FCW DYNA MMA 500S, DYNA MMA 500HS, DYNA MMA 500GTS, DYNA MMA 630S, DYNA MMA 630GTS Operating Manual

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MODEL

• DYNA MMA 500S

• DYNA MMA 500GTS

• DYNA MMA 500(H)S

• DYNA MMA 500(H)GTS

• DYNA MMA 630S

• DYNA MMA 630GTS

Operating Manual

(Owner’s Manual)

IMPORTANT: Read these instructions before installing, operating, or servicing this system.

Second Edition Manual No. E0904

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

CONTENTS

SYMBOL LEGEND---------------------------------------------------------------------------------------------------2

STATEMENT OF WARRANTY------------------------------------------------------------------------------------3

1.0 GENERAL INFORMATION-------------------------------------------------------------------------------4

1.01 Notes, Cautions and Warnings------------------------------------------------------------------------4

1.02 Important Safety Precautions--------------------------------------------------------------------------4

1.03 Transporting methods-----------------------------------------------------------------------------------6

2.0 INSTALLATION RECOMMENDATION----------------------------------------------------------------7

2.01 Electrical Input Connections---------------------------------------------------------------------------8

2.02 Specifications----------------------------------------------------------------------------------------------9

2.03 Duty cycle--------------------------------------------------------------------------------------------------9

3.0 OPERATOR CONTROLS-------------------------------------------------------------------------------10

3.01 DYNA MMA controls-----------------------------------------------------------------------------------10

3.02 Weld parameter description--------------------------------------------------------------------------12

3.03 Weld parameter for DYNA MMA series------------------------------------------------------------13

4.0 SET-UP FOR MMA (STICK) AND GTAW (TIG)----------------------------------------------------14

4.01 Stick welding---------------------------------------------------------------------------------------------15

4.02 DC TIG welding-----------------------------------------------------------------------------------------15

5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES-----------------------------16

6.0 BASIC TIG WELDING GUIDE--------------------------------------------------------------------------17

6.01 Electrode Polarity---------------------------------------------------------------------------------------17

6.02 Tungsten Electrode Current Ranges---------------------------------------------------------------17

6.03 Tungsten Electrode Types----------------------------------------------------------------------------17

6.04 Guide for Selecting Filler Wire Diameter----------------------------------------------------------17

6.05 Shielding gas selection--------------------------------------------------------------------------------18

6.06 TIG welding parameters for low carbon & low alloy steel pipe-------------------------------18

6.07 Welding parameters for steel------------------------------------------------------------------------18

7.0 BASIC ARC WELDING GUIDE------------------------------------------------------------------------19

7.01 Electrode polarity---------------------------------------------------------------------------------------19

7.02 Effects of stick welding various materials---------------------------------------------------------19

8.0 MAINTENANCE--------------------------------------------------------------------------------------------20

9.0 BASIC TROUBLESHOOTING-------------------------------------------------------------------------20

9.01 Check the item and excrescent phenomenon exclusion method---------------------------20

9.02 TIG welding problems---------------------------------------------------------------------------------22

9.03 Stick welding problems--------------------------------------------------------------------------------23

9.04 Power source problems-------------------------------------------------------------------------------24

10.0 PARTS LIST-------------------------------------------------------------------------------------------------25

11.0 REMARK-----------------------------------------------------------------------------------------------------30

APPENDIX: INTERCONNECT DIAGRAM

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

SYMBOL LEGEND

Amperage

Stick (SMAW)

Voltage

Pulse Current Function

(GTAW)

Hertz (frequency)

Spot Time (GTAW)

SEC

Seconds

Remote outputs control

(Panel/Remote)

Percent

Remote Function

DC (Direct Current)

Arc Control (SMAW)

AC (Alternating Current)

Gas Post-Flow Time

2T (GTAW)

Gas Pre-Flow Time

4T (GTAW)

VRD

Voltage Reduction

Device Circuit

Repeat Function (GTAW)

—

Negative

Spot Function (GTAW)

Positive

High Frequency Starting

(GTAW)

Gas Input

Lift Start （GTAW）

Gas Output

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

STATEMENT OF WARRANTY

LIMITED WARRANTY: "FCW" warrants to customers of its authorized distributors hereafter "FCW" that its products will be free

of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to

the FCW products as stated below, FCW shall, upon notification thereof and substantiation that the product has been stored,

installed, operated, and maintained in accordance with FCW’s specifications, instructions, recommendations and recognized

standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable

repair or replacement, at FCW ‘s sole option, of any components or parts of the product determined by FCW to be defective.

The FCW COMPA NY MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: FCW shall not under any circumstances be liable for special, indirect or consequential damages,

such as, but not limited to, lost profits and business interruption. The remedies of the Purchaser set forth herein are exclusive

and the liability of FCW with respect to any contract, or anything done in connection therewith such as the performance or

breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by FCW whether

arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein,

exceed the price of the goods upon which such liability is based. No employee, agent, or representative of FCW is authorized to

change this warranty in any way or grant any other warranty.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN FCW’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY FCW PRODUCT. PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to

the Purchaser. Not with standing the foregoing, in no event shall the warranty period extend more than the time stated plus one

year from the date FCW delivered the product to the authorized distributor.

POWER SUPPLIES

POWER SUPPLIES & WIRE FEEDERS

MAIN POWER MAGNETICS (STATIC& ROTATING) 1YEAR

ORIGINAL MAIN POWER RECTIFIER 1YEAR

POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD 1YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS,

SOLENOIDS, PUMPS, SWITCHES, MOTORS

Warranty repairs or replacement claims under this limited warranty must be submitted to FCW by an authorized FCW repair

facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid under

this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the

Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous FCW

warranties.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

1.0 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.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND

HAZARDOUS TO YOUR HEALTH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions

before using the equipment. Call 86-21-69171135 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the Arc welding or cutting process can be dangerous and hazardous to

your health.

z Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

z Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

z The kinds of fumes and gases from the arc welding/cutting depend on the kind of metal being used,

coatings on the metal, and the different processes. You must be very careful when cutting or welding

any metals which may contain one or more of the following:

Antimony Arsenic Barium Beryllium Cadmium Chromium Cobalt Copper Lead

Manganese Mercury Nickel Selenium Silver Vanadium

z Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you

are using. These MSDSs will give you the information regarding the kind and amount of fumes and

gases that may be dangerous to your health.

