ESAB LAW 510 Bedienungsanleitung

0740 800 025 9708

LAW 400/500

LAW 410/510

Welding rectifier

Service manual

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LIST OF CONTENTS Page

READ THIS FIRST 3...............................

COMPONENT DESCRIPTION LAW 400/500 4........

CONNECTION DIAGRAM, LAW 400/500 400--415 V

Validformachinenumber 434 ... .... 6.................

CONNECTION DIAGRAM, LAW 400/500 230--500 V

Validformachinenumber 434 ... .... 8.................

CONNECTION DIAGRAM, LAW; 400--415 V

Valid from machine number 512 . . . . . . .10................

CONNECTION DIAGRAM, LAW; 230--500 V

Validfrommachinenumber 512 ... .... 12................

AP1 COMPONENT POSITIONS

Circuit board with part no. 0486 220 880 15..................

AP1 COMPONENT POSITIONS

Circuit board with part no. 0486 291 880 16..................

AP1 COMPONENT POSITIONS

Circuit board with part no. 0486 480 880 (version A) 17.........

FUNCTION DESCRIPTION 18.......................

AP2 SUPPRESSION CIRCUIT BOARD 30.............

TEST ROUTINE 31.................................

FITTING INSTRUCTIONS, THERMAL CUTOUT 33.....

FITTING INSTRUCTIONS, THYRISTOR MODULES 33..

LOAD CHARACTERISTIC 36........................

TECHNICAL DATA 37...............................

PRIMARY CONNECTIONS LAW; 230--500 V 38.......

CONTROL PANEL AND CONNECTIONS 39...........

MAINTENANCE 39.................................

ACCESSORIES 40..................................

DESIGN CHANGES 41..............................

SPARE PARTS LIST LAW 400/500 43................

SPARE PARTS LIST LAW 410/510 55................

Rights reserved to alter specifications without notice

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READ THIS FIRST

This service manual is intended for use by technicians with electrical/electronic training, for

help in connection with fault--tracing and/or repair.

Use the connection diagram as a form of index for the description of operation and the

component description. 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 connection diagram are listed in the component description.

This manual contains details of all design changes that have been made up to and including

August 1997.

The LAW 400/500 and 410/510 are designed and tested in accordance with interna-

tional standard

EN 60 974--1 (IEC 974--1).

On completion of any service or repair, it is the responsibility of the person or

organisation performing the service to ensure that the product still complies with the

above standard.

WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

SInstall and earth the welding unit in accordance with applicable standards.

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

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

SKeep your head out of the fumes.

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

the general area.

ARC RAYS -- Can injure eyes and burn skin.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

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

NOISE -- Excessive noise can damage hearing

SProtect your ears. Use ear defenders or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

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COMPONENT DESCRIPTION LAW 400/500

The LAW welding rectifiers 500 are 6--pulse thyristor rectifier units intended for

semi--automatic welding. They are available for different mains voltages and with or without

integral cooling units: see the table in the spare parts list on page 55. The component

description below refers to the electrical circuit diagrams on page 6 to 12.

AP1 Circuit board with control electronics: see the function description

on page 18.

AP2 Suppression circuit board, see circuit diagram on page 30.

AP2 has been fitted with effect from machine no. 550 . . . ....

C1 Capacitor, 3 ←F 400 V. Start and run capacitor for fan motor EV1.

C2--C4 Suppression capacitors 0.1 ←F 250 V.

C5 Capacitor, 5 ←F 400 V. Start and run capacitor for pump motor M1. Only

in machines with water cooler.

C6 Capacitor, 6 ←F 400 V. For speed reduction of the cooling fan.

This capacitor has been fitted with effect from machine no. 512 . . . . . .

EV1 Fan

FU1 Circuit breaker, 10 A. Protects the 42 V supply to the wire feed unit.

HL1 Indicating lamp, 42 V, white. Lights when switch QF1 is in the ON

position.

KM2 Contactor 42 V 50 Hz. For speed control of the fan: see ST2 below.

This capacitor has been fitted with effect from machine no. 512 . . . ....

L1 Interphase transformer. When connecting the interphase transformer to

the inductor, it is important that all parts are fitted exactly as shown in

Figure A on page 49.

L2 Inductor. When connecting the inductor, it is important that all parts

are fitted exactly as shown in Figures A, C and D on page 49.

M1 Pump motor, 230 V 50 Hz 0.2 kW. Only in machines with water cooler.

P1 Digital display. Accessory, see the list on page 40. The instrument is

described in the service manual for the MEK 4.

QF1 Main ON/OFF switch.

QF2 Cooling water pump switch. Only on machines with water cooler.

R1 Resistor, 0.43 τ.

RS1 Shunt, 60 mV / 600 A

ST1 Thermal overload cutout. Protects the machine against excessive

temperature. See the function description, item 6, on page 21.

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.

LAW 400/410: ST2 is fitted in the interphase transformer winding, L1.

LAW 500/510: ST2 is fitted in the inductor winding, L2.

Thermal switch ST2 is fitted from machine no. 512 . . . ....

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TC1 Control power supply transformer for LAW with 400--415V mains voltage.

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TC1 Control power supply transformer for LAW with 230--500V mains voltage.

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TM1 Main transformer. Connection instructions for the LAW 400/500 and

LAW 410/510 with 230 -- 500 V mains connection are on page 38.

V1--V6 Thyristor module. See the fault--tracing instructions on page 26 and the

fitting instructions on page 33.

V7 LED, yellow. Lights to indicate operation of the thermal cutouts.

XS1 Connector, 23--pole. For connection to/from the wire feed unit.

XS2--XS4 Main welding current contact, single--pole.

XS5--XS8 Sleeve contacts

XS9 4--pole contact. Only on the LAW 500/510.

XS10--XS15 Sleeve contacts

XT1 9--pole terminal block. Only on machines with 230 -- 500 V mains

connection. See the connection instructions on page 38.

XT2 3--pole terminal block.

Z1--Z6 RC filter.

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CONNECTION DIAGRAM, LAW 400/500 400--415 V

Validformachinenumber 434 ... ....

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1 POWER SUPPLY 8 SHUNT INPUT

2 DISPLAY OUTPUT 9 VOLTAGE REFERENCE

3 MACHINE TYPE / TEST INPUT 10 CRATER FILL

4 CONTROLLED / FIXED FIRING ANGLE 11 START / STOP

5 SYNCHRONISING 12 THYRISTOR CIRCUITS

6 THERMAL OVERLOAD CUTOUT 13 PROCESSOR

7 ARC VOLTAGE

The numerals 1 -- 13 refer to the function description on page 18.

CONNECTION DIAGRAM, LAW 400/500 230--500 V

Validformachinenumber 434 ... ....

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Terminal block XT1 and transformer TC1 are connected for 400 -- 415 V 50 Hz: see the connection instructions on page 38.

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1 POWER SUPPLY 8 SHUNT INPUT

2 DISPLAY OUTPUT 9 VOLTAGE REFERENCE

3 MACHINE TYPE / TEST INPUT 10 CRATER FILL

4 CONTROLLED / FIXED FIRING ANGLE 11 START / STOP

5 SYNCHRONISING 12 THYRISTOR CIRCUITS

6 THERMAL OVERLOAD CUTOUT 13 PROCESSOR

7 ARC VOLTAGE

The numerals 1 -- 13 refer to the function description on page 18.

CONNECTION DIAGRAM, LAW; 400--415 V

Validfrommachinenumber 512 ... ....

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AP2fittedfrommachineno.550 ... ....

Pulse function is added, see page 29.

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