Huayuan Electric ZD7-1600IGBT User manual

1
ZD7-1600/2000IGBT
SUBMERGED ARC WELDING MACHINE
MANUAL
INSTRUCTION
(PLEASE READ IT CAREFULLY BEFORE OPERATION)

2
Safety Depends on You
HUAYUAN 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.
Special Notes (Very Important):
1. Pay attention to avoiding the machine falling down when it is placed on the gradient ground.
2. It is forbidden to unfreeze the pipeline by the cutter.
3. The shield rank of this series of cutter is IP21S, so working in rain is not suitable.
4. The external static characteristic of this series welding machine includes CC and CV mode. The rated duty cycle is 100%,
which means the machine can work continuously at the rated cutting current. The machine has the function of thermal
protection. When the internal temperature exceeds a set temperature, thermal protection moves on and the abnormity
indicator lamp on the panel turns ON, then there is no output in machine. The machine can become normal and work only
after the internal temperature drops down and the abnormity indicator lamp on the panel turns OFF.
Purchase Date：____________________
Serial Number：____________________
Machine Model：___________________
Purchase Place：___________________

3
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. Be sure
that qualified professionals perform all installation, maintenances and repair procedures.
1 Electric shock: The welding circuits are not insulated when welding. If you touch the two output
electrodes of the machine with your bare skin at the same time, it will lead to electric shock,
sometimes even fatal dangers. Users need to follow the items below to avoid electric shocks:
If possible, lay some insulating materials, which are dry and large enough, in your working field.
Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as possible as you can.
Components in the automatic and semiautomatic welding machine such as the welding wire reel, feed wheel, contact
tip and welding head are all electriferous.
Always be sure the machine has been connected perfectly to the work piece with the work cables and should be as
close as possible to the working area.
The work piece should be grounded perfectly.
Make sure that the insulating material of the electrode holder, the grounding clamp, the welding cable and the welding
head are not affected by damp, mildewed or spoilt, and be replaced momentarily.
Never dip 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.
2Arc: Use an arc welding mask to protect your eyes and skin from sparks and the rays of the arc, pay
special attention to the filter glass, which must be conformable to the national standard.
Use clothing made from durable flame-resistant material or sailcloth to protect your skin from hurting
by the arc rays.
Remind other nearby personnel before working lest arc rays hurt them by accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous to health. Avoid breathing
these fumes and gases. While working in limited room, use enough ventilation and/or exhaust to keep
fumes and gases away from the breathing zone, or use the respirator. Do not weld at the same time
when using of degreasing, cleaning or spraying operations. The heat and rays of the arc can react with
these gases to form phosgene, a highly toxic gas,
Some protective gases used in welding might displace the oxygen in the air, and can lead to hurt or even death.
Read and understand the manufacturer’s instructions for this equipment, and validate the health certification of
consumptive materials, make sure they are innocuous.
4 Spatter: Spatter can cause fire or explosion.
Remove fire hazards from the welding area. Remember that spatter from welding can easily go
through small cracks and touch fire hazards. Protect all kinds of lines going though 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 welding stops, make certain that no live part is touching the work piece or the work stage. Accidental contact can
create a fire hazard.
Do not weld containers or lines, which are not proved to be innocuous.
It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work until the proper steps
have been taken to insure that there is no flammable or toxic gas.

4
Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair to
prevent from burning by spatter. Wear the ear shield when performing sideways or face up welding. Always wear safety
glasses with side shields when being in a welding area.
The welding cables should be as close to the welding area as possible, and the short, the better. Avoid welding cables
going through the building framework, lifting chains, AC or DC cables of other welding machines and appliances. The
welding current is strong enough to damage them while having short circuit with them.
5 Cylinder: Damage of it might cause explosion.
Make sure that the gas in the storage cylinder is qualified for welding, and the decompression
flow-meter, the adapter and the pipe are all in good condition.
Make sure that the installation of cylinder is by the wall and bundled tightly by a chain.
Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
It is forbidden to touch cylinder with the welding clamp or 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.
HUAYUAN welding equipment is Ι class safeguard equipment; please install the equipment in
accordance with the manufacturer’s recommendations by specific persons.
Ground the equipment perfectly in accordance with the manufacturer’s recommendations.
7 Power:(For engine driven welding and cutting equipment)
Work in ventilated place or outdoors.
Do not add fuel near to fire or during engine starting or welding. When not working, add fuel after
engine is cooling down; otherwise, the evaporation of hot fuel would result in dangers. Do not splash
fuel out of the fuel tank, and do not start the engine until complete evaporation of the outside fuel.
Make sure that all the safeguard equipments, machine cover and devices are all in a good condition. Be
sure that arms, clothes and all the tools do not touch all the moving and rotating components including
V belt, gear and fan etc.
Sometimes having to dismantle some parts of the device during maintenance, but must keep safety
awareness strongly every time.
Do not put your hand close to fans and do not move the brake handle while operating.
Please remove the connection between the engine and the welding equipment to avoid sudden starting during
maintenances.
When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt by the hot vapor.
8 Electromagnetic: Welding current going though any area can generate electromagnetic, as well as the
welding equipment itself.
Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should consult 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. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding cable is by your
left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.