z Use special equipment, such as water or down draft welding/cutting tables, to capture fumes and

gases.

z Do not use the welding torch in an area where combustible or explosive gases or materials are

located.

z Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove

all sources of these vapors.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

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.

z Never touch any parts that are electrically “live” or “hot.”

z Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding

circuit.

z Repair or replace all worn or damaged parts.

z Extra care must be taken when the workplace is moist or damp.

z Install and maintain equipment according to NEC code, refer to relative standards.

z Disconnect power source before performing any service or repairs.

z Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the arc weld.

z Be sure there is no combustible or flammable material in the workplace. Any material that cannot be

removed must be protected.

z Ventilate all flammable or explosive vapors from the workplace.

z Do not cut or weld on containers that may have held combustibles.

z Provide a fire watch when working in an area where fire hazards may exist.

z Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut

underwater, or while using a water table. Do not cut aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Arc welding/cutting processes can cause noise levels to exceed

safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

z To protect your hearing from loud noise, wear protective ear plugs and/ or ear muffs. Protect others

in the workplace.

z Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

ARC WELDING RAYS

Arc Welding/ Cutting Rays can injure your eyes and burn your skin. The arc welding/cutting process produces

very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are

not properly protected.

z To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

z Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

z Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

z Protect others in the work area from the arc rays. Use protective booths, screens or shields.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

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.

z Lift unit with handle on top of case.

z Use handcart or similar device of adequate capacity.

z If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

2.0 INSTALLATION RECOMMENDATION

Installation Environment

DYNA MMA Series is designed for use in hazardous environments.

Examples of environments with increased hazardous environments are -

In locations in which freedom of movement is restricted, so that the operator is forced to perform the work

in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts; In locations which

are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or

accidental contact by the operator, or in wet or damp hot locations where humidity or perspiration

considerable reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductive parts in

the near vicinity of the operator, which can cause increased hazard, have been insulated.

Installation Location

Be sure to locate the welder according to the following guidelines:

z In areas, free from moisture and dust. z In areas, not subjected to abnormal vibration or

shock. z In areas, free from oil, steam and corrosive

gases. z Place at a distance of 304.79mm or more from

walls or similar that could restrict natural airflow for cooling.

z In areas, not exposed to direct sunlight or rain. z Ambient temperature: between -10 degrees C

to 40 degrees C.

WARNING 1

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:

Minimum primary current

circuit size （Vin/Amps）

Current & Duty cycle

Model

Primary

supply lead

size

TIG STICK TIG STICK

DYNA MMA 500S Minimum 6.0mm2

380V/ 33A

415V/ 30.2A

380V/ 41A

415V/ 37.5A

500A/30V@100%

500A/40V@60%

450A/38V@100%

DYNA MMA 500GTS Minimum 6.0mm2

380V/ 33A

415V/ 30.2A

380V/ 41A

415V/ 37.5A

500A/30V@100%

500A/40V@60%

450A/38V@100%

DYNA MMA 500(H)S Minimum 6.0mm2

380V/ 33A

415V/ 30.2A

380V/ 41A

415V/ 37.5A

500A/30V@100% 500A/40V@100%

DYNA MMA 500(H)GTS Minimum 6.0mm2

380V/ 33A

415V/ 30.2A

380V/ 41A

415V/ 37.5A

500A/30V@100% 500A/40V@100%

DYNA MMA 630S Minimum 8.0mm2

380V/ 44A

415V/ 40.3A

380V/ 54A

415V/ 49.4A

630A/35.2V@100%

630A/44V@60%

500A/40V@100%

DYNA MMA 630GTS Minimum 8.0mm2

380V/ 44A

415V/ 40.3A

380V/ 54A

415V/ 49.4A

630A/35.2V@100%

630A/44V@60%

500A/40V@100%

Table 1 Primary current circuit sizes to achieve maximum current

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

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.

Electrical Input Requirements

Operate the welding power source from three phases 50/ 60 Hz, AC power supply. The input voltage must

match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the

local electric utility for information about the type of electrical service available, how proper connections

should be made, and inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical power

from the welding power supply whenever necessary to inspect or service the unit.

According to Table 1 and below as a guide to select line fuses for the disconnect switch.

Phases Input Voltage Fuse Size Model

Three phases 380/415V AC 60A

MMA 500S、500GTS、500(H)S、500(H)GTS

Three phases 380/415V AC 80A

MMA 630S、630GTS

Table 2

Notice: Fuse size is based on not more than 200 percent of the rated input amperage of the

welding power source (Based on Article 630, National Electrical Code).

Figure 1 Electrical input connections

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

2.02 Specifications

Model

MMA 500S MMA 500GTS MMA 500(H)S

MMA

500(H)GTS

MMA 630S MMA 630GTS

Input voltage and

frequency

380/415V

50/60Hz

380/415V

50/60Hz

380/415V

50/60Hz

380/415V

50/60Hz

380/415V

50/60Hz

380/415V

50/60Hz

KVA @ max

output

27KVA 27KVA 27KVA 27KVA 35.5KVA 35.5KVA

Max current

500A 500A 500A 500A 630A 630A

Output current

10~500A 10~500A 10~500A 10~500A 10~630A 10~630A

Open circuit

voltage

78/85V 78/85V 78/85V 78/85V 78/85V 78/85V

Down slope time

0~5s 0~5s 0~5s

Gas post-flow

time

0~5s 0~5s 0~5s

Duty cycle at

40℃

60% 60% 100% 100% 60% 60%

Weight 65kg 67kg 70kg 72kg 80kg 82kg

Dimensions

560×365×640 560×365×640 560×365×640 560×365×640 560×365×640 560×365×640

Table 3

2.03 Duty cycle

The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be

operated at a given output without causing overheating and damage to the unit. If the welding amperes

decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty

cycle will decrease.

WARNING: Exceeding the duty cycle ratings will cause the thermal overload

protection circuit to become energized and shut down the output until has cooled

to normal operating temperature

Continually exceeding the duty cycle ratings

can cause damage to the welding power source.

