Panasonic YD-500GP5 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Panasonic Manuals
  4. Portable Generator
  5. YD-500GP5
  6. Operating instructions manual
Panasonic YD-500GP5 Operating Instructions Manual

Panasonic YD-500GP5 Operating Instructions Manual

Digital igbt control mig/mag power source
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operating Instructions
Digital IGBT control
MIG/MAG Power Source
YD-500GP5
Model No. :
● Thank you for your purchase of Panasonic welding power source.
● Before operating this product, please read the instructions carefully and save this manual
for future use First of all, please read "Safety precautions" or "Safety manual".
● SPEC. No.：YD-500GP5HNX.
Panasonic Welding Systems (Tangshan) Co., Ltd.
WTD038TE0PA02

Advertisement

Table of Contents
loading

Related Manuals for Panasonic YD-500GP5

Summary of Contents for Panasonic YD-500GP5

  • Page 1 YD-500GP5 Model No. : ● Thank you for your purchase of Panasonic welding power source. ● Before operating this product, please read the instructions carefully and save this manual for future use First of all, please read “Safety precautions” or “Safety manual”.
  • Page 2 ■ Features ● LED digital display and soft-touch buttons for easy and convenient operation ● The wire feeder equipped with encoder provides stable and high-precision wire feeding control. ● The welding parameters can be recorded & called. ● The enhanced mobility, robust structure and dust tightness ■...
  • Page 3 15，20 × DC pulse × Si- Al 100%Ar × DC pulse × × Al-Mg DC pulse 100%Ar × × × Al-Mg DC pulse 100%Ar × Note: × stands for no data, ○ stands for standard configuration data.

  • Page 4: Table Of Contents

    6 CONNECTION ······························· 20 13 CIRCUIT DIAGRAM ························ 56 ..20 HE CONNECTION OF OUTPUT CABLE HE CONNECTION OF THE GROUNDING WIRE 13.1 C YD-500GP5 ..56 IRCUIT DIAGRAM FOR 14 APPENDIX ··································· 57 .... 21 HE CONNECTION OF INPUT CABLE .... 22 HE CONNECTION OF INPUT CABLE 14.1 CO2...

  • Page 5: Safety

    Disclaimer： ◆ Panasonic Welding Systems（Tangshan） Co., Ltd., (hereinafter called “PWST”) and its affiliates (including any subcontractor, sales company or agent) shall not assume or undertake any responsibility or liability of the followings: •Any problem arising out of, or directly or indirectly attributable to the failure of user to carry out those normal maintenance, normal adjustment and periodical check of this product.

  • Page 6: Safety Precautions

    Safety 1.2 Safety precautions (10)Perform periodic checks without fail and repair or Welding power source replace any damaged parts before using the power Observe the following instructions to source. prevent the hazard. Ventilation and protective equipment (1)Never use the welding power source for other than Oxygen deficit, fume and gas welding purpose.
  • Page 7 Safety performing maintenance work or repair work, provide Installing shielding (curtain etc.) fence or the like around the welding machine so that unauthorized person can not come close carelessly. Arc flash, flying spatter, slugs, and noise generated during welding can Welding wire damage your eyes, skin and Welding wire, especially wire tip part...

  • Page 8: Rated Specifications

    Rated Specifications 2 Rated Specifications 2.1 Specifications table Contents Item Unit YD-500GP5 Control method digital IGBT control Rated input· 3-phase AC 400 V Number of phases Input power frequency 50/60 Rated input capacity kVA/kW 29.9/23.9 the power source 82.5 efficiency...
  • Page 9 Rated Specifications Cooling capacity of 1.3 （ Test at 1 L / min flow rate ） liquid cooling system >1 （ Matching Panasonic products ） Coolant flow L/min Maximum range of coolant Overall dimensions 840X383X1240 ( LXWXH ) Mass...

  • Page 10: Rated Duty Cycle

    Rated Specifications 2.2 Rated duty cycle ■ YD-500GP5 ● The rated duty cycle is 60 %. This means that the machine can cut for a total of 6 minutes out of any 10 minutes at the rated current, and then, during the remaining 4 minutes, the machine must be cooled down to prevent overheating.

  • Page 11: Dimensions

    Rated Specifications 2.4 Dimensions 机型 YD-500GP5HNX 1240...

  • Page 12: Installation And Power Supply

    Installation and Power supply facility 3 Installation and Power supply facility When installing or transporting the welding machine, wear long sleeve shirts, leather gloves and safety shoes to prevent injury. 3.1 Installation site (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.

  • Page 13: Installation Transportation

    Installation and Power supply facility 3.2 Installation transportation When hanging this product for transportation, hang it at two eyebolts. ●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.

