1、.ZX7-400(PE50-400)Arc Welding Power SourceOperational ManualBeijing Time Technology Co., Ltd.;Table of ContentsPrecaution11 Overview述52 Structure52.1 Appearance52.2 Structure of Front/rear Panel and Description明63 Main Function Unit and Working Principle principle 63.1 Main Power Circuit73.2 Control

2、, Protection and Display Circuit73.3 Power and Drive Circuit73.4 Remote Control Circuit (option)74 Technology characteristics 74.1 Main Parameters74.2 Characteristics curve 85 Installation and Operation95.1 Installation115.2 Operation115.3 Operation of Remote Controller (option)126 Fault and Mainten

3、ance126.1 Overheating Protection126.2 Over Current Protection136.3 Under Voltage Protection136.4 Over Voltage Protection136.5 Common Problems and Troubleshooting137 Maintenance and Care138 Wiring Diagram Figure 159 List of Main Spare Parts16Note: This product is subject to innovation. Any change wil

4、l not be informed in advance. 1 OverviewThis Time ZX7-400 (PE50-400) arc welding power source is a DC manual arc welding power source produced by Beijing Time Technology Co., Ltd., adopting advanced semiconductor switching device IGBT module as main power device, and advanced inverter control techno

5、logy, international advanced, suitable for welding of various acid/ alkaline welding electrodes, featuring easy arc ignition, less splash, no adhering of welding electrode etc.The inverter frequency of this welding machine is 20kHz, featuring compact main transformers and reactors, and compact and l

6、ight welding machine, reducing copper/iron loss, enhancing efficiency and power factor, and featuring obvious energy-saving effect. This machine works outside acoustic frequency so as to avoid noise pollution.Advanced control technology brings excellent external characteristic and dynamic characteri

7、stics of power than other welding machines, meeting welding process requirements, ensuring high quality weld, and the operator can enjoy successful work.2 Structure2.1 AppearanceFigure 2-1 Appearance of welding machine2.2 Structure of Front/Rear Panels and DescriptionFront panel Rear panel1. Negativ

8、e terminal (Black) 11. Overheating alarm lamp2. Positive terminal (Red) 12. Wire remote controller socket (Optional)3. Voltmeter- display of zero load voltage or arc voltage (Optional) 13. Inclined characteristics switch4. Amperemeter- display of setting current or welding current 14. Remote control

9、ler switch5. Current knob 15. Air switch - power switch6. Thrust knob 16. Three-phase power input line 380VAC7. Arc ignition current knob 17. Fan casing8. Under voltage alarm lamp 18. Grounding terminal9. Over voltage alarm lamp10. Over current alarm lamp3 Main Functional Unit and Working PrincipleT

10、his ZX7-400 arc welding power source is mainly consisting of main power circuits, control/protection/display circuits, power and drive circuits, remote control circuits etc, and the working principle is described as following:3.1 Main Power CircuitAfter switching on the machine, the three-phase AC p

11、ower from grid is converted into DC power with small ripple after rectifying/filtering by the rectifying circuit, then inverted into high frequency AC power by the inverter circuit, and reduced by the main transformer, rectified and filtered by the final-stage rectifying circuit, realizing DC output

12、.3.2 Control, Protection and Display CircuitThe control circuit is mainly designed to control output current, meeting requirements for output external characteristic and dynamic characteristics, and monitor the status of main circuit.The protection circuit is mainly designed to guarantee safe work o

13、f the main circuit. In case of abnormities of main circuit, such as over current on switch elements, overheating of power devices, grid voltage reduced to lower limit, the main circuit is cut off to avoid damage to the elements and grids.The display circuit is designed to display the set current/wel

14、ding current (no display of setting current for inclined characteristics), zero load voltage/arc voltage (optional) via LEDs. The operator may pre-set accurate welding current directly via digital display, which is the arcing current. The actual welding current contains thrust current.3.3 Power and

15、Drive CircuitThe power and drive circuit is designed for two functions: one, supply power for drive circuit and control circuit; two, drive power devices for inverting.3.4 Remote Control Circuit (option)The remote control circuit is mainly used for remote or overhead tasks, and control of parameters

16、 such as welding current and thrust current etc remotely. At this time the two function knobs on the panel of the welding machine are invalid. Our RC-4 wireless remote controller or H28-18 wire remote controller are available for this machine.4 Technical Characteristics4.1 Main ParametersMain parame

