ESAB LAW 510 Service Manual
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ESAB LAW 510 Service Manual

ESAB LAW 510 Service Manual

Welding rectifier
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LAW 400/500
LAW 410/510
Welding rectifier
Service manual
0740 800 025
9708

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  • Page 1 LAW 400/500 LAW 410/510 Welding rectifier Service manual 0740 800 025 9708...

  • Page 2: Table Of Contents

    LIST OF CONTENTS Page READ THIS FIRST ....... COMPONENT DESCRIPTION LAW 400/500 .

  • Page 3: Read This First

    READ THIS FIRST This service manual is intended for use by technicians with electrical/electronic training, for help in connection with fault- -tracing and/or repair. Use the connection diagram as a form of index for the description of operation and the component description.

  • Page 4: Component Description Law 400/500

    COMPONENT DESCRIPTION LAW 400/500 The LAW welding rectifiers 500 are 6- -pulse thyristor rectifier units intended for semi- -automatic welding. They are available for different mains voltages and with or without integral cooling units: see the table in the spare parts list on page 55. The component description below refers to the electrical circuit diagrams on page 6 to 12.
  • Page 5 Control power supply transformer for LAW with 400- - 415V mains voltage. claw0e06 Control power supply transformer for LAW with 230- - 500V mains voltage. claw0e05 Main transformer. Connection instructions for the LAW 400/500 and LAW 410/510 with 230 - - 500 V mains connection are on page 38. V1- - V6 Thyristor module.

  • Page 6: Connection Diagram, Law 400/500 400- -415 V

    CONNECTION DIAGRAM, LAW 400/500 400- -415 V Valid for machine number 434 ..claw0e - - 6 - - claw0de1...
  • Page 7 1 POWER SUPPLY 8 SHUNT INPUT 2 DISPLAY OUTPUT 9 VOLTAGE REFERENCE 3 MACHINE TYPE / TEST INPUT 10 CRATER FILL 4 CONTROLLED / FIXED FIRING ANGLE 11 START / STOP 5 SYNCHRONISING 12 THYRISTOR CIRCUITS 6 THERMAL OVERLOAD CUTOUT 13 PROCESSOR 7 ARC VOLTAGE The numerals 1 -- 13 refer to the function description on page 18.

  • Page 8: Connection Diagram, Law 400/500 230- -500 V

    CONNECTION DIAGRAM, LAW 400/500 230- -500 V Valid for machine number 434 ..claw0e03 Terminal block XT1 and transformer TC1 are connected for 400 - - 415 V 50 Hz: see the connection instructions on page 38. - - 8 - - claw0de1...
  • Page 9 1 POWER SUPPLY 8 SHUNT INPUT 2 DISPLAY OUTPUT 9 VOLTAGE REFERENCE 3 MACHINE TYPE / TEST INPUT 10 CRATER FILL 4 CONTROLLED / FIXED FIRING ANGLE 11 START / STOP 5 SYNCHRONISING 12 THYRISTOR CIRCUITS 6 THERMAL OVERLOAD CUTOUT 13 PROCESSOR 7 ARC VOLTAGE The numerals 1 -- 13 refer to the function description on page 18.

  • Page 10: Connection Diagram, Law; 400- -415 V

    CONNECTION DIAGRAM, LAW; 400- -415 V Valid from machine number 512 ..AP2 fitted from machine no. 550 ..Pulse function is added, see page 29. claw0e21 - - 10 - - claw0de1...
  • Page 11 1 POWER SUPPLY 9 VOLTAGE REFERENCE 2 DISPLAY OUTPUT 10 CRATER FILL 3 MACHINE TYPE / TEST INPUT 11 START / STOP 4 CONTROLLED / FIXED FIRING ANGLE 12 THYRISTOR CIRCUITS 5 SYNCHRONISING 13 PROCESSOR 6 THERMAL OVERLOAD CUTOUT 14 PRESET 7 ARC VOLTAGE 15 PULSE 8 SHUNT INPUT...

