ESABMig 630tw MAGMA.pdf

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ESABMig 630tw MAGMA
Service manual
0349 300 047
031218
Valid for serial no. 323−xxx−xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 630tw MAGMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Mains synchronising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Start and stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Test input and method select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Galvanically insulated voltage reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. The display output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Inductor short−circuiter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Thyristor trigger circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Control circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. Reset circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM, CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT POSITIONS, CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST POINTS ON CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST PROGRAM FOR CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION OF ESABMig 630tw MAGMA IN MMA MODE . . . . . . . . . . .
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOCK DIAGRAM, ESABMig 630tw MAGMA IN MMA MODE . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM, CIRCUIT BOARD AP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT POSITIONS, CIRCUIT BOARD AP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM, CIRCUIT BOARD AP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAY BOARD P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM, DISPLAY BOARD P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 December 2003.
The ESABMig 630tw MAGMA designed and tested in accordance with international
and European standard IEC/EN 60974−1 and EN 50199.
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.
INTRODUCTION
The ESABMig 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.
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TECHNICAL DATA
ESABMig 630tw
Mains voltage
Permissible load at
60% duty cycle (MIG/MAG)
80 % duty cycle (MIG/MAG)
100% duty cycle (MIG/MAG)
100% duty cycle (MMA)
Setting range (DC)
(MIG/MAG)
Setting range (DC)
(MMA)
Open circuit voltage
Power factor
at maximum current
Efficiency
at maximum current
Control voltage
Dimensions lxwxh
Weight
Operating temperature
Enclosure class
Application classification
230/400−415/500V, 3∼ 50Hz
230/400−460/550V, 3∼ 60Hz
630A / 44V
560A / 42V
500A / 39V
500A / 40V
75A/18V−630A/44V
40A/21V−500A/40V
18−55V
0,90
78%
42V, 50/60 Hz
900 x 640 x 835mm
268kg
−10
to +40°C
IP 23
Cooling unit
Cooling power
Coolant
Coolant quantity
Maximum water flow
2500 W at40°C temp. difference and flow 1,5l/min
50 % water / 50% glycol
5,5 l
2,0 l/min
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WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
S
Observe precautions for handling electrostatic
sensitive devices.
Use proper static−proof bags and boxes.
AP1
AP2
AP3
C1
C2
C3, C4, C5
C6
EV1
FU1
HL1
HL2
KM1
KM2
KM3
KM4
L1
M1
Circuit board, control.
Interference suppressor circuit board: see circuit diagram.
Circuit board, controlling the main thyristors during MMA welding and
air−arc gouging.
Capacitor, 3uF 400V. Start and run capacitor for fan motor EV1.
Capacitor, 1uF 400V.
Suppression capacitors, 0,1uF 250V
Capacitor, 4uF 250V, for reducing the speed of fan motor EV1.
Fan.
Miniature circuit breaker, 10A, anti surge. Protects the 42V supply from
transformer TC1.
Indicating lamp, 42−48V, white. Indicates that the main power supply
switch is ON.
Indicating lamp, 42−48V, yellow.
Main contactor, 42V, 50Hz. Controlled by the welding torch contact.
It is also energized when the MMA or arc−air gouging mode is activated.
Contactor 42V 50Hz. For speed control of the fan: see ST1, ST3 below.
Contactor 42V 50Hz. For activation of the pump motor: see SA1 below.
Contactor 42V 50Hz. For machine disabling in case of overheating or lack
of coolant flow.
Inductor. The purpose of the inductor is to limit the short−circuit current
and reduce welding harshness.
Pump motor, 230V 50Hz 0.2kW.
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