5
9 Lift Equipment: carton or wooden boxes package the welding machines supplied by HUAYUAN.
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 HUAYUAN 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.
Be sure that the appurtenances are all removed off when lifting.
When lifting, make sure that there is no person below the welding machine, and remind people passing
by at any moment.
Do not move the hoist too fast.
10 Noise: HUAYUAN Welding Machine Manufacture reminds users: Noise beyond the limit (over 80
db) can cause injury to vision, heart and audition depending on oneself. Please consult local medical
institution. Use the equipment with doctor’s permission would help to keeping healthy.

6
CONTENT
Specifications................................................................................................................................................. 8
1、Technical specification .......................................................................................................................8
2、static characteristic ............................................................................................................................9
Panel function .............................................................................................................................................. 10
1、Front panel function ........................................................................................................................10
2、Output terminal function.................................................................................................................11
3、Back panel function .........................................................................................................................11
Installation and operation ........................................................................................................................... 12
1、Hoisting instruction..........................................................................................................................12
2、Basement installation dimension.....................................................................................................13
3、Input power installation...................................................................................................................13
4、Power source operation...................................................................................................................14
Working theory........................................................................................................................................... 15
1、Working principal.............................................................................................................................15
2、Machine electric diagram(see attachment).....................................................................................16
Maintenance and repair............................................................................................................................. 16
Attachment.................................................................................................................................................. 18

7
Product Introduction
1. Model Introduction
The main difference between ZD7-1600IGBT and ZD7-2000IGBTis the output current.
2. The main usage and application
ZD7 series inverter multi-function power source can be used for automatic submerged arc welding, electro-slag
welding, sticking welding and arc air gouging, it also has good performance on DC single wire welding and strip
surfacing. The main circuit of power source is IGBT inverter circuit with high reliability, fast response speed, good
dynamic characteristic, and it can auto-compensate the fluctuation of grid voltage, ensure arc burning steadily,
good-shaped welding seam.
3. Symbol Description
Read manual
carefully
Positive Pole
Over heating
Negative Pole
Voltage Abnormal
Voltage Input
Panel Control
Voltage Input
Remote control
ON
CV
OFF
CC
On-Off Bottom ”Popup”
Status
Air breaker
On-Off
Bottom ”Popdown”
Status
Current
Ground connection
Voltage
Dangerous voltage
Values
Increase/Decrease

8
4. Environment condition
The elevation should be less than 1000m；
Ambient temperature range
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.
It should be stored in a dry and windy place to prevent the sunshine and rain;
Keep the welding power source away from wall and other power source at least 30cm;
i. Power supply
Input power：3～380V/50Hz；
Input voltage fluctuation range＜±10%；
The frequency fluctuation range＜±1%；
Three phrase power supply asymmetry rate＜±5%；
If use engine generator, the generator output power should be 2 times higher than the rated input power
of the welding power source, and the compensating coils are required.
Specifications
1、Technical specification
No.
Item
Unit
ZD7-1600IGBT
ZD7-2000IGBT
1.
Rated input power
V/Hz
3～380±10% 50/60
2.
Rated input capacity
kVA
84
108
3.
Rated input current
A
127
164
4.
Efficiency
%
90
88
5.
Power factor
-
0.93
0.92
6.
Rated output current
A
1600
2000
7.
Rated output voltage
V
44
8.
Rated duty cycle
-
100%（40℃）
9.
Rated open circuit voltage
V
97

9
10.
Output current adjust range
A
100-1600
100-2000
11.
Cooling mode
-
Fan cooling
12.
Insulation grade
F
13.
Protection grade
-
IP21S
14.
Dimension （L×W×H）
mm
1050×475×1250
15.
Net weight
kg
210
212
2、static characteristic
Constant current, suitable for carbon gouging and stick welding
100 200 300 400 500 600 700 8 00 900 10 00 1 1 00 1 20 0 1 30 0 14 0 0 15 000
10
20
30
40
50
60
70
80
90
U
100
I
1600 1700 1 80 0 19 0 0 20 00
U=20+0.04×I
Constant current，suitable for submerged arc welding
10 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0 80 0 9 0 0 1 0 0 0 1 1 0 0 1 2 00 1 3 0 0 1 4 0 0 1 50 0 1 6 0 0 1 7 0 0 18 0 0 1 9 0 0 2 0 0 0 I 2 1 0 0 2 2 00 2 3 0 00
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
U
1 0 0
U = 2 0 +0 . 0 4 ×I

