FCW DYNA MMA 500S Operating Manual Download

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MODEL

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DYNA MMA 500S

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DYNA MMA 500GTS

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DYNA MMA 500(H)S

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DYNA MMA 500(H)GTS

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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

Summary of Contents for DYNA MMA 500S

Page 1: ...MA 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 Secon...

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 0...

Page 4: ...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...

Page 5: ...ut 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 agen...

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 respirato...

Page 7: ...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 hydro...

Page 8: ...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 equi...

Page 9: ...bration 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 expos...

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 connectio...

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 uni...

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 Ne...

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...

Page 14: ...trodes 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 provi...

Page 15: ...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...

Page 16: ...urrent 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...

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 s...

Page 18: ...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...

Page 19: ...es 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...

Page 20: ...0 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...

Page 21: ...ating 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 a...

Page 22: ...nd 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...

Page 23: ...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 mo...

Page 24: ...ruck 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 val...

Page 25: ...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...

Page 26: ...th 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 wo...

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: ...ITP002706011 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 L...

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 100 4RX27D20W100H 2 2 2 2 2 2 37 FAN 2...

Page 31: ...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 2...

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 protec...

Page 33: ...PCB 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...

Page 34: ...AY 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 2...

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