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FCW DYNA MMA 500S Operating Manual

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MODEL
• DYNA MMA 500S
• DYNA 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

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Summary of Contents for FCW DYNA MMA 500S

  • Page 1 MODEL • DYNA MMA 500S • DYNA 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.

  • Page 3: Table Of Contents

    MAINTENANCE--------------------------------------------------------------------------------------------20 BASIC TROUBLESHOOTING-------------------------------------------------------------------------20 9.01 Check the item and excrescent phenomenon exclusion method---------------------------20 9.02 TIG welding problems---------------------------------------------------------------------------------22 9.03 Stick welding problems--------------------------------------------------------------------------------23 9.04 Power source problems-------------------------------------------------------------------------------24 10.0 PARTS LIST-------------------------------------------------------------------------------------------------25 11.0 REMARK-----------------------------------------------------------------------------------------------------30 APPENDIX: INTERCONNECT DIAGRAM - 1 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 4: Symbol Legend

    Gas Post-Flow Time 2T (GTAW) Gas Pre-Flow Time Voltage Reduction 4T (GTAW) Device Circuit — Repeat Function (GTAW) Negative Spot Function (GTAW) Positive High Frequency Starting Gas Input (GTAW) Lift Start （GTAW） Gas Output - 2 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 5: Statement Of Warranty

    FCW ‘s sole option, of any components or parts of the product determined by FCW to be defective.

  • Page 6: General Information

    Do not use the welding torch in an area where combustible or explosive gases or materials are located. Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. - 4 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...
  • Page 7 Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. Protect others in the work area from the arc rays. Use protective booths, screens or shields. - 5 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 8: Transporting Methods

    Lift unit with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure unit on a proper skid before transporting. - 6 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 9: Installation Recommendation

    40 degrees C. WARNING 1 FCW advises that this equipment be electrically connected by a qualified electrician. The following Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this Power Supply:...

  • Page 10: Electrical Input Connections

    Notice: Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code). Figure 1 Electrical input connections - 8 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 11: Specifications

    Due to variations that can occur in manufacture products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service. - 9 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 12: Operator Controls

    Main Circuit Breaker Arc Selection—Long Arc/ Short Arc. Current Control Stick/ Lift TIG Select Switch (DYNA MMA 500S、500(H)S、630S); Stick/ HF TIG Select Switch (DYNA MMA 500GTS、500(H)GTS、630GTS) Remote Amperage Positive Terminal—connect to work ground cable in TIG (in Stick, connect to the weld clamp).
  • Page 13 Torch switch Remote Amp Remote Amp 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. - 11 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 14: Weld Parameter Description

    This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten electrode. Table 5 Weld parameter description for DYNA MMA series - 12 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 15: Weld Parameter For Dyna Mma Series

    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 - 13 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 16: Set-Up For Mma (Stick) And Gtaw (Tig)

    Primary power supply is switched off. CAUTION 2: Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source. - 14 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 17: Stick Welding

    Argon Gas flow thickness (mm) diameter (mm) diameter (mm) (L/min) 0.3-0.5 1-1.6 5-30 0.5-1.2 1.6-2 10-50 1.2-1.6 1.2-2 1.6-2 10-50 1.2-1.6 1.2-2 1.6-2 30-70 1.6-2.0 60-100 1.6-2.0 7-10 100-200 2.0-2.5 1-15 Table 8 - 15 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 18: Power Supply Controls Indicators And Reatures

    Stick/ LIFT TIG (HF TIG) Select Switch Remote amperage Arc Force Control Hot Start Control Down Slope Time Control Post flow Time Control 10. Meter Selection 11. Digital Meter 12. Warning indicator 13. AC Power indicator - 16 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 19: Basic Tig Welding Guide

    200—350 Table 11 Filler wire selection guide ： Notice The filler wire diameter specified in Table 11 is a guide only, other diameter wires may be used according to the welding application. - 17 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 20: Shielding Gas Selection

    80—100 65—85 butt/ corner 90—115 90—110 lap/ fillet 115—135 100—125 butt/ corner 140—165 125—150 lap/ fillet 160—175 135—160 butt/ corner 170—200 160—180 lap/ fillet Table 14 DC TIG welding parameters - 18 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 21: Basic Arc Welding Guide

