Panasonic YD-500GP5 Operating Instructions Manual Download Page 1

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Operating Instructions

Digital IGBT control

MIG/MAG Power Source

Model No. :

YD-500GP5

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Thank you for your purchase of Panasonic welding power source.

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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”.

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SPEC. No.

：

YD-500GP5HNX.

Panasonic Welding Systems (Tangshan) Co., Ltd.

WTD038TE0PA02

Summary of Contents for YD-500GP5

Page 1: ... 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 ...

Page 2: ...e this function please contact Distributor to activate this function welding methods welding wire material welding method shielding gas pulse wire diameter mm extension length mm Root welding semi automatic automatic welding carbon steel CO2 100 CO2 DC pulse OFF 0 8 HND 10 1 0 HND 15 1 2 HND 15 20 1 4 HND 25 1 6 HND 30 MAG Ar 18 CO2 DC pulse OFF 0 8 HND 10 1 0 HND 15 1 2 HND 15 20 1 4 HND 25 1 6 H...

Page 3: ... HND 15 20 1 6 HND 15 DC pulse OFF 1 2 HND 15 1 6 HND 15 Al Mg MIG 100 Ar DC pulse ON 1 0 HND 15 1 2 HND 15 1 6 HND 15 Al Mg MIG 100 Ar DC pulse OFF 1 2 HND 15 1 6 HND 15 Note stands for no data stands for standard configuration data ...

Page 4: ... AND TERMINATION PROCESSINGS 31 7 1 PREPARATION 31 7 2 TERMINATION PROCESSING STEPS AFTER WELDING OPERATION 31 8 SETTINGS 32 8 1 FUNCTION SETTINGS 32 8 1 1 F ADJ 32 8 1 2 CALL AND RECORD 36 8 2 THE WELDING MACHINE FACTORY DEFAULTS RESET 36 8 3 WELDING PREPARATION 37 8 4 CHECKING SHIELD GAS 37 9 OPERATION 38 9 1 WELDING CURRENT CALIBRATION 38 9 2 NO CRATER 38 9 3 CRATER 39 9 4 INI CRATER 40 9 5 CRA...

Page 5: ...and periodical check of this product Any problem arising out of any force majeure including but not limited to act of god Any malfunction or defect of this product that is directly or indirectly the result of any malfunction or defect of one or more related parts or products that are not supplied by PWST Or any problem arising out of or directly or indirectly attributable to the combination of thi...

Page 6: ...working above floor level 9 Turn off all equipment when not in use 10 Perform periodic checks without fail and repair or replace any damaged parts before using the power source Ventilation and protective equipment Oxygen deficit fume and gas generated during welding can be hazardous 1 When conducting welding in the bottom of the tank boiler or hold as well as legally defined sites use a local exha...

Page 7: ...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 work or repair work provide fence or the like around the weldin...

Page 8: ...ctor 200 EMC classification Class A Cooling method forced air cooling Applicable welding wire type flux core solid Applicable welding wire diameter mm solid 0 8 1 0 1 2 1 4 1 6 Al Si Al Mg1 2 1 6 Flux core carbon steel1 2 1 4 1 6 Core stainless steel1 2 Welding wire material carbon steel carbon steel flux core Stainless steel Stainless steel flux core High strength steel MUP Memory 100 channels ca...

Page 9: ...ations 5 Cooling capacity of liquid cooling system kW 1 3 Test at 1 L min flow rate Coolant flow L min 1 Matching Panasonic products Maximum range of coolant m 20 Overall dimensions mm 840X383X1240 LXWXH Mass kg 133 ...

Page 10: ...he performance degradation or damage The figure above shows the ideal value of cutting current and duty cycle Please use the machine within the corresponding duty cycle of cutting current 2 3 Thermal protection Cutting power source is equipped with a thermal switch at the radiator fin of IGBT to monitor the temperature When the abnormal temperature happens the thermal switch takes action and cut o...

Page 11: ...Rated Specifications 7 2 4 Dimensions 机型 W H L YD 500GP5HNX 383 1240 840 ...

