Panasonic YD-500GP5 User manual

Operating Instructions
Digital IGBT control
MIG/MAG Power Source
Model No.: YD-500GP5
●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

■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
■The applicable welding methods
●carbon steel CO2welding,
●carbon steel MAG welding
●carbon steel flux core welding.
Note: 【Deepen 】function is an optional software package. The test welding for this function can last for 3
hours ( Section 5.4), after setting P menu. If you are willing to continue 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
CO2100%CO2DC 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
HND
30
×
DC pulse
ON
0.8 HND 10 ×
0.9
HND
15
×
1.0
HND
15
×
1.2 HND 15，20 ×
1.4
HND
25
×
1.6
HND
30
×
stainless steel MIG Ar+2.5%CO2
DC pulse
OFF
0.8
HND
×
×
1.0
HND
×
×
DC pulse
ON
0.8
HND
10
×
1.2
HND
15，20
×
1.6
HND
30
×
1.0
HND
15
×
Silicon bronze MIG 100%Ar DC pulse
ON
1.0
HND
×
×
1.2
HND
×
×
Aluminum
bronze MIG 100%Ar DC pulse
ON
1.0
HND
×
×
1.2
HND
×
×
Al MIG 100%Ar DC pulse
ON
1.2 HND 15 ×
1.6 HND 15 ×
2.0 HND × ×

Si- Al
MIG 100%Ar
DC pulse
ON
1.2 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.

Table of Contents
1SAFETY········································ 1
1.1 WARNING SYMBOLS FOR SAFE USAGE......... 1
1.2 SAFETY PRECAUTIONS................................ 2
2 RATED SPECIFICATIONS················ 4
2.1 SPECIFICATIONS TABLE............................... 4
2.2 RATED DUTY CYCLE.................................... 6
2.3 THERMAL PROTECTION............................... 6
2.4 DIMENSIONS .............................................. 7
3 INSTALLATION AND POWER SUPPLY
FACILITY··········································· 8
3.1 INSTALLATION SITE...................................... 8
3.2 INSTALLATION TRANSPORTATION ................. 9
3.3 POWER SUPPLY EQUIPMENT..................... 10
4 CONFIGURATION··························11
4.1 EQUIPMENT NECESSARY FOR WELDING ......11
4.2 CONNECTING CABLE................................. 12
4.2.1 ABOUT CONNECTING CABLE...................... 12
4.2.2 CAUTIONS ABOUT USING CONNECTING CABLE
...........................................................12
4.3 CONNECTIONS&OPERATIONS OF THE
COOLING SYSTEM............................................... 13
5 NAMES AND FUNCTIONS···············16
5.1 THE POWER SWITCH................................. 16
5.2 REAR SIDE................................................ 16
5.3 FRONT PANEL........................................... 17
6 CONNECTION·······························20
6.1 THE CONNECTION OF OUTPUT CABLE ........ 20
6.2 THE CONNECTION OF THE GROUNDING WIRE
21
6.3 THE CONNECTION OF INPUT CABLE............ 21
6.4 THE CONNECTION OF INPUT CABLE............ 22
6.5 CONNECTING JIG(S) ................................. 30
6.5.1 THE LOCATION OF JIG TERMINALS.............. 30
6.5.2 LAYOUT OF JIG TERMINALS........................ 30
7 PREPARATION AND TERMINATION
PROCESSINGS··································31
7.1 PREPARATION .......................................... 31
7.2 TERMINATION PROCESSING (STEPSAFTER
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 “CRATER REPEAT”OPERATION...................41
9.6 “ARC SPOT”...........................................42
10 MAINTENANCE AND INSPECTION···43
10.1 DAILY CHECK............................................43
10.1.1WELDING MACHINE (THIS PRODUCT).........43
10.1.2CABLES ...................................................43
10.1.3OTHER DEVICES.......................................44
10.2 PERIODIC CHECK......................................44
10.3 PRECAUTIONS FOR WITHSTAND VOLTAGE
TESTAND INSULATION RESISTANCE .................... 42
10.3.1TEST PREPARATION ..................................45
10.3.2AFTER COMPLETION OF THE TEST .............46
11 TROUBLESHOOTING·····················47
11.1 ERROR INDICATION ...................................47
11.2 TROUBLESHOOTING TABLE........................49
12 PARTS LIST ·································50
12.1 PARTS LIST FOR GP5................................50
12.2 GP5 PARTS DIAGRAM................................53
13 CIRCUIT DIAGRAM························56
13.1 CIRCUIT DIAGRAM FOR YD-500GP5 .........56
14 APPENDIX ···································57
14.1 CO2 WELDING CONDITIONS TABLE:SOLID
WIRE (REFERENCE)............................................57
14.2 MAG WELDING CONDITIONS TABLE:SOLID
WIRE (REFERENCE)............................................59
14.3 ARC SPOT WELDING CONDITIONS TABLE
(REFERENCE) ....................................................59