10
Constant voltage，suitable for submerged arc welding and electrode slag welding
10 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0 80 0 9 0 0 1 0 0 0 1 1 0 0 1 2 00 1 3 0 0 1 4 0 0 1 50 0 1 6 0 0 1 7 0 0 18 0 0 1 9 0 0 2 0 0 0 I
2 1 0 0 2 2 00 2 3 0 0
U = 2 0 + 0 . 04 ×I
0
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
U
1 0 0
Panel function
1、Front panel function
（1）INPUTFAULT：if the input voltage is abnormal, this red indicator on;
（2）OVERLOAD：If the machine is overheating, this yellow indicator on;
（3）Voltmeter(V)：Indicate the actual welding voltage;
（4）Ammeter (A)：Indicate the actual welding current;
（5）Function selection switch:
Selection of the welding mode, stick/air carbon arc gouging/SAW/electro-slag welding；
When set on “LOCAL”: the default mode is CC, suit for Stick welding & Air gouging;
When set on “REMOTE”, the default mode is CV, suit for SAW/electro-slag welding;
（6）Characteristic selection：“CONST.VOLT. ”and“CONST.CUR. ”selection；
（7）Parameter adjust knob：when function selection switch put on “LOCAL ”，characteristic selection put on
“CONST.CUR.”to adjust the current，characteristic selection put on “CONST.VOLT.”to adjust voltage
（5）
（6）
（7）
（4）
（3）
（2）
（1）

11
2、Output terminal function
（1）Positive output terminal：“ ”；
（2）Remote control plug：“ ”；
（3）Workpiece signal inspection terminal：connect with workpiece
（4）Negative output terminal：“ ”；
3、Back panel function
（1）Power switch: this is for breaker, when overload or error happen, it will turn off automatically to protect the
machine. When put upside, it will connect. The machine on and off should use the power switch on the grid.
（2）Cable connect: use for the machine input power
（3）Ground connect screw: use for the ground connect to ensure the equipment safety, make sure use the following
table cable, and connect stably.
（4）Press pad: to fix the input cable
（2）
（3）
（1）
（4）
Wire connection

12
Installation and operation
Completely read the operator's manual before installation, strictly follow the installation requirements.
The 3 phase input cable should steadily connected, any one of the three disconnect or poor connect will cause abnormal
work.
Slowly and softly adjust the rotary knob, do not continue to turn when it reaches the endpoint.
If there is significantly worse of the performance during the welding process, the machine should be stopped to check.
The potentiometers on the control circuit has different functions, they have been routine tested before delivery, please do
not adjust.
Only qualified personnel should perform this welding machine.
Wear protective garments such as gloves, heavy shirts, trousers and high shoes according to the related safety precautions.
Power off immediately if the abnormal indicator on, then check the input voltage, cooling fan motor, or if there is lack-phase
or overheat. Then turn on the machine again when it cooled down, if still have problem, please contact Huayuan company.
1、Hoisting instruction
（1）、（ 2）、（ 3）and （4）are hoisting hole，can use（1）and（4）or （2）and（3）or（1）、（ 2）、（3）（ 4）.
（2）
（4）
（3）
（1）

13
2、Basement installation dimension
3、Input power installation
# 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. The wire CSA should no less than the following table:
Model
CSA for input copper
wire (mm2)
Breaker capacity
(A)
Fuse protector
(A)
CSA for ground
lead cable(mm2)
ZD7-1600IGBT
≥50
≥25
160
160
ZD7-2000IGBT
≥70
≥35
250
250
# Power lead connection
Open the insulation cover of the terminal box on the rear, use the power lead as above requires, connect it well,
and cover the box
# The connection of the ground cable
The ground cable should be connected well.
Press pad
Cable connection
Ground connect screw
Cable connection
Breaker

14
4、Power source operation
This power source can be used for submerged arc welding, electrode slag welding, strip cladding, carbon gouging and
stick welding.
（1）For carbon gouging and stick welding
① Turn off the machine, connect as following photo show
（carbon gouging/MMA）
② Turn on the machine, select “LOCAL” and “CONST.CUR.”, adjust the panel parameter.
Carbon gouging
Gouging rod
（mm）
Φ6
Φ8
Φ10
Φ12
Φ13
Φ16
Φ19
Gouging
cur.（A）
180～300
240～400
300～500
750～850
800～900
900～1000
1000～1300
Rectangle
rod
（mm）
4×12
5×12
5×15
5×18
5×20
5×25
6×20
Gouging
cur.（A）
200～250
300～350
350～400
380～430
430～480
480～550
550～600
（2）submerged arc welding, electrode slag welding, cladding function
② ①Turn off the machine, connect as following photo show
Output terminal