  • Page 14: Power Supply Equipment

    Installation and Power supply facility 3.3 Power supply equipment Observe the following to prevent burnout, destruction of parts and unstable arc. welding power source YD-500GP5 Three phase ,400V AC, Input power source 50 / 60 Hz (common) Commercial power source...

  • Page 15: Configuration

    Configuration 4 Configuration 4.1 Equipment necessary for welding item remarks item remarks Welding Grounding ⑥ 6 mm or higher ① power YD-500GP5HNX cable source Distribution ⑦ 3-phase AC400 V ② wire feeder YW-50DNW1HAG + TSMWV660 power ③ Torch YT-40MFW2HTF ⑧ source 6 mm or higher...

  • Page 16: Connecting Cable

    （5） Connect the base metal voltage detection wire (-) to the base metal voltage detection terminal (-). （6） Do not use the connecting cable as a junction cable. Welding power source Cross section Length L≤18.2 m YD-500GP5 70 mm...

  • Page 17: Connections& Operations Of The Cooling System

    Configuration 4.3 connections& operations of the cooling system ● Precautions when adding coolant When adding or replenishing coolant, please proceed from the front [coolant supply port Contact with live parts will cause fatal electric shock. To avoid casualty accident, please observe the following precautions When adding coolant, the power switch and the switch of power distribution box must be turned off exhaust In the process of coolant replacement,...
  • Page 18 Configuration ● About coolant （1） ensure to use antifreeze as coolant Please use ethylene glycol antifreeze (other salts and alcohol antifreeze may corrode metal parts such as welding gun and water pump). NOTE: When using the coolant, please use the same brand of antifreeze from the same manufacturer. It is forbidden to mix the antifreeze from different manufacturers.
  • Page 19 2 of terminal block P. please refer to sections 8.1 and 8.2 for the location of terminal block P. If you need to install casters for the disassembled welding power supply, please order from Tangshan Panasonic agent, caster model: 2-3688-52 Rubber cover: SG30AK (two)

  • Page 20: Names And Functions

    5.1 The power switch About power switch: ● When the power switch is turned off automatically, do not turn it on again. (Consult with sales distributor of Panasonic representatives.) ● When activating a power generator, turn off the power switch. Power source switch note・...

  • Page 21: Front Panel

    Names and functions 5.3 Front panel Note: for robot welding, be sure to set the machine on “ crater OFF ” status. name description ● When abnormal rise in important components temperature occurs, temperature temperature abnomal alarm is sent, this lamp blinks and the welding operation stops. Welding ○...
  • Page 22 Names and functions ● When Mode selection key ○ is set to “ Weld ”, (refer to description in ○ )・ when key ○ selects different options, please adjust corrosponding set value according different items. ・During welding, “ Welding ” current can be adjusted. However “ initial ” and “...
  • Page 23 Names and functions ● The function is used to feed welding wire into the liner before welding by holding manual wire ○ this key. feeding button ・manual wire feeding speed is decided by the welding current. ● To switch the setting among“ initial ”, “ Weld ”, “ crater ” current. ○...

  • Page 24: Connection

    Connection 6 Connection ● The installation shall be done by qualified installation personnel and should conform to all national andlocal codes. Important ● Type and capacity of protection devices, such as breaker and fuse, to be applied should conform to all national and local codes. ●...

  • Page 25: The Connection Of The Grounding Wire

    Connection 6.2 The connection of the grounding wire Water supply pipes, building iron frames, etc. do not serve as sufficient ground. Do not connect any grounding wire to them. ●The yellow-green wire of the input cable is the ground wire. ●One side of the ground wire has been reliably grounded to the chassis inside the welding power source.

  • Page 26: The Connection Of Input Cable

    Connection 6.4 The connection of input cable （1）Digital interface connection ■ This product is equipped with standard RS485 digital interface, used to connect to external equipment, suitable for use in automated welding production occasions.  Digital interface wiring connection  In order to prevent external interference from entering the signal line and affecting the communication process, please keep away from welding torches and output...
  • Page 27 Connection （2）Ethernet connection ■ This product is equipped with a standard Ethernet communication interface, connected to a local area network through a network cable, and communicates with the PC running the company's intelligent welding management system iWeld software to realize the record management and parameter setting of welding data. Internet connection ...
  • Page 28 Connection （3）Connection mode configuration ■Configuration software IOT_CONFIG use The configuration software IOT_CONFIG is a special software used to configure the external connection function of this product. It can be run on a PC with Windows XP and above operating systems. The interface after installation and operation is as follows: The operation steps for setting welding machine parameters through software are as follows 【1】...
  • Page 29 Connection...
  • Page 30 Connection...
  • Page 31 Connection...
  • Page 32 Connection The functions that support the configuration of the welding machine are as follows Function Configurable parameters Function Description Note ●Both Ethernet and GPRS networking Select networking export Ethernet、WIFI、GPRS mode modes are enabled by default version only ●The two networking methods of Ethernet networking has Ethernet.
  • Page 33 Connection （4）Connection of base metal voltage detection line ●Position and switching method of base metal voltage detection line This welding power supply reserves the base metal voltage detection terminal. If you need to use this terminal, please switch the power connector terminal. The location of the connector is shown in the figure below. Note: a.

