GYS COSMOS 500 G – Multi-Process MIG/MAG Pulse Welding Machine

The GYS COSMOS 500 G (Ref. 085596) is a state-of-the-art 500 A three-phase multi-process welding power source, developed primarily for high-performance MIG/MAG welding. Featuring advanced digital control, exceptional arc dynamics and a high duty cycle, the COSMOS 500 G combines more than 20 years of GYS welding expertise into a powerful industrial platform designed for experienced professional welders.

Designed for demanding fabrication and production environments, the COSMOS 500 G supports MIG/MAG, MMA DC/Pulse, TIG DC Lift/Pulse and air-arc gouging. For MIG/MAG welding, it accommodates steel and stainless steel wires from Ø0.6–1.6 mm, aluminium and CuSi/CuAl wires from Ø0.8–1.6 mm, and flux-cored wire from Ø0.9–2.4 mm with polarity inversion. MMA welding supports basic, rutile and cellulosic electrodes up to Ø6 mm, while air-arc gouging can be performed with carbon electrodes up to Ø8 mm.

The COSMOS 500 G offers more than 70 synergic welding programs for Steel, AlMg, AlSi and CrNi, together with five dedicated MIG/MAG welding modes: Standard, Pulse, ModulArc, Root and Manual. Its digitally controlled arc provides rapid ignition and controlled bead termination, while the pulsed process can achieve up to 30% higher welding speeds, improving productivity while reducing spatter and post-weld finishing.

Built for modern industrial production, the COSMOS 500 G also provides extensive connectivity and job-management functions. It can store up to 200 welding programs, transfer machine configurations and user jobs by USB, provide weld traceability according to EN 3834, and support multiple user profiles. Compatibility with separate WF 36 and WF 51 wire feeders allows the system to be configured according to the operator's working requirements.

Engineered for challenging working environments, the COSMOS 500 G features an IP23-rated industrial enclosure, on-demand ventilation to limit dust ingress, two steel handles for transportation or suspension, optional dust filtration, generator compatibility and interconnection cables up to 20 metres for an extended working area.

Key Features & Benefits

• 500 A three-phase industrial welding power source
• Multi-process capability: MIG/MAG, MMA DC/Pulse, TIG DC Lift/Pulse and air-arc gouging
• Designed primarily for high-performance MIG/MAG welding
• Advanced digital arc control
• More than 70 synergic welding programs
• Synergies available for Steel, AlMg, AlSi and CrNi
• 5 MIG/MAG welding modes: Standard, Pulse, ModulArc, Root and Manual
• Pulsed welding can achieve up to 30% higher welding speeds
• Pulse mode helps reduce spatter and post-weld finishing
• ModulArc for high-quality aluminium welding appearance
• Root mode simplifies unsupported root-pass welding
• Stores up to 200 welding programs (Jobs)
• USB connectivity for machine updates, job storage and configuration transfer
• Weld traceability according to EN 3834
• Compatible with WF 36 and WF 51 separate wire feeders
• Optional RC-HD3 digital remote control
• IP23-rated for challenging industrial environments
• On-demand ventilation system helps reduce dust ingress
• Generator compatible – 30 kW
• Interconnection cables available up to 20 m
• Heavy-duty construction with two steel carrying handles
• Made in France
• Manufactured in accordance with EN 60974-1

Premium MIG/MAG Welding Modes

The COSMOS 500 G features more than 70 synergic programs for Steel, AlMg, AlSi and CrNi, together with five dedicated MIG/MAG welding modes. Its pulsed arc can achieve up to 30% higher welding speeds.

Intelligent Interface & Connectivity

The COSMOS 500 G is paired with the WF 51 wire feeder featuring a 5-inch interface. The WF 51 provides two display modes: Easy mode for straightforward operation and Expert mode for experienced welders who require manual control over the different stages of the welding cycle.
Additional connectivity features include:

• Storage of up to 200 welding Jobs
• Complete machine and synergy updates via USB
• Loading, saving and transferring user Jobs and machine configurations via USB
• Weld bead traceability according to EN 3834
• Calibration mode for welding accessories
• Multi-user operating mode

Technical Specifications

The electrical ratings and duty-cycle values above are specified according to EN 60974-1 at 40°C.

The supplied GYS datasheet displays TIG values of 400 A at 60% and 500 A at 100%. These figures have been reproduced exactly as shown in the source document.

Welding Process Specifications