  • Page 12: Connection Diagram, Law; 230- -500 V

    CONNECTION DIAGRAM, LAW; 230- -500 V Valid from machine number 512 ..AP2 fitted from machine no. 550 ..Pulse function is added, see page 29. claw0e23 Terminal block XT1 and transformer TC1 are connected for 400 - - 415 V 50 Hz: see the connection instructions on page 38. - - 12 - - claw0de1...
  • Page 13 1 POWER SUPPLY 9 VOLTAGE REFERENCE 2 DISPLAY OUTPUT 10 CRATER FILL 3 MACHINE TYPE / TEST INPUT 11 START / STOP 4 CONTROLLED / FIXED FIRING ANGLE 12 THYRISTOR CIRCUITS 5 SYNCHRONISING 13 PROCESSOR 6 THERMAL OVERLOAD CUTOUT 14 PRESET 7 ARC VOLTAGE 15 PULSE 8 SHUNT INPUT...
  • Page 14 - - 14 - - claw0de1...

  • Page 15: Ap1 Component Positions

    AP1 COMPONENT POSITIONS Circuit board with part no. 0486 220 880 Points GND1 -- GND6 are connected to the screen casing and to the electronic neutral, 0V claw0e19 - - 15 - - claw0de1...

  • Page 16: Ap1 Component Positions

    AP1 COMPONENT POSITIONS Circuit board with part no. 0486 291 880 Points GND1 -- GND6 are connected to the screen casing and to the electronic neutral, 0V. claw0e24 - - 16 - - claw0de1...

  • Page 17: Ap1 Component Positions

    AP1 COMPONENT POSITIONS Circuit board with part no. 0486 480 880 (version A) - - 17 - - claw0de1...

  • Page 18: Function Description

    FUNCTION DESCRIPTION Sections 1 - - 15 below refer to the diagrams on page 6 to 12. The circuit board is screened by a screened enclosure that is connected to 0 V on the circuit board. The component position drawings on page 15 to 17 also shows components that are not fitted to the circuit board.
  • Page 19 +12V Power supply to the display board and for loss of voltage detection. See also Items 2 and 13 below. +15VB Power supply to circuits that are galvanically or high- - resistance separated from other electronics on the circuit board. +/- - 15V Internal power supply for the circuit board.
  • Page 20 MACHINE TYPE / TEST INPUT claw0e09 J3 and J4 must be linked in the LAW 500/510: if the link is removed, the machine will operate as an LAW 400. But never link J3 and J4 in an LAW 400/410. Test input Use the test inputs to test the performance of several input and output signals on the circuit board.
  • Page 21 SYNCHRONISING Firing is synchronised to the mains by three zero crossing detectors, IC11;1, IC11;2 and IC11;13. The voltage between the phases at inputs E1, E2 and E3 is about 19 V in the LAW 400/410 and about 25 V in the LAW 500/510. THERMAL OVERLOAD CUTOUT claw0e12 LED V7 lights if the cutout operates.
  • Page 22 ARC VOLTAGE Applies to machines with serial numbers of 434 ..Circuit board AP1 486 220- -880 claw0e13 Inputs D7 and D8 measure the voltage between the positive and negative (- - B) welding current terminals. The arc voltage is used with two different time constants : A time constant of 0.5 s for voltage indication on the digital display.
  • Page 23 ARC VOLTAGE Applies to machines with serial numbers of 512 ..and above. Circuit boards AP1 0486 291 880 / 0486 480 880 claw0e25 Inputs D7 and D8 measure the arc voltage between the welding wire and one welding terminal on the power unit, regardless of the polarity of the welding wire (positive or negative).
  • Page 24 SHUNT INPUT claw0e14 Shunt RS1 provides a 10 mV signal at 100 A. The shunt voltage is linear in relation to the current through the shunt. IC12 amplifies the shunt signal voltage. The shunt signal voltage is connected to the processor via two different time constants: A time constant of 0.5 s, for indication of the welding current on the digital display.
  • Page 25 CRATER FILLING claw0e16 The crater filling function can be used only with an MEK 4, 4S or 4SP wire feed unit. When the wire feed unit sends a crater fill signal to the power unit, input L4 switches high and low four times. Each time that the voltage changes, the welding voltage is reduced.
  • Page 26 THYRISTOR CIRCUITS claw0e18 The thyristor firing circuits consist of operational amplifiers IC7 and IC9. Their inverting inputs are connected to the processor and their non- - inverting inputs are connected to a fixed voltage of 1.35 V. If the +5 V power supply is lost, potential divider R99 - - R100 pulls the input voltage to the non- -inverting inputs down to - - 0.3 V, thus disabling the firing pulses.
  • Page 27 PROCESSOR In addition to the features already described, the processor performs the following functions : Frequency measurement Measures the mains frequency when the unit is turned on. If the frequency is either 50 ¦4 Hz or 60 ¦4 Hz, the processor starts the main program. If the frequency is not within the tolerances, the main program that controls the machine will not start.
  • Page 28 PRESETTTING Preset XS1;M claw0e26 This input is used only when an MEK 4S or MEK 4SP wire feed unit is connected to the LAW power unit. The wire feed unit has a switch that the welder uses when he want to see set values for wire feed speed and voltage instead of measured values of welding current and arc voltage.
  • Page 29 PULSE WELDING Pulse welding can only be performed with the LAW 400/410 when used together with wire feed unit MEK 4SP. The LAW 400 must have circuit board AP1 with part no. 0486 480 880 to perform pulse welding. And additional wires 064, 065 and 066 between connectors XS1 and XS15.

