Hwayuan Electric ZDE7-1200 Manual Instruction
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Hwayuan Electric ZDE7-1200 Manual Instruction

Inverter ac/dc submerged arc welding machine
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ZDE7-1200
INVERTER AC/DC SUBMERGED ARC WELDING MACHINE
MANUAL
INSTRUCTION
(PLEASE READ IT CAREFULLY BEFORE OPERATION)

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Summary of Contents for Hwayuan Electric ZDE7-1200

  • Page 1 ZDE7-1200 INVERTER AC/DC SUBMERGED ARC WELDING MACHINE MANUAL INSTRUCTION (PLEASE READ IT CAREFULLY BEFORE OPERATION)
  • Page 2 S a f e t y D e p e n d s on Y ou The arc welding and cutting equipments are designed and built with ample safety consideration. However, proper installing and operating the machine can increase your safety. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL THROUGHOUT.

  • Page 3: Table Of Contents

    CONTENT Safety warnings ......................3 Product summary ......................1 Technical parameters ..................... 3 Panel function ....................... 5 Insert function ....................... 8 Machine Installation ....................10 Operation ........................17 Working principle ......................21 Maintenance, repair and discard .................. 21 Trouble shooting ...................... 22 Packing list .......................

  • Page 4: Safety Warnings

    1 Safety warnings Cautions Arc and arc rays can hurt. All performing welding workers ought to have health qualification from the authority organization to prevent you and others from arc radiation and burn. It should be prevented for children to enter into dangerous area as well. Be careful reading the following important items and the welder safety byelaw from the authority organization.
  • Page 5 welding area, including hydraulic lines in the wild.  Where compressed gases are to be used in the field, special precautions should be used to prevent explosion.  When not welding, make certain that no electriferous part is touching the work piece or the work stage. Accidental contact can create a fire hazard.
  • Page 6 one’s doctor first.  The effect of electromagnetic to one’s health is not confirmed, so it might have some negative effect to one’s health.  Welders may use following method to reduce the hazardous of electromagnetic: a. Bundle the cable connected to the work piece and the welding cable together. b.

  • Page 7: Product Summary

    2 Product summary 2.1 Model instruction 2.2 Main features Adopting digital control technology, easy to operate with beautiful outlook. With arc voltage inspection and sensor react technology, welding cable can lengthen to 70m 100% duty cycle, suitable for heavy industry Software technology, with small volume, light weight and low consumption With AC square wave control technology, adjustable AC frequency, DC deviation and wave balance parameter to improve the arc voltage stability, control the welding seam depth and deposition speed to get good performance...
  • Page 8 2.4 Working circumstance The machine protection grade is IP21S, can’t work or stock under the rain Working in living quarters is not recommended Ambient temperature range：When welding：-10～+40℃；transport and store -25～+55℃ Relative humidity：40℃≤50%； 20℃≤90% The dust, corrosive and acid air or material should be within normal range, except the air come from the welding process.

  • Page 9: Technical Parameters

    3 Technical parameters 3.1 Technical parameter Model Item Unit ZDE7-1200HD Input Power V/Hz 3~380/415 ±10% 50 Rated Input Capacity 63.8 KＶA Rated Input Current Rated Output Current 1200 Rated Output Voltage Rated AC Output Current/Voltage 100A/20V～1200A/44V Range Rated Open Circuit Voltage Rated Duty Cycle 100%（40℃）...
  • Page 10 （2） CV model （3） Sharply CC mode 3.3 Rated duty cycle...

  • Page 11: Panel Function

    Rated duty cycle X=100% means take 10min as a circle, machine can work 10min, that means machine can 24 hours work without stop. The machine working is under temperature -10℃～+40℃，if ambient temperature over 40℃ or too much dust inside the machine will cause the duty cycle reduce, maybe the machine will be burnt. 3.4 Overheat protection This machine adopt temperature relay for heat protection, if machine work over the rated duty cycle or ambient temperature over 40℃...
  • Page 12 the indicator will automatically turn to current indicator on. Polarity select knob: AC/DCEP/DCEN exchange knob ）indicator: it will be on when under AC function AC（ DCEP （DC＋） indicator: it will be on when under DCEP function(welding head terminal is +,work piece terminal is -) DCEN （DC－）...
  • Page 13 ）terminal，connect with arc 4.Arc voltage inspection signal: work piece side arc voltage inspection signal input（ voltage inspection cable from work piece side （1） （2） （3） （4） 4.3 Back panel instruction （1） Power switch: over current protection switch, when machine abnormal, this switch will power off to protect the machine.

  • Page 14: Insert Function

    （1） （2） （3） （4） （5） （6） （7） 5 Insert function Item Factory set Instruction  Step 1: press “parameter selection” for 5s, come into insert function set mode, voltmeter show “00.”  Step 2: adjust “parameter adjust” make ammeter show “2”, press “characteristic select”, come into DCEP penetration setting ...
  • Page 15 Item Factory set Instruction  Step 1: press “parameter selection” for 5s, come into insert function set mode, voltmeter show “00.”  Step 2: adjust “parameter adjust” make ammeter show “7”, press “characteristic select”, come into factory set, storage and exit. ...

