Hwayuan Electric ZDE7-1200 Manual Instruction Download | Manualshive

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Summary of Contents for ZDE7-1200

Page 1: ...ib ZDE7 1200 INVERTER AC DC SUBMERGED ARC WELDING MACHINE MANUAL INSTRUCTION PLEASE READ IT CAREFULLY BEFORE OPERATION ...

Page 2: ...G THIS MANUAL THROUGHOUT Special Attention Very Important BE SURE TO AVOID THE WELDING MACHINE FALLING DOWN WHEN IT IS PLACED ON THE GRADIENT GROUND IT S FORBIDDEN UNFREEZING THE PIPELINE BY THE WELDING MACHINE THE SHIELD RANK OF THIS SERIAS OF WELDING MACHINES IS IP21S SO WORKING IN RAIN IS NOT SUTABLE This machine EMC is A Purchase Date ___________________ Serial Number ____________________ Mach...

Page 3: ... summary 1 3 Technical parameters 3 4 Panel function 5 5 Insert function 8 6 Machine Installation 10 7 Operation 17 8 Working principle 21 9 Maintenance repair and discard 21 10 Trouble shooting 22 11 Packing list 23 12 Electric Diagram 24 ...

Page 4: ...p the electrode in water for cooling Never touch electriferous parts of two welding machines at the same time because this voltage is supposed to be two times of welding voltage while the grounding mode is not clear While working high above the ground or other places having the risk of falling please be sure to wear safety belt to avoid losing balance caused by electric shock 2 Arc Use an arc weld...

Page 5: ...r the work cables Avoid facing the cylinder while installing the decompression flow meter or the gasometer When not working please tighten the valve 6 Power For electrically powered welding and cutting equipment Turn off input power before installation maintenances and repair so that avoid accident The welding equipment is Ι class safeguard equipment please install the equipment in accordance with...

Page 6: ...ny There is no lifting equipment in its wrapper Users can move it to the prospective area by a fork lift truck and then open the box If having rings the machine can be transited using rings While D H SÉCHERON Welding Machine Manufacture reminds users there is possible risk to damage the welding machine It is better to push the welding machine moving in use of its rollers unless special situations ...

Page 7: ...formance 6 With AC DC revert connection and DCEN connection exchange function can get exchange without change the cable connection 7 Power source can parallel to work to enlarge the output current which suitable for huge current welding situation and increase the efficiency 2 3 Application This AC DC square wave arc welding rectifier is a power source with multi functions for submerged arc welding...

Page 8: ...uld be no more than 10 if machine work on the tilting place anti tilting measurements should be taken Distance from machine to machine from machine to wall should be more than 50cm Working situation should fit standard of GB T8118 2010 2 5 Symbol instruction Read instruction manual Danger overheat Input 3 380V Input abnormal Power indicator Input control Output control Remote control Panel control...

Page 9: ...Current A 1200 Rated Output Voltage V 44 Rated AC Output Current Voltage Range 100A 20V 1200A 44V Rated Open Circuit Voltage V 92 Rated Duty Cycle 100 40 Efficiency 78 Power Factor 0 91 Wave Shape Balance 25 75 DC Bias 25 75 Cooling Mode Air Cooling Insulation Grade F Ingress Protection IP21S Dimension L W H mm 930x470x1250 Net Weight kg 180 3 2 Characteristics 1 Slowly CC mode ...

Page 10: ...4 2 CV model 3 Sharply CC mode 3 3 Rated duty cycle ...

Page 11: ...r panel control adjust AC frequency wave balance and DC deposition parameter under remote control 4 Power supply indicator to indicate if the power is energized 5 Over load indicator when machine is under over load the indicator lamp is on 6 Voltage abnormal indicator when the voltage is abnormal the indicator lamp is on 7 Parameter selection select AC frequency wave balance and DC deposition unde...

Page 12: ...el instruction 1 Remote control plug power source remote control communication plug the pin function of the plug as following table 2 Welding head output terminal connect with cable from welding head side 3 Work piece output terminal connect with cable from work piece side Pin Name Function Note 1 Remote control A Start signal Remote control and panel control affected by this signal 2 H Power give...

Page 13: ... Pin 1 is for whole communication signal A pin 2 is for whole communication signal B other 5 pin is for reservation 3 Communication plug X2 power source parallel control connecter or synchronize control communication plug input plug Pin 1 is for whole communication signal A pin 2 is for whole communication signal B other 5 pin is for reservation 4 Fuse FU1 5A used for control transformer over curr...

Page 14: ...r the penetration is lightest the 4 th gear penetration is deepest press pole select to storage then exit 2 Up down slope adjust for AC current exchange 0 off Step 1 press parameter selection for 5s come into insert function set mode voltmeter show 00 Step 2 adjust parameter adjust make ammeter show 3 press characteristic select come into AC current up down slope adjust setting Step 3 voltmeter sh...

