OTC HR 22 User manual

HR-22-23
User Manual

Usage Limits
2
HR-22-23 (EN)
1 Contents
1Contents ........................................................................................................................................................... 2
2Foreword .......................................................................................................................................................... 3
3Regulations for the prevention of accidents...................................................................................................... 4
3.1Connection of the power source............................................................................................................. 4
3.2Operator protection ................................................................................................................................ 5
3.3Prevention of fire and slag ..................................................................................................................... 5
3.4Risk of poisoning.................................................................................................................................... 6
3.5Installation of the Cooling Unit ............................................................................................................... 6
3.6Safety measures .................................................................................................................................... 7
4Description ....................................................................................................................................................... 8
5Technical Data ................................................................................................................................................. 8
6Usage Limits (IEC 60974-1) ............................................................................................................................. 9
7 Installation ....................................................................................................................................................... 9
8Outer view of the HR-22-23............................................................................................................................ 10
9Electrical wiring of the welding cooling unit and successive mechanical coupling.......................................... 11
10Start-up / d rainage .................................................................................................................................. 12
11Maintenance............................................................................................................................................. 13
12 MEANING OF GRAPHIC SYMBOLS ON THE MACHINE ................................................................. 14
13WIRING DIAGRAM .................................................................................................................................. 15
13.1Key to the electrical diagram................................................................................................................ 15
13.2Colour key............................................................................................................................................ 15
14Hydraulic diagram..................................................................................................................................... 16
14.1Key to the electrical diagram................................................................................................................ 16
15Spare parts list ......................................................................................................................................... 17
15.1Ordering spare parts ............................................................................................................................ 19

Foreword
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HR-22-23 (EN)
2 Foreword
Thank you for choosing our product. Your new welding equipment from OTC DAIHEN EUROPE GmbH offers you
the highest quality and latest technology.
To exploit the full capabilities of this device and to enjoy it for many years, please read these instructions carefully
before connecting and commissioning the device. It’s very important to operate your device as instructed.
The reliability and functionality of the device can only be guaranteed if you follow the general safety and accident
prevention Instructions in this manual. We assume no liability for damages caused by improper use or incorrect
operation.
Important
Please ensure that all persons who operate with the device have red and understood the operating instructions in
this manual. If you don’t have sufficient knowledge and experience concerning the operation and the safe use of
this machine, please contact our staff.
If you have any questions about the installation, the connection or the use of this device you can always contact
the manufacturer (customer service department).
Please keep this manual at a safe place in case of need to be
able to access it at any time!
Warning
The arc welding equipments from the company OTC DAIHEN EUROPE GmbH correspond to the "EN 50199
standard" for electromagnetic compatibility. The operators are required to operate according to manufacturer's
instructions when installing and handling the device.
In case of electromagnetic interference, the operators have to contact the manufacturer and search a solution.

Regulations for the prevention of accidents
4
HR-22-23 (EN)
3 Regulations for the prevention of accidents
The use of welding equipment and welding itself are always associated with a certain safety risk. Therefore each
set up and operation of the device assumes that the instruction manual is understood and complied. The properly
used welding machine grants a high degree of operational security but can, in case of improper handling, lead to
property and personal damage.
Be sure that you observe the following safety rules:
3.1 Connection of the power source
The installation and maintenance of the system must be carried out in accordance with the general
safety and accident prevention regulations of the legislature.
The state of the power cord and plug must be checked and any damage eliminated. The
electrical equipment must be tested at regular intervals. Use cables of sufficient diameter.
The ground cable must be fastened as close as possible to the work area of the work piece be. Is it
connected directly to the building design or too far away from the work area, this can lead to energy
loss or discharging.
The system may not be used in damp areas and in no case encounter water or other liquids.
Direct contact with hands or with wet clothing to components that might be under tension is to be
avoided. Make sure that your gloves and protective clothing are dry.
When working in damp rooms or on metal surfaces, use protective gloves and work shoes with
rubber soles.
The system has to be cut off at each interruption, even at sudden loss of power. Accidental ground
contact can lead to overheating of the system and cause a fire. The system must therefore never
be turned on without supervision.

