OPERATOR’SMANUALen.hwayuan.com/.../3cde4ec2-02c7-4136-a4e5-d786e1bf387f.pdf2015/10/29 · PARAMETER NB-200IGBT NB-250IGBT NB-315IGBT NB-350IGBT NB-500IGBT NB-630IGBT Shieldrank

NB-200/250/315/350/500/630IGBTInverter MIG/MAG/CO2 Welding Machines

OPERATOR’S MANUAL(PLEASE READ CAREFELLY BEFORE OPERATION)

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO., LTD.

NB-200/250/315/350/500/630IGBT OPERATOR’S MANUAL

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Safety Depends on YouHuayuan arc welding and cutting equipments are designed and built with safety in mind. However, youroverall safety can be increased by proper installation.DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL ANDTHE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you actand be careful.

Special Attention (Very Important):● AVOID FALLING DOWNWHEN THE WELDING MACHINE IS PLACED ON THE

INCLINED PLANE.● IT’S CAN NOT BE USED FOR UNFREEZING PIPELINES.● THE SHIELD RANK OF THIS SERIES OFWELDING MACHINE IS IP21S, AND IT IS NOT

SUTABLE FORWORKING IN THE RAIN.

Purchase Date：Serial Number：Machine Type：Purchase Place：


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Cautions Arc and arc rays may harm health.

Arc welding can be hazardous. All performing welding workers ought to have healthqualification that provided by authority organization. Protect yourself and others from possible seriousinjury or death. Keep children away. Pacemaker wearers should consult with their doctor beforeoperating. Be sure that all installation, operation, maintenance and repair procedures are performedonly by qualified individuals.

1 Electric shock can kill: The electrode and work (or ground) circuits are electrically “hot” whenthe welder is on. Do not touch these “hot” parts with your bare skin or wet clothing, Wear dry,hole-free gloves to insulate hands. Users need to follow the below items to avoid electric

shocks: Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover

your full area of physical contact with work and ground. Otherwise, use automatic or semiautomatic weldingmachines, DC welding machines as possible as you can.

In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically“hot”.

Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

Ground the work or metal to be welded to a good electrical(earth) ground. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition.

Replace damaged insulation. Never dip the electrode in water for cooling. Never simultaneously touch electrically“hot”parts of electrode holders connected to two welders, because voltage

between the two can be the total of the open circuit voltage of both welders. When working above floor level, please do wear safety belt to avoid falling or losing balance on electric shock.

2 Arc rays can burn: Use a shield with the proper filter and cover plates to protect your eyesfrom sparks and the rays of the arc when welding or observing open arc welding. Headshieldand filter lens should conform to nation standards.

Use suitable clothing made from durable flame-resistant material to protect your skin and that ofyour helpers from the arc rays.

Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc norexpose themselves to the arc rays or to hot spatter or metal.

3 Fumes and Gases can be dangerous: Welding may produce fumes and gases hazardous tohealth. Avoid breathing these fumes and gases. While working in limited room, use enoughventilation and/or exhaust to keep fumes and gases away from the breathing zone, or use therespirator.

Shielding gases used for arc welding can displace air and cause injury or death. Always use enoughventilation,especially in confined areas, to insure breathing air is safe.

Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or sprayingoperations.The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, andother irritating products.

Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, includingthe material safety data sheet (MSDS) and follow your employer’s safety practices. Make sure they are asepsisand innocuity.

4 Spatter: Welding or cutting spatter can cause fire or explosion. Remove fire hazards from the welding area.If this is not possible, cover them to prevent the

welding sparks from starting a fire. Remember that welding sparks and hot materials fromwelding can easily go through small cracks and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available. 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 contact can create a fire hazard. Do not weld containers or lines, which are not proved to be innocuity.Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that suchprocedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even thoughthey have been“cleaned”. 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. Alwayswear 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 weldingcables going through the building framework, lifting chains, AC or DC cables of other welding machines and


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appliances. The welding current is strong enough to damage them while having short circuit with them.