Page 12: ...nstallation surface Max 10 7 Do not block cooling air intake of the cutting power source From the wall 200 mm or more 8 Avoid wind to the arc Provide windshields 9 Free from abnormal amounts of dust acid corrosive gases or substances etc other than those generated by the cutting process Note In case the machine with wheels is placed on an inclined surface machine may slide by itself Please use sto...

Page 13: ... parts which comply with strength assessment The model number of the eye bolt is R825M10 Pushing the machine by hands There are wheels under the machine The machine can be pushed by hands During moving please do not make sharp turn to protect wheels and floor Please do NOT place the machine on the slope The Product has wheels which cause the machine to move on the inclined surface by itself Do not...

Page 14: ...ted capacities of fuses and breakers or leakage protectors are only for reference 2 When the machine is working at the places where are moist or on the iron plate or stand please be sure to install leakage protector Note please follow the regulations listed below to avoid any damage of parts unstable arc and overheat or damage of the machine The fluctuation range of input the allowable rated input...

Page 15: ...achine can be even damaged Before using the Product with other standard products please read the operation manual carefully NO item remarks Welding power source YD 500GP5HNX wire feeder YW 50DNW1HAG TSMWV660 Torch YT 40MFW2HTF Gas regulator YX 25AJ1 base metal welding cable 70 mm 2 or higher NO item remarks Grounding cable 6 mm 2 or higher Distribution box 3 phase AC400 V power source input cable ...

Page 16: ... Cautions about using connecting cable Select a model properly and use connecting cable properly or adverse impact on welding operation such as voltage drop may result Voltage drop may be resulted from the reactance caused by the conductor resistance or cable routing manner The longer the cable is or smaller the cross section is the more likely an adverse impact occurs To minimize such adverse imp...

Page 17: ...er cable on the wire feeder to the coolant outlet Operation confirmation 1 Confirmation before operation In order to avoid idling it is necessary to confirm whether the connections are reliable and whether the liquid level of the coolant tank is above the minimum level line NOTE Air transfer will cause pump failure 2 Confirmation in operation After turning on the power switch make sure that there ...

Page 18: ...ch is inserted into the coolant inlet of the liquid cooling system and the exhaust joint is inserted into the coolant outlet of the liquid cooling system Blow the compressed air from the exhaust joint to discharge the coolant from the outlet pipe joint of the welding gun Installation and disassembly of liquid cooling system By default the machine is an integrated machine of welding power supply an...

Page 19: ...ply please pay attention to short circuit the temporary stop 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 3 When installing the liquid cooling system please refer to the disassembly diagram and install in rever...

Page 20: ...ay the software version number after about 1 second About 4 seconds after the software version number is displayed the AC contactor is closed and the cooling fan behind it will start to run Base material side output terminal Reserve accessory holes AC 36V heater socket and8A fuse Input cable lock nut Wire feeder connector Torch side output terminal Air inlet for cooling fan Please do not place oth...

Page 21: ...ected else the corresponding channel can NOT be selected When the channel stored with data is selected the channel and parameters are displayed alternately and welding can start When Mode selection key 12 is set to Record Section 5 6 By turning the Jog dial 7 channel number can be selected LED shows CH setting current and voltage Flashing means welding parameters are being stored Press selection k...

Page 22: ...n 5 6 By turning the Jog dial 7 channel number can be selected LED shows CH setting current and voltage The flashing means welding parameters to be stored Press selection key 12 to return to Weld from Record and the corresponding parameters are recorded in the channel being selected When a self diagnosable error occurs For troubleshooting Section 13 1 It shows alarm signal number 6 setting voltage...

Page 23: ...crater ON regular welding crater welding initial ON initial welding regular welding crater welding spot welding The welding lasts certain seconds according to the spot welding time being set The welding stops automatically when the spot welding time is up 14 welding method To select the welding method Standard No pulse during welding OP1 Reserve root welding NO pulse root welding 1 Deepen NO pulse...