Regulations for the prevention of accidents
5
HR-22-23 (EN)
3.2 Operator protection
All people must be protected during the welding process, with appropriate measures against UV
radiation, noise, heat and gas pollutants emitted during welding. Never expose yourself to the influences
of arc and the hot metal slag without a protective mask and appropriate protection. Welding work without
consideration of these standards could cause serious health problems.
Always wear protective clothing: gloves (fire resistant), shirts with long sleeves, long pants
without cuffs and high closed shoes. Protective clothing protects the skin from the arc and
the hot metal.
Wearing a cap or a helmet is required!
Protect your eyes with safety glasses and adequate protection level (at least NR10 or
more). The same goes for the ears, face and skin. All people must be informed of the
dangers.
In the workroom, all people have to wear earmuffs!
When you manually remove the hot metal slag wearing safety glasses with side flaps is required.
Present persons have to keep their distance!
The entire welding area must be secured with a fireproof bulkhead, in order to protect present
persons from the created radiation, slag and sparks.
3.3 Prevention of fire and slag
The glowing slag and the resulting spark can ignite a fire at any time. Explosions or
the outbreak of fire can be prevented if you meet the following requirements:
Remove all flammable objects in the vicinity of the welding machine or cover them with refractory
materials.
These flammable objects include the following: wood, saw dust, clothing, paints and solvents, gasoline,
fuel oil, natural gas, acetylene, propane, etc.
Even after emptying the collection vessels and pipes is caution while welding very important.
A fire extinguisher, sand or water must always be present in the workplace in order to be able to react quickly in
case of fire.
Never weld at adjoining tanks or piping. Do not weld in open containers or pipes that may contain flammable
substances.

Regulations for the prevention of accidents
6
HR-22-23 (EN)
3.4 Risk of poisoning
Gases and fumes that are harmful when inhaled for a longer time can be released while
welding.
Because of this, the following safety guidelines have to be observed:
Ensure that you have adequate ventilation for the work area.
During the processing of materials such as, beryllium, potassium, zinc, or galvanized and painted
pieces, you must set up forced ventilation.
The operator has to protect his airway with appropriate equipment.
Wherever a sufficient air supply is ensured, you must use respirators and additional air supply.
In small rooms (in boilers, in the ditch, etc.), the welders have to be backed up by another person.
Provided that all requirements are met to prevent accidents.
Weld never near degreasing and painting, because there may be released bleach-water, which
transform under the influence of heat into phosgene, a highly toxic gas.
The signs of inadequate ventilation or a possible poisoning are charms in the eyes, nose and
throat. In this case, you have to interrupt the welding work and ventilate the work area. If you feel
uncomfortable anyway stop the welding work.
3.5 Installation of the Cooling Unit
When setting up the cooling unit please mind the follwing instructions:
WARNING
The cooling unit may only be installed horizontally.

Regulations for the prevention of accidents
7
HR-22-23 (EN)
3.6 Safety measures
Before using the machine, the following rules have to be observed:
Ensure the appropriate working conditions for the welder. At the work area no inflammable
substances may be presented. Reconciliation of dust and other substances that prevent the
isolation of the device must be removed.
Back up the welder properly when working outdoors.
If you notice any overheating or smoke, fire, find strange sounds and unusual vibrations, you have
to switch off the machine immediately and disconnect it from power. In such cases the device has
to be inspected by an expert.
In the event of a power outage, or when you realize power on the housing of the device, switch off
the machine immediately and disconnect it from power. The same applies in the case of
mechanical damage.
Too high humidity in the work area can reduce the insulation class and cause a short circuit.
During welding some parts of the machine exceeds 100 °C. Therefore these parts are protected
with a thermostat. Whenever you will notice any overheating, you have to turn off the power
immediately.
Use environment:
The device is not suitable for bathrooms, showers, swimming pools or similar areas. If it’s
necessary to work in these environments, you have to ensure that water can’t damage the
machine. The welding equipment isn’t suitable for use in rain or snow!
The welding equipment can’t be used in areas, where it is exposed to shock or vibration. Areas that
should be avoided necessarily are for example, road-, rail- and cable handling equipment, aircraft,
water crafts, cranes and parts of machine tools.
Dust and cooling system:
The device has to be positioned in a way that sufficient air can flow through the cooling fins and the
cooling channels. The unit adjusts the cooling system automatically! Please pay attention, that no
metal dust can be sucked.
Stability:
The unit can be installed on up to 15° tilted planes. If the plane is tilted steeply, the welding
equipment can overturn!