  • Page 16: Machine Installation

    *Insert function: can set on the front up panel as the above table 4 shows. *Power source protection function: 6s after power on, the machine can have output. *Intelligent fan function: fan work 2s after machine power source. It continue work on remote control mode. It start to work when machine power on under remote control mode, and stop work 8min after machine stop work.
  • Page 17 6.3 6Machine connection 6.3.1、Input power cable connection This machine requires 3 phase 380v/50Hz power input, so the related power cable and distribution box is needed, as well as the circuit breaker and ground lead. Reliably connect the protective ground and the yellow-green wire which on the back of the machine.
  • Page 18 square meter is big enough and connection is stable. The overheat of the cable shall be caused by small cable or connect unstable. （2） Make the cable roll up, like the following drawing 12（a）show is prohibited. If roll up is unavoidable, it better use the way like 12（b）show, make the welding head cable and work cable nearby to reduce circuit inductance.
  • Page 19 （6） Arc voltage inspection cable shall be as short as possible to reduce the inductance （7） Taking the position opposite from the work piece during the welding can get better welding performance （8） When the power used for multi arc and parallel function, after ensure the min. distance for each power source, the communication cable shall be the shorter the better , communication cable shall be less than 1200m 6.3.4、Single wire connection （1）...
  • Page 20 （2） Work with gantry machine Drawing 14 Turn off the three phase input breaker, connect two power source as drawing 13 shows, connect three phase power source, earth cable, welding head side cable, work piece side cable, 12 pin control cable and arc voltage inspection cable accordingly.
  • Page 21 AC/DC tandem welding connection as above drawing show. Fix two power source in suitable position, Turn off the three phase input breaker, connect two power source as drawing 14 shows(when ZDE7-1200HD work ad DC power source, work piece arc voltage inspection cable connect with work piece terminal can connect with power source work piece terminal directly) 6.3.6、Multi power source connection (Drawing 16 ) When use multi wire welding, many source connect with one work piece only, when the distance is far, need use one...
  • Page 22 Fix three power source in suitable position. Turn off the three phase input breaker, connect three power source as drawing 14 and 16 shows, 2 pin communication cable (X1 of the first source connect with X2 of the second source, X1 of the second source connect with the X2 of the third source) at the back of the power source connect the 120Ω/2W resistor plug(X2 of the first source, X1 of the third source) 6.3.8、Triple power source parallel...

  • Page 23: Operation

    7 Operation 7.1 Procedure This power source can be used for submerged arc welding and stick welding. It adopts module design, which can be used for single wire welding, also can be used for multi wire welding, max. 6 arc welding, it can also be parallel for other applications.
  • Page 24 （4） Power on the machine, set the function of the power source, select panel control, according to the electrode procedure require, choose AC, DCEP or DCEN. （5） Adjust the parameter refer to following table （6） Start the machine Work piece thickness ≤3 4～5 6～12...
  • Page 25 10Hz 60Hz I(A) I(A) 1200 1200 -600 -600 -1200 -1200 （b）Wave balance set: wave balance increase, weld with and penetration increase, melt stirring improve 25％ 75％ I(A) I(A) 1200 1200 -600 -600 -1200 -1200 （c）DC deposition set: DC deposition increase, weld penetration increase, weld width decrease, weld speed decrease 25％...
  • Page 26 （3） Start the machine 7.5 For multi-arc and multi-wire welding machine Multi-arc welding system should set the current position to avoid the magnetic interruption for each arc, which mean control the different arc wave shape. the set value as 0°、90°、180°、270°、0°、90°……which indicate the current wave shape position, each arc position set separately: The first arc Second arc...

  • Page 27: Working Principle

    （1） Power off, refer to 6.3 connect the machine （2） Power on the machine, set the parallel function of the power source, select the function and set parameter on the panel, choose the power source characteristics, select AC, DCEP, DCEN. Choose the AC frequency, all power source set the remote control, wave balance 50％...

  • Page 28: Trouble Shooting

    9.2 Repair  Only qualified person can repair the machine  Check the three phase input cable first before open the machine, then check the breaker at back of the machine, finally check the welding cable connection. 9.3 Discard  The capacitor on the PCB burnt may cause explosion ...

  • Page 29: Packing List

    welding PCB damage Repair or replace PCB voltage is 0 IGBT or diode damage Check reason and replace module Ambient temperature too high, too much dust Radiator overheat inside machine Overheat Fan not work Check reason and take measurement indicator on Temperature relay damage Replace temperature relay Three input lack phase...

  • Page 30: Electric Diagram

    12 Electric Diagram C1 -3 Electric Drawing C1 3 1 0. C1 -1 C1 -2 4 0. 4 1. 1 2. 1 3. 1 6. 4 2. C5 -1 C5 -2 C5 -3 C5 -4 C1 1 4 3. 1 5. 4 4.
  • Page 31 The final explanation right is reserved to Huayuan Company! If there is any change in the manual, please forgive not to inform separately! Chengdu Huayuan Electric equipment Co.,Ltd. Address: Wuhou National Science Park, Chengdu, China Postcode: 610045 Telephone:0086-28-85744098 Fax:0086-28-85744095 E-mail: hy_sales@126.com huayuansales@163.com www.hwayuan.com...

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