FCW DYNA MMA 500GTS Operating Manual Download

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DYNA MMA 500S

、

500GTS

、

500(H)S

、

500(H)GTS

、

630S

、

630GTS Operating Manual

LABEL GROUND

2LAM8800003

1 1 1 1 1 1

CAP PROTECTION

2FP8647000

4 2 4 2 4 2

PANEL BACK FP8.041.018

2FPPR8041018 1 1 1 1 1 1

OVERLAY CONTROL

2LAC8807037

1 1 1 1 1 1

OVERLAY CONTROL MMA500S

2LAF8802026 1

OVERLAY CONTROL MMA500GTS

2LAF8802068

OVERLAY CONTROL MMA500HS

2LAF8802016

OVERLAY CONTROL MMA500HGTS

2LAF8802073

OVERLAY CONTROL MMA630S

2LAF8802064

OVERLAY CONTROL MMA630GTS

2LAF8802069

LABLE

（

+ PPG -)

2LAU8803002

1 1 1 1 1 1

SWITCH KNX202

4KNX202

4 4 4 4 4 4

POTENTIONMETER 2W 100K

4WTHRV24YN100K

1 3 1 3 1 3

KNOB

4KYZPN8E20R3 2 4 2 4 2 4

POTENTIONMETER 2W 5K

4WTHRV24YN5K 1 1 1 1 1 1

KNOB

4KYZPN8D24

1 1 1 1 1 1

POTENTIONMETER 2W 10K

4WTHRV24YN10K

1 1 1 1 1 1

FTG,GAS BARBED 1/4 TBG 5/8-18 FEMALE

3KITP000113000

1 1 1

INSULATOR BULKHEAD REAR

2FP7854005

2 2 2 2 2 2

INSULATOR BULKHEAD FRONT

2FP7854010

2 2 2 2 2 2

RECEPTACLE

2AD7735011

2 2 2 2 2 2

BRACKET COVER FP7.854.009

2FP7854009

2 2 2 2 2 2

PANEL CONTROL FP8.041.016

2FPPC8041016 1 1 1 1 1 1

PANEL FRONT FP8.041.022

2FPPF8041022 1 1 1 1 1 1

INSULATOR POTENTIONMETER

2FP7854006

3 5 3 5 3 5

INSULATOR POTENTIONMETER

2FP7854007

3 5 3 5 3 5

RECEPTACLE 14 PIN

4WP143102A

1 1 1 1 1 1

RESISTANCE 50W 500

Ω

4RX27D50W500H 1 1 1 1 1 1

HF PCB FP7.820.020C-03

3KITP002005031 1 1 1

HF PCB FP7.820.020C-02

3KITP002005010

1 1 1

INDUCTOTR ASSY,OUTPUT

3EER22012

1 1 1 1 1 1

INDUCTOTR ASSY,INPUT

3EER21003

1 1 1 1 1 1

FILTER PCB FP7.822.000-01

3KITP002706080 1 1 1 1 1 1

TRANSFORMER,POWER ASSY,500S

3EER31012

1 1 1 1 1 1

CAPACITANCE 400V2700UF

4CDJ400V2700 4 4 4 4 4 4

MUTUAL INDUCTANCE RING

4EER400072

1 1 1 1 1 1

PLASTIC BOX

7BOX00001

1 1 1 1 1 1

INSULATOR BULKHEAD FRONT

422CBB630V104 4 4 4 4 4 4

Summary of Contents for DYNA MMA 500GTS

Page 1: ...MMA 500GTS DYNA MMA 500 H S DYNA MMA 500 H GTS DYNA MMA 630S DYNA MMA 630GTS Operating Manual Owner s Manual IMPORTANT Read these instructions before installing operating or servicing this system Second Edition Manual No E0904 ...

Page 2: ......

