ESAB KHM 500 PS - CC/CV User manual

KHM 500 PS - CC/CV

Service manual

0794 999 921 01/04

Valid for serial No 109 - XXX - XXXX (50Hz version)

Valid for serial No 114 - XXX - XXXX (60Hz version)

Valid for serial No 109 - XXX - XXXX (110V version)

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TABLE OF CONTENENTS SM 1

READ THIS FIRST SM 2

TROUBLE SHOOTING SM 3

TESTING SM 4

COMPONENT POSITION ON THE WELDING CONTROL PCB SM 5

:,5,1*',$*5$0 M 61.1-2-3-4-5-6

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23(5$7,21 M 3, 20, 21.3, 22.1, 31, 32, 38.7, 43, 43.3,

44.2, 45, 51, 52, 53

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ORDERING OF SPARE PARTS R 1,

SPARE PARTS EE 1, EE 1.1,

SPARE PARTS EE 2, EE 2.1,

SPARE PARTS EE 3, EE 3.1,

SPARE PARTS EE 4, EE 4.1,

KIT DECAL

SITE TOW FOR KHM 500/600 KA 9

PHG 1 KD 10

20/3/01 76503SM1GB

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This service manual is intended for use by technicians

with electrical/electronic traning, for help in connection

with fault-tracing and/or repair.

Use the wiring diagram on pages

M 61.1-2-3-4-5-6, 60

and the description of operation on pages SM 5 when

foult-tracing.

A brief user guide is included on page M 2, 2.1, 2.5,

2.5.1, 2.7,4, 6.3, 2.6, 3, 20, 21.3, 22.1, 31, 32, 38.7,

43, 43.3, 44.2, 45, 51, 52, 53 to assist understand-

ing how the machine is used.

The manuals contains details of all design modifications

up to and including May 2000.

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This product is intended for industrial use. In a domestic

environment this product may cause radio interference.

It is the user’s responsibility to take adeguate precaution.

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• Install and earth the welding unit in accordance with applicable standards.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

• Insulate yourself from earth and the workpiece.

• Ensure your working stance is safe.

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• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and the

general area.

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• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

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• Protect your ears. Use ear defenders or other hearing protection.

• Warm bystanders of the risk.

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1) Low battery voltage. 1) Check battery level electrolyte. 2

2) Defective engine protection

unit.

2) Check voltage supply and fuse F1. 1

The engine doesn’t start.

3) Defective fuel cut off valve. 3) Check voltage supply. 6

The engine starts badly. 1) Defective glow plug. 1) Check voltage supply and fuse F2. 9

1) Defective fuel cut off valve. 1) Check voltage supply. 6

2) Defective oil pressure sen-

sor.

2) Check voltage supply and sensor. 3 - 4

The engine stops just

after starting.

3) Defective temperature

gauge.

3) Check voltage supply. 5

The fuel indicator doesn’t

work.

1) Defective fuel gauge. 1) Check voltage supply. 7 - 8

Low battery voltage while

running.

1) Defective battery charge. 1) Check battery charge voltage. 11

1) Defective diode bridge.

1) Check the open circuit welding voltage.

If it is OK the main diode bridge is OK.

18

2) Defective references on

welding PCB.

2) Check reference values.

from 19

to 24

3) Defective diode bridge. 3) Check the thyristors of bridge. 25

4.1) Is the remote control switch in the local position? -

No welding current but

auxiliary output is OK.

4) Problem with welding cur-

rent control PCB.

4.2) Check the supply to the thyristor bridge.

If it is OK replace the PCB.

15

1.1) Check the open circuit welding voltage.

If it is OK the diode main bridge is OK.

18

1.2) Check the open circuit welding voltage of base

current bridge.

17, a.

1) Defective diode bridge.

1.3) If it is 1/3 or 2/3 of the nominal value check the

thyristors and diodes.

25

Welds poorly.

2) Problem with welding cur-

rent control PCB.

2) If the main diode bridge is OK replace the PCB. -

1.1) Check that the pins of the connectors are clean

and making good contact.

-

1) Bad connections to welding

current PCB.

1.2) Check that shunt connections are tight. -

Intermittently welds

poorly.

2) Problem with welding cur-

rent control PCB.