15
④Turn on the machine, select remote, “CONST.VOLT.”or“CONST.CUR.”, set the welding parameter on the control box
Submerged arc welding procedure
Wire dia.（mm）
Φ3.0
Φ4.0
Φ5.0
Welding current（A）
350～600
500～800
700～1000
Welding voltage（V）
28～35
30～37
31～40
Electro slag or strip cladding procedure
Material
Cladding cur.
（A）
Cladding volt.
(V)
Cladding speed
(mm/min)
Nozzle length
(mm)
Submerged cladding welding
60mm×0.5mm
750
24
100
20～35
Electro slag welding
60mm×0.5mm
1250
24
160
25～40
Note: welding voltage/cladding voltage is the voltage between nozzle and workpiece during welding
Working theory
1、Working principal
ZD7 series inverter multi-function welding machine adopts the inverter main circuit. Three-phase AC power is
converted to 20KHz high-frequency DC current after being rectified by three phase rectifier. Then under the
function of IGBT inverter the DC current is inverted to AC high frequency current, which is inverted to DC current
after experiencing voltage reduction in high frequency transformer, current rectifying in fast recovery diode. This DC
current is filtered through reactor, and controlled by current negative feedback, and then the step-less adjustable
current which can meet the welding requirement is obtained.
Remote
control
Test terminal
Output terminal

16
Control circuit controls the output current through adjusting the pulse width of driving signal. The current
negative feedback signal is checked on output wire, then after enlarging it is input into inverting end of error
amplifier by using pulse width adjusting integrated circuit, then it can control the conductive time of IGBT, hence
inverter rectifier can get the required external characteristic.
2、Machine electric diagram(see attachment)
Maintenance and repair
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.
1. The welding power should be opened and checked regularly (Once a year at least), clear the dust inside the
machine with impressed air to avoid any of fault or short circuit.
2. The welding cables (Input and output) should be checked regularly (Once a week at least) to protect the
reliable connection.
Troubleshooting
Fault
Cause
Troubleshooting
1. Turn on the power source,
the cooling fan doesn`t
work
1. The input wire of three phase
power source is under trouble.
2. The fuses on the front panel is
broken；
3. Toggle switch is broken；
4. The cooling fan is damaged.
1. Check the three phase power
source.
2. Replace the fuse（3A）；
3. Check the toggle switch；
4. Repair or replace the cooling fan.
1. Turn on the power switch,
cooling fan only one work or
work slow, no output
1. Three phase input lack phase
2. Cooling fan damage
1. Check input power
2. Repair or replace fan
3. Turn on the machine, digital
display not on
1. Three phase power input
problem
2. Control transformer fuse break
3. Breaker damage
4. Digital display meter damage
5. Control circuit damage
1. Check three phase input
2. Replace fuse
3. Check breaker
4. Replace digital meter
5. Check control circuit

17
Attention: If the troubles cannot be resolved, please inform our local agent of the specific problems or contact us
directly.
Packing list
No.
Item
Model
Qty
1.
Power source
ZD7-1600/2000IGBT
1
2.
Documents
Manual/guarantee card/qualified card
1
4. Welding current is out
of control.
1. The connection of hall sensor
for current checking installed
inside machine output terminal
is loosen.
2. The main control board is
damaged；
3. The connection of remote
control cable is loosen.
4. Check the Hall sensor, and ensure it is
connected firmly；
5. Repair or replace the main control
board；
6. Well connect the remote control cable.
4. Machine non-load, selection
local switch, machine have
abnormal noise or breaker
off
1. Three phase bridge rectifier
damage
2. IGBT damage
1. Check three phase bridge rectifier
2. Check IGBT。
6. During welding, the arc
extinguishes suddenly and
no arc striking immediately,
after a moment the
machine work normally
again.
1. The machine is over load,
which cause over heat
protection of temperature
relay.
2. The temperature relay is
damaged.
1. Pay attention to ambient temperature
and rated duty cycle.
2. Replace the temperature relay with
same model.
5. Voltage abnormal indicator
on
1. Three input lack phase or
voltage
1．Check three phase input
6. Turn on the breaker,
selection local switch,
machine can't strike arc
1．Overheat or lack voltage
protection
2．PCB damage
1．Check if the protection function work
2．Repair or replace PCB

18
Attachment

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:[phone]
Fax:[phone]
E-mail: [e-mail] [e-mail]
www.hwayuan.com