Safety
1
1 Safety
1.1 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.
●
The followings explains harzardous conditions or
damages that are classi-
fied into the following
three levels.
●
The following symbols indicates things to be
observed.
Things that MUST NOT be
performed.
A hazardous situations including death or serious
personal injury is imminent.
Things that MUST be performed.
The potential for a hazardous accident including death
or serious personal injury is high.
Things attention must be paid to.
The potential for hazardous accident including light
personal injury and/or the potential for property
damage are high.
◆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.
•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 this product with any other product, equipment, devices or software
that is not supplied by PWST.
•Any problem arising out of, or directly or indirectly attributable to user’s failure to strictly carry out or follow all of the
condition sand instructions contained in this instruction manual, or user’s misusage, mishandle, operational miss
or abnormal operation.
•Any problem arising out of this product or the use of it, the cause of which is other than the foregoing but is also
not attributable to PWST.
•Any claim of a third party that this product infringes the intellectual property rights of such third party that are
directly or indirectly caused by user’s use of this product and relate to the method of production.
●The description of this manual is based on the contents as of December, 2020.
●The contents of this manual are subject to change without further notice.
●English version is the original instructions.

Safety
2
1.2 Safety precautions
Welding power source
Observe the
following instructions to
prevent the hazard.
(1)Never use the welding power source for other than
welding purpose. (e.g. Never attempt to use the
welding power source for pipe thawing.)
(2)It is very important to comply with all instructions,
safety warnings, cautions and notes mentioned.
Failure to do so can result in serious injury or even
death.
(3)Work of driving source at the input side, selecting
work site, handling, storage and piping of high
pressure gas, storage of welded products and also
disposal of waste should be performed according to
the operating instructions and national, state and
local codes and regulations.
(4)Prevent any unauthorized personnel to enter in and
around the welding work area.
(5)Pacemaker wearers should consult their doctor
before going near arc welding. Magnetic fields can
affect pacemakers.
(6)Only educated and/or skilled persons who well
understand this welding power source should
install, operate, maintain and repair the unit.
(7)Only educated and/or skilled persons who well
understand the operating instructions of the unit
and are capable of safe handling should perform
operation of the unit.
Against electric shock
Observe the following instructions to
prevent the hazard.
(1)Do not touch live parts.
(2)Grounding of the case of the welding power and
base metal or a jig electrically connected to the
base metal must be performed by educated and/or
skilled persons.
(3)Before installation or maintenance work, turn off
power at the power box, wait it for at least five
minutes to discharge capacitors. Significant voltage
may exist on capacitors after turning off power at
the power box so it is imperative to check to make
sure that no charged voltage present at capacitors
before touching any parts.
(4)Do not use undersized, worn, damaged or bare
wired cables.
(5)Connect cables firm and insulate connection parts.
(6)Keep all cases, panels and covers securely in
place.
(7)Do not handle the welding power source with torn
or wet gloves.
(8)Wear safety harness in case of 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 exhauster specified by the applicable laws and
regulations (occupational safety and health
regulation, rules on preventing suffocation or etc.)
or wear protective breathing gear.
(2)To prevent dust injury or poisoning by the fume
generated during welding, use a local exhauster
specified by the applicable law (occupational safety
and health regulation, rules on preventing injury by
inhaled dust or etc.), or wear protective breathing
gear.
(3)When conducting welding in a confined area, make
sure to provide sufficient ventilation or wear
protective breathing gear and have a trained
supervisor observe the workers.
(4)Do not conduct welding at a site where degreasing,
cleaning or spraying is performed. Conducting
welding near the area where any of these types of
work is performed can generate toxic gases.
(5)When welding a coated steel plate, provide
sufficient ventilation
or wear protective breathing
gear. (Welding of coated steel plates generates
toxic fume and gas.)
Against fire, explosion or blowout
Observe the following cautions to
prevent fires explosion or
blowout.
(1)Remove any combustible materials at and near the
work site to prevent them from being exposed to
the spatter. If they cannot be relocated, cover them
with a fireproofing cover.
(2)Do not conduct welding near combustible gases.
(3)Do not bring the hot base metal near combustible
materials immediately after welding.
(4)When welding a ceiling, floor or wall, remove all
flammables including ones located in hidden
places.
(5)Properly connect cables and insulate connected
parts. Improper cable connections or touching of
cables to any electric current passage of the base
metal, such as steel beam, can cause fire.
(6)Connect the base metal cable at a section closest
to the 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.