5 Cylinder may explode if damaged. Make sure that the gas in the storage cylinder is qualified for welding, and the decompression

flowmeter, the adapter and the pipe are all in good condition. Always keep cylinders in an upright position securely chained to an undercarriage or fixed

support. Be sure to put the cylinder in the working space with no crash or shake, and far from welding area. Never allow the electrode, electrode holder or any other electrically“hot”parts to touch a cylinder. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for

use.6 Power: (For electrically powered welding and cutting equipment) Turn off input power before

installation, maintenance and repair to avoid accidents. Huanyuan 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 afterengine is cooling down; otherwise, the evaporation of hot fuel would result in dangers. Do notsplash fuel out of the fuel tank, and do not start the engine until complete evaporation of theoutside fuel.

Make sure that all the safeguard equipments, machine cover and devices are all in a goodcondition. Be sure that arms, clothes and all the tools do not touch all the moving and rotatingcomponents including V belt, gear and fan etc.

Sometimes some parts of the equipment have to be dismantled during maintenance, but you stillhave to keep the strongest safety awareness .

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, and 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 byyour 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. D e. Do not work near to the welding power source.

9 Lifting equipment: carton or wooden boxes package the welding machines supplied byHuayuan. There is no lifting equipment in its wrapper. Users can move it to the prospective areaby a fork-lift truck, then open the box.

If there are rings, the machine can be transited by rings. While Huayuan Welding MachineManufacture reminds users, there is potential risk to damage the welding machine. So it is betterto push the welding machine by 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 (over80 db) can cause injury to vision, heart and audition depending on oneself. Please consult localmedical institution. Use the equipment after doctor’s permission would help to keep healthy.


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CONTENTS1. Usage notices -------------------------------------------------6Model ExplanationFeatures &AdvantagesUsageSafetyEnvironmental AreaInput power conditionsInstallation diagramComponents name and Function Introductions

2. Connections --------------------------------------------------11Connections of the power supply cable and the ground wireConnection of the manual welding output cableConnections of Gas-shielded Welding2.3.1 Connection of the output cable2.3.2 Connections of the power source, wire feeder and the welding torch2.3.3 Connections of the gas cylinder and the gas adjustor

3. Directions of the manual welding mode ---------------124. Directions of the Gas-shielded Welding mode---------12Checking items ,methods and requests & preparations before operation4.1.1Wears of safeguards4.1.2 Checking after connections4.1.3 Operation of switches & adjustment of gas flux4.1.4 Installation of the welding wire4.2 Directions of the basic welding4.2.1Welding operation with arc ending function4.2.2Welding operation without arc ending function

5. Directions of prolonged output cable -----------------146. Technical conditions ------------------------------------- 14

6.1 Technical parameters6.2 Instructions of keywords6.3 Examples of welding condition

7.Working principle ----------------------------------------187.1 Summarize of working principle7.2Main electric elementary diagram

8.Troubles and troubleshooting---------------------------189. Packing list -------------------------------------------------20


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1. Usage Notices1. 1 Model Explanation

Model: N B — □□□ IGBTIGBT inverterRated welding currentSemi-Automatic weldingMelt electrode gas shieldedwelding machine

Features &AdvantagesStrike arc at high voltage and slow wire feeding , which makes steady arc starting and high success

rate.Unique control circuit of arc voltage and current feedback, which makes stable welding process,

low spatter, beautiful welding shaping, strong length change adaptability and wide adjusting range ofcurrent&voltage matching.Excellent F.T.T - Globule control circuit makes positive striking of arc.Function of arc crater filling to improve the quality of the arc-ending seam.PWM inverter technique is adapted, the frequency can achieve 20KHz with high speed of dynamic

response.It can be widely used in Gas-shielded welding, carbon arc air gouging and manual welding.

UsageIt is suitable for welding mild steel, stainless steel, aluminum and their alloy.It is fit for flat welding, stand welding, face-upward welding and across welding, both for solidwelding wire and flux-cored welding wire with the diameter of Ф1.0、Ф1.2、Ф1.6.

SafetyFor you and others safety, please do obey the below items.□ The machine have to be grounded reliablyTo prevent electric shock, make sure the grounded bolt of the power source is grounded well.□ The safeguards should be wornTo prevent injury of your eyes and skin from the ultraviolet radiation, strong sparks and splash,please be sure to conform to the rules and byelaws related to the working protection to wear certainsafeguards.□ Don`t inbreathe the deleterious welding gasThe gases and fumes produced by welding are hazardous to health. Make sure to conform to therules and byelaws related to the working protection to wear certain safeguards and install theventilator.□ The shielded gas cylinder have to be located in a fixed place to avoid being shocked.□ The machine and working area should keep away from those flammable things.□ Prevent sundries from getting into the machine and sharp thing from cutting cables.□ Prevent the machine from damage by falling or hitting. Once it falls or be hit, the machine

cannot be used again without professional checking.Environmental Area

If the work conditions fall short of the below items, the working performance may not meet thetechnical criterion, and the machine will be damaged.