Description
8
HR-22-23 (EN)
4 Description
The device, particularly suited for cooling by means of water circulation utilized in particularly heavy welding
operations, is composed in its essential parts of:
• A single-phase electric pump.
• A plastic tank.
• A radiator.
• A pressure switch.
• A protection fuse.
Compact, lightweight, it must be used only together with or as an integral part of the welder.
5 Technical Data
Table1
Model HR22 HR23
Single-phase input V 1~230 ±20% 3~400 ±20%
Frequency Hz 50/60 50/60
Max power supply kW 0,3 0,3
Max current absorbed A 1,35 0,9
Delayed fuse A 2 1,6
Coolant • 20%-30% antifreeze
• 70%-80% distilled water
Cooling power Φ1
@ 1 l/min kW 0,5 0,5
@ 1,6 l/min (with TIG torch) kW 0,65 0,65
Capacity with 4 m TIG torch l/min 1,6 1,6
Max pressure bar 4,3 4,3
Protection class IP 23 IP 23
Insulation class F F
Tank ca
p
acit
y
2,5 2,5
Dimensions LxBxH 515-225-185 545-225-185
Weight kg 9,5 10
Weight with liquid kg 12 12,5

Usage Limits
9
HR-22-23 (EN)
6 Usage Limits (IEC 60974-1)
The cooling device is designed for cooling by means of water circulation in the welder in a continuous
manner. As a work cycle, it is considered at 100%.
7 Installation
The installation site for the system must be carefully chosen in order to ensure its satisfactory and safe use. The
user is responsible for the installation and use of the system in accordance with the producer’s instructions
contained in this manual. Before installing the system the user must take into consideration the potential
electromagnetic problems in the work area. In particular, we suggest that you should avoid installing the system
close to:
• Signalling, control and telephone cables.
• Radio and television transmitters and receivers.
• Computers and control and measurement instruments.
• Security and protection instruments.
Persons fitted with pace-makers, hearing aids and similar equipment must consult their doctor before going near
a machine in operation. The environment in which the equipment is installed must be suitable for the casing’s
protection level. This system is cooled by means of the forced circulation of air, and must therefore be placed in
such a way that the air may be easily sucked in and expelled through the apertures made in the frame.
The welding unit is characterized by the following levels:
• Protection level IP 23 indicates that the equipment can be used both indoors and outdoors.

Outer View of the HR-22-23
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HR-22-23 (EN)
8 Outer view of the HR-22-23
CONTROL APPARATUS (Image 1 )
Pos. 1
Pos. 2
Pos. 3
Pos. 4
Pos. 5
Pos. 6
Red snap-in connector for water intake.
Blue snap-in connector for water outlet.
Cap with micro valve for filling the tank with coolant.
Cable for electric connection of the cooling unit to the welding power source.
Level indicator for presence of coolant in the tank (the level of the liquid must never be inferior to
the notch indicated).
Protection fuse.
Image 1

Electrical wiring of the welding cooling unit and successive mechanical coupling
11
HR-22-23 (EN)
9 Electrical wiring of the welding cooling unit and
successive mechanical coupling
The cooling unit cannot function in an autonomous manner, therefore it must be connected electrically, in order to
operate, to the welding power source, making the coupling between the 3x2 pole male connector in the cooling
devise (Pos. 4, Image 1) and the corresponding female on the welding power source (to ignite the female
connector just remove its specific covering (Image 2) located under the base of the machine) following the
assembly instructions attached and contained in the accessories packet.
Prior to beginning, the operator has to assure that close at hand there is both the welding power source
(example: DTX-2200 AC/DC) and the cooling device (example: HR 22) and that both are working at the same
feed voltage (see the two data panels positioned under the respective bases).
Upon final connection, even the pressure switch will be connected. The pressure switch has a protective function.
It does not allow the welding power source to emit voltage in case the water pressure and therefore the cooling
capacity, is inferior to the calibration value.
Having terminated the electrical connections, complete the mechanical coupling by means of screws and
fastening clamps following the assembly instructions attached and contained in the accessories packet.
Image 2