NOTICE：

Due to variations that can occur in manufacture products, claimed performance, voltages, ratings, all

capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and

ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

3.0 OPERATOR CONTROLS

3.01 DYNA MMA controls

Figure 2

1. Main Circuit Breaker

2. Arc Selection—Long Arc/ Short Arc.

3. Current Control

4. Stick/ Lift TIG Select Switch (DYNA MMA 500S、500(H)S、630S); Stick/ HF TIG Select Switch (DYNA MMA 500GTS、500(H)GTS、630GTS)

5. Remote Amperage

6. Positive Terminal—connect to work ground cable in TIG (in Stick, connect to the weld clamp).

7. 14-Pin Receptacle

8. Output Gas Fitting (DYNA MMA 500GTS, 500(H)GTS, 630GTS)

9. Negative Terminal—connect to the TIG torch in TIG (in Stick, connect to the work ground cable).

10. Arc Force Control

11. Hot Start Control

12. Down Slope Time Control (DYNA MMA 500GTS, 500(H)GTS, 630GTS)

13. Post flow Time Control (DYNA MMA 500GTS, 500(H)GTS, 630GTS)

14. Meter Selection

15. Digital Meter

16. Warning indicator

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

17. AC Power indicator

18. Fuse

19. Input Gas Fitting (DYNA MMA 500GTS, 500(H)GTS, 630GTS)

20. Fuse

21. Ground Screw

22. Input Power Cable Port

Figure 3

Pin Function

A Torch switch

B Torch switch

C Remote Amp

D Remote Amp

E Remote Amp

Table 4

WARNING

When the welder is connected to the primary supply voltage, the internal electrical components maybe at primary potential with respect to earth.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

3.02 Weld parameters description

Figure 4 DYNA MMA series front panel with parameter description

Parameter Description

Welding Current This parameter sets the welding current when pulse is off.

Arc Force

This parameter provides a suitable short circuit current in STICK welding to improve

electrode sticking and arc stability.

Hot Start

This parameter operates in STICK weld mode and is used to improve the start

characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak

start current on top of the (WELD) current.

Long Arc

This control provides a long Arc in STICK welding to improve characteristics for

STICK electrodes.

Short Arc

This control provides a short Arc in STICK welding to improve electrode restart

quickly.

Down Slope Time

This parameter operates in TIG modes only and is used to set the time for the

welding current to ramp down, this control is used to eliminate the crater that can

form at the completion of a weld.

Post-Flow

This parameter operates in TIG modes only and is used to adjust the post gas flow

time once the arc has extinguished. This control is used to dramatically reduce

oxidation of the tungsten electrode.

Table 5 Weld parameter description for DYNA MMA series

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

3.03 Weld parameter for DYNA MMA series

Model MMA 500S

MMA

500GTS

MMA

500(H)S

MMA

500(H)GTS

MMA 630S

MMA

630GTS

PEAK CURRENT 500A 500A 500A 500A 630A 630A

TIG

10~500A 10~500A 10~500A 10~500A 10~630A 10~630A

WELD

CURRENT

STICK

10~500A 10~500A 10~500A 10~500A 10~630A 10~630A

ARC FORCE 0~100A 0~100A 0~100A 0~100A 0~100A 0~100A

HOT START 0~100A 0~100A 0~100A 0~100A 0~100A 0~100A

DOWN SLOPE 0~5s 0~5s 0~5s

POST-FLOW 0~5s 0~5s 0~5s

Table 6 Weld parameters for DYNA MMA series

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

4.0 SET-UP FOR MMA (STICK) AND GTAW (TIG)

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. Current delivered to the arc is dependent on the

welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding

current at any one setting would vary according to the type of electrode in use. The operator should use the

welding current range values as a guide, and then finally adjust the current setting to suit the application.

Figure 5 Set up for DYNA MMA Series

WARNING:

Before connecting the work clamp to the work and inserting the electrode in the electrode holder

make sure the Primary power supply is switched off.

CAUTION 2:

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the

Welding Power Source.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

4.01 Stick welding

z Connect work lead to negative terminal.

z Connect electrode lead to positive terminal.

z Switch machine on.

z Set welding current control (see table 7).

Workpiece thickness mm

0.5-2.0 2.0-5.0 5.0-7.0

Electrode diameter mm

1.0-2.0 2.0-3.2 3.2-4.0

Welding current（A）

10-50 50-150 150-250

Table 7

4.02 DC TIG welding

z Connect work lead to positive terminal.

z Connect TIG torch to negative terminal.

z Switch machine on.

z Set welding current control (see table 8).

z Use TIG torch with value control.

Workpiece

thickness (mm)

Tungsten

diameter (mm)

Welding current

(A)

Filler wire

diameter (mm)

Argon Gas flow

(L/min)

0.3-0.5 1-1.6 5-30 3-8

0.5-1.2 1.6-2 10-50 1.2-1.6 4-8

1.2-2 1.6-2 10-50 1.2-1.6 4-8

1.2-2 1.6-2 30-70 1.6-2.0 6-9

2-4 2-4 60-100 1.6-2.0 7-10

4-6 3-4 100-200 2.0-2.5 1-15

Table 8

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

5.0 POWER SUPPLY CONTROLS INDICATORS AND REATURES

Figure 6 DYNA MMA series front panel

1. Main Circuit Breaker

2. Arc Selection—long Arc/ short Arc

3. Current Control

4. Stick/ LIFT TIG (HF TIG) Select Switch

5. Remote amperage

6. Arc Force Control

7. Hot Start Control

8. Down Slope Time Control

9. Post flow Time Control

10. Meter Selection

11. Digital Meter

12. Warning indicator

13. AC Power indicator

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

6.0 BASIC TIG WELDING GUIDE

6.01 Electrode Polarity

Connect the TIG torch to the - / torch terminal and the work lead to the + / work terminal for direct current

straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows

limited wear of the electrode since 70% of the heat is concentrated at the work piece.

6.02 Tungsten Electrode Current Ranges

Electrode Diameter (mm) DC current (A)

1.0 30—60

1.6 60—115

2.4 100—165

3.2 135—200

4.0 190—280

4.8 250—340

Table 9 Current ranges for varies tungsten electrode sizes

6.03 Tungsten Electrode Types

Tungsten type

(Ground finish)

Welding Application Features

Color

code

Thoriated 2%

DC welding of mild steel, stainless steel and copper

Excellent arc starting, Long life, high current carrying capacity

Red

Ceriated 2%

DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Longer Life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc

Grey

Table 10 Tungsten electrode types

6.04 Guide for Selecting Filler Wire Diameter

Filler wire diameter DC current range (Amps)

1.6 20—90

2.4 65—115

3.2 100—165

4.8 200—350

Table 11 Filler wire selection guide

Notice：

The filler wire diameter specified in Table 11 is a guide only, other diameter wires may be used according to the welding application.