Page 24: ...ct with the welding arc part at wiring For safety reasons provide base material with grounding work Wiring and grounding work should be done by qualified electricians Observe the followings to prevent a fire caused by overheat of cables Use cables with specified size or larger Fasten all cable connections securely 6 1 The connection of output cable Connecting cable from base metal Connect cable fr...

Page 25: ...ource Reliably ground the other side of the ground wire 6 3 The connection of input cable Install one distribution box each for this product Disconnect the switch of the distribution box user s equipment Connect the other side of the input cable to the output terminal of the switch of the distribution box No Name Note a Input cable b Input power User equipment c Distribution box User equipment d s...

Page 26: ... torches and output cables when wiring The wiring length should be within 10m Digital interface description The RS485 9 pin terminal used for communication between the special plane and this product in which port 1 is T R 3 is T R and 5 is the power ground Digital interface enabled When using RS485 to connect an external special machine you need to use the PC serial cable to connect to the RS232 c...

Page 27: ...onfiguration The default IP address of the welding machine is 172 16 XX XX and the subnet mask is 255 255 0 0 If you want to realize data communication between the welding machine and the PC through the Ethernet you need to set the IP address of the PC to 172 16 70 250 and the subnet mask to 255 255 0 0 which can be used without changing the IP address of the welding machine Realize the connection...

Page 28: ...ws The operation steps for setting welding machine parameters through software are as follows 1 Connect the RS232 serial port to the welding machine 2 Click Set detection port set the baud rate default is 19200 and open the serial port 3 Click connect and read configuration read welding machine parameters 4 Click to download configuration to IOT to configure welding machine parameters 5 Restart th...

Page 29: ...Connection 25 ...

Page 30: ...Connection 26 ...

Page 31: ...Connection 27 ...

Page 32: ...nd the iWeld software cannot be connected The export version only has Ethernet Modify the sampling frequency of the welder 0 2s 0 5s 1s Set the real time data upload frequency of the welding machine The export version only has 1s Set connection parameters Welder password welder address communication method The welding machine password needs to be consistent with the PLC special machine password Th...

Page 33: ...t the agent of our company to purchase the base metal voltage detection cable the model is YRYY4X500SS if you prepare by yourself please use an insulated cable above 0 75mm 2 Wire feeder cable Test Line for base metal voltage Base cable 200mm Torch cable The inner area circle of the dotted line should be as small as possible Please follow the diagram above to route the base metal voltage detection...

Page 34: ...ce To send out the current detection signal to a jig or another device Location On the chassis inside the product 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...

Page 35: ...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 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 Turning on power...

Page 36: ...ents Set range Increment Default Note P00 SLOW DOWN 1 5 5 0 1 0 1 Fine adjustment of slowdown speed Increase the set value to increase the slow down speed P04 PRE FLOW TIME 5 s 5 s 0 1s 0 1s It specifies time to feed wire after starting gas supply by turning on the torch switch P05 AFTER FLOW TIME 5s 5 s 0 1s 0 1s It specifies time to stop gas supply after stop ping thearcbyturningoffthetorch swit...

Page 37: ... machine and Robot NO Menu contents Set range Increment Default Note P09 Wire adhesion detection ON OFF 0 or 1 1 0 When the Product works with special purpose machine or robot the setting can be used When welding finishes or starts the adhesion between welding wire and base metal can be detected automatically P23 Given current and voltage setting 0 1 or 2 1 Input signal voltage setting correspondi...

Page 38: ... 0 The role of micro adjustment of the arc voltage Positive value direction of the arc voltage adjustment time longer Pulse control NO Menu contents Set range Increment Default Note P15 Dual pulse frequency 5 5 Hz 5 Hz 0 1Hz 0 P16 Low pulse duty ratio 50 50 1 50 the second pulse output duty ratio P17 Low pulse current 50 200 1 120 Low pulse current set point P18 low pulse voltage 9 9V 9 9V 0 1V 0V...