2) Replace the welding current control PCB. -

No auxiliary power at the

sockets.

1) Defective G.F.I (ground fault

interrupter).

1.1) Check operation of G.F.I (ground fault inter-

rupter).

14

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1) Short circuit in wiring.

1) Check the wiring inside the welder for a short cir-

cuit between cables or to ground.

-

2) Defective capacitor box.

2) If the wiring is OK, short circuit the capacitor box to

be sure that it is discharged, disconnect all wires from

it and check the capacitance.

10

3) Defective stator.

3) If the capacitor box is OK, disconnect all leads from

the stator except for those going to the capacitor box

and check the output from the alternator.

If there is no output from the welding winding and the

auxiliary winding, replace the stator.

12, a, b

– 13, a,

b, c.

15 –

16, a.

4) Short circuited diode bridge.

4) If there is output from all windings reconnect the

diode bridge and check if there is welding voltage.

If not the diode bridge is defective.

15 –

16, a.

No welding output and no

auxiliary power output.

5) Short circuit in the line.

5) If there is welding voltage connect the auxiliary

power leads one at a time until there is no output; at

this point, the short circuit is in that line.

12, a, b

– 13, a,

b, c.

Low power and quality of

welding current.

1) Setting of welding PCB.

1) Before replacing the PCB, check the dip switches

position and trimmer setting.

26 - 27

1.1) Check fuse F – 0.5A

1.2) Check inibit relay N3

No voltage at the welding

sockets in CV mode

1) Defective wire feeder con-

nections circuit.

1.3) Check voltage supply SS - TS

28

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Turn ignition on and make sure all the LED’s momen-

tarily light up on the Engine Protection Unit.

 Check the supply to the Engine Protection Unit.

Measure between terminal 15 and ground (battery

voltage).

It should be between ___12___VDC and

___13.6___VDC

If there is no supply, check fuse ___F1___.

 Check the battery voltage;

It should be between ___12___VDC and

___13.6___VDC (average value 12.8 VDC).

 Check the supply to the oil pressure sensor. Re-

move wire number 4 from the sensor and measure

voltage to ground;

it should be___5.5___VDC.

 Check the oil pressure sensor. Measure the resis-

tance between the sensor and ground.

The resistance should be ___0___

 Check the supply to the water temperature gauge.

Measure between wire number 3 and ground.

The voltage should be ___5.5___VDC.

 Check the supply to the fuel cut off valve. Measure

voltage between wire number 5 and ground;

it should be ___12___VDC.

 Check the supply to the fuel gauge sensor switch.

Remove wire number 6 from the sensor and measure

voltage to ground.

The voltage should be ___12___VDC.

 Check the voltage from the fuel gauge sensor.

Remove wire number 8 from the gouge and measure

voltage to ground.

The voltage should be ___10___VDC.

F 1RWH: the voltage corresponds to a full

tank should be ___0.4___VDC.

The voltage corresponds to an empty tank

should be ___8___VDC.

 Check the supply to the glow-plug. Measure be-

tween wire 12 and ground while pressing the glow-

plug button on the front panel.

The voltage should be ___12___VDC.

If there is no supply, check fuse___F2___.

 Check excitation capacitors. Remove the wires

and busbars from the capacitors and measure the

capacitance between the terminals on each capaci-

tor.

The capacitance for each capacitor should be

___90BBB )

Reconnect busbars and wires to capacitor bank.

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 Check that the battery is being charged.

Measure the voltage across the battery; it should be

___14___VDC.

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Check the exitation voltage. Measure between R1

and S1, R1 and T1, and S1 and T1 at the capacitors.

The voltage should be ___480___VAC.

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Check the exitation voltage. Measure between R1

and S1, R1 and T1, and S1 and T1 at the capacitors.

The voltage should be ___440___VAC.

E Check the generator output for auxiliary power.

Measure between R and S, R and T, and S and T on

the terminal board.

The voltage should be ___430___VAC.

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Check single phase voltage. Measure between Y

(neutral) and R, S and T.

The voltage should be ___250___VAC.

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Check single phase voltage. Measure between Y

(neutral) and R1, S1 and T1.

The voltage should be ___250___VAC.