17、tersRated input voltage50/60Hz 380V three-phase ACRated output power14.4kWZero load voltage80V(excluding specially customized)Zero load consumption200300WCurrent adjustment scope26410ADuty cycle60% for work current of 400AWork period10minPower factorCOS0.8Efficiency85%Insulation gradeFCase protectio

18、n gradeIP21SOverall dimension (mm)700×340×610Weight (kg)36.54.2 Characteristics CurveFigure 4-1 Falling characteristics curve Figure 4-2 Inclined characteristics curve5 Installation and OperationFigure 5-2 ZX7-400 (PE50-400) installation diagramNote: Distribution box is prepared by userDis

19、tribution boxArc welding power sourceWire remote controller (optional)GroundingWorking pieceWelding headWireless remote controller (option)Wiring of distribution box1: Distribution box power switch2: 60A fuse3: Protective earth wire (Yellow/green)4: Welding machine cableNote: Live working is forbidd

20、en!Connect the wire by special electrician.Never connect two welding machines with one switch box.PrecautionNote:l Install and debug strictly according to following steps!l Only conduct electrical connection after the distribution box switch is switched off.WarningElectric shock may cause person inj

21、ury or even death!Welding may cause fire or explosion!l The weld splash may ignite nearby flammable substance. Keep flammable substance 10m away from the welding field at least.l Avoid falling of splash on clothing or body.l Switch off distribution box power switch before wiring!l Never touch bare c

22、onductive elements.Weld fume harmful for health.l Never inhale weld fume.l Clean any stain on the work piece.l Keep the welding place ventilated.l Set fume discharging device in welding place.Luminous arc will bring injury to eyes and skin.l Strong luminous arc will bring damage to eyes.l Ultra-viol

23、et generated by arc will bring injury to skin and eyes. Wear protective clothing during welding.Over hot part may burn skin.l Never touch over hot welding part.l Never touch hot welding cable or head.High speed moving objects may bring damage.l Never insert your hand or thin articles into the fan ca

24、sing.l Close the housing before welding.To avoid damage to eye and skin, please observe labor safety and sanitation rules. Wear necessary protective articles!Perform welding according to applicable labor safety stipulation!5.1 Installation(1) Connect the power input line (AC INPUT) from the rear pan

25、el of welding machine with 50Hz/60Hz 380V three-phase AC power (Note: 4-core wire is used for the power line, of which, three are for live wires and the yellow-green one is for earth wire).(2) Insert the cable plug with welding head into the red socket (positive pole) under the front panel and tight

26、en clockwise.(3) Insert the cable plug with earth wire clamp into the black socket (negative pole) under the front panel and tighten clockwise.(4) Earth the casing at the position with grounding mark.The above items 5.1 (2) and 5.1 (3) are for direct current electrode negative method. The operator m

27、ay also choose direct current electrode positive method based on base metal materials and welding electrodes. In general, direct current electrode negative method (welding electrode connected with positive pole) is recommended for alkaline welding electrodes, and no special stipulation for acid weld

28、ing electrodes.5.2 Operation(1) After correct installation in above steps, close the air switch on the rear panel, the welding machine starts. Now the voltmeter displays zero load voltage, and the amperemeter displays negative current, which is the pre-set current. Turn the current knob, the current

29、 value displays within -26 - 406A.(2) Scope of thrust current: 25200A.(3) Adjust the welding current and thrust current based on the specification and model of welding electrode. Clamp the welding electrode, and weld via short-circuit arc ignition. The welding parameters are shown in Table 5-1.(4) T

30、his welding machine adopts self-adapting plus thrust technology, resolving the problems of no thrust for welding with extended wire, meeting requirements for welding with extended wire.(5) An Inclined Characteristics selection switch is set on the front panel. In case the operator will not use the i

31、nclined characteristics mode, turn this switch to “OFF” position. As the inclined characteristics mode is used, pay attention that, the pre-set current doesnt display, and the thrust knob doesnt work. For too long wire, the inclined characteristics may be activated, and the current setting may be ad

32、justed higher (max 230A current during welding) until to that for normal welding.Table 5-1Dia. of welding electrode (mm)Recommended welding current (A)Recommended welding voltage (V)1.0206020.822.41.6448421.7623.362.06010022.424.02.58012010814824.3224.924.014018024.627.25.018022027.228.86

33、.022026028.830.4Note: This table applies to welding of low carbon steel, for other materials, per relating materials and process manual.Prompt:High arc ignition current is recommended in general; for too thin work pieces, to avoid burning of work pieces, or as less arc ignition splash during welding

