0349 300 028
Valid from serial no. 118--XXX--XXXX010430
LAY 500
Service manual
2
1. Circuit diagram of LAY500 .......................................................................................
4
2. Components layout, printed circuit board LA07 (A1) ...............................................
10
3. Circuit diagram of board LA07 (A1) .........................................................................
11
4. Description of board LA07 (A1) operation ............................................................
12
5. Technical data ........................................................................................................
13
6. Output characteristic .............................................................................................
13
7. Components layout of board VA01 ........................................................................
14
8.Circuit diagram of board VA01 ................................................................................
15
9. Meter VA01 assembly instruction ...........................................................................
16
10. Components layout of board LA01 .......................................................................
17
11.Circuit diagram of board LA01 ................................................................................
18
12. Meter LA01 assembly instruction ...........................................................................
19
13. Start up and operation of the unit ..........................................................................
20
14. Spare parts list .......................................................................................................
23
15. Assembling of KIT 0349 302 208 to increase stability of LAY 500 power source
26
3
!WARNING!
WELDING PROCESSES CAN BE DANGEROUS FOR OPERATOR AND OTHER PERSOSNS. KEEP
EXTREME CAUTION DURING WELDING. FOLLOW SAFETY INSTRUCTIONS OBLIGATORY IN A
COMPANY . PREPARED ACCORDING TO EQUIPMENT MANUFACTURER’S RECOMMENDATIONS.
ELECTRIC SHOCK – can cause death
• Install the unit according to obligatory regulations.
• Do not touch with bare hands or wet gloves any live elements, including electrodes.
• Ensure safety of workplace.
SMOKE AND GASES – can be harmful.
• Keep head away from stream of smoke.
• Provide ventilation plus smoke and gas exhaust from working area.
ARC RADIATION – can cause grave damages to sight and skin.
• Protect eyes and body. Use appropriate head screen or shield with proper filter glass and protective
clothing.
• Protect other personnel with appropriate screens and shields
FIRE DANGER
• Metal spattering can cause fire. Check for flammable materials in the vicinity of work place.
INAPPROPRIATE OPERATION OF EQUIPMENT - if a unit works in the faulty way, consult a trained
technician.
READ AND COMPREHEND THE UNIT BEFORE INSTALLATION OR START-UP OF UNIT
PROTECT YOURSELF AND OTHERS !
! WARNING !
All maintenance and repair works should be performed by skilled personnel and electrical
repairs by a skilled electrician only. Inexperienced persons shall not be allowed to service,
clean or repair equipment. Use recommended spare parts only.
4
Circuit diagram of LAY500 – 400V with meter VA01
5
Circuit diagram of LAY500 – 400V with meter LA01
6
Circuit diagram of LAY500 – 400/500V with meter VA01
7
Circuit diagram of LAY500 – 400/500V with meter LA01
8
Circuit diagram of LAY500 – 400V with meter LA01, without cooling liquid system
9
DIAGRAM ELEMENTS
A1 Control board LA07 M1 Fan
A2 Welding current and voltage meter M2 Pump
T1 Transformer F1 Fuse 2A delayed
V3 Bridge rectifier F2 Fuse 4A delayed
L1 Choke F3 Fuse 8A delayed
RI Shunt F4 Fuse 500mA delayed
C1,C2,C3 Capacitor 2uF 450V B1,B2 Temperature switch
K1 Contactor B3 Flow sensor
Q2 Circuit breaker H1 LED diode (green /yellow)
Q1 Rotary cam-switch H2 LED diode (yellow)
Q3 Rotary cam-switch H3 LED diode (green)
Q4 Rotary cam-switch X1 Socket
T2 Control transformer X2 Connector
F5,F6 Fuse 3A, 500V delay X4 Terminal strip
CONNECTIONS DIAGRAM
Rotary cam switch Q3 (àK 40/8.853)
12345
1-2 x
3-4 x
5-6 x
7-8 x
9-10 x
11-12 x
13-14 x
15-16 x
17-18 x
19-20 x
21-22 x
23-24 x
25-26 x
27-28 x
29-30 x
Rotary cam switch Q4 (àK 40/8.883)
12345678
1-2 x
3-4 x
5-6 x
7-8 x
9-10 x
11-12 x
13-14 x
15-16 x
17-18 x
19-20 x
21-22 x
23-24 x
25-26 x
27-28 x
29-30 x
31-32 x
10
COMPONENTS LAYOUT, PRINTED CIRCUIT BOARD LA07 (A1)
11
CIRCUIT DIAGRAM OF BOARD LA07 (A1)
12
DESCRIPTION OF BOARD LA07 (A1) OPERATION
Power supply
The board is supplied with 24V a.c. voltage (contacts 8, 9 connectors X1). Two step voltage regulation
(elements T9, U1) provides voltage 15 V ± 5% for control system of power supply.