Safety
3
Installing shielding (curtain etc.)
Arc flash, flying spatter, slugs, and
noise generated during welding can
damage your eyes, skin and
hearing.
(1)Install a protective curtain around the welding
manipulator site to prevent the arc flash from
entering the eyes of people in the surrounding area.
(2)When welding or monitoring welding, wear safety
glasses with sufficient light blocking structure or
use a protective mask designed for welding
operation.
(3)When welding or monitoring welding wear protective
clothing designed for welding operation, such as
leather gloves, leg cover and leather apron, and also
wear long-sleeve shirts.
(4)Be sure to wear noise-proof protective equipment if
the noise level is high.
(5)The larger the welding current is, or in case of AC
TIG or MIXTIG welding, the larger the AC frequency
is, the larger the arc sound becomes.
Gas cylinder and gas flow regulator
Overturn of gas cylinder and blowout
of gas flow regulator can cause
injury.
(1)The gas cylinder must be handled properly according
to the applicable law and in-house standards.
(2)Use the gas flow regulator that is supplied or recom-
mended by our company.
(3)Read the instruction manual of the gas regulator prior
to using it, and observe the cautions in the manual.
(4)Secure the gas cylinder to a dedicated gas cylinder
stand.
(5)Do not expose the gas cylinder to high temperature.
(6)When opening the valve of the gas cylinder, do not
bring your face close to the discharge outlet.
(7)When the gas cylinder is not used, be sure to install a
protective cap.
(8)Do not hang the welding torch on the gas cylinder, or
touch the gas cylinder with the electrode.
(9)Do not attempt to disassemble or repair the gas
regulator. Such works require special knowledge.
Rotating parts
Rotating parts can cause injury.
(1)Keep away from rotating parts such as cooling fans，
and 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 work or repair work, provide
fence or the like around the welding machine so that
unauthorized person can not come close carelessly.
Welding wire
Welding wire, especially wire tip part
can cause injury.
(1)Do not perform inching operation or pull the torch
switch with your eyes, face or body close to the end
of the welding torch - wire extends out from the
end of the welding torch and may stick into the
eye, face or body.
(2)In case of using a torch cable with the resin liner,
straighten the torch cable and reduce the preset
feed amount (current) to a half or less before
applying the wire inching.
(3)Performing wire inching while torch cable has been
bent extremely can cause the wire to pierce the
resin liner and cable. Make sure to replace any
damaged liner or cable with a new one, or
damaged liner/wire can cause gas leak or dielectric
degradation.
. Against insulation deterioration
Insulation deterioration can cause fire of
welding power source.
(1)Keep enough distance from welding power source
when performing welding or grinding work so as to
prevent spatters or iron particles from getting
into the power source.
(2)Perform check and maintenance work periodically
so as to prevent insulation deterioration due to
accumulated dust or dirt.
(3)When spatters or iron particles get into the welding
power source, turn off the power switches of the
welding power source and power distribution box,
and then blow out.
(4)Make sure to replace any damaged liner or cable
with a new one as use of damaged liner/cable may
cause gas leak or dielectric degradation.
(5)In order to avoid dust and dirt to be collected inside
of the power source, make sure not to leave the
panel and bolts (including eyebolts) open and
removed.