Page 15: ...et the master power source Multi function 0 off Step 5 voltmeter show 2 to set the arc order turn parameter adjust press pole selection when ammeter show 1 to set the first arc Press pole selection when ammeter show 2 6 to set the 2 nd to 6 th arc 5 Lack voltage and phase inspection 280 Step 1 press parameter selection for 5s come into insert function set mode voltmeter show 00 Step 2 adjust param...

Page 16: ...e 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 it continue work under overheat situation 6 Machine Installation 6 1 Hoisting As following drawing show 1 2 3 4 hoisting hole can choose 1 and 4 or 2 and 3 or 1 2 3 4 together 2 1 3 4 6 2 6Foot install dimen...

Page 17: ...t 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 Welding cable shall be no less than 140mm 2 2 When power source integrated the control cable one side connect power source output terminal stably the other side connect controller make sure the 12 pin control cable no less th...

Page 18: ... welding head cable and work cable nearby to reduce circuit inductance a b Drawing 12 3 When work piece too long it better use slipper mode for ground connect to reduce the cable length welding cable length shall be no more than 70m 4 Too much inductance for the welding circuit will cause SC welding current and voltage unstable cause the power source stability and burn the parts inside 5 Arc volta...

Page 19: ...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 Work with single wire tractor Drawing 13 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...

Page 20: ...ee 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 6 3 5 Tandem connection Drawing 15 ...

Page 21: ... 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 integrated cable which can reduce the resist consumption to improve the efficiency like drawing 16 show 6 3 7 Trip...

Page 22: ...e power source in suitable position Turn off the three phase input breaker connect three power source as drawing 14 shows use the welding head side arc voltage inspection cable instead of the 12 pin control cable one side of the welding head side arc voltage inspection cable connect the deputy source 12 pin remote control plug the other side connect with welding head The 2 pin communication plug X...

Page 23: ...z wave balance 50 DC deposition 50 weld penetration low weld speed fast arc stability high Normally used for the backward welding for tandem to ensure the weld speed and performance Welding efficiency is times higher than single wire welding Refer to above drawing b 3 Changeable AC procedure frequency 10Hz 60Hz wave 25 75 DC deposition 25 75 cab set AC parameter penetration depth can adjust weld s...

Page 24: ...g voltage wire feed speed wire dia And characteristic at the remote control terminal 3 Start the machine 7 4 For AC submerged arc welding machine 1 Power off refer to 6 3 connect the machine 2 Power on the machine set the function of the power source select the function and set parameter on the panel choose the power source characteristics Choose the AC frequency 50Hz set the remote control wave b...

Page 25: ...ance increase weld with and penetration increase melt stirring improve 25 75 I A 1200 600 600 1200 0 I A 1200 600 600 1200 0 T T c DC deposition set DC deposition increase weld penetration increase weld width decrease weld speed decrease 25 75 I A 1200 600 600 1200 0 I A 1200 600 600 1200 0 T ...

Page 26: ... 6 3 connect the machine 2 Power on the machine set the l 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 and DC deposition 50 finally set the welding current welding voltage wire feed speed wire dia And characteristic at the re...

Page 27: ... principle Electric principle drawing as below Main electric principle of ZDE7 arc welding rectifier as attached 9 Maintenance repair and discard Specially note Please turn off the power before any of maintenance and repairing of this welding power source and because of the capacitor discharge any of operation should be done at least 5 minutes after turning off the power 9 1 Maintenance 1 The weld...

Page 28: ...ge Repair power supply 6 Indicator damage Repair panel 2 Turn on the power source the cooling fan doesn t work 1 The input wire of three phase power source is under trouble Check three phase input 2 The fuses on the front panel is broken Replace fuse 3 Control circuit damage Repair or replace PCB 4 The cooling fan is damaged Repair or replace fan 5 Machine have abnormal shake or power switch trip ...

Page 29: ...ltage abnormal indicator on 1 Three input lack phase Check three phase input 2 Three input lack voltage Check the input voltage and cable square meter too small or not 3 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...

Page 30: ... XS4L 5 V G ND G ND 1 5 V 96 90 95 89 94 88 93 87 92 86 91 85 5 V 5 G ND 5 1 5 V 3 1 5 V 2 4 V 3 G ND 3 1 XS3A 2 XS3B 3 XS3C 4 XS3D 5 XS3E 6 XS3F 7 XS3G 8 XS3H 9 XS3I 10 XS3J 1 5 V 4 G ND 4 9 V 4 G ND 4 1 XS2A 2 XS 8 XS2H 1 5 V 7 G ND 7 9 V 7 G ND 7 1 5 V 8 G ND 8 84 79 83 78 82 77 81 76 80 75 74 70 1 5 V 2 G ND 2 9 V 2 G ND 2 X4 1 引脚线号 106 远控弧压工件 110V H L D 2 113 3 112 4 111 5 107 6 59 7 102 8...

Page 31: ... 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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