Inputs
1. Auxiliary contact of main contactor type NO - 11,12 X1,
2. Contact of temperature sensor type NC - 4,1 X1,
3. Contact of liquid pressure sensor type NO - 2,3 X1,
4. Reserved input - 6,7 X1,
5. Reserved input - 5,10 X1.
Outputs
1. Fan switch contact NO, MOV 275V - 1,6 X2, (6- common phased contact)
2. Pump switch contact NO, MOV275V - 3,6 X2, (6- common phased contact)
3. Power supply switch for feeder type
NO , MOV 75V - 1,2 X4,
4. Power supply for LED diode green-yellow (H1) - 1,2,3 X3 (2-common cathode)
5. Power supply for LED diode green (H2) - 6,7 X3 (6-cathode)
6. Power supply for LED diode green (H3) - 4,5 X3 (5-cathode)
LED diodes – external
1. H1 – two colours : green - unit on signal,
yellow - unit off signal ,
2. H2 – yellow: on when unit overheated
3. H3 – green: on when cooling liquid flow is correct
Operation
After switching on the unit, power is supplied to the wire feeder (relay PK1), fan (relay PK2) and pump (relay
PK3). If within 5s the signal form liquid pressure sensor (contact NO) is not supplied, power supply circuit of
wire feeder shall be disconnected. Power supply shall be restored after signal from pressure sensor has been
received. Correct pressure (liquid flow) is indicated by illuminating green diode on front panel of the unit (H3).
Supply of power feeder is disconnected also by means of signal from external thermal switches of NC type.
Overheating is indicated by illuminating yellow diode (H2) on front panel of the unit. Power supply of wire
feeder shall be restored after the temperature has dropped.
Counter-oscillator U2 is reset when main contactor operates and during overheating. 5 minutes after
contactor has been switched off and overheating temperature has dropped, the pump is switched off (relay
PK3), and after 10-minute period – fan is switched off (relay PK2). When the fan is switched off, the unit
turns into idle mode, which is indicated by illuminating yellow diode H1. Power is still supplied to wire feeder
(relay PK1).
In idle mode, with switched off pump, it is possible to start welding process by means of switch on the torch.
Then contactor is switched on again, counter-oscillator U2 is reset, fan and pump are switched on. Within 5s
signal from liquid pressure sensor shall be received. If not, power supply circuit of wire feeder shall be
disconnected (relay PK1). Power supply shall be restored after signal form pressure sensor is received.
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TECHNICAL DATA
Power source LAY 500 0349 302 001 0349 302 070 0349 302 074
Mains voltage 3x400V, 50Hz 3x400V, 3x500V, 50Hz 3x400V, 50Hz
Power cable cross-section 4x6mm
2
4x6mm
2
4x6mm
2
Fuse Mains supply 3x400V 35 A delay 35 A delay 35 A delay
Mains supply 3x500V ----- 25 A delay -----
Rated power consumption 27 kVA 27 kVA 27 kVA
Rated primary current for duty
cycle 60%
Mains supply 3x400V 39A 39A 39A
Mains supply 3x500V ----- 31A -----
Rated welding current Duty cycle* 60% 500A 500A 500A
Duty cycle* 100% 390A 390A 390A
Welding current range
50÷500A 50÷500A 50÷500A
Open circuit voltage
18÷55V 18÷55V 18÷55V
Dimensions Length
Width
Height
1080
515
920
1080
515
920
1080
515
920
Weight ~238kg ~238kg ~238kg
Flow of cooling liquid at pressure of 2,5 bar 1 dm
3
/min (60l/h) 1 dm
3
/min (60l/h) -----
Selection of cooling liquid depending on ambient temperature
- Distilled water
- Solution 30% Antifreeze Coolant + 70% distilled water
from 0°C to +40°C
do -10°C
from 0°C to +40°C
do -10°C
-----
Tank capacity 5 dm
3
5 dm
3
-----
*Duty cycle is based on 10-minute period. Cycle of 60% means that after 6 minutes of the operation, 4
minutes break is required. Cycle of 100% means that the unit can operate continuously.
Warning:
The unit is characterised by the following:
- Safety class IP 23 which means that the unit can be used indoors and outdoors
- Application class S which means that the unit can be used in areas with increased electric shock
LAY 500 units are equipped with four wire cables of 5 m length which enable to connect three phase supply
voltage 3x400V/3x500V. Power supply circuit should have a safety mains switch and appropriate fuses or
automatic switches appropriate to nominal power supply parameters.
OUTPUT CHARACTERISTIC
0
10
20
30
40
50
60
0 100 200 300 400 500 600
I2(A)
U2(V)
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COMPONENTS LAYOUT, PRINED CIRCUIT BOARD OF METER VA01 (without HOLD function)
DESCRIPTION OF CONTROL ELEMENTS
P1- current reading zero adjustment
P2- compensation of voltage drop in external circuit
P3- ammeter calibration
P4- voltmeter calibration
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CIRCUIT DIAGRAM OF METER VA01
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METER VA01 ASSMBLY INSTRUCTION
1. Take out a hole cover, insert meter and fasten it with two screws with slides.
2. Disconnect socket “+” from the bridge fasten shunt and bus to “+” bridge rectifier and next connect
cable to free end of shunt.