34、 is necessary, adjust the current lower.Proper thrust current shall be chosen. In case of large thrust current, the welding electrode will not be adhered during welding, but much splash will occur. For welding of thin welding electrode and small current or all-position welding, proper thrust current

35、 is much important. The actual parameters are based on the welding process requirements.5.3 Operation of Remote Controller (option)Rotate the “Remote/Local” switch on the front panel to “Remote” position, the machine is controlled remotely. Now the current and thrust settings on the front panel are

36、invalid.The Model RC-4 wireless remote controllers or H28-18 wire remote controllers are available for this machine.(1) Operation of wire remote controller: insert the plug of remote controller into the corresponding socket on the front panel. Turn the current knob or thrust knob to pre-set the weld

37、ing current or thrust current.(2) Operation of wireless remote controller: Connect the two lead wires of the remote controller with the welding wire and earth wire respectively. Press the “Select” key until the red LED illuminates (and the green LED goes off at the same time). Press the “Increase” o

38、r “Decrease” key so that the LED displays the expected value. Press the “Send” key, the LED is off for about 1 second, meaning the value is being sent. Then the LED displays again, meaning the value is sent, and the welding current is pre-set. Press the “Select” key until the green LED illuminates (

39、and the red LED goes off at the same time). Press the “Increase” or “Decrease” key so that the LED displays the expected value. Press the “Send” key, the LED is off for about 1 second, meaning the value is being sent. Then the LED displays again, the value is sent, and the thrust current is pre-set.

40、For operation of wireless remote controller, see the remote controller Operational Manual.6 Fault and MaintenanceThis ZX7-400 (PE50-400) features overheating, over current, under voltage and over voltage etc protection. In case of long time working with large load, main circuit power device overheat

41、ing, IGBT over current, grid under voltage or short-circuit of the machine etc, the main circuit of the welding machine is shut off automatically to avoid damage to the welding machine or grid.6.1 Overheating ProtectionIn case long time working with large load, the duty cycle exceeds the rating, the

42、 welding machine will heat up. To avoid damage to internal elements due to high temperature of the welding machine, and after the temperature of the main power devices rises to the predefined value, the overheating protection circuit acts, the overheating LED on the front panel illuminates, and the

43、main circuit is cut off. No current is output from the welding machine, the amperemeter displays the current setting, and the voltmeter displays 000. The machine may be not switched off, and will restore normal working automatically after the power devices cools down.6.2 Over Current ProtectionIn ca

44、se of over current of the IGBT of main circuit, the IGBT may be damaged, now the main circuit of the welding machine will be cut off automatically and locked. The over current LED on the front panel illuminates. Switch off the machine in this case and start the machine again after some time. If the

45、over current protection occurs again, record and report to the maintenance persons for troubleshooting before operating the welding machine.6.3 Under Voltage ProtectionAs the grid voltage decreases under 280V, the welding machine will not work normally, the under voltage LED on the front panel illum

46、inates, and the main circuit is cut off. The machine may be not switched off, and will restore normal working automatically after the grid restores normal.6.4 Over Voltage ProtectionAs the grid voltage exceeds 470V, the welding machine will not work normally, the over voltage LED on the front panel

47、illuminates, and the main circuit is cut off. The machine may be not switched off, and will restore normal working automatically after the grid restores normal.6.5 Common Problems and Troubleshooting1. Fan fails to rotate or abnormal speed after starting of the machine: may be due to power phase fai

48、lure or grid under voltage. Check the power line and/or the grid. Connect the power line, or wait until the grid restores normal.2. Fail to generate normal arc: the same as above.3. Arc ignition: for difficult arc ignition, increase the arc ignition current properly; in case of strong arc ignition o

49、r too large arc molten pool or even burning of work piece during arc ignition, decrease the arc ignition current properly.4. Splash and arc breaking: increase the thrust in case of adhering of electrode or arc breaking during welding; decrease the thrust in case of much splash or poor weld shape.5.

50、Welding head too hot: may be due to too small rated current of the welding head; Use welding head with large rated current.6. Others: please contact our company.7 Maintenance and CareNote:1. Never open the case by persons other than our maintenance persons or professionals.2. Switch off the power fo

51、r the welding machine and distribution box before opening the casing. Warning Electric shock may bring injury to persons or even death!l Never touch potential live electrical elements!l Switch off the power for the welding machine and distribution box before opening the casing. NoticeThe rotating fan may bring injury to persons!l Away from rotating vanes!l Close the case before starting the machine.12 l Never keep the welding machine in sun for long time.l Dont operate the welding machine in strong sun.l Never keep