ESAB Mig 630tw Magma User manual

Mig 630tw Magma
ESAB
Brand
ESAB
Model
Mig 630tw Magma
Category
Welding System
Type
User manual
0349 300 068 Valid for serial no. 635--xxx--xxxx071024
Mig 630tw MAGMA
Origo
S
e
r
v
i
c
e
m
a
n
u
a
l
-- 2 --TOCe
READ THIS FIRST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig 630tw MAGMA 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION IN MIG/MAG MODE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control circuit board 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Power supply, circuit board AP1 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Display output 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Machine type / Test input, Fixed / controlled firing angle 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Synchronising 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Thermal overload switch, flow guard 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Arc voltage input 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Shunt input 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Voltage reference 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Crater filling 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Start / Stop 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Thyristor circuits 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Processor 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Presetting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 CAN interface 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Component positions 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2 Suppression circuit board 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION IN MMA MODE 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block diagram, Mig 630tw MAGMA in MMA mode 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of operation, circuit board AP3 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit diagram, circuit board AP3 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component positions, circuit board AP3 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting instructions, thyristor modules 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal switch (thermostat) replacement procedure 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of components 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and control devices 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Semi--automatic welding 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual welding (MMA) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc--air gouging 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water flow guard 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductance 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the coolant 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- 3 --TOCe
FAULT TRACING 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edition 071024
-- 4 --
1m630twm
READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault--tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and
including October 2007.
The Mig 630tw MAGMA is designed and tested in accordance with international and
European standard IEC/EN 60974--1 and EN 60974--10.
On completion of service or repair work, it is the responsibility of the person(s) etc.
performing the work to ensure that the product does not depart from the requirements
of the above standard.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!
INTRODUCTION
The Mig 630tw MAGMA is thyristor--controlled power unit for MIG/MAG welding and arc--air
gouging. The main circuit consists of three thyristors and three diodes, connected to form a
full--wave bridge. Voltage ripple (particularly at low welding voltages) is reduced by applying
a base voltage of 15 V via diodes V7--V9, supplied from a separate winding for this purpose
on the main transformer TM1.
Similarly, a base current is arranged by rectifying the output from the main transformer
secondary winding via diodes V10--V12 and connecting it to the positive welding terminal
through a 1,1Ω resistor. Note that the no--load voltage of the machine is about 50 V as a
result of the voltage contribution from the base current winding. In order to be able to
measure the true no--load voltage, it is necessary to disconnect conductor 070 from the
base current winding. With the base current winding disconnected, the no--load voltage is
about 17 V when RP1 is at its minimum position, and about 48 V with RP1 at its maximum
position. Conductor 070 must be disconnected and reconnected only when the machine is
disconnected from its mains power supply.
Edition 071024
-- 5 --1m630twm
TECHNICAL DATA
Mig 630tw
Mains voltage 230/400--415/500V, 3∼ 50Hz
230/400--460/550V, 3∼ 60Hz
Permissible load at
60% duty cycle (MIG/MAG)
80 % duty cycle (MIG/MAG)
100% duty cycle (MIG/MAG)
100% duty cycle (MMA)
630A / 44V
560A / 42V
500A / 39V
500A / 40V
Setting range (DC) (MIG/MAG) 75A/18V--630A/44V
Setting range (DC) (MMA) 40A/21V--500A/40V
Open circuit voltage 18--55V
Power factor at maximum current 0,90
Efficiency at maximum current 78%
Control voltage 42V, 50/60 Hz
Dimensions lxwxh 900 x 640 x 835mm
Weight 268kg
Operating temperature --10 to +40˚C
Enclosure class IP 23
Application classification
Cooling unit
Cooling power 2500 W at40˚C temp. difference and flow 1,5l/min
Coolant 50 % water / 50% glycol
Coolant quantity 5,5 l
Maximum water flow 2,0 l/min
Edition 071024
-- 6 --
1m630twm
WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S
SS
S Observe precautions for handling electrostatic
sensitive devices.
S
SS
S Use proper static--proof bags and boxes.
ESD
AP1
Circuit board, MIG/MAG mode control of V1, V3, V5 thyristors.
AP2
Interference suppressor circuit board: see circuit diagram.
AP3
Circuit board, controlling the main thyristors during MMA welding and
air--arc gouging.
C1
Capacitor, 3uF 400V. Start and run capacitor for fan motor EV1.
C2
Capacitor, 1uF 400V.