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

6.05 Shielding gas selection

Alloy Shielding gas

Aluminium & alloys Argon

Carbon steel Argon

Stainless steel Argon

Nickel alloy Argon

Copper Argon

Titanium Argon

Table 12 Shield gas selection

6.06 MMA welding parameters for low carbon & low alloy steel pipe

Tungsten type &

diameter

Current range DC

(Amperes)

Filler rod for root pass Joint preparation

Thoriated 2%

3/32” (2.4mm)

120—170 Yes

Thoriated 2%

3/32” (2.4mm)

100—160 Yes

Thoriated 2%

3/32” (2.4mm)

90—130 No

Table 13 MMA welding parameters for low carbon & low alloy steel pipe

6.07 Welding parameters for steel

Base metal

thickness

(mm)

DC current

for mild

steel (A)

DC current

for stainless

steel (A)

Tungsten

diameter

(mm)

Filler rod

diameter (if

require) (mm)

Argon gas

flow rate

(litres/min)

Joint type

1.0

35—45 40—50

20—30 25—35

1.0 1.6 5—7

butt/ corner

lap/ fillet

1.2

45—55 50—60

30—45 35—50

1.0 1.6 5—7

butt/ corner

lap/ fillet

1.6

60—70 70—90

40—60 50—70

1.6 1.6 7

butt/ corner

lap/ fillet

3.2

80—100

90—115

65—85

90—110

1.6 2.4 7

butt/ corner

lap/ fillet

4.8

115—135 140—165

100—125 125—150

2.4 3.2 10

butt/ corner

lap/ fillet

6.4

160—175 170—200

135—160 160—180

3.2 4.0 10

butt/ corner

lap/ fillet

Table 14 DC TIG welding parameters

Page 21

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

7.0 BASIC ARC WELDING GUIDE

7.01 Electrode polarity

Stick electrodes are generally connected to the “+” terminal and the work lend to the “-“ terminal but if in

doubt consult the electrode manufacturers literature.

7.02 Effects of stick welding various materials

High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld

area, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes size, short runs for larger electrode deposits or tempering in a furnace.

Manganese steels

The effect on manganese steel slow of cooling from high temperature is to embrittle it. For this reason it

is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

Cast iron

Most types of cast iron, expect white iron, are weldable. White iron, because of its extreme brittleness,

generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

Copper and alloys

The most important factor is the high rate of heat conductivity of copper, so making preheating of heavy

sections necessary to give proper fusion of weld and base metal.

Types of Electrodes

Arc welding electrodes are classified into a number of groups depending on their applications. There are

a great number of electrodes used for specialized industrial purposes, which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of welding machines.

Metals being joined Electrode Comments

mild steel 6013

Ideal electrodes for all general purpose work. Features include out standing operator appeal, easy arc starting and low spatter.

mild steel 7014

All positional electrodes for use on mild and galvanized steel furniture, plates, fences, gates, pipes and tanks etc. Especially suitable for vertical-down welding.

cast iron nickel 99% Suitable for joining all cast irons except white cast iron.

stainless steel 318L-16

High corrosion resistance. Ideal for dairy work, etc. On stainless steels.

copper, bronze, brass etc.

bronze

5.7ERCUSI-A

Easy to use electrode for marine fittings, water taps and valves, water trough float arms, etc. Also for joining copper to steel and for bronze overlays on steel shafts.

high alloy steels, dissimilar

metals, crack resistance, all

hard-to-weld jobs

312-16

It will weld most problematical jobs such as springs, shafts, broken joins mild steel to stainless and alloy steels. Not suitable for Aluminum.

Table 15 Types of Electrodes

Page 22

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

8.0 MAINTENANCE

If this equipment does not operate properly, stop work immediately and investigate the cause of the

malfunction. Maintenance work must be performed by an experienced, qualified person only. Any electrical

work must be performed by an electrician or other person properly trained in servicing electrical equipment.

Do not permit untrained persons to inspect, clean or repair this equipment. Use only recommended

replacement parts when servicing this machine.

Periodically clean the inside of the welding power source by using clean dry compressed air of not over

25psi as normal preventive maintenance. At the time of the cleaning, a full inspection of the welding machine

and setup should be performed. Check warning labels on the machine for readability; replace if necessary.

Check input and output connections as well as frame ground connections to the machine to insure that they

are tight and the wires are not frayed or overheated. Inspect internal wiring of machine for loose or frayed

connections; tighten or repair as necessary. It would also be advisable to check connections to wire feeders,

fixtures, etc., at this time. Any damaged cable or hoses should be replaced.

DANGER: HIGH VOLTAGE is present internally even with the control power switch in the

OFF position. Before inspecting, cleaning, or servicing, disconnect and lock out input power to

the power source.

9.0 BASIC TROUBLESHOOTING

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.

The basic level of troubleshooting is that which can be performed without special equipment or

knowledge.

9.01 Check the item and excrescent phenomenon exclusion method

Page 23

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

Troubleshooting Guide

Fault Cause Remedy

1. The AC power indicator light is not lit and welding arc can not be established.

1. No power input or main power switches damage.

2. Indicator damage.

1. Check input power or replace main power switch.

2. Replace indicator light.

2. The AC power indicator light on and welding arc can not be established.

1. Input voltage unstable.

2. Diode damage.

1. Connect stabilizer or reset power switch.

2. Replace diode.

3. The warning indicator light on. Over load.

Reduce current or wait moment.

a. No argon flow

no spark.

1. TIG torch switch leads are disconnected.

2. TIG torch switch damage.

1. Reconnect.

2. Replace TIG torch switch.

b. Argon flow

ontinues no

spark.

1. HF starter dirty or spark gaps not enough.

2. HF starter damage.

1. Clean the starter and adjust the spark gap between 0.3~0.8mm.

2. Replace HF starter.

c. No argon flow

have spark.

1. TIG torch damage.

2. Gas hose is cut.

3. Solenoid value damage.

4. Control PCB damage.

1. Replace TIG torch.

2. Replace gas hose.

3. Replace solenoid value.

4. Replace Control PCB.

4. TIG mode no high frequenc y starts.

d. Argon flow

continues have spark.