Rated Specifications
4
2 Rated Specifications
2.1 Specifications table
Item Unit
Contents
YD-500GP5
Control method - digital IGBT control
Rated input·
Number of phases
- 3-phase AC 400 V
Input power frequency
Hz
50/60
Rated input capacity
kVA/kW
29.9/23.9
the power source
efficiency
% 82.5
the idle state power
consumption watts 394
Output characteristics - CV( constant voltage characteristics )
Rated output current A
Pulse OFF
：
DC 500
Pulse ON
：
DC 400
Rated output voltage V 39
Rated duty cycle % 60
Rated output no-load
voltage V DC 87
Output current range
(
※
Note)
A
Pulse OFF
：
DC 60~500
Pulse ON
：
DC 60~400
Output voltage range
(
※
Note)
V Pulse OFF：17~39
Pulse ON
：
17~34
Welding method - individual / unitary
Enclosure protection
class - IP23S
Insulation class - main transformer 155 ℃( inductor 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 can be called, welding parameters
recordable
Sequence -
welding / welding — crater / initial — welding — crater /
spot welding
Shielding gas -
CO
2
welding CO
2
: 100%
MAG welding Ar: 80%, CO2: 20%
MIG welding Ar:98%, O2:2%
Gas check time - 60s ( longest gas check time )
Pre-flow time - 0 s–5.0 s continuous adjustment (0.1 s increment)
After-flow time - 0 s–5.0 s continuous adjustment (0.1 s increment)
Spot welding time - 0.3 s–10.0 s continuous adjustment (0.1 s increment)
Capacity of liquid
cooling system
L 9
Cooling mode of liquid
cooling system
Coolant circulation cooling / water pump forced circulation

Rated Specifications
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
m20
Overall dimensions mm 840X383X1240 ( LXWXH )
Mass
kg
133

Rated Specifications
6
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 minutesout of any 10 minutes at the
rated current, and then, during the remaining 4 minutes, the machine must be cooled down to prevent overheating.
●Exceeding allowable duty cycle can cause the temperature rise higher than the maximum allowable temperature,
resulting in the 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 off the output.
●Please be sure not to use under the conditions listed here:
●Over the rated output voltage.
●The air inlet or outlet is blocked.
●The ambient temperature is higher than 40°C.
●The cooling fan stops.

Rated Specifications
7
2.4 Dimensions
机型
W
H
L
YD-500GP5HNX 383 1240 840

Installation and Power supply facility
8
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.
<Note>
If exposed to the rain or water spray, or dew
condensation occurred, dry the product
before using it.
(3) Ambient temperature
(a) During cutting operation: -10 °C to 40 °C
(b) During transportation/storage: -20 °C to 55 °C
(4) Humidity relative to temperature
(a) Up to 50 % at 40 °C.
(b) Up to 90 % at 20 °C.
(5) Altitude above sea level: Up to 1 000 m.
(6) Inclination to installation 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 stop device
●Please do NOT turn over and lay the machine down
on the floor.
●Up-side-down use can worsen cooling performance
of the machine and may cause the machine burnt or
overheated.
●Please vertically place the machine on the horizontal
surface.
Please
● When the product is installed on the floor where it is t
oo low to operate, customers
are required to prepare a table to mount the product on.
●
Such table should be provided with flanges on the mounting surface to prevent the
product to slide off the table.
200 mm
or more
300 mm
or more