□ The machine should be put on where there is low humidity, little dust and no direct sunlight,rain, flammable things, corrosive gas and materials.


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□ The environment temperature range should be -10℃～40℃.□ Avoid metal sundries entering into the power source.□ The distance between the power source and wall or other close things should be more than

30cm. The distance between two machines should be more than 30cm.□ It should be operated in where there’s no wind.□ It should be operated in where the altitude is less than 1000m.

Input Power conditionsPower supply : 3～50Hz380VACThe fluctuation range of distribution voltage:＜±15%The fluctuation range of frequency: ＜±1%The imbalance rate of three-phase voltage :＜±5%While using engine generator, the output power should be two times larger than the rated input

power of the welding power source and compensation coil is needed.Installation diagram

Connection between welding equipments and other equipments(Please refer to the Figure 1).1.8 Components name and Function Introductions (Please refer to the Figure 2)

1. Voltage meter: to indicate the actual welding voltage2. Current meter: to indicate the actual welding current3. Current adjustment knob:When switch 10 is placed on the manual welding position, this

knob can adjust the manual welding current. When switch 10 is placed in the gas-shieldwelding position, this knob can adjust the gas-shield welding current.

4. Arc ending voltage adjustment knob: adjust the arc ending voltage5. Arc characteristic adjustment knob: While used as gas-shield welding, it is to adjust and

control the current changing rate in different duration of the melt drop transfer in thewelding process. It will directly influence arc’s soft and rigid characteristics, quantity ofspatter, shaping of welding seam and the stability of arc. It is advised to use standardcharacteristic. Adjust it to the soft characteristic while doing as small criterion welding, andadjust it to the rigid characteristic while doing as middle and large criterion welding. (Note:the softer arc, the less spatter, vice versa.)

6. Under voltage indicator lamp: When the distribution voltage is lower than 320VAC, itlights, and the output current will be cut automatically. After the voltage is back to normal,the machine will work again.

7. Over heat indicator lamp: If it runs in excess of its rated duty cycle, or in a hightemperature environment, the power radiator’s temperature achieves 75℃±5℃, the heatprotection circuit begins to work, and the heat indicator lamp lights, the output current willbe cut off. However, the fan will keep working, wait until the temperature is below thefixed and lamp is turned off, you can restart the machine. If the entrance of the gas path isjammed or the fan doesn’t work, the lamp will also light.

8. Power source indicator lamp: As soon as start the machine, it lights.9. Welding model conversion switch: It is to switch the welding model from manual welding

to gas-shield welding.10. Welding wire diameter conversion switch: It is to switch the standard welding wire’s

diameter to adopt the machine. It is actually to choose the suitable welding program. Turnthe switch to the diameter matched with the welding wire.

11. Welding wire type conversion switch: It is to switch the standard welding wire’s type toadopt the machine. Turn it to the solid position while using solid welding wire; turn it to theflux-cored position while using flux-cored welding wire.


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12. Arc ending conversion switch：It is to determine whether fill the arc holes at the end ofwelding. That means to determine whether use arc ending function or not.

13. Gas-supply conversion switch：To check gas flow, turn it to "checking" position; to weld,turn it to "welding" position.

14. Power overload protection switch: To cut off power and protect the machine whenabnormal, it is only used for protection, you should use other power switch while installing.

15. Control signal interface: Output interface of arc striking, to control automatic weldingequipments. The rated control load ability is 3A/250VAC or 3A/30VDC.(This interface isoptional)

16. Power interface of heater: Power socket of the gas heater, its output voltage is 36VAC.17. Power source fuse base: This fuse wire is used in the welding control system, its

specification is RF1-20-3A.18. Input connection line of three phase power: connect it to distribution box, the

green-yellow line should be connected to protective ground line well.19. Adjustment knob of welding current: To adjust the welding current.20. Adjustment knob of welding voltage: To adjust the welding voltage.21. Manual wire feeding button：Press the button, the wire feeder begins to feed wire. The

speed of wire feeding can be adjusted by the welding current adjustment knob. While usingthinner wire, the feeding speed should be slowed down to avoid distorting the wire.