1. TIG cable disconnected.

2. Poor tungsten electrode.

1. Reconnect.

2. Replace.

5. TIG mode unstable Arc.

1. Wrong tungsten electrode.

2. TIG torch bad contact or damage.

3. Argon flow control is improper, not pure argon gas.

4. TIG torch gas hose is cut.

5. TIG torch wrong position (negative for TIG torch).

6. Control PCB damage.

1. Choose right tungsten.

2. Replace TIG torch.

3. Replace argon gas capacity.

4. Replace TIG torch.

5. Reconnect.

6. Replace control PCB.

6. TIG mode incorrect output.

1. TIG torch/ electrode holder.

2. Wrong setting.

3. Control PCB damage.

1. Replace.

2. Reset.

3. Replace control PCB.

7.The arc weld has no output

1. The function switch set incorrectly.

2. Three phase commutate bridge damage.

3. IGBT damage.

4. Drive board damage.

1. Correctly set the function switch.

2. Replace.

3. Replace.

4. Repair or replace.

8. Arc start difficult or often break off in arc welding.

1. The weld current setting too low.

2. The power supply voltage is too low or the cable is too thin.

3. Control Board damage.

1. Increase.

2. Replace.

3. Replace.

4. Repair or replace.

9. Can not display the amperage or voltage or faulty display.

Display Board damage. Repair or replace.

Table 16

Page 24

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

9.02 TIG welding problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper

welding technique.

Description Possible Cause Remedy

1. Excessive bead build-up or poor penetration or poor fusion at edges of weld.

Welding current is too low.

Increases weld current, and/ or faulty joint preparation.

2. Weld bead too wide and flat or undercut at edges of weld or excessive burn through.

Welding current is too high. Decreases weld current.

3. Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.

Travel speed too fast. Reduce weld speed.

4. Weld bead too wide or excessive bead build up or excessive penetration in butt joint.

Travel speed too low. Increase travel speed.

5. Uneven leg length in fillet joint.

Wrong placement of filler rod. Re-position filler rod.

6. Dirty weld pool.

A Electrode contaminated through

contact with work piece or filler rod material.

B Gas contaminated with air.

A Clean the electrode by grinding off

the contaminates.

B Check gas lines for cuts and loose

fitting or change gas cylinder.

7. Electrode melts or oxidizes when an arc is struck.

A Electrode is connected to the “+”

terminal.

B No gas flowing to welding region.

C Torch is clogged with dust. D Gas hose is cut. E Gas passage contains impurities.

F Gas regulator turned off. G Torch valve is turned off. H The electrode is too small for the

welding current.

A Connected the electrode to the “-”

terminal.

B Check the gas lines for kinks or

breaks and gas cylinder contents. C Clean torch. D Replace gas hose. E Dismantle a soft tube from the

torch then raise gas pressure and

blow out impurities. F Turn on. G Turn on. H Increase electrode diameter or

reduce the welding current.

8. Poor weld finish. Inadequate shielding gas.

Increase gas flow or check gas line for gas flow problems.

9. Arc flutters during TIG welding.

A Tungsten electrode is too large

for the welding current.

B Absence of oxides in the weld

pool.

A Select the right size electrode.

Refer to basic TIG welding guide.

B Refer basic TIG welding guide for

ways to reduce arc flutter.

10. Welding arc can not be established.

A Work clamp is not connected to

the work piece or the work/ torch leads are not connected to the

right welding terminals. B Torch lead is disconnected. C Gas flow incorrectly set, cylinder

empty or the torch valve is off.

A Connect the work clamp to the

work piece or connect the work/ torch leads to the right welding

terminals. B Connect it to the “−” terminal. C Select the right flow rate, change

cylinders or turn torch valve on.

Page 25

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

11. Arc start is not smooth.

A Tungsten electrode is too large

for the welding current.

B The wrong electrode is being

used for the welding job.

C Gas flow rate is too high.

D Incorrect shielding gas is being

used.

E Poor work clamp connection to

work piece.

A Select the right size electrode.

Refer to basic TIG welding guide. B Select the right electrode type.

Refer to basic TIG welding guide C Select the correct rate for the

welding job. D Select the right shielding gas.

Refer to Basic TIG Welding Guide. E Improve connection to work piece.

Table 17

9.03 Stick welding problems

Description Cause Remedy

1 Gas pockets or

voids in weld metal (Porosity).

A Electrodes are damp. B Welding current is too large. C Surface impurities such as: oil,

grease, paint, etc.

A Dry electrodes before use. B Reduce welding current. C Clean joint before welding.

2 Crack occurring in

weld metal soon after solidification commences.

A Rigidity of joint.

B Insufficient throat thickness.

C Cooling rate is too high.

A Redesign to relieve weld joint of

severe stresses or use crack resistance electrodes.

B Travel slightly slower to allow greater

build up in throat.

C Preheat plate and cool slowly.

3 A gap is left by

failure of the weld metal to fill the root of the weld.

A Welding current is too low. B Electrode too large for joint. C Insufficient gap. D Incorrect sequence.

A Increase welding current. B Use smaller diameter electrode. C Allow wider gap. D Use correct build-up sequence.

4 Portions of the weld

run do not fuse to the surface of the metal or edge of the joint.

A Small electrodes used on heavy cold

plate. B Welding current is too low. C Wrong electrode angle.

D Travel speed of electrode is too high. E Scale or dirt on joint surface.

A Use larger electrodes and preheat

the plate. B Increase welding current. C Adjust angle so the welding is

directed more into the base metal. D Reduce travel speed of electrode. E Clean surface before welding.

5 Non-metallic

particles are trapped

in the weld metal

(slag inclusion).

A Non-metallic particles may be trapped

in undercut from previous run.

B Joint preparation too restricted.

C Irregular deposits allow slag to be

trapped.

D Lack of penetration with slag trapped

beneath weld bead.

E Rust or mill scale is preventing full

fusion.

F Wrong electrode for position in which

welding is done.

A If bad undercut is present, clean slag

out and cover with a run from a

smaller diameter electrode. B Allow for adequate penetration and

room for cleaning out the slag. C If very bad, chip or grind out

irregularities. D Use smaller electrode with sufficient

current to give adequate penetration.

Use suitable tools to remove all slag

from corners. E Clean joint before welding.

F Use electrodes designed for position

in which welding is done, otherwise

proper control of slag is difficult.

Table 18

Page 26

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

9.04 Power source problems

Description Possible Cause Remedy

1 The welding arc can not

be established.