  • Page 34: Connecting Jig(S)

    Connection 6.5 Connecting jig(s) When touching a printed circuit board, observe the following item to prevent electrostatic destruction of the printed circuit board. Before starting an operation, for example, touch any metal part of the case with your hand to discharge static electricity. jig terminals The location of 6.5.1...

  • Page 35: Preparation And Termination Processings

    Preparation and termination processings 7 Preparation and termination processings 7.1 Preparation  Use of protective equipment To protect you and other people from gases, fumes and lack of oxygen that may be generated during the welding operation, make sure to prepare ventilation facilities and use protective equipment, etc.

  • Page 36: Settings

    Settings 8 Settings 8.1 FUNCTION settings 8.1.1 “F. ADJ” The following table shows the pages and parameters for fine adjustment/settings using the “F. ADJ”. (1) Use the Mode selection key ○ to select F. Adj. (During welding, it can NOT be selected.) It shows P00 in ○ and 00 in ○...
  • Page 37 Settings Menu contents Set range Increment Default Note Fine adjustment of output voltage during burn-back time. (The setting reflects on the FTT Voltage -50～50 wire burning at arc end.) Increase the set value for stronger wire burning. The time of the main welding voltage to the BURNBACK TIME back burning voltage, -50～50...
  • Page 38 Settings 【Arc control】 Menu contents Set range Increment Default Note Arc ignition Fine adjustment of peak current of arc. energy -50～50 It increases when the direction is adjusted compensation positive value. Fine adjustment of the arc voltage value. Arc ignition The peak current of the arc is increased voltage -5～5...
  • Page 39 Settings 【INIT·CRATER】 Menu contents Set range Increment Default Note 1: enabled, 0: disabled. CRATER 0 or 1 （ REPEAT Chapter 8） CRATER The setting of the value of the time of REPEAT 0 s～5 s closing arc repeating. TIME NOT 0: The arc current is [Welding current] * [Setting value] %;...

  • Page 40: Call" And "Record

    Settings 8.1.2 “CALL” and “RECORD” Reminder when delivery, Record & Call functions are set as disabled status. ●“Call” is a function to use stored welding conditions and “Record” is to store the well-tuned welding conditions. Record/Call operation is applicable to the set values of current ・ voltage, spot welding time, arc characteristics, penetration control, welding control, pulse ON/OFF, material, wire diameter, gas and F.

  • Page 41: Welding Preparation

    0.9 mm Use of a wire in small diameter may cause unstable wire feeding. In case of using such wires, please feed the wire at low speed or contact Panasonic representatives. Press the “INCHING” (8) button on the operation panel to feed the wire manually.

  • Page 42: Operation

    Operation 9 Operation Depending on the CHANGE 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.

  • Page 43: Crater

    Operation 9.3 “CRATER” Operation: Turn the torch switch on and off twice.

  • Page 44: Ini. &Crater

    Operation 9.4 “INI. &CRATER” Operation: Turn the torch switch on and off twice. (Turn the torch switch ON to start initial welding and turn it OFF to switch to main welding. Then turn it ON again to start crater operation.)

  • Page 45: Crater Repeat" Operation

    Operation 9.5 “Crater repeat” operation To repeat crater operation turn ON the torch switch within a preset time (Trep)* after turning off the previous crater operation. (In this manner, it is possible to repeat the cra- ter operation again and again.) *: Trep: About 2 seconds Note: If the torch switch is not turned on within the preset time, the function is cancelled.

  • Page 46: Arc Spot

    Operation 9.6 “ARC SPOT” Press (turn on) and hold down the torch switch until the welding arc is turned off automatically. Note： If the torch switch is released while generating the welding arc (before Tspt ends), the welding arc is turned off immediately.

  • Page 47: Maintenance And Inspection

    ● Check the items indicated in the following table, and conduct the cleaning and replacement of parts when necessary. Welding machine (This product) 10.1.1 ● For replacement of parts, make sure to use our genuine parts for Panasonic welding machine to keep its performance and functions Check item Check point...

  • Page 48: Ther Devices

    Maintenance and inspection Other devices 10.1.3 Check item Check point Remarks Welding torch, Wire feeder, Follow the operating instructions of the individual Remote controller, Gas regulator devices. If joint is fastened securely. If there is any defect, In case a hose band is used,if there is any loose additional fastening, Gas hose attachment.