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Check 110 single phase voltage. Measure between R2

and T2.

The voltage should be ___115___VAC.

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Check 110 single phase voltage. Measure between Y

and T2.

The voltage should be ___120___VAC.

 Check operation of Ground Fault Interrupter

(G.F.I.). Push test button and check that the circuit

breaker switches off.

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 Check the supply to the thyristor bridge. Measure

between RS, SS, and TS.

The voltage should be ___45___VAC.

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Check the supply to the Base current bridge. Meas-

ure between 11, 12 and 13.

The voltage should be ___13___VAC.

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Check the supply to the Base current bridge. Meas-

ure between 11, 12 and 13.

The voltage should be ___10___VAC.

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Check output from Base current Bridge. Measure

across the

+ and - terminals on the bridge.

The voltage should be ___18___VDC.

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Check output from Base current Bridge. Measure

across the + and - terminals on the bridge.

The voltage should be ___14___VDC.

 Check open circuit voltage. Measure across the

welding output terminals.

The voltage should be ___60___VDC.

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Check voltage feedback to PCB. Measure across pins

13 and 14 at connector CN5 on the PCB. Voltage

should correspond to OCV and it should be

___60___ VDC.



Check Current/Voltage control potentiometer value.

Remove the CN3-cable from PCB. Make sure remote

control switch is in the ‘’Off’’ position and that the

CV/CC switch is in the CV position. Measure the resis-

tance between pin 6 and pin 9 on CN3-cable.

The resistance should be ___5k___

 Check potentiometer operation. Switch settings

should remain the same as in number 20 above.

Measure the resistance between pin 8 and pin 9 on

CN3-cable while turning potentiometer from minimum

to maximum setting.

The resistance should be ___0 – 5k___

 Reconnect CN3-cable to the PCB. Measure voltage

on PCB. Check voltage across pin 10 and pin 11 on

connector CN3.

With switch in CC position the voltage should

be ___0___VDC.

With switch in CV position the voltage should

be ___3.3___VDC.

D Check voltage supply to Current/Voltage control

pot. Measure between pin 9 and 6 on connector CN3.

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2 >

1) Ch 1: 20 Volt 2 ms

2

)

Ref A: 20 Volt 10 ms

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2

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1) Ch 1: 20 Volt 2 ms

2) Ref A: 20 Volt 5 ms

T

1

>

2

>

1) Ch 1: 20 Volt 2 ms

2) Ref A: 1 Volt 10 ms

Make sure CV/CC switch is in CV position and the

current range switch is in the max position.

The voltage should be between ___3.8___

and ___4.2___ VDC.

E Check voltage supply to Current/Voltage control

pot. Measure between pin 9 and 7 on connector CN3.

Make sure CV/CC switch is in CC position and the

current range switch is in the max position.

The voltage should be between ___4.2___

and ___4.6___ VDC.

 Check voltage across pins pin 3 and pin 5 on con-

nector CN3.

With switch in CC position the voltage should

be ___14___VDC.

With switch in CV position the voltage should

be ___6.6___VDC.

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GATE WAVE FORM: PCB OUTPUT-THYRISTOR

(0794000099 p.c.b. code).

Condition:

a) no load

b) max position welding current knob.

Measure:

Between “-“ welding diode bridge and each gate thyristor

(7-8-9).

Output CC

Output CV

Measure:

Between “+“ welding diode bridge and each gate

thyristor (1-2-3).

Output CC or CV

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Note:

switch setting: ON

DIP 1,2,3 – filtering for hall sensor current signal

(no for ESAB machines).

DIP 4,5,6 – filtering – voltage signal.

DIP 7,8 - filtering for shunt current signal (on

ESAB machines).

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R 49 ⇒ minimum welding current value (turn in clock

wise direction to increase).

R 49 setting: →value checked in factory.

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!CV mode

!Wire feeder supply “ARC VOLTAGE”

!Knob, welding current regulation, max position

F1RWHo.c.v. 50 VDC

R 131 ⇒ trigger setting

(turn in clock wise direction to increase).

R 131 setting: →always in max position (totally clock

wise direction).

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With switches in:

- CV mode

- 42 V.a.c. supply

measure the voltage on the terminal strip:

- between A and B: the voltage should be 45 V.a.c.