A The Primary supply voltage

has not been switched on.

B The welding power source

switch is switched off.

C Loose connections internally.

A Switch on the primary supply voltage.

B Switch on the welding power source.

C Have an accredited FCW service

agent repair the connection.

2 Maximum output welding

current can not be

achieved with nominal

Mains supply voltage.

Defective control circuit.

Have an accredited FCW service agent

inspect then repair the welder.

3 Welding current reduces

when welding.

Poor work lead connection to

the work piece.

Ensure that the work lead has a positive

electrical connection to the work piece.

4 No gas flow when the

torch trigger switch is

depressed.

A Gas hose is cut.

B Gas passage contains

impurities.

C Gas regulator turned off.

A Replace gas hose.

B Disconnect gas hose from the rear of

power source then raise gas

pressure and blow out impurities.

C Turn gas regulator on.

Table 19

Notice:

Can move the equipments that the power supply doesn't fixedly mean to link to work with gearing at the some

position.

Page 27

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

10.0 PARTS LIST

Page 28

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

Page 29

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

Figure 7

QTY.

500S 500GTS 500HS 500HGTS 630S 630GTS

Se qu en

Name Order No

P/N:

610008999

P/N:

610011999

P/N:

610018999

P/N:

610024999

P/N:

610031999

P/N:

610034999

CONTROL PCB FP7.820.041C-03

3KITP002702011 1 1 1

CONTROL PCB FP7.820.041C

1 1 1

DRIVE PCB FP7.820.040B-04

3KITP002702024 1 1 1 1 1 1

DISPLAY PCB B FP7.824.002B

3KITP002706015 1 1 1 1 1 1

DISPLAY PCB A FP7.824.002A

3KITP002706011 1 1 1 1 1 1

TRANSFORMER CONTROL BOD100

4EER400113 1 1 1 1 1 1

BREAKER 75A

4KAMM3R75A 1 1 1 1 1 1

TERMINAL 2*9

4CC010207 1 1 1 1 1 1

TERMINAL 2*3

4CC010203 1 1 1 1 1 1

LABEL L1-L2-L3

2LAM8806014 1 1 1 1 1 1

FUSE HOLDER

4FUSH15X250XD6 2 2 2 2 2 2

BUSHING,STRAIN RELIEF PG29

4SXJPG29 1 1 1 1 1 1

PANEL CENTER

2FPUT8038017 1 1 1 1 1 1

BUSHING SNAP BS26

4WRKSSBS26 4 4 4 4 4 4

BUSHING SNAP BS16

4WRKSSBS1216 1 1 1 1 1 1

SCREW INSULATION

4PCS002H18 12 12 12 12 12 12

HEATSINK DIODE

2HS7061011 1 1 1 1 1 1

RECTIFIER MZS150-16

4AB3P150A1R6KV 1 1 1 1 1 1

DIODE ULTRA FAST RECOVERY FR300BA50

4V2HFR300BA50 4 4 4 4 4 4

Page 30

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

THERMOSTAT SD301

4KNCROT85 2 2 2 2 2 2

SENSOR CS400E

4SNOCS400E 1 1 1 1

SENSOR CS600E

4SNOCS600E 1 1

CAPACITANCE 3KV103

481CC3KV103 15 15 15 15 15 15

RESISTANCE 15W 10Ω

4RX27D15W10 2 2 2 2 2 2

BUS BAR FP7.725.025

3BB7725025 2 2 2 2 2 2

BUS BAR FP7.725.026

3BB7725026 1 1 1 1 1 1

SUBASSEMBLY IGBT 300GB128D

3KITP002701011 2 2 2 2 2 2

25-1

IGBT 300GB128D

4SKM300GB128D 2 2 2 2 2 2

25-2

GRID PCB FP7.820.047-02

3KITP003205000 2 2 2 2 2 2

RESISTANCE 20W 1Ω

4RX27D20W1H 4 4 4 4 4 4

BRACKET

2FPPP8610117 3 3 3 3 3 3

HEATSINK IGBT FP7.061.019

2HS7061019 1 1 1 1 1 1

BUS BAR FP7.725.021

3BB7725021 1 1 1 1 1

BUS BAR FP7.725.029

3BB7725029 1 1 1 1 1 1

BUS BAR FP7.725.019

3BB7725019 1 1 1 1 1 1

BUS BAR FP7.725.018

3BB7725018 1 1 1 1 1 1

BUS BAR FP7.725.020

3BB7725020 1 1 1 1 1 1

BUS BAR FP7.725.028

3BB7725028 1 1 1 1 1 1

CONTACTOR NC1-1801/220V

4KNC11801220 1 1 1 1 1 1

RESISTANCE 20W 100Ω

4RX27D20W100H 2 2 2 2 2 2

FAN 200FZYZ-D

4FAN001SA200F 2 2 2 2 2 2

BRACKET MOUNTING FAN FP8.044.006

2FPBG8044006 1 1 1 1 1 1

BRACKET GAS VALVE FP8.044.006

2FPBZ8610025 1 1 1

GAS VALVE

3KITP000112004 1 1 1

CAPACITANCE 400V20UF

422CBB400V20 4 4 4 4 4 4

BRACKET MOUNTING CAPACITANCE FP8.610.010

2FPBS8610010 2 2 2 2 2 2

BRACKET MOUNTING CAPACITANCE FP8.604.010

2FPBS8604010 1 1 1 1 1 1

BRACKET MOUNTING CONTACTOR FP8.604.056

2FPBS8604056 1 1 1 1 1 1

SCREW M8*20

5GBBT5783M8X20 1 1 1 1 1 1

LABEL VOLTAGE INPUT 415V 3P

2LAM8806006 1 1 1 1 1 1

LABEL MANUFACTURERS MMA 500S

2LAN8808044 1

LABEL MANUFACTURERS MMA 500GTS

2LAN8808199 1

LABEL MANUFACTURERS MMA 500HS

2LAN8808198 1

LABEL MANUFACTURERS MMA 500HGTS

2LAN8808200 1

LABEL MANUFACTURERS MMA 630S

2LAN8808201 1

LABEL MANUFACTURERS MMA 630GTS

2LAN8808202 1

LABEL REAR FUSE

2LAR8806005 1 1 1 1 1 1

Page 31

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

LABEL GROUND

2LAM8800003 1 1 1 1 1 1

CAP PROTECTION

2FP8647000 4 2 4 2 4 2

PANEL BACK FP8.041.018

2FPPR8041018 1 1 1 1 1 1

OVERLAY CONTROL

2LAC8807037 1 1 1 1 1 1

OVERLAY CONTROL MMA500S

2LAF8802026 1

OVERLAY CONTROL MMA500GTS

2LAF8802068 1

OVERLAY CONTROL MMA500HS

2LAF8802016 1

OVERLAY CONTROL MMA500HGTS

2LAF8802073 1

OVERLAY CONTROL MMA630S

2LAF8802064 1

OVERLAY CONTROL MMA630GTS

2LAF8802069 1

LABLE （+ PPG -)