Installation and Power supply facility
9
3.2 Installation transportation
When hanging this product for transportation, hang it at two eyebolts.
●The hoisting operation
● During hoisting operation, please do NOT use the handles.
● When the machine is moved downwards by hoist, please be
sure to use the eye bolts and hang the machine with two points.
●The machine is carried by hands
● When the machine is carried manually, single person can NOT
carry it on. More than one person are required to do this job.
Note:
● If the eye bolts are missing or damaged, please contact with
the distributor of the Company.
● Please purchase the genuine 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 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.
●Do not leave the product on a sl
ope. (The product is provided with
casters.)
●When pushing this product for transportation, do not make a sharp turn,
or casters or floor may be damaged.
Storage, installation, transportation please do not pile up over two layers.
Two-point
suspension

Installation and Power supply facility
10
3.3 Power supply equipment
Observe the following to prevent burnout, destruction of parts and unstable
arc.
welding power source YD-500GP5
Input power source Three phase ,400V AC,
50 / 60 Hz (common)
Capacity Commercial power source 35 kVA or more
Engine generator Two times rated input or more
Input protection
(Power distribution box)
Fuse breaker 63 A
Molded case circuit breaker
(or leakage breaker) 80 A
Cross-section area
Of cable
Input power cable 10 mm2or more
Output power cable 70 mm
2
or more
Ground cable The same as input power cable or bigger
Protection level IP23S
Insulation level main transformer 155 ℃( inductor 200 ℃)
class of pollution Class 3
EMC classification Class A
*1. The listed 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 voltage is 304V ~ 456V.
● When the generator is used, the rated input capacity should be two times of welding power source or higher.
The generator should be equipped with compensating coils.
● The wiring of input side: please equip each welding power source with one fuse switch or non-fuse breaker (or
leakage breaker) of which capacity complies with the rated one of the cutting power source.
● Please select the proper breaker (or leakage breaker) which is applicable to electric distribution, such as cutting,
electric motor or transformer.

Configuration
11
4 Configuration
4.1Equipment necessary for welding
Note:
the diagram below shows the connection with the welding power source. Please be sure to use the wire
feeder, welding gun, gas regulator of the Product as set equipment. Otherwise the welding performance may
be affected or the machine can be even damaged.
Before using the Product with other standard products, please read the operation manual
carefully.
NO. item remarks
①
Welding
power
source YD-500GP5HNX
②wire feeder YW-50DNW1HAG + TSMWV660
③Torch YT-40MFW2HTF
④Gas
regulator YX-25AJ1
⑤
base metal
welding
cable 70 mm2or higher
NO item remarks
⑥Grounding
cable 6 mm2or higher
⑦Distribution
box 3-phase AC400 V
⑧
power
source
input cable
6 mm2or higher
⑨Grounding
cable 6 mm2or higher
⑩shielding
gas Same as the selected gas
Reminder

Configuration
12
4.2Connecting cable
Caution against getting the cable wet.
Avoid the connecting cable to get wet.
If there is a chance of getting the cable exposed to rain or water splay,
make sure to protect the connection with waterproof cover.
Water seeping into the machine may degrade the insulation between
terminals, which may cause an error or damage this product or wire
feeder.
4.2.1 About connecting cable
● The connecting cable (separately sold) is useful to expand the working space in welding operation. (See
the table on the right for model numbers.)
● Apply the connecting cable between torch output terminal (+) of the product and the torch cable of the wire
feeder.
● Depending on work conditions, it may be necessary to extend the base metal cable.
Note:
It is not possible to use the connecting cable as a junction cable.
4.2.2 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 impact, pay attention to the fol- lowing points.
（1）Relationship among extending length, cross section, allowable current and duty cycle.
（2）Arrange the base metal cable corresponding to the applied connecting cable.
（3）Do not extend the cable unnecessarily. (A shorter cable is preferable)
（4）Do not use leave the connecting cable slackened. Never coil the connecting cable when welding, or the
welding arc may become unstable.
（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
YD-500GP5 70 mm2L≤18.2 m