Page 3: ... welding 15 5 0 POWER SUPPLY CONTROLS INDICATORS AND REATURES 16 6 0 BASIC TIG WELDING GUIDE 17 6 01 Electrode Polarity 17 6 02 Tungsten Electrode Current Ranges 17 6 03 Tungsten Electrode Types 17 6 04 Guide for Selecting Filler Wire Diameter 17 6 05 Shielding gas selection 18 6 06 TIG welding parameters for low carbon low alloy steel pipe 18 6 07 Welding parameters for steel 18 7 0 BASIC ARC WEL...

Page 4: ...t Spot Time GTAW SEC Seconds Remote outputs control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current t2 Gas Post Flow Time 2T GTAW t1 Gas Pre Flow Time 4T GTAW VRD Voltage Reduction Device Circuit Repeat Function GTAW Negative Spot Function GTAW Positive High Frequency Starting GTAW Gas Input Lift Start GTAW Gas Output ...

Page 5: ...out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of FCW is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WH...

Page 6: ... welding or cutting process can be dangerous and hazardous to your health z Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume z Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases z The kinds of fumes and gases from the arc welding cutting depend on the kind of metal being used coatings on the metal and the differe...

Page 7: ...t z Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table Do not cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels ...

Page 8: ...T TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage z Lift unit with handle on top of case z Use handcart or similar device of adequate capacity z If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Page 9: ...ibration or shock z In areas free from oil steam and corrosive gases z Place at a distance of 304 79mm or more from walls or similar that could restrict natural airflow for cooling z In areas not exposed to direct sunlight or rain z Ambient temperature between 10 degrees C to 40 degrees C WARNING 1 FCW advises that this equipment be electrically connected by a qualified electrician The following P...

Page 10: ... the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to...

Page 11: ... Table 3 2 03 Duty cycle The duty cycle of a welding power source is the percentage of a ten 10 minute period that it can be operated at a given output without causing overheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will caus...

Page 12: ... H GTS 630GTS 5 Remote Amperage 6 Positive Terminal connect to work ground cable in TIG in Stick connect to the weld clamp 7 14 Pin Receptacle 8 Output Gas Fitting DYNA MMA 500GTS 500 H GTS 630GTS 9 Negative Terminal connect to the TIG torch in TIG in Stick connect to the work ground cable 10 Arc Force Control 11 Hot Start Control 12 Down Slope Time Control DYNA MMA 500GTS 500 H GTS 630GTS 13 Post...

Page 13: ... MMA 500GTS 500 H GTS 630GTS 20 Fuse 21 Ground Screw 22 Input Power Cable Port Figure 3 Pin Function A Torch switch B Torch switch C Remote Amp D Remote Amp E Remote Amp Table 4 WARNING When the welder is connected to the primary supply voltage the internal electrical components maybe at primary potential with respect to earth ...

Page 14: ...ctrodes It sets the peak start current on top of the WELD current Long Arc This control provides a long Arc in STICK welding to improve characteristics for STICK electrodes Short Arc This control provides a short Arc in STICK welding to improve electrode restart quickly Down Slope Time This parameter operates in TIG modes only and is used to set the time for the welding current to ramp down this c...

Page 15: ...S MMA 630GTS PEAK CURRENT 500A 500A 500A 500A 630A 630A TIG 10 500A 10 500A 10 500A 10 500A 10 630A 10 630A WELD CURRENT STICK 10 500A 10 500A 10 500A 10 500A 10 630A 10 630A ARC FORCE 0 100A 0 100A 0 100A 0 100A 0 100A 0 100A HOT START 0 100A 0 100A 0 100A 0 100A 0 100A 0 100A DOWN SLOPE 0 5s 0 5s 0 5s POST FLOW 0 5s 0 5s 0 5s Table 6 Weld parameters for DYNA MMA series ...

Page 16: ...Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide and then finally adjust the current setting to suit the application Figure 5 Set up for DYNA MMA Seri...

Page 17: ... Welding current A 10 50 50 150 150 250 Table 7 4 02 DC TIG welding z Connect work lead to positive terminal z Connect TIG torch to negative terminal z Switch machine on z Set welding current control see table 8 z Use TIG torch with value control Workpiece thickness mm Tungsten diameter mm Welding current A Filler wire diameter mm Argon Gas flow L min 0 3 0 5 1 1 6 5 30 3 8 0 5 1 2 1 6 2 10 50 1 2...