    It will weld most problematical jobs such as springs, shafts, metals, crack resistance, all 312-16 broken joins mild steel to stainless and alloy steels. Not hard-to-weld jobs suitable for Aluminum. Table 15 Types of Electrodes - 19 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 22: Maintenance

    WARNING There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an accredited FCW service agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the welding power source must be returned to an accredited FCW service agent for repair.
  • Page 23 3. Replace. 3. Control Board damage. 4. Repair or replace. 9. Can not display the amperage Display Board damage. Repair or replace. or voltage or faulty display. Table 16 - 21 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 24: Tig Welding Problems

    B Connect it to the “−” terminal. C Gas flow incorrectly set, cylinder C Select the right flow rate, change empty or the torch valve is off. cylinders or turn torch valve on. - 22 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 25: Stick Welding Problems

    E Clean joint before welding. fusion. F Wrong electrode for position in which F Use electrodes designed for position welding is done. in which welding is done, otherwise proper control of slag is difficult. Table 18 - 23 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 26: Power Source Problems

    B The welding power source B Switch on the welding power source. be established. switch is switched off. C Loose connections internally. C Have an accredited FCW service agent repair the connection. Maximum output welding current Have an accredited FCW service agent Defective control circuit.

  • Page 27: Parts List

    10.0 PARTS LIST - 25 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...
  • Page 28 - 26 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...
  • Page 29 FUSE HOLDER 4SXJPG29 BUSHING,STRAIN RELIEF PG29 2FPUT8038017 PANEL CENTER 4WRKSSBS26 BUSHING SNAP BS26 4WRKSSBS1216 BUSHING SNAP BS16 4PCS002H18 SCREW INSULATION 2HS7061011 HEATSINK DIODE 4AB3P150A1R6KV RECTIFIER MZS150-16 DIODE ULTRA FAST RECOVERY 4V2HFR300BA50 FR300BA50 - 27 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...
  • Page 30 LABEL MANUFACTURERS MMA 500S 2LAN8808199 LABEL MANUFACTURERS MMA 500GTS 2LAN8808198 LABEL MANUFACTURERS MMA 500HS 2LAN8808200 LABEL MANUFACTURERS MMA 500HGTS 2LAN8808201 LABEL MANUFACTURERS MMA 630S 2LAN8808202 LABEL MANUFACTURERS MMA 630GTS 2LAR8806005 LABEL REAR FUSE - 28 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...
  • Page 31 HF PCB FP7.820.020C-03 3KITP002005010 HF PCB FP7.820.020C-02 3EER22012 INDUCTOTR ASSY,OUTPUT 3EER21003 INDUCTOTR ASSY,INPUT 3KITP002706080 FILTER PCB FP7.822.000-01 3EER31012 TRANSFORMER,POWER ASSY,500S 4CDJ400V2700 CAPACITANCE 400V2700UF 4EER400072 MUTUAL INDUCTANCE RING 7BOX00001 PLASTIC BOX 422CBB630V104 INSULATOR BULKHEAD FRONT - 29 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

  • Page 32: Remark

    11.6 When long-time does not use, every two months should electrify a time, a humidity month of every two week should electrify use a time, by use own thermal row of tide. - 30 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...
  • Page 33 APPENDIX: DYNA MMA 500S, 500(H)S, 630S INTERCONNECT DIAGRAM 15W10 103/3KV IGBT1 IGBT2 20u/400V FR300BA50 100R/20W 100R/20W 1R/20W 1R/20W 75A/1200V 2700u/400V 3P 380V 103/3KV 103/3KV 33K/5W FR300BA50 0.1u/630V 33K/5W 2700u/400V 103/3KV 103/3KV 20u/400V 0.1u/630V 200A/4V FR300BA50 1R/20W 1R/20W 500/50W 2700u/400V 20u/400V...
  • Page 34 T IG 1211-4 6XP2 6XP3 拟 制 1121-2 FP7.822.000 MMA 500GTS FILLTER PCB 审 核 6XP1 2001-8 MMA 500HGTS 阶段标记 第 张 共 张 MMA 630 GTS 标准化 批 准 14PIN PLUG - 32 - DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual...

This manual is also suitable for:

Dyna mma 500hsDyna mma 500gtsDyna mma 630sDyna mma 630gtsDyna mma 500hgts

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