2LAU8803002 1 1 1 1 1 1

SWITCH KNX202

4KNX202 4 4 4 4 4 4

POTENTIONMETER 2W 100K

4WTHRV24YN100K 1 3 1 3 1 3

KNOB

4KYZPN8E20R3 2 4 2 4 2 4

POTENTIONMETER 2W 5K

4WTHRV24YN5K 1 1 1 1 1 1

KNOB

4KYZPN8D24 1 1 1 1 1 1

POTENTIONMETER 2W 10K

4WTHRV24YN10K 1 1 1 1 1 1

FTG,GAS BARBED 1/4 TBG 5/8-18 FEMALE

3KITP000113000 1 1 1

INSULATOR BULKHEAD REAR

2FP7854005 2 2 2 2 2 2

INSULATOR BULKHEAD FRONT

2FP7854010 2 2 2 2 2 2

RECEPTACLE

2AD7735011 2 2 2 2 2 2

BRACKET COVER FP7.854.009

2FP7854009 2 2 2 2 2 2

PANEL CONTROL FP8.041.016

2FPPC8041016 1 1 1 1 1 1

PANEL FRONT FP8.041.022

2FPPF8041022 1 1 1 1 1 1

INSULATOR POTENTIONMETER

2FP7854006 3 5 3 5 3 5

INSULATOR POTENTIONMETER

2FP7854007 3 5 3 5 3 5

RECEPTACLE 14 PIN

4WP143102A 1 1 1 1 1 1

RESISTANCE 50W 500Ω

4RX27D50W500H 1 1 1 1 1 1

HF PCB FP7.820.020C-03

3KITP002005031 1 1 1

HF PCB FP7.820.020C-02

3KITP002005010 1 1 1

INDUCTOTR ASSY,OUTPUT

3EER22012 1 1 1 1 1 1

INDUCTOTR ASSY,INPUT

3EER21003 1 1 1 1 1 1

FILTER PCB FP7.822.000-01

3KITP002706080 1 1 1 1 1 1

TRANSFORMER,POWER ASSY,500S

3EER31012 1 1 1 1 1 1

CAPACITANCE 400V2700UF

4CDJ400V2700 4 4 4 4 4 4

MUTUAL INDUCTANCE RING

4EER400072 1 1 1 1 1 1

PLASTIC BOX

7BOX00001 1 1 1 1 1 1

INSULATOR BULKHEAD FRONT

422CBB630V104 4 4 4 4 4 4

Page 32

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

RESISTANCE 5W 33KΩ

4RX27D5W33K 4 4 4 4 4 4

BASE FP8.031.008

2FPB8031008 1 1 1 1 1 1

BUS BAR FP7.725.022

3BB7725022 1 1 1 1 1 1

BUS BAR FP7.725.024

3BB7725024 2 2 2 2 2 2

PANEL LEFT FP8.048.013

2FPPS8048013GJ 1 1 1 1 1 1

PANEL RIGHT FP8.048.014

2FPPS8048014GJ 1 1 1 1 1 1

PANEL TOP FP8.040.003

2FPPT8040003GJ 1 1 1 1 1 1

LABEL FCW

2LAS8809008 2 2 2 2 2 2

LABEL WARNING

2LAW8805000 1 1 1 1 1 1

flying rings M8

5GBTRT825M8BK 2 2 2 2 2 2

SCREW M6*16

5FPS8918001 30 30 30 30 30 30

SCREW M8*16

5FPS8918003 2 2 2 2 2 2

COUPLING COIL

3EER10010 1 1 1

LABEL GAS INPUT

2LAU8801001 1 1 1

GAS HOSE 4*6

8HPU4X6BK001 0.5 0.5 0.5

remark MOUNT NPRN JJ20

4JFT10X20 4 4 4 4 4 4

Table 20

11.0 Remark

11.1 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.

11.2 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.

11.3 Ambient temperatures high when big electric current long time continuous working, the welding machine has stopped because of the heat outputting, gets down until the temperature drop only then restores.

11.4 When welding machines do not use temporarily, its depository should maintain dryly, cleanly. The environment relative humidity is not bigger than 85%.

11.5 Storing ambient temperature is -25℃~ +55℃.

11.6 When long-time does not use, every two months should electrify a time, a humidity month of every two week should electrify use a time, by use own thermal row of tide.

Page 33

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DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

APPENDIX: DYNA MMA 500S, 500(H)S, 630S INTERCONNECT DIAGRAM

批准

标准化

审核

拟制

标记数量更改单号签名日期

阶段标记第张共张

MMA 500S MMA 500HS

GND

1 2

HL2 200A/4V

FR300BA50

ZL2

K7K5

Thermostat

VR1 5K(4K7)