Page 39: ...rrent value Note After the linkage percentage is set the initial current will not exceed the maximum value of the welding current 350 A 500 A P27 INIT CRATER Switch 0 or 1 1 0 1 AUTO 0 Manual Others NO Menu contents Set range Increment Default Note P24 Arc shape 99 99 1 0 The higher value you set the more concentrated arc you get The lower the less concentrated arc P25 Welding display mode 0 or 1 ...

Page 40: ...select 12 and return to welding mode Till now data recording finishes Note During Call operation 13 14 15 16 17 8 2 The welding machine factory defaults reset operation does not function If 7 segment LED cannot display correctly after turning ON the power source the damage of internal data may happen Please follow the steps here to restore machine to factory settings The operation sequence 1 Disco...

Page 41: ...ng 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 The wire is fed forward while this button is pressed And the lamp is on while feeding the wire Inching is available when the welder is in standby state Current set value for the main welding is used to determine the wire i...

Page 42: ...1 Welding current calibration Welding current is tested and calibrated with following welding wire extension it may need read justment with moved welding parameters such as torch angle wire type shieling gas and other welding conditions Welding current 50A 100A 150A 200A 250A 300A 350A Extended wire length Tip Base metal distance 0 9 wire 0 8 wire 12 12 12 15 18 1 2 wire 1 0 wire 15 15 15 18 18 22...

Page 43: ...Operation 39 9 3 CRATER Operation Turn the torch switch on and off twice ...

Page 44: ...on 40 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: ...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 To stop welding raise the torch until arc is cut ...

Page 46: ...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 Example of wrong operation ...

Page 47: ...tachment Check if any foreign matter is attached to the cooling air intake vent Top panel Bottom panel Side panel Eyebolts and other bolts Breakage or loose attachment If there is any defect additional fastening parts replacement etc are required Casters Breakage or loose attachment Panels Loose attachment Overall Appearance Check if there is any trace of heat generation such as discoloration If t...

Page 48: ...p the proper performance of this product for a long time In the periodic check check the product thoroughly including checking and cleaning of the inside of this product Conduct the periodic check every 6 months normally If there is a mass of fine dust oily smoke etc around this product perform the regular check every 3 months as a guideline Check guideline While details for checking are shown bel...

Page 49: ...0 3 1 Test preparation Connection cables and signal wires 1 Turn off power at distribution box customer preparation and then disconnect the input cables from the load side terminal of the distibution box and from the input power terminal of this unit Turn off power to all related devices jigs 2 Disconnect cables and signal cables connected to the following terminals and connectors Front Base metal...

Page 50: ...may malfunction Remove all the short circuited cables for the test and return the disconnected cables as they were according to the following procedure Reconnect the ground cables and connectors on the PC board as they were Return the dust cover top panel right panel and left panel as they were Connect the input power cable to the input terminal and return the terminal cover Connect the input powe...

Page 51: ... again The displays can NOT beautomatically turned off until thepower switch is turnedOFFevenwhen thecause is removed after connecting the power source 7 segment display cannot be shown normally Err S N Error type Group Probable causes and remedy Err 001 emergency stop B The connection of external equipment emergency stop on the output terminal block Turnpower switchOFF refer to thelistbelowand re...

Page 52: ...etected when the power switch is turned on Remedy Turn power switch OFF and then check the followings to remove 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 Err 010 external interruption 1 A The external equipment the connecting to output terminal block receives interruption signal temporary stop 1 Re...

Page 53: ... on the front panel Blown fuse Wire feeder Size of the wire for feed roller SUS tube is wrong Crack clogging or breakage at the feed roller Insufficient fastening of pressure rod Accumulation of wire powder at SUS tube inlet Fuse for voltage detection wire is blown Torch cable Cables for power and torch switch are severed Loose connection to the wire feeder Signs of dropping impact Torch cable is ...

Page 54: ...Parts list 50 12 Parts list 12 1 Parts list for GP5 Front view Rear view Top view 20 101 ...

Page 55: ...Parts list 51 Right view Left view 35 4 26 25 8 2 6 9 7 5 26 14 10 40 59 60 61 30 106 ...