  • Page 30: Ap2 Suppression Circuit Board

    AP2 SUPPRESSION CIRCUIT BOARD Circuit diagram Component positions - - 30 - - claw0de1...

  • Page 31: Test Routine

    TEST ROUTINE The test routine can be used if either the power unit or the wire feed unit has a digital instrument. It must not be used when the gate connections are connected to the circuit board. Activate the test routine by linking contacts J1 and J4 before energising the machine. claw0e20 The test device Do the following to activate the test routine.
  • Page 32 LL.9 - - L.11 Measurement of the synch pulses at contacts E1- -E3. The display shows 50 if the synch voltage frequency is 50 Hz. L.12 Welding gun switch. The display shows 1 1 1 when the welding gun switch is closed and 0 0 0 when it is open.

  • Page 33: Fitting Instructions, Thermal Cutout

    FITTING INSTRUCTIONS, THERMAL OVERLOAD CUTOUT These instructions apply only to machines with serial numbers 434 ..Remove all dirt from contact surface of the cooling fins where they contact the thermal overload cutout ST1. Apply a thin layer of thermal paste to the contact surfaces.
  • Page 34 FITTING INSTRUCTIONS, THYRISTOR MODULES, LAW 400/410 These instructions apply only to machines with serial numbers 512 ..and above. The machines are originally delivered with thyristor modules according to the descriptions below. When ordering a thyristor module as a spare part, thyristor module Semikron SKMT 91/04D, with the part number 0456 536 001, is delivered.
  • Page 35 THYRISTOR MODULE 0456 536 001 (Semikron SKMT 91/04D) From machine number 550 644 ..The red cathode cables are connected to the cathode copper bar. THYRISTOR MODULE 0456 536 001 (Semikron SKMT 92/04D) From machine number ..- - 35 - - claw0de1...

  • Page 36: Load Characteristic

    LOAD CHARACTERISTIC LAW 400/410, connected to 400 V mains power supply claw0p08 LAW 500/510, connected to 400 V mains power supply claw0p09 - - 36 - - claw0de1...