Page 18: ...6 DYNA MMA series front panel 1 Main Circuit Breaker 2 Arc Selection long Arc short Arc 3 Current Control 4 Stick LIFT TIG HF TIG Select Switch 5 Remote amperage 6 Arc Force Control 7 Hot Start Control 8 Down Slope Time Control 9 Post flow Time Control 10 Meter Selection 11 Digital Meter 12 Warning indicator 13 AC Power indicator ...

Page 19: ...ies tungsten electrode sizes 6 03 Tungsten Electrode Types Tungsten type Ground finish Welding Application Features Color code Thoriated 2 DC welding of mild steel stainless steel and copper Excellent arc starting Long life high current carrying capacity Red Ceriated 2 DC welding of mild steel stainless steel copper aluminium magnesium and their alloys Longer Life More stable arc Easier starting W...

Page 20: ...30 No Table 13 MMA welding parameters for low carbon low alloy steel pipe 6 07 Welding parameters for steel Base metal thickness mm DC current for mild steel A DC current for stainless steel A Tungsten diameter mm Filler rod diameter if require mm Argon gas flow rate litres min Joint type 1 0 35 45 40 50 20 30 25 35 1 0 1 6 5 7 butt corner lap fillet 1 2 45 55 50 60 30 45 35 50 1 0 1 6 5 7 butt co...

Page 21: ...eating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel ce...

Page 22: ...und connections to the machine to insure that they are tight and the wires are not frayed or overheated Inspect internal wiring of machine for loose or frayed connections tighten or repair as necessary It would also be advisable to check connections to wire feeders fixtures etc at this time Any damaged cable or hoses should be replaced DANGER HIGH VOLTAGE is present internally even with the contro...

Page 23: ...e 3 Replace solenoid value 4 Replace Control PCB 4 TIG mode no high frequenc y starts d Argon flow continues have spark 1 TIG cable disconnected 2 Poor tungsten electrode 1 Reconnect 2 Replace 5 TIG mode unstable Arc 1 Wrong tungsten electrode 2 TIG torch bad contact or damage 3 Argon flow control is improper not pure argon gas 4 TIG torch gas hose is cut 5 TIG torch wrong position negative for TI...

Page 24: ...truck A Electrode is connected to the terminal B No gas flowing to welding region C Torch is clogged with dust D Gas hose is cut E Gas passage contains impurities F Gas regulator turned off G Torch valve is turned off H The electrode is too small for the welding current A Connected the electrode to the terminal B Check the gas lines for kinks or breaks and gas cylinder contents C Clean torch D Rep...

Page 25: ...o low B Electrode too large for joint C Insufficient gap D Incorrect sequence A Increase welding current B Use smaller diameter electrode C Allow wider gap D Use correct build up sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy cold plate B Welding current is too low C Wrong electrode angle D Travel speed of electrode...

Page 26: ...ith nominal Mains supply voltage Defective control circuit Have an accredited FCW service agent inspect then repair the welder 3 Welding current reduces when welding Poor work lead connection to the work piece Ensure that the work lead has a positive electrical connection to the work piece 4 No gas flow when the torch trigger switch is depressed A Gas hose is cut B Gas passage contains impurities ...

Page 27: ... 25 DYNA MMA 500S 500GTS 500 H S 500 H GTS 630S 630GTS Operating Manual 10 0 PARTS LIST ...

Page 28: ... 26 DYNA MMA 500S 500GTS 500 H S 500 H GTS 630S 630GTS Operating Manual ...

