostatic destruction of semiconductor parts and the

4.3.1 Slide switch (SW1)

4.3.2 DIP switches (DSW1)

Control board: YEP10070

DSW1 Description ON OFF Remarks

(*1): This switch is effective on ly when the pulse setting is OFF.

4.4 Remote controller (YD-40GTR1)

(2) (1) (3)

WELD Specify “PULSED” or “NO PULSE”

• Specify welding current.

In Unitary setting: Cable

Note Applied gas quality (that affects welding result.)

5.1 What’s needed for welding operation

Model number/ (10)

* For details of specification, rates of the above (6)

5.1.2 Hard aluminum welding

Model number/ (10)

* For details of specification, rates of the above

5.2 Connection cable (optional unit)

CAUTION Avoid the connection cable to get wet.

If exposure to rain or water splay is expected, make

Wire feed control cable

Note Cautions about using connection cable

• Using a connection cable between positive side output