  • Page 37: Technical Data

    TECHNICAL DATA LAW 410/410W LAW 410/410W LAW 510/510W LAW 510/510W LAW 400/400W LAW 400/400W LAW 500/500W LAW 500/500W 400 - - 415 V 230 - - 500 V 400 - - 415 V 230 - - 500 V Mains voltage...

  • Page 38: Primary Connections Law; 230--500 V

    PRIMARY CONNECTIONS LAW; 230 - - 500 V claw0e04 Terminal block XT1 and transformer TC1 are fitted as shown below. The machine is delivered connected for 400 - - 415 V. If it is to be connected to a 230 V supply, the mains supply cable cross- -sectional area must be increased, as shown in the table on the previous page.

  • Page 39: Control Panel And Connections

    CONTROL PANEL AND CONNECTIONS Mains supply ON/OFF. Cooling unit ON/OFF, only LAW with water cooler. Indicating lamp, mains supply ON. Indicating lamp, thermal overload. Digital display (accessory). Circuit breaker for 42 V power supply to the wire feed unit. Welding current terminal - -A. Welding current terminal - - B.

  • Page 40: Accessories

    ACCESSORIES Item Order no. Designation 0455 173 881 Digitalinstrument 0156 654 883 Mounting post (supplied with LAW) 0469 792 881 Holder with support arm 0156 746 880 Mast 0456 693 880 Counter balance device, sprung coil Order no. Order no. Order no.

  • Page 41: Design Changes

    DESIGN CHANGES Below is a short description of design changes made to the LAW machines. The details you find in the previous chapters of this manual. Changes introduced with effect from machine no. 512 ..Speed control of the fan: see items C6, KM2, and ST2 in the component description and items 324 and 325 in the spare parts list.
  • Page 42 Changes introduced to LAW 400 with effect from machine number 550 644 . . . New thyristor module 0456 536 001 (Semikron SKMT 91/04D). Changes introduced with effect from machine type LAW 410 and LAW 510 New design of the main transformer, new ordering number for the main transformer, see the spare parts list.

  • Page 43: Spare Parts List Law 400/500

    Spare parts list - - Reservdelsförteckning - - Ersatzteilverzeichnis - - Liste de pièces détachées Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to the spare parts list.
  • Page 44 SPARE PARTS LIST LAW 400/500 Spare parts list - - Reservdelsförteckning - - Ersatzteilverzeichnis - - Liste de pièces détachées Item Ordering no. Denomination Notes 0368 265 002 Securing strap Before machine no 550 646 ..0321 173 001 Securing chain From machine no 550 646 .
  • Page 45 SPARE PARTS LIST LAW 400/500 claw0p01 claw0p21 - - 45 - - claw0se1...
  • Page 46 SPARE PARTS LIST LAW 400/500 C = component designation in the circuit diagram Item Ordering no. Denomination Notes 0469 882 001 Control transformer 400- -415 V mains voltage 0455 306 001 Control transformer 230- -500 V mains voltage 0469 899 001 Terminal 230- -500 V mains voltage 0469 899 002...
  • Page 47 SPARE PARTS LIST LAW 400/500 - - 47 - - claw0se1...
  • Page 48 SPARE PARTS LIST LAW 400/500 C = component designation in the circuit diagram Item Ordering no. Denomination Notes 0469 678 001 Centre plate 0469 675 001 Intermediate plate 0469 876 880 Inductor 0469 876 881 Inductor With thermal cutouts L2, ST1, ST2 from machine No 512 ...
  • Page 49 SPARE PARTS LIST LAW 400/500 claw0p03 - - 49 - - claw0se1...
  • Page 50 SPARE PARTS LIST LAW 400/500 C = component designation in the circuit diagram Item Ordering no. Denomination Notes 0469 691 001 Cover 0193 609 105 Insulator 0469 878 881 Shunt 60mV/600A Screw M8x25 Washer ⊘ 16/8.4x1.5 Cable set See item 321 Screw M5x12 Thyristor bridge...
  • Page 51 SPARE PARTS LIST LAW 400/500 414, 419 421, 416 420, 415 421, 416 claw0p04 claw0p18 - - 51 - - claw0se1...
  • Page 52 SPARE PARTS LIST LAW 400/500 LAW 4/5 = LAW 400/500 LAW 4/5W = LAW 400W/500W C = component designation in the circuit diagram Item Ordering no. Denomination Notes 4/5W Before machine no...649 ..0365 803 008 Quick connector Female, red 0365 803 009 Quick connector Female, blue...
  • Page 53 SPARE PARTS LIST LAW 400/500 claw0p05 The pump motor is fitted horizontal from machine number 550 642 . . - - 53 - - claw0se1...
  • Page 54 - - 54 - - page...