- between SS* and F: the voltage should be 0 V.a.c.

- between B and F: the voltage should be 45 V.a.c.

(* see electrical diagram).

Connect together B and F (temporary connection): you

must have voltage at the welding sockets.

F1RWH - between N and C:

welding voltage to wire feeder instrument

- L – K – J: voltage reference to P.C.B.

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A : Alternator

B : Wire connection unit

C : Capacitor

D : G.F.I. (ground fault interrupter)

F : Fuse

G : 400V 3-phase socket

H : 230V 1phase socket

I : 110V 1-phase socket

M : Hour-counter

N : Voltmeter

R : Welding control P.C.B.

S : Welding current ammeter

T : Welding current regulator

U : Current transformer

V : Welding voltage voltmeter

Z : Welding sockets

X : Shunt

W : D.C. inductor

Y : Welding diode bridge

G1 : Fuel level transmitter

H1 : Oil or water thermostat

L1 : Oil pressure switch

Q1 : Starter key

R1 : Starter motor

S1 : Battery

T1 : Battery charge alternator

U1 : Battery charge voltage regulator

Z1 : Solenoid valve

W1: Remote control switch

X1 : Remote control socket

Y1 : Remote control plug

C2 : Fuel level gauge

F3 : Stop push-button

I3 : Range switch

N3 : Relay

O3 : Resistor

G4 : Preheating glow plugs

I4 : Preheating indicator

P4 : Circuit breaker

X4 : Base current diode bridge

A5 : Base current switch

M5 : Engine protection EP5

N5 : Pre-heat push-button

M6 : Switch CC/CV

R6: EMC filter

S6: Wire feeder supply switch

T6: Wire feeder socket

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

- In the envelope where you found this manual you will

also find an Owner’s manual for the engine, and ac-

cessories (if required).



This product has been designed for welding and genera-

tion of electrical power for tools and other electrical devices

used in construction; ANY OTHER USE, is not permitted

and we cannot be held responsible for injuries or damages

resulting from such incorrect use.

Our products are made in conformity with the safety norms

in force in order to avoid injury to persons or damage to the

machine or other things.

+ :DUUDQW\ LV QRW YDOLG LI QRW FDUULHG RXW E\

(6$%DXWKRUL]HGVHUYLFHDJHQW

Making modifications to the machine without our written

authorization will void the warranty and release us from

any liability.



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Before using the machine please read this manual atten-

tively and follow the instructions contained in it. This will

help avoid problems, possible injury and damage to the

machine.

The manual is written for experienced, qualified personnel,

who are familiar with health and safety laws and related

regulations.

This manual is an integral part of the product and should be

kept in a safe place so that it will be available for consulta-

tion during the life of the product. If the machine is sold the

manual should be transferred to the new owner.

Some figures contained in this manual are designed to help

identify certain parts and may not correspond to the ma-

chine in your possession.

+ 1RWLFHWKHPDQXIDFWXUHUPD\PDNHLPSURYHPHQWVRU

PRGLILFDWLRQVWRWKHSURGXFWRULWVDFFHVVRULHVDVGH

VFULEHGLQWKLVPDQXDOZLWKRXWXSGDWLQJWKHPDQXDO



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The headings used in this manual are designed to call your

attention to potential hazards and important aspects of the

operation of the machine…

lndìcates a strong possíbility of severe personal injury or

death ìf ínstructions are not followed.

lndìcates a possibìlìty of personal ínjury or equipment dam-

age if ìnstructions are not followed

lndícates that equipment or property damage can result if

instructions are not followed.

These headings give helpful information about the prepara-

tion, operation and care of the machine.

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

6723²Read with great attention

Read with attention

:5(1&+Use the correct tools for the type of

work being done

:$51,1*6<0%2/6

$77(17,21 If this advice is not followed peo-

ple or things can be hurt or damaged.

+,*+92/7$*( Do not touch – risk of injury

or death.



),5( Risk of fire.



+($7 Hot surfaces.



(;3/26,9( Explosive material or danger of

explosion, in general.



12:$7(5'RQRWXVHZater as it can cause

shortcircuits or other damage.





12602.,1*&igarettes, matches or lighters

can start a fire or explosion.