C3, C4, C5
Suppression capacitors, 0,1uF 250V
C6
Capacitor, 4uF 250V, for reducing the speed of fan motor EV1.
EV1
Fan.
FU1
Miniature circuit breaker, 10A, anti surge. Protects the 42V supply from
transformer TC1.
HL1
Indicating lamp, 42--48V, white. Indicates that the main power supply
switch is ON.
HL2
Indicating lamp, LED, yellow. Indicates overheating and insufficient flow of
cooling liquid in 600tw machine.
KM1
Main contactor, 42V, 50Hz. Controlled by the welding torch contact.
It is also energized when the MMA or arc--air gouging mode is activated.
KM2
Contactor 42V 50Hz. For speed control of the fan: see ST1, ST3 below.
KM3
Contactor 42V 50Hz. For activation of the pump motor: see SA1 below.
L1
Inductor. The purpose of the inductor is to limit the short--circuit current
and reduce welding harshness.
M1
Pump motor, 230V 50Hz 0.2kW.
P1
Digital display.See page 29. Digital display is an accessory,
see Accessories listed in User Manual.
Edition 071024
-- 7 --1m630twm
QF1
Main On/Off switch and mode selector. Semi--automatic, manual welding
and arc--air gouging is set by turning switch QF1.
R1, R2
Resistors, 100Ω 50W. They provide a dummy load for the thyristors
to enable them to fire properly when operating on no--load.
R3
Resistor, 0,7Ω.
R4
Base current resistor, 1,1Ω ±5%.
RP2
Potentiometer, 2,5 kΩ 2W, for welding current control at MMA
and arc--air gouging.
RS1
Shunt 630A / 120mV with a centre connection for 60mV at 600A.
SA1
Cooling water pump switch, activates contactor KM3. Connected in
parallel with the ELP switch on the ESABFeed wire feeder.
SA2
Selector switch, Remote/Local control of the welding current at MMA
welding and air--arc gouging.
SL1
Flow guard. (An accessory, see Accessories listed in User Manual.)
ST2
Thermal switch. Controls the speed of fan motor EV1. The switch closes
when the temperature exceeds 80_C, energising contactor KM2. This
short--circuits capacitor C6, allowing the fan to run at full speed.
The switch opens when the machine temperature has fallen to 60_C.
ST1, ST3
Thermal switches. Protect the machine against excessive temperature.
ST1 is fitted in L1 winding. It opens at 160_C and closes at 130_C.
ST3 is fitted in V1--V6 thyristor--diode bridge. It opens at 80_C
and closes at 60_C.
TC1
Control power supply transformer.
TC3
Transformer for CO
2
heater.
(An accessory, see Accessories listed in User Manual.)
TM1
Main transformer, having three secondary windings:
S The main winding supplies current to the thyristor rectifiers.
S The base voltage winding supplies current to diodes V7--V9. The purpose of
the base voltage is to even out the voltage peaks at low welding currents.
S The synchronising winding, supplying a synchronising signal for controlling
the thyristors firing points to circuit board AP1 and AP3.
The winding voltage, as measured between terminals
A1--A2, A1--A3 and A2--A3 on circuit board AP1, is 18,5 V ±0,4 V
at nominal mains voltage.
V1--V6
Thyristor--diode module.
V7--V9
Base voltage diodes.
V10--V12
Base current diodes.
V13
Freewheel diode.
Edition 071024
-- 8 --
1m630twm
V14
Inductor short--circuiting switch, option. The thyristor short--circuits the
inductor for about 100 ms when welding starts, ensuring a stable start.
XS1
23 pole sleeve socket, connection to the wire feeder.
XS2, XS3
Current terminals, single pole.
XS7
12 pole sleeve socket outlet connector for remote control of welding
current in the MMA welding mode.
XT1
6 pole terminal block.
XT2
9 pole terminal block.
Z1--Z4
RC filter.
Edition 071024
-- 9 --1m630twm
Mig 630tw MAGMA
Edition 071024
-- 10 --
1m630twm
DESCRIPTION OF OPERATION IN MIG/MAG MODE
The description refers to the diagram on page 9.
In MIG/MAG mode the main thyristor--controlled rectifier (V1 -- V6) is assisted by base
voltage rectifier (V7 -- V9). The base rectifier is connected via contacts (1 -- 6) of QF1 switch
excusively in MIG/MAG mode.
