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

Inverter ac/dc submerged arc weldingmachine
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ZDE7-1200HD
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 ZDE7-1200HD

  • Page 1 ZDE7-1200HD INVERTER AC/DC SUBMERGED ARC WELDING MACHINE MANUAL INSTRUCTION (PLEASE READ IT CAREFULLY BEFORE OPERATION)
  • Page 2 Sa f e t y De p e n d s on Yo u 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. Sp e c i a l At t e n t i o n (V e r y Im p o r t a n t ) : BE SURE TO AVOID THE WELDING MACHINE FALLING DOWN WHEN IT IS PLACED ON THE GRADIENT GROUND.

  • Page 3: Table Of Contents

    CONTENT Safety warnings ......................3 Product summary ......................1 Technical parameters ...................... 3 Panel function ........................ 5 Insert function ........................ 7 Machine Installation ..................... 10 Operation ........................17 Working principle ......................21 Maintenance, repair and discard ...................21 Trouble shooting ......................22 Packing list ........................ 25 Electric Diagram ......................26...

  • 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 ...
  • 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 Range 100A/20V～1200A/44V Rated Open Circuit Voltage Rated Duty Cycle 100%（40℃）...
  • Page 10 （3） Sharply CC mode 3.3 Rated duty cycle 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.

  • Page 11: Panel Function

    4 Panel function 4.1 Front top panel instruction Ammeter：Indicate the actual welding current;； Voltmeter：Indicate the actual welding voltage; PARAMETER ADJ. ） :adjust the welding current under panel control, adjust AC frequency, wave balance and DC deposition parameter under remote control Power supply indicator：to indicate if the power is energized;...
  • Page 12 Panel control（ ）indicator: machine under panel control when indicator on Remote control（ ）indicator: machine under remote control when indicator on 4.2 Front bottom panel instruction 1. Remote control plug: power source remote control communication plug, the pin function of the plug as following table: Name Function...

  • Page 13: Insert Function

    4.3 Back panel instruction （1） Power switch: over current protection switch, when machine abnormal, this switch will power off to protect the machine. Please separately connect power switch when install the machine （2） Communication plug X1: power source parallel control connecter or synchronize control communication plug, input plug （...
  • Page 14 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 Step 3: voltmeter show “0”, turn “parameter adjust”, press “pole selection” ...
  • Page 15 Item Factory set Instruction setting Step 3: voltmeter show “0”, turn  Step 5: voltmeter show “2”, to  “parameter adjust”, press “pole set the arc order, turn selection” when ammeter show “parameter adjust”, press “pole “0”, to off the parallel and multi arc selection”...

  • Page 16: Machine Installation

    *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. Each time the fan start/stop time need no less than 5s.
  • Page 17 CSA for input copper Breaker capacity Fuse protector CSA for ground lead wire (mm cable(mm ZDE7-1200HD ≥25 ≥16 ≥150 6.3.2、Output terminal cable connection （1） Take away the protection pad of the output terminal, connect the welding head and work piece stably with the power source output terminal, make sure the protection pad ≥10mm away from the cables after the pad installed.
  • Page 18 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. （a） （b）...
  • Page 19 （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 )
  • 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 Power on the machine, set the function of the power source, select panel control, according to the electrode （4） procedure require, choose AC, DCEP or DCEN. Adjust the parameter refer to following table （5） Start the machine （6） Work piece thickness ≤3 4～5 6～12...
  • Page 25 （b）Wave balance set: wave balance increase, weld with and penetration increase, melt stirring improve （c）DC deposition set: DC deposition increase, weld penetration increase, weld width decrease, weld speed decrease Start the machine （3）...
  • Page 26 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

    （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

    finally check the welding cable connection. 9.3 Discard The capacitor on the PCB burnt may cause explosion  The rubber cover and pad burnt may cause dangerous gas  Please deal as industrial waste  10 Trouble shooting Fault Cause Troubleshooting Three phase input wrong Check three phase input...
  • Page 29 Voltage inspection too sensitive Lower the sensitivity ※Attention: If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact our service department for technical assistance. Main parts list ZDE7-1200HD...
  • Page 30 Item Model Note Choke inductance LT03 Bridge rectifier MDS100-12 Capacitor HYC2007 IGBT 2MBI150HJ-120-50 Capacitor HYC4002 Linear inductance Capacitor 500VAC-100μF Resistor RXG13-400W-20Ω-J Inverter transformer Hall sensor HAS500-S/SP50 Capacitor HYC3001 Filter reactor Cooling fan TG28080HA2BL-C Diode MMF150S120DA Diode MMF150S120DK PD04 Capacitor CBB88-500VAC-100μF-K Diode MMF2X100J120D IGBT...

  • Page 31: Packing List

    Control transformer TD02 PD03 Three phase inductance Air breaker CDM3-125S(125A) 11 Packing list ZDE7-1250 AC/DC square wave arc welding rectifier 1 set  Operator’s manual 1 copy  Product certificate 1 copy ...

  • Page 32: 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 -2 C5 -3 C5 -4 C5 -1 C1 1 4 3. 1 5. 4 4.
  • Page 34 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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