$&,'6Danger of corrosion or burns.



6$)(7<6<0%2/6



8VHWKHFRUUHFWSURWHFWLYHGHYLFHVIRUWKHW\SHRIZHOG

LQJEHLQJGRQH

Use protective clothing, etc. specifically

designed for the type of welding being done.



3URWHFW\RXUVHOIZKHQGRLQJPDLQWHQDQFHRQWKHPD

FKLQH

It is advisable to protect yourself when carrying

out maintenance, such as filling the battery, refu-

elling, etc.

3D\DWWHQWLRQWRVDIHW\SUHFDXWLRQVZKHQPRYLQJWKH

PDFKLQH

Refer to the instructions before moving the ma-

chine





:HDULQGLFDWHGVDIHW\FORWKLQJ

It is compulsory to wear the personal pro-

tection items shown when using the equip-

ment.

8VHUHTXLUHGVDIHW\GHYLFHV

Safety devices suitable for the type of welding

and the location of the job must be used.



'RQRWXVHZDWHURQHOHFWULFDOILUHV

It is prohibited to use water to put our fires in

electrical equipment.

'RQRWWRXFKZLWKRXWKDYLQJGLVFRQQHFWHGWKH

HOHFWULFLW\

It is prohibited to work on the machine until the

electricity has been turned off.



:HOGLQJSURKLELWHG

It is forbidden to weld in areas containing explo-

sive gases.



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+ Read and understand these instructions.

+

Before installing, operating or servicing this equipment, read

the operating manuals of the welder and of the engine

.

+

Not observing the information in the manuals can result in

personal injury and/or damage to the equipment and other

property.

+

Respect all safety regulations and laws when operting this

equipment.

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'RQRWUHPRYHRUGLVDEOHSURWHFWLYHGHYLFHV

Removing or disabling protective devices on the ma-

chine is prohibited.

'RQRWXVHWKHPDFKLQHLILWLVQRWLQJRRGWHFKQLFDOFRQ

GLWLRQ

The machine must be in good working order before be-

ing used. Defects, especially those which. regard the

safety of the machine, must be repaired before using

the machine.

(1*,1()8(//,1*

⇒ Stop engine when fuelling.

⇒ Do not smoke, avoid open flames and sparks, and

do not use electric tools when fueling.

⇒ Unscrew the fuel cap slowly to let out the fuel va-

pours.

⇒ Do not over-fill the tank.

⇒ Avoid spilling fuel on hot engine.

⇒ Wipe up spilled fuel before starting engine.

⇒ Shut off fuel cock, if present, or remove fuel from

tank before moving machine

)25%$77(5<(48,33('81,7621/<

⇒ Sparks may cause the explosion of battery vapours

:$7(5&22/('(1*,1(621/<

⇒ Slowly unscrew the cooling liquid cap of a hot en-

gine to allow vapours to escape.

⇒ Hot vapor and heated cooling liquid under pressure

can burn face, eyes, skin.

F),567$,' In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas or what-

ever event which may cause serious injuries or death, predispose the first aid in accordance with the ruling labour

accident standards or of local instructions.

Skin contact Wash with water and soap

Eyes contact Irrigate with plenty of water, if the irritation persists contact a specialist

Ingestion Do not induce vomit as to avoid the intake of vomit into the lungs, send for a doctor

Suction of liquids from lungs If you suppose that vomit has entered the lungs ( as in case of spontaneous vomit ) take the

subject to the hospital with the utmost urgency

Inhalation In case of exposure to high concentration of vapours take immediately to a non polluted zone

the person involved

F),5(35(9(17,21 In case the working zone,for whatsoever cause goes on fire with flames liable to cause se-

vere wounds or death, follow the first aid as described by the ruling norms or local ones.

(;7,1&7,210($16

Appropriated Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water

Not to be used Avoid the use of water jets

Other indications Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces

close to the fire

Particular protection Wear an autorespiratory mask when heavy smoke is present

Useful warnings Avoid, by appropriate means to have oil sprays over metallic hot surfaces or over electric

contacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep in mind

that the inflamability point is very low.

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ESAB KHM 500 PS - CC/CV User manual

ESAB KHM 500 PS - CC/CV User manual

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