Thyristor--controlled rectifier sets firing angle the way that output voltage is approximately
linear function of reference voltage. No voltage feedback is applied.
AP1 Control circuit board
The circuit board is screened by that is connected to 0 V on the circuit board. It contains
thyristor control circuit, measurement circuits, display control circuit and contactor control
circuit.
1 Power supply, circuit board AP1
The power supply supplies the following DC voltages :
+25 VA, +25 VZ, ¦15 V, +15 VB, +5 V and +2.5 V.
+5V
Internal power supply on the circuit board. Voltage regulator VR2 is adjustable: the
voltage is adjusted to 5.00 ¦0.01 V when the board is manufactured.
+2.5V
Power supply to the microprocessor core.
Edition 071024
-- 11 --1m630twm
+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.
+25VA
Internal power supply for the circuit board, protected by a PTC resistor, R150.
The resistance value of this resistor increases in the event of current overload.
+25VZ
Internal power supply for the circuit board. Supplies IC7 and IC9 and the reset
circuit for the gate pulses. See item 12 on page 17.
+9V
Circuit marked +9V serves as detector of switching the machine off.
Check of voltages +15V, --15V, +15VB, +5V, +2.5V can be run with use of ESAT
(see page 33).
2 Display output
Outputs G1 -- G3 are used for serial data transfer of the welding current and arc
voltage to a digital display instrument, which may be fit either in the power unit or in
the wire feed unit. The instrument is described in the service manual for the wire
feeders Origo
TM
Feed 30x and Origo
TM
Feed 48x.
Outputs G4 and G5 supply +12 V to the instrument. This supply is protected by
PTC resistors R155 and R154, and switched off by MOSFET switch. The latter
serves for energy storing during switching off and serves as power source for
system closing procedure.
Display and display outputs check can be run with use of ESAT (see page 33).
Edition 071024
-- 12 --
1m630twm
3 Machine type / Test input, Fixed / controlled firing angle
Origo
TM
Mig 630tw MAGMA operates excusively with fixed firing angle, i.e. firing
angle is directly proportional to the reference voltage. No voltage feedback is
applied.
The link between J2 and J4 is absolutely necessary for proper operation of the
machine. Damage of rectifier may occur if J2 and J4 are not linked.
Machine type is possible to determine with use of ESAT (see page 33).
Edition 071024
-- 13 --1m630twm
4 Synchronising
Firing is synchronised to the mains by three zero crossing detectors, IC11;1, IC11;2
and IC11;13.
Phases check can be run with use of ESAT (see page 33).
5 Thermal overload switch, flow guard
Lamp HL2 lights if the cutout operates. When the cutout operates the thyristor
ignition pulses are blocked.
If the optional flow guard is fit, wire 135 is removed. Lamp HL2 lights if there is no
cooling water flow and the thyristor ignition pulses are blocked. Contact KM3 is
open when the pump motor is On.
Check of thermal overload switch can be run with use of ESAT (see page 33).
Edition 071024
-- 14 --
1m630twm
6 Arc voltage input
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).
If the welding wire is negative:
The upper amplifier in IC10 is active, measuring the arc voltage between the
positive terminal of power unit (0V) and the welding wire (XS1;H).
If the welding wire is positive:
The lower amplifier in IC10 is active, measuring the arc voltage between the
negative terminal of power unit (inductor terminal B) and the welding wire (XS1;H).
If there is no connection between D7 and the welding wire, the arc voltage will be
measured between the positive terminal of power unit (0V) and inductor terminal B.
Time constants are as follows:
S a 0.5 s for arc voltage readout on the digital display.
S b 22 ms, arc voltage feedback, for control purposes.
S c 1 ms for detection of cessation of short--circuiting.
This signal is used at welding start and for control purposes. If short circuits of
longer duration occurs this signal acts together with the overload protection,
see: 8 Shunt input on next page.
Calibration and check of the voltage measurement can be run with use of ESAT
(see page 33).
Edition 071024
-- 15 --1m630twm
7 Shunt input
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:
S a A time constant of 0.5 s, for indication of the welding current on the digital
display.
S b A time constant of 7.26 ms for overload protection.
See below under Item 13.
S c A time constant of 1 ms is currently not used.
The electronic neutral, 0 V, is connected to the positive welding current pole via
contact D5. Capacitor C4, which is connected to the case screen, decouples
interference to the machine case.
Calibration and check of the current measurement can be run with use of ESAT
(see page 33).