Page 29: ...KITP002706011 1 1 1 1 1 1 5 TRANSFORMER CONTROL BOD100 4EER400113 1 1 1 1 1 1 6 BREAKER 75A 4KAMM3R75A 1 1 1 1 1 1 7 TERMINAL 2 9 4CC010207 1 1 1 1 1 1 8 TERMINAL 2 3 4CC010203 1 1 1 1 1 1 9 LABEL L1 L2 L3 2LAM8806014 1 1 1 1 1 1 10 FUSE HOLDER 4FUSH15X250XD6 2 2 2 2 2 2 11 BUSHING STRAIN RELIEF PG29 4SXJPG29 1 1 1 1 1 1 12 PANEL CENTER 2FPUT8038017 1 1 1 1 1 1 13 BUSHING SNAP BS26 4WRKSSBS26 4 4 ...

Page 30: ... 33 BUS BAR FP7 725 020 3BB7725020 1 1 1 1 1 1 34 BUS BAR FP7 725 028 3BB7725028 1 1 1 1 1 1 35 CONTACTOR NC1 1801 220V 4KNC11801220 1 1 1 1 1 1 36 RESISTANCE 20W 100Ω 4RX27D20W100H 2 2 2 2 2 2 37 FAN 200FZYZ D 4FAN001SA200F 2 2 2 2 2 2 38 BRACKET MOUNTING FAN FP8 044 006 2FPBG8044006 1 1 1 1 1 1 BRACKET GAS VALVE FP8 044 006 2FPBZ8610025 1 1 1 39 GAS VALVE 3KITP000112004 1 1 1 40 CAPACITANCE 400V...

Page 31: ...8 18 FEMALE 3KITP000113000 1 1 1 61 INSULATOR BULKHEAD REAR 2FP7854005 2 2 2 2 2 2 62 INSULATOR BULKHEAD FRONT 2FP7854010 2 2 2 2 2 2 63 RECEPTACLE 2AD7735011 2 2 2 2 2 2 64 BRACKET COVER FP7 854 009 2FP7854009 2 2 2 2 2 2 65 PANEL CONTROL FP8 041 016 2FPPC8041016 1 1 1 1 1 1 66 PANEL FRONT FP8 041 022 2FPPF8041022 1 1 1 1 1 1 67 INSULATOR POTENTIONMETER 2FP7854006 3 5 3 5 3 5 68 INSULATOR POTENTI...

Page 32: ... 1 Welding machines rear panels meet the plume to have good to turn on the earth grounding by guarantees the welder safety When welder operation should wear protects the mirror the glove puts on protects the clothing 11 2 When the electrical network voltage is higher than 420V 460V the out put will appear the class the overload the welding machine automatically has stopped outputting and giving th...

Page 33: ... LH FP7 820 041C CONTYOLPCB FP7 820 040B DRIVE PCB FP7 824 002A DISPLAY PCB A FP7 824 002B DISPLAY PCB B FP7 820 020C HF PCB FP7 820 047C IGBTPCB 1 2 3 4 5 CN1 1211 5 1 5 FP7 820 047C IGBTPCB 1 2 3 4 5 CN1 1211 5 1 5 1 2 3 4 5 6 1CN4 1211 6 1 2 1CN8 1211 2 1 2 3 1CN7 2001 3 1 2 3 4 1CN3 1211 4 1 2 3 4 5 1CN6 1211 5 1 2 1CN11 1211 2 1 2 3 4 5 1CN2 2001 5 1 2 3 4 1CN5 2001 4 1 2 3 4 5 1CN13 1211 5 1...

Page 34: ...7 824 002A DISPLAY PCB A FP7 824 002B DISPLAY PCB B FP7 820 020C HF PCB FP7 820 047C IGBTPCB 1 2 3 4 5 CN1 1211 5 1 5 FP7 820 047C IGBTPCB 1 2 3 4 5 CN1 1211 5 1 5 1 2 3 4 5 6 1CN4 1211 6 1 2 1CN8 1211 2 1 2 3 1CN7 2001 3 1 2 3 4 1CN3 1211 4 1 2 3 4 5 1CN6 1211 5 1 2 1CN11 1211 2 1 2 3 4 5 1CN2 2001 5 1 2 3 4 1CN5 2001 4 1 2 3 4 5 1CN13 1211 5 1 2 3 4 5 1CN10 1211 5 1 2 3 4 5 1CN9 1211 5 1 1 5 1 5...

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