  • Page 55: Spare Parts List Law 410/510

    Spare parts list - - Reservdelsförteckning - - Ersatzteilverzeichnis - - Liste de pièces détachées Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to the spare parts list.
  • Page 56 SPARE PARTS LIST LAW 410/510 Spare parts list - - Reservdelsförteckning - - Ersatzteilverzeichnis - - Liste de pièces détachées Item Ordering no. Denomination Notes 0321 173 001 Securing chain 0469 868 001 Handle 0469 681 001 Cover 0468 797 001 Seal 0468 796 001 Support plate...
  • Page 57 SPARE PARTS LIST LAW 410/510 claw0p21 claw0p01 - - 57 - - claw0se2...
  • Page 58 0457 114 001 Panel with text LAW 410 0457 115 001 Panel with text LAW 410W 0457 129 001 Panel with text LAW 510 0457 130 001 Panel with text LAW 510W 0455 201 002 Light- -emitting diode Yellow 0455 201 001...
  • Page 59 SPARE PARTS LIST LAW 410/510 - - 59 - - claw0se2...
  • Page 60 SPARE PARTS LIST LAW 410/510 C = component designation in the circuit diagram Item Ordering no. Denomination Notes 0469 678 001 Centre plate 0469 675 001 Intermediate plate 0469 876 880 Inductor 0469 876 881 Inductor With thermal cutouts L2, ST1, ST2 0469 704 001 Front panel 0469 703 001...
  • Page 61 SPARE PARTS LIST LAW 410/510 claw0p03 - - 61 - - claw0se2...
  • Page 62 SPARE PARTS LIST LAW 410/510 C = component designation in the circuit diagram Item Ordering no. Denomination Notes 0469 691 001 Cover 0193 609 105 Insulator 0469 878 881 Shunt 60mV/600A Screw M8x25 Washer ⊘ 16/8.4x1.5 Cable set See item 321 Screw M5x12 Thyristor bridge...
  • Page 63 SPARE PARTS LIST LAW 410/510 414, 419 421, 416 420, 415 421, 416 claw0p04 - - 63 - - claw0se2...
  • Page 64 SPARE PARTS LIST LAW 410/510 LAW 4/5 = LAW 410/510 LAW 4/5W = LAW 410W/510W C = component designation in the circuit diagram Item Ordering no. Denomination Notes 4/5W 0365 803 011 Quick connector Female, red, with non- -return valve 0365 803 012 Quick connector Female, blue, with non- -return valve...
  • Page 65 SPARE PARTS LIST LAW 410/510 claw0p05 The pump motor is fitted horizontal in all LAW 410 and 510 machines - - 65 - - claw0se2...
  • Page 66 ESAB subsidiaries, representative offices and agents Europe NORWAY Asia/Pacific IRAN AS ESAB Kavosh Azmoon AUSTRIA AUSTRALIA Larvik Teheran ESAB Ges.m.b.H ESAB Australia Pty Ltd Tel: +47 33 12 10 00 Tel: +98 21 884 39 14 Vienna- -Liesing Ermington Fax: +47 33 11 52 03...

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