Configuration
13
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 pa
rts 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
In the process of coolant replacement,
please insert the exhaust connector at
the coolant outlet. After the coolant is
filled, please pull out the exhaust
connector in time. The exhaust
connection is suspended near the
coolant outlet.
NOTE:it may cause faults once there is coolant splashing on the power supply or this product. Wipe the liquid drop
immediately
To avoid injury, please observe the following rules
When the temperature of the coolant increases during operation, the
exchange of coolant should be conducted after the temperature drops
1. Replace the coolant after the temperature drops.
2. Do not touch the hose plug during operation
3. Check and maintain after confirming the temperature drop.
●Coonection
（1）Connection for coolant outlet
Connect the water outlet cable on the wire feeder to the coolant outlet
（2）Coolant inlet connection
Connect the return water 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 is cooling air blowing out from the side panel of the
liquid cooling system. Otherwise, the power supply should be disconnected immediately to find out the cause.
（3）Operation sequence
・Turn on the power supply of the welding machine, the water pump and fan start to run, and the coolant
circulates in the welding gun
NOTE:For the first time, it takes about 10 seconds from the start of pump operation to the completion of the
first water circulation
（It varies according to the length of the waterway）。
・Due to the long pipeline, it takes up more coolant. If the coolant level is below the lower limit (min), stop
the operation for coolant replenishment, and add the coolant to the position above the min
・At the end of the operation, the power should be turned off after the welding gun has cooled down
sufficiently
・When the welding machine is standby for more than 7 minutes, the coolant circulation device will
automatically stop running and enter the power saving mode. When the welding gun switch is pressed
again, the cooling liquid circulating device will run again
exhaust
connector

Configuration
14
●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.
Please buy antifreeze according to the local minimum temperature. The freezing point of antifreeze should
be lower than the minimum temperature of the environment
（2）In order to avoid the formation of coolant scale in the bucket, please change the coolant regularly.
Antifreeze once a year
（3）When not in use for a long time, be sure to remove the coolant from the coolant tank and coolant pipe
Some components in the coolant will precipitate in the coolant pipe, which will cause the water pump not to
operate normally Method of removing cooling liquid
The water inlet pipe joint of the welding torch 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 and liquid cooling system, which can
be disassembled into independent welding power supply and liquid cooling system according to needs
The disassembly sequence of the liquid cooling system is as follows：
(1)Remove the welding power supply top cover and side plate (left side version), and disconnect the three
connectors as shown in the figure below
It is not allowed to drink the coolant in the coolant tank and wash the eyes with coolant
Otherwise, diarrhea and poisoning may occur.
Before the installation or disassembly of the liquid cooling system, be sure to disconnect
the welding power supply
After disassembly, there is high voltage in the 3 connectors disconnected from the
welding power supply. Please pay attention to binding and protection
Connectors (three)

Configuration
15
(2) As shown in the figure below, use a cross screwdriver to remove the four screws connecting the welding power
supply and the liquid cooling system. After removing the screws, pull up the handle to separate the welding power
supply from the liquid cooling system. Before independent use of welding power supply, 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 reverse
order
Rubber cover: SG30AK (two)
Note: Do not discard the cover after
disassembly
Please install the cover when
assembling

Names and functions
16
5 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.
5.2 rear side
note・Turn the power switch knob clockwise to turn on
the power, and the LED digital tube will display 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.
①
(
－
) Base material side output terminal
②Reserve accessory holes
③AC 36V heater socket and8A fuse
④Input cable lock nut
⑤Wire feeder connector
⑥(＋) Torch side output terminal
⑦Air inlet for cooling fan
Please do not place other objects nearby.
⑧Coolant inlet
Water can circulate through the coolant inlet.
⑨Coolant outlet
Water can circulate through the coolant
⑩Coolant supply port
Coolant supply port
Power source switch
①
⑩