  • Page 49: Est Preparation

    The withstand voltage test and the insulation resistance measurement shall be performed by service engineers specified by Panasonic representatives, or educated and/ or skilled persons who well undersand and/or who are familiar with welders and electricity.

  • Page 50: Fter Completion Of The Test

    Maintenance and inspection After completion of the test 10.3.2 If power is ON without removing the jumper bar for test, devices may be damaged or burnt out. Unless cables removed for test are returned, the unit may not operate or may malfunction. Remove all the short-circuited cables for the test and return the disconnected cables as they were according to the following procedure.

  • Page 51: Troubleshooting

    Troubleshooting 11 Troubleshooting Touching the current-carrying parts may cause a fatal electric shock or burn injury. To prevent a physical accident, such as an electric shock, burn injury, etc., make sure to observe the followings. ● To ensure safety, troubleshooting work shall be done by qualified personnel. ●...
  • Page 52 Troubleshooting Error type Group Probable causes and remedy The input voltage exceeds allowable range (higher than AC 437V). primary over- After input voltage returns within the allowable range, voltage then turn power switch back ON again. The input voltage is lower than allowable range (lower than AC 304V) or input power source phase failure happens.

  • Page 53: Troubleshooting Table

    Troubleshooting 11.2 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 condition ● Welded tip ● Wire runs into the base metal ●...

  • Page 54: Parts List

    Parts list 12 Parts list 12.1 Parts list for GP5 Front view Rear view Top view...
  • Page 55 Parts list Right view Left view...
  • Page 56 Parts list...

  • Page 57: Gp5 Parts Diagram

    Parts list 12.2 GP5 parts diagram The No. column and digital S/N are in accordance with the same on parts configuration diagram. Symbol Part Name Part Number Quantity Remarks Main Transformer TSMTU244 FCH Unit WTDLU00010ZZ Inductor TSMLU187 Ring Inductor TSMLU188 ●...
  • Page 58 Parts list Part Name Part Number Remarks Symbol Quantity ●★TSMDZ95-CK Welding cable coupling device with stop device ●★TSMDZ95-CR Control Transformer TSMU0891-口口 Control Transformer TSMU1022-口口 ●★660GH80ULTC Fuse FU7, FU8 Input Filtering Assembly TSMW4966-口口 ●TSMP576 口 K Switch Power Source PC Board PC Board ●TSMP697 口...
  • Page 59 Parts list ● YT516-10X260X105 ● TSMTU244 YT516-5X210X105 ● YT511-23X600X90 ● TSMLU187 YT516-2X350X90 ● Insulating paper YT511-23X178X103 ● YT511-23X29X160 TSMLU188 ● YT516-2X28X6 ● YT516-10X120X270 ● WTDLU00010ZZ YT516-5X180X140 TSMLU187 ● Insulating paint TSMLU188 R-611-9 TSMTU244 WTDLU00010ZZ ● Silicon steelsheet For TSMLU187 50JN1000 ●...

  • Page 60: Circuit Diagram

    Circuit diagram 13 Circuit diagram 13.1 Circuit diagram for YD-500GP5...

  • Page 61: Appendix

    Appendix 14 Appendix Followings are rough indications of standard welding conditions as reference data. In actual welding operation, it is necessary to set values in consideration of shape of the workpiece, welding position and so on. 14.1 CO2 welding conditions table: Solid wire (Reference) Wire Tip-to-work Thickness...
  • Page 62 Appendix Leg length Wire Tip-to-work Thickness (mm) diameter Current (A) Voltage (V) Position distance Speed Gas flow Fillet Welding ① ② （ ） (mm) (mm) (cm/min) (L/min) (Horizontal position) (At low-speed) ① 2.5-3 0.8, 0.9 70-80 17-18 50-60 10-15 ① 3-3.5 0.9, 1.0 85-90...

  • Page 63: Mag Welding Conditions Table: Solid Wire (Reference)

    Appendix 14.2 MAG welding conditions table: Solid wire (Reference) MAG gas: 80% argon and 20% CO2 Tip-to-work Thickness Route gap G Wire diameter Speed Gas flow Butt Joint Welding Current (A) Voltage (V) distance （ ） （ ） (mm) (cm/min) (L/min) (Square groove joint) (mm)
  • Page 64 In case of disposal of the product, please sign the assignment agreement on disposal treatment with the authorized organization and then assign the organization to dispose the product. Panasonic Welding Systems (Tangshan) Co., Ltd. Add：No.9 Qingnan Road, New & Hi-Tech Development Zone, Tangshan,Hebei, China Post Code：063020 Tel：400-612-5816...

Table of Contents