Page 56: ...Parts list 52 30 102 103 104 105 24 ...

Page 57: ...Magnetic Biasing Capacitor MKPHR1 5UF750V AC 2 12 R4 R7 Secondary Power Resistor RX274H40W5R0JW 4 13 D2 D3 Diode Module FRS300BA70 2 D2 D3 D4 D5 14 Thp1 Thermal Relay 0HD3 83B02 1 15 FAN Fan TG22580HA2BL 1 16 FAN Fan Protective Cover WZ TG22580 1 17 MS AC Contactor NDC1T 5011MS 1 18 TM1 TM2 Output Terminal PC Board TSMP735 口 1 19 R14 Cement Resistor SFW40A471 1 20 FU5 Fuse 61NR080H 1 wire feeder f...

Page 58: ...embly TSMY0252 1 47 PM Pump LNY2841 M0022 1 48 TR3 Control Transformer TSMU1019 口口 1 49 IOT IOT Board TSMPA297 口口 1 50 IOT Power Board TSMP492 口 1 51 Communication board TSMP704 口 1 52 FAN Fan 9WG1224J103 1 55 Ethernet socket RJ45F71 1 56 RS485 communication components TSMW3167 口口 1 57 Network parameter configuration line TSMW3163 口口 1 59 Push in connector blue BD 802042 1 60 Push in connector red...

Page 59: ...20X270 YT516 5X180X140 For WTDLU00010ZZ Insulating paint R 611 9 For TSMLU187 TSMLU188 TSMTU244 WTDLU00010ZZ Silicon steelsheet 50JN1000 For TSMLU187 Bare aluminum wire AAW45X22 For TSMLU187 Bare copper wire TBR3X16 For TSMLU188 Enameled wire Q ZY XY 2 200D3 0 For WTDLU00010ZZ Rubber sheathed flexible cable YC4X6 Bare copper cable TS 24 Note stands for safety parts stands for key materials ...

Page 60: ...Circuit diagram 56 13Circuit diagram 13 1 Circuit diagram for YD 500GP5 ...

Page 61: ... 40 50 15 15 20 Back 1 2 1 5 1 2 230 260 24 26 40 50 15 15 20 9 Front 1 2 1 5 1 2 320 340 32 34 40 50 15 15 20 Back 1 2 1 5 1 2 320 340 32 34 40 50 15 15 20 Butt Joint Welding Square groove joint With backing Thickness mm Route gap G mm Wire diameter mm Current A Voltage V Speed cm min Tip to work distance mm Gas flow L min Copper backing 0 6 0 0 6 40 16 60 10 15 20 1 0 8 0 0 6 40 16 5 45 10 15 20...

Page 62: ... 7 1 2 1 6 270 380 29 35 40 45 25 20 25 12 7 8 1 2 1 6 300 380 32 35 35 40 25 20 25 Fillet Welding Flat position Thickness mm Leg length mm Wire diameter mm Current A Voltage V Speed cm min Tip to work distance mm Gas flow 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...

Page 63: ...0 15 3 2 3 5 4 1 0 1 2 150 170 21 22 45 50 15 15 20 4 5 4 5 5 1 0 1 2 180 200 23 24 40 45 15 15 20 6 5 5 5 1 2 230 260 25 27 40 45 20 15 20 8 9 6 7 1 2 1 6 270 380 29 35 40 45 25 20 25 12 7 8 1 2 1 6 300 380 32 35 35 40 25 20 25 14 3 Arc spot welding conditions table Reference Thickness TopxBottom Wire diameter mm Welding time s Welding current A Welding voltage V Bead diameter mm Tip to work dist...

Page 64: ...ct is designed and manufactured according to ENIEC60974 1 EN60974 10 This product may not conform to the local laws and standards of other countries Please be absolutely sure to consult with us before attempting to relocate or resell this product to other countries ATTENTION The disposal of the product In case of disposal of the product please sign the assignment agreement on disposal treatment wi...

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