FR300BA50

R13 500/50W

Z1 75A/1200V

3P 380V

ZQ1

R S T G

FAN2

SA1725A2

100R/20W

R2 100R/20W

BOD100

F1 3A

FAN1

SA1725A2

380V

415V

460V

220V

27V

27V 20V

20V

4 5

ZL1

G1 G2K1 K2

IGBT1

6 7 2

IGBT1

150GB128D

C17

20u/400V

C18

20u/400V

2700u/400V

103/3KV

C10 103/3KV

C11

103/3KV

C12

103/3KV

R9 1R/20W

R10 1R/20W

33K/5W

0.1u/630V

2700u/400V

R5 33K/5W

R6 33K/5W

0.1u/630V

6 7 2

IGBT2

150GB128D

C13

103/3KV

C14 103/3KV

C15 103/3KV

C16 103/3KV

R7 1R/20W

R8 1R/20W

C20

20u/400V

C19

20u/400V

R11

15W10

C21

103/3KV

R12

15W10

C22

103/3KV

long arc short arc

202

-12VGND+1 2V+24V

VR2 100K

VR3

10K

hot start

arc force

202

CURRENT

voltage

G1 G2K1 K2

IGBT2

K9A

202

REMOTE

MMA TIG

12345678910111213

14PIN PLU G

FP7.820.041C

CONTYOL PC B

FP7.820.040B

DRIVE PCB

FP7.824.002A

DIS PLA Y PC B A

FP7.824.002B

DISP LA Y PCB B

FP7.820.020C

HF PC B

FP7.820.047C

IGBT PCB

12345

CN1

1211-5

FP7.820.047C

IGBT PCB

12345

CN1

1211-5

1CN4 1211-6

1CN8

1211-2

123

1CN7 2001-3

123

1CN3 1211-4

12345

1CN6

1211-5

1CN11

1211-2

1CN2

2001-5

1 2 3 4

1CN5 2001-4

1 2 3 4 5

1CN13

1211-5

12345

1CN10 1211-5

12345

1CN9 1211-5

FP7.820.026A PWM

板

123

1CN1

123456710111213

65123

131211

789

CNX

123

2CN1

1211-4

12345

2CN2

1211-5

2CN4 2001-2

12345

2CN6

2001-6

12345

2CN7

2001-5

2CN8 2001-3

1 2 3 4 5 6 7

2CN9

2001-7

2CN10

2001-6

1 2 3 4

2CN11

1211-4

123

2CN14

2001-3

1234567

2CN15 200 1-7

2CN5 1121-2

123

2CN3

2001-3

12345

CN6

2001-6

1 2 3 4 5 6 7

CN3

2001-7

CN2

1121-2

12345

CN7

2001-5

123

CN1

1121-3

123

CN5

2001-3

1 2 3

CN9

2001-3

151

12345

CN3

2001-6

1 2 3 4

CN12 2001-4

CN4

2001-2

1 2 3 4 5

CN10

2001-5

123

CN6

2001-3

1 2

CN7

2001-2

4CN1 1211-03

4CN2

1211-02

4XP114XP2

4XP314XP414XP5

11111

FP7.822.000

FILLTER PCB

123

6XP3

1211-4

6XP2

1121-2

1234567

6XP1 2001-8

1510

1 2 3 4 5 6 7 8

PISPLAY

current

MMA 630S

Page 34

- 32 -

DYNA MMA 500S、500GTS、500(H)S、500(H)GTS、630S、630GTS Operating Manual

APPENDIX: DYNA MMA 500GTS, 500(H)GTS, 630GTS INTERCONNECT DIAGRAM

批准

标准化

审核

拟制

标记数量更改单号签名日期

阶段标记第张共张

MMA 500GTS MMA 500HGTS

GND

1 2

HL2 200A/4V

FR300BA50

ZL2

K7K5

Thermostat

VR1 5K(4K7)

FR300BA50

R13 500/50W

Z1 75A/1200V

3P 380V

ZQ1

R S T G

FAN2

SA1725A2

100R/20W

R2 100R/20W

BOD100

F1 3A

FAN1

SA1725A2

380V

415V

460V

220V

27V

27V 20V

20V

4 5

ZL1

G1 G2K1 K2

IGBT1

6 7 2

IGBT1

150GB128D

C17

20u/400V

C18

20u/400V

2700u/400V

103/3KV

C10 103/3KV

C11

103/3KV

C12

103/3KV

R9 1R/20W

R10 1R/20W

33K/5W

0.1u/630V

2700 u/40 0V

R5 33K/5W

R6 33K/5W

0.1u/630V

6 7 2

IGBT2

150GB128D

C13

103/3KV

C14 103/3KV

C15 103/3KV

C16 103/3KV

R7 1R/20W

R8 1R/20W

C20

20u/400V

C19

20u/400V

R11

15W10

C21

103/3KV

R12

15W10

C22

103/3KV

long arc short arc

202

-12VGND+12V+24V

VR2 100K

VR3

10K

hot start

arc force

202

CURRENT

voltage

G1 G2K1 K2

IGBT2

REMOTE

MMA

TIG

12345678910111213

14PIN PLU G

FP7.820.041C

CONTYOL PCB

FP7.820.040B

DRIVE PCB

FP7.824.002A

DISPLAY PCB A

FP7.824.002B

DISPLAY PCB B

FP7.820.020C

HF PC B

FP7.820.047C

IGBT PCB

12345

CN1

1211-5

FP7.820.047C

IGBT PCB

12345

CN1

1211-5

1CN4 1211-6

1CN8

1211-2

123

1CN7 2001-3

123

1CN3 1211-4

12345

1CN6

1211-5

1CN11

1211-2

1CN2

2001-5

1 2 3 4

1CN5 2001-4

1 2 3 4 5

1CN13

1211-5

12345

1CN10 1211-5

12345

1CN9 1211-5

FP7.820.026A PWM

板

123

1CN1

123456710111213

65123

131211

789

CNX

123

2CN1

1211-4

12345

2CN2

1211-5

2CN4 2001-2

12345

2CN7

2001-5

2CN8 2001-3

1 2 3 4 5 6 7

2CN9

2001-7

2CN10

2001-6

1 2 3 4

2CN11

1211-4

123

2CN14

2001-3

2CN5 1121-2

123

2CN3

2001-3

12345

CN6

2001-6

1 2 3 4 5 6 7

CN3

2001-7

CN2

1121-2

12345

CN7

2001-5

123

CN1

1121-3

123

CN5

2001-3

1 2 3

CN9

2001-3

151

12345

CN3

2001-6

1 2 3 4

CN12 2001-4

CN4

2001-2

1 2 3 4 5

CN10

2001-5

123

CN6

2001-3

1 2

CN7

2001-2

4XP114XP2

4XP314XP414XP5

11111

FP7.822.000

FILLTER PCB

123

6XP3

1211-4

6XP2

1121-2

1234567

6XP1 2001-8

1510

1 2 3 4 5 6 7 8

PISPLAY

curren t

MMA 630 GTS

3 4

202

遥控

手工焊

氩弧焊

12345

2CN6

2001-6

1234567

2CN15

2001-7

4CN1 1211-03

4CN2

1211-02

2CN12 1121-2

100K 100K

Down slope tim ePost flow time

FCW DYNA MMA 500S, DYNA MMA 500HS, DYNA MMA 500GTS, DYNA MMA 630S, DYNA MMA 630GTS Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual