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Summary of Contents for FCW DYNA POWER 503CV
- Page 1 MODEL • DYNA POWER 350CV • DYNA POWER 503CV • DYNA POWER 500CV • DYNA POWER 630CV • DYNA POWER 630HCV Operating Manual (Owner’ s Manual) IMPORTANT: Read these instructions before installing, operating, or servicing this system. First Edition September, 2007...
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Page 2: Table Of Contents
CONTENTS SYMBOL LEGEND---------------------------------------------------------------------------------------------------2 STATEMENT OF WARRANTY------------------------------------------------------------------------------------3 GENERAL INFORMATION-------------------------------------------------------------------------------4 1.01 Notes, Cautions and Warnings------------------------------------------------------------------------4 1.02 Important Safety Precautions--------------------------------------------------------------------------4 1.03 Transporting methods-----------------------------------------------------------------------------------6 INSTALLATION RECOMMENDATION----------------------------------------------------------------7 2.01 Electrical Input Connections---------------------------------------------------------------------------8 2.02 Specifications----------------------------------------------------------------------------------------------9 2.03 Duty cycle--------------------------------------------------------------------------------------------------9 OPERATOR CONTROLS-------------------------------------------------------------------------------10 3.01 DYNA POWER controls-------------------------------------------------------------------------------10 3.02 Weld parameter description--------------------------------------------------------------------------12 3.03 Weld parameters for DYNA POWER series------------------------------------------------------13 SET-UP FOR MIG/MAG---------------------------------------------------------------------------------14 POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------15... -
Page 3: Symbol Legend
SYMBOL LEGEND Amperage Stick (SMAW) Pulse Current Function Voltage (GTAW) Hertz (frequency) Spot Time (GTAW) Remote outputs control Seconds (Panel/Remote) Percent Remote Function DC (Direct Current) Arc Control (SMAW) AC (Alternating Current) Gas Post-Flow Time 2T (GTAW) Gas Pre-Flow Time Voltage Reduction 4T (GTAW) Device Circuit... -
Page 4: Statement Of Warranty
FCW ‘ s sole option, of any components or parts of the product determined by FCW to be defective. -
Page 5: General Information
GENERAL INFORMATION 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. - Page 6 ELECTRIC SHOCK Electric Shock can injure or kill. The arc welding process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. Never touch any parts that are electrically “ live” or “ hot.” Wear dry gloves and clothing.
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Page 7: Transporting Methods
1.03 Transporting methods These units are equipped with a handle for carrying purposes. WARNING: ELECTRIC SHOCK can kill. DO NOT 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. -
Page 8: Installation Recommendation
40 degrees C. WARNING 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: Primary... -
Page 9: Electrical Input Connections
2.01 Electrical Input Connections WARNING: ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts SHUT DOWN welding power source, disconnect input power employing lockout/ tagging procedures. Lockout/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. -
Page 10: Specifications
2.02 Specifications POWER POWER POWER POWER POWER MODEL 350CV 503CV 500CV 630CV 630HCV Input voltage and frequency and 380/415V 3ph 380/415V 3ph 380/415V 3ph 380/415V 3ph 380/415V 3ph phases KVA @ max output 25.3KW 14.5KW 25.3KW 41KW 41KW 500A Max current 350A 500A 630A... -
Page 11: Operator Controls
OPERATOR CONTROLS 3.01 DYNA POWER controls Figure 2 Main Circuit Bleaker— Switching to the ON position energizes the welding power source. Fuse 8A Fuse 2A Fuse 2A Inductance Control (GMAW) Down Slope Voltage Control (Options) Down Slope Wire Feed Speed Control (Options) Wire Feed Speed Control Voltage Control/ Amperage Control 10. - Page 12 16. Positive Terminal— 95mm Screw receptacle (for wire feeder). 17. 14-Pin Receptacle— Used to connect the wire feeder. Figure 3 Function Torch switch Torch switch Remote voltage Remote voltage Remote voltage Remote amp Remote amp Remote amp Inch switch Inch switch Solenoid valve Solenoid valve Motor...