Start-up / drainage
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HR-22-23 (EN)
10 Start-up / d rainage
Before connecting the unit to the welding power source, check the rating plate and make sure the voltage
and
frequency of th e main power correspond.
C
heck that the main circuit break er on the equipment is turned to “O”.
Upon the first usage following a period of extended inactivity of the cooling unit or in the case in which the
electro pump does not go under pressure (slight whistle), it is necessary to undertake drainage in order to
eliminate all the air bubbles present within the hydraulic circuit.
Carry out the following operations following the assembly instructions indicated here (Image 3) and also
contained in the accessories packet:
A) Unscrew the tank’s cap and, using a funnel, fill it with distilled water. In case of particularly rigid climates
with
air temperature near to 0° C it is necessary to add antifreeze to the cooling distilled water. Do not use
antifreeze containing propylene because it could provoke blockage of the electro pump.
B) Connect the tube provided to the blue rapid mount and insert the other end of the tube into the tank.
C) Start up the welder by rotating the main switch to the 1 position and wait approximately 30 seconds so that the
cooling device can allow the liquid to circulate.
D) Wait for the exit of the liquid. The operation will be terminated when the liquid exits in a constant way and
without any traces of air bubbles.
E) Upon the completion of the operation, turn the welder off.
F) After that, screw the tank’s cap shut and connect the welder prior to beginning operation.
Bild 3

Maintenance
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HR-22-23 (EN)
11 Maintenance
WARNING: Prior to undertaking any kind of inspection within the machine, unplug the device from the
power supply.
• Periodically check the level of the cooling fluid.
• Add fluid whenever it drops below the minimum level indicated.
• Add antifreeze when the room temperature is below 2°C (table 2).
• Make sure all joints are tight and that there are no leaks
• Periodically clean the radiator with compressed air to eliminate the dust that reduces the cooling capacity.
IMPORTANT: Original spare parts have been specially
de- signed for our equipment. The use of non-original
spare parts may cause variations in performance or reduce the foreseen level of safety. We decline all
responsibility for the use of non- original spare parts.
Table 2
Distilled
water

Antifreeze External
temperature
0°C -10°C -15°C -20°C
80% 20% 
75% 25% 
70% 30% 
65% 35% 

Meaning of graphic symbols on the machine
14
HR-22-23 (EN)
12 MEANING OF GRAPHIC SYMBOLS ON THE
MACHINE
Fuse
Cold water outlet
Hot water intake for cooling in the unit
Grounding
Warning!
Before using the equipment you should carefully read the instructions included in this
manual.
Product suitable for free circulation in the European Community

Wiring diagram
15
HR-22-23 (EN)
13 WIRING DIAGRAM
13.1 Key to the electrical diagram
13.2 Colour key
Bl Blue
Gg Grey
GV Yellow-Green
Mr Brown
Nr Black
• CA Power supply connector
• F Fuse
• M Electric pump
• W Pressure switch

Hydraulic diagram
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HR-22-23 (EN)
14 Hydraulic diagram
14.1 Key to the electrical diagram
• IL Depth gauge
• IN Torch outlet (red)
• M Electric pump
• OUT Torch intake (blue)
• R Radiator
• S Tank
• T Tank cap with micro valve
• V Fan
• W Pressure switch

Spare parts list
17
HR-22-23 (EN)
15 Spare parts list
Pos. HR 22 HR 23 Description
1403632 403632 Red quick connection
2403625 403625 Blue quick connection
3403783 403783 Terminal for 3x2 poles male connector
4403779 403779 3x2 Poles male connector
5413535 413535 Auxiliary wiring
6446631A 420926B Right panel
7451740 451740 Fuse holder
8428879 429049 Fuse
9420918A 420928B Cover
10 466451 466451 Tank cap with microvalve
11 352454A 352454A Front panel
12 446630A 420927B Left panel
13 352456A 352456A Rear panel

Spare parts list
18
HR-22-23 (EN)
Pos. HR 22 HR 23 Description
14 460253 460253 Tank
15 457761 457761 Water distributing frame
16 453246 453246 Pressure switch
17 486564 486564 Fan
18 418846 418846 Capacitor
19 465464 465464 Electropump support
20 345460 345461 Electropump
21 404932 404914 Base
22 485191 485191 Water tube

Spare parts list
19
HR-22-23 (EN)
15.1 Ordering spare parts
To ask for spare parts clearly state:
1) The code number of the piece
2) The type of device
3) The voltage and frequency read on the rating plate
4) The serial number of the same
EXAMPLE
2 Pieces Article number 352453 - for DTX-2600TIG -
400 V - 50/60 Hz
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OTC DAIHEN EUROPE GmbH
Krefelder Strasse 675-677,
D-41066 Mönchengladbach, Germany
Phone: [phone], Fax: [phone]