8 Voltage reference
The voltage reference potentiometer is fit in the wire feed unit. The power supply to
the potentiometer, +15 VB, is protected against short circuits to the arc voltage.
Check of voltage ref. input can be run with use of ESAT (see page 33).
Edition 071024
-- 16 --
1m630twm
9 Crater filling
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. The table
below shows the percentage of the set voltage at each step, together with the
corresponding L4 signal levels.
Crater filling sequence
Phase
1
2
3
4
L4
low
high
low
high
%
90
72
65
58
Each step lasts for a maximum of 1.27 seconds. See the Origo
TM
Feed service
manual for further information.
Check of crater filling input can be run with use of ESAT (see page 33).
10 Start / Stop
The start/stop input L5 is driven by triac placed in wire feeder compartment, which
is represented by closing contact symbol.
Check of start/stop input can be run with use of ESAT (see page 33).
Edition 071024
-- 17 --1m630twm
11 Thyristor circuits
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.
During the first moment of mains power connection the firing circuits are blocked by
reset signal.
Resistors R143 -- R148 limit the thyristor gate currents to about 1.3 A.
The peak value of the firing voltage is about 22 V when the thyristors are
disconnected.
If a thyristor fails, always check the gate pulses before starting up the new
thyristors. If a thyristor has short--circuited, the other thyristors will also have been
damaged, which can reduce their lives. If one thyristor has failed, all should be
replaced.
A3--A4, A7--A8, A11--A12 otputs are not used in Origo
TM
Mig 630tw MAGMA.
Checking the thyristors
Remove connector “A” from the circuit board. Open the cover over the thyristors.
Remove the screws and rails. Measure the resistance of the thyristors with a DMM.
The gate and cathode can be tested at connector XS14.
Make each measurement in both directions of polarity (i.e. reverse the test
connections from the DMM). The measured values must be in the range as shown
below, regardless of polarity.
S Gate -- cathode: 5 -- 40 Ω
S Anode -- cathode: not less than 10 kΩ
S Anode -- gate: not less than 10 kΩ
Thyristors test can be run with use of ESAT (see page 33).
Edition 071024
-- 18 --
1m630twm
12 Processor
In addition to the features already described, the processor performs the following
functions:
S 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.
S Voltage monitoring
By sensing that the power supply, +9 V, to the main electronics board is
present, the processor monitors the power supply to the board. If the supply is
lost, the closing procedure is started and the main program is stopped.
S Short--circuit protection
The machine incorporates short--circuit protection (fast current trip),
set at 1000 A.
S Firing pulses
The processor generates firing pulses as required by the set welding voltage.
S Display management
The processor supplies information on the welding voltage and welding current
to the digital display instrument.
S Crater filling
Reduces the arc voltage when the wire feed unit calls for crater filling.
S Elevated starting voltage (Hot Start)
The starting voltage is 35% higher than the set voltage. Arc voltage control
comes into operation 200 ms after the arc strikes, which reduces the arc
voltage to the set value.
Edition 071024
-- 19 --1m630twm
13 Presetting
This input is used only when an Origo
TM
Feed wire feed unit with control panel M14
is connected to the Origo
TM
Mig 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. When the switch on the wire feed unit is closed, circuit
board input H7 is connected to 0 VB.
Test of presetting input can be run with use of ESAT (see page 33).
Wire feed speed reference XS1;P
This input is used only when an Origo
TM
Feed wire feed unit with control panel M14
is connected to the Origo
TM
Mig power unit.
The wire feeder sends an analogue wire feed speed signal to the Origo
TM
Mig for
display in the digital display.
The input also senses if a Origo
TM
Feed unit with control panel M14 is connected.
Scaling of the voltage reference changes if a M14 control panel is connected,
relative to the scaling used if a M13 control panel or MEK 20 wire feed unit is
connected.
Calibration and test of the wire speed reference can be run with use of ESAT (see
page 33).
Edition 071024
-- 20 --
1m630twm
14 CAN interface
CAN interface is used for production, fabrication and service. A list of service
functions is available using ESAT. CAN interface is not powered in Origo
TM
Mig
400t/500t. An extra transformer that is included in CAN Supply Service KIT 0xxx
xxx xxx is required to supply the interface.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46

ESAB Mig 630tw Magma User manual

Mig 630tw Magma
ESAB
Brand
ESAB
Model
Mig 630tw Magma
Category
Welding System
Type
User manual
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers

Other documents