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Page 13: Weld Parameter Description
3.02 Weld parameters description (DYNA POWER 500CV、630CV、630HCV front panel) Figure 4 DYNA POWER series front panel with parameter description Parameter Description Welding Voltage This parameter sets the welding voltage. Inductor This parameter sets the electrode inductor. MIG only. Burnback time is the difference between the wire feed motor stopping and Burnback switching off of the welding current. -
Page 14: Weld Parameters For Dyna Power Series
3.03 Weld parameter for DYNA POWER series POWER POWER POWER POWER POWER Model 350CV 503CV 500CV 630CV 630HCV PEAK CURRENT 350A 500A 500A 630A 630A WELD VOLTAGE 15.5~31.5V 15.5~39V 15.5~39V 15.5~44V 15.5~44V Table 6 Weld parameters for DYNA POWER series - 13 - DYNA POWER 350CV、503CV、500CV、630CV、630HCV Operating Manual... -
Page 15: Set-Up For Mig/Mag
SET-UP FOR MIG/MAG Conventional operating procedures apply when using the welding power source, i.e. connect work lead directly to work piece and welding cable is used to electrode holder. Wide safety margins provided by the coil design ensure that the welding power source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only. -
Page 16: Power Supply Controls Indicators And Reatures
POWER SUPPLY CONTROLS INDICATORS AND REATURES Figure 6 DYNA POWER series front panel Main Circuit Bleaker— Switching to the ON position energizes the welding power source. Fuse 8A Fuse 2A Fuse 2A Inductance Control (GMAW) Control Switch— 2T/4T. Gas Switch— Switching to the ON position activate the gas. Remote Control Switch—... -
Page 17: Basic Mig Welding Guide
5.01 Basic MIG Welding Guide The welding power supply has two control settings that have to balance. These are the wire speed control and the voltage control switches. The welding current is determined by the wire speed control, the current will increase with increased wire speed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. -
Page 18: Spot Welding Operation
Thickness of the metal to be welded. Type of joint. Capacity of the wire feed unit and power supply. The amount of penetration required. The deposition rate required. The bead profile desired The position of welding and cost of the electrode wire. Weld metal deposition rate is proportional to current density. -
Page 19: 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 20 Troubleshooting Guide Fault Cause Remedy 1. The AC power indicator light is 1. No power input or main power 1. Check input power or replace not lit and welding arc can not switches damage. main power switch. be established. 2. Indicator damage. 2.
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Page 21: Solving Problems Beyond The Welding Terminals
1. Wrong tungsten electrode. 1. Choose right tungsten. 2. TIG torch contact 2. Replace TIG torch. damage. 3. Argon flow control is improper, 3. Replace argon gas capacity. 10. TIG mode unstable Arc. not pure argon gas. 4. TIG torch gas hose is cut. 4. - Page 22 Welding dirty, oily, painted oxidized or greasy plate. Clean contaminates off plate. Distance between the MIG gun Keep the distance between the MIG gun nozzle and the work piece to a minimum. Refer to distance from the MIG gun nozzle to the work piece in 5.03. Maintain the MIG gun in good work order Ensure that the gas holes are not blocked and gas is exiting out of the gun nozzle.
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Page 23: Weld Problems
E Cooling rate too fast. E Slow the cooling rate by preheating part to be weld or cool slowly. A Faulty rectifier unit. A Have an accredited FCW service agent to B Loose welding cable test then replace the faulty component. -
Page 24: Power Source Problems
ON. Indicator A Primary fuse is blown. A Replace Primary fuse. light is not lit and welding B Broken connection in primary B Have an accredited FCW service circuit. agent check primary circuit. established. Input power indicator... -
Page 25: 8.0 Remark
8.0 Remark 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. 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 the red candle demonstration warning.
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