3. Install fuse socket and fuse F4 on fuse bracket.
4. Install enclosed wiring. Connect it according to unit’s schematic diagram.
5. If necessary, compensate readings of voltmeter. It can be done in the following way:
a) Using a thin screwdriver, take out voltmeter glass. The potentiometer P2 can be seen on the board.
b) Connect load to complete semi-automatic unit through feeding unit, welding torch earth cable. Connect
model voltmeter to load.
c) Switch on the unit. Apply load so that current value exceeds 100A.
d) Synchronise the readings of both voltmeters by means of potentiometer P2.
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COMPONENTS LAYOUT, PRINTED BOARD OF METER LA01 (with HOLD function)
DESCRIPTION OF CONTROL ELEMENTS
R7 - compensation of voltage drop external circuit
R11 - ammeter calibration
R23 - voltmeter calibration
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CIRCUIT DIAGRAM OF METER LA01
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METER LA01 ASSEMBLY INSTRUCTION
1.
*)
Take out a hole cover of meter housing on front panel of power source LAY 500.
2.
*)
Connect cable of meter LA01, and put free ends of cables through the hole in housing of the meter.
Next insert adaptor and meter to the housing (replacing the hole cover).
3. Disconnect socket „+” from the bridge, fasten shunt and bus to „+” bridge rectifier and next connect
cable to free end of shunt.
4. Install fuse socket with cables (fuse F4) on fuse bracket.
5. Connect according to unit’s diagram.
6. If necessary compensate readings of voltmeter. It can be done in the following day:
a) Connect load to complete semi-automatic unit through feeding unit, torch and earth cable.
Connect model voltmeter to load.
b) Switch on the unit. Apply load so that current value exceeds 100A.
c) Synchronise readings of both voltmeters by means of potentiometer P7.
*)
Only for the units with serial numbers from 942 943 0011 to 020 022 0180.
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START UP AND OPERATION OF THE UNIT
! WARNING !
Before connecting cables to terminals and or output sockets of the unit, disconnect mains switch (in
switch board) and disconnect power supply from mains.
1. Put cylinder with shielding gas shelf in the back of power source and protect from falling with a fastened
chain.
2. Remove gas cylinder cap and open valve for a short time in order to remove impurities which might
collect in connector.
3. Install regulator to cylinder.
If CO
2
used first install gas heater and next regulator on cylinder. Power supply cable to gas heater to be
connected to LAY 500 through a hole in a back panel and connect to terminal strip X2 places inside the
unit near the hole.
Warning: If neutral of mixed gases are used, it is not allowed to use gas heater.
4. Connect regulator with connector in the back panel of wire feeder by means of gas hose.
5. Connect current cable with vice to welded material in area providing good electrical contact, and on the
other side to one of three current sockets "-" marked as
, and .
6. Connect current socket "+" of power source and current plug "+" of wire feeder with current cable.
7. Connect socket of power source and plug of wire feeder with control cable.
8. Connect welding torch of appropriate rated current and wire feeder by means of quick-connecting joint.
9. Prepare wire feeder to be ready to operate according to instruction manual. If required wire feeder might
be placed on power source on guide pin (Fig. 10.1) or next to power source.
10. Fill cooling system tank with cooling liquid. Correct level of cooling liquid is marked with a symbol
on
the back panel of power source.
Depending on ambient temperature the following cooling liquid shall be used:
- Distilled water at temperature from 0°C to +40°C
- Solution 30% Antifreeze Coolant + 70% distilled water at temperature from -10°C
11. Connect connecting pipes of welding torch cooling installation and proper quick-connecting joints of wire
feeder, next connect wire feeder with power source observing that colours of hoses and their endings
are synchronised with colours of quick-connecting joint.
WARNING: If welding troches cooled with gas are used (no water cooling), close water cooling
system with a connector supplied with power source. Connector shall be fixed between
connecting pipes of the torch situated on the front panel of the wire feeder.
WARNING: Welding with water cooled torch with simultaneous closing of cooling system with
connector will cause damage of the torch!
A. POWER ON/OFF SWITCH (in the front panel of the unit) Turning this switch to the “I” position (Fig. 5.1,
pos.1) applies power to the unit. The green LED diode (Fig.5.1, pos.4) will illuminate indicating that power
is supplied to the equipment. The cooling fan and pump motor will also be switched on. Illuminating green
LED diode (Fig. 5.1, pos.5) indicates correct liquid circulation in the system. When the welding process is
stopped, the pump is disconnected after 5 minutes. After another 5-minute period the fan is disconnected
and the unit turns into idle mode. Yellow LED diode (Fig.5.1, pos.4) will illuminate. When welding
process is started again fan and pump are activated automatically.
WARNING: If pump emits irregular noises after activation it indicates presence of air inside it. In this
case the unit must be switched off and immediately switched on again.
B. WELDING VOLTAGE SETTING is carried out by means of coarse control 5 position switch (Fig. 5.1,
pos. 2) and fine control 8 position switch (Fig.5.1, pos.3). It is therefor possible to select 40 different
welding voltage outputs.
WARNING: Operating these voltage switches (Fig. 5.1, pos. 2,3) during welding process with loaded
power source can cause damage to the unit!
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