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Figure 1. Connection between the welding equipment and other equipments

Gas Cylinder

GasPipe

Connecttothe‘+’output

Connect

tothe

control

socketofthewirefeeder

Connecttothe‘-’output

3-Phase PowerSwitch Box3-Phase Power Line

Power source of the GasHeater

Workpiece


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Figure 2. Names of the components


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2. Connections(The user should choose the power cables, switches, fuses and power switches that on the switchboardaccording to the table below)

2.1 Connections of the power supply cable and the grounding cableMethods and requirementsMake sure the power source is cut off before connecting.Do not connect with wet hands.Do not place anything on the power supply cable.Make sure all the connections are reliable.Connect the green-yellow wire of the three-phase input cable to the grounding wire on the

switchboard reliably.2.2 The output cable connection of manual welding

Methods and requirements:Please make sure the power switch is cut off before connecting.Connect the copper connector of workpiece cable to the ‘+’ and ‘--’ output socket that on the

welding power source. When it is negative connection， the welding electrode holder should beconnected to the ‘+’. When it is positive connection，the welding electrode holder should be connectedto the ‘--’

The welding cable and workpiece should be reliably connected by bolts, and keep good contact.2.3 Connections of Gas-shielded Welding2.3.1 Connection of the output cable

Methods and requirementsPlease make sure the power switch is cut off before connecting.Connect the copper connector of wire feeder cable to ‘+’ output that on the welding power source;Connect the copper connector of workpiece cable to ‘--’ output that on the welding power source,

connect the other side to workpiece with bolts;Insert the aviation plug(six cores) of control cable into the control socket(six cores) of wire feeder,

then tighten the ring nut, connect the other side of control cable to wire feeder.2.3.2 Connections of the power source, wire feeder and welding torch(please refer tofigure 1)

Methods and requirementsMake sure the power switch is cut off before connecting;Wire feeders that produced by our company are requested to match with the certain welding

machine. Otherwise the welding performance maybe bad and even damage the machine;Insert the aviation plug(six cores) of control cable into the control socket(six cores) of wire feeder,

then tighten the ring nut;Aim the control plug of the welding gun at the guide slot, then insert it into the control output

socket (2 pins), then tighten the ring nut. After the connector of welding torch aiming at guide slot,you can insert it completely. And then turn 90° by clockwise rotation and tighten the bolts; Connectthe gas pipe of welding torch to the gas output connector of wire feeder, and then tighten the nuts.

2.3.3 Connections of the gas cylinder and gas adjustorMethods and requirementsInstall the gas adjustor to the gas cylinder, and screw down the nuts.Connect the aero plug of the gas heater to the heater’s power source socket on the back panel of the

machine, and screw down the nuts.Connect the windpipe of the wire feeder to the gas output connector of the gas heater, fix it by a

SpecificationNB-200/250I

GBT

NB-315/350I

GBT

NB-500IG

BT

NB-630IG

BT

Switch capacity（A） 25 40 63 100

Fuse capacity（A） 18 32 40 63

Section surface of power supply cables（mm2） 2.5 4 6 8

Section surface of grounding cables（mm2） 2.5 4 6 8


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tightener.When used as CO2 shield welding, make sure the gas meet the requests of welding. Otherwise

welding defeat may appear.When used as MAG welding, make sure the mixed gas meet the requests of MAG welding. To

avoid the mixed gas being asymmetrical, please use compounding device of proportioned gases.

3. Directions of the manual welding modeTurn on the power switch of distribution box.Turn the welding model switch to the manual welding model.Before welding, make sure the output terminal of the welding machine is connected to the welding

cable reliably according to the section 2.2 above. The welding current is adjusted by the currentadjustment knob on the panel.Please wear fur glove and safety shoes, wear a shield filter glass that match with different welding

current.

4. Directions of the Gas-shielded Welding mode( Please read this manual carefully and operate according to it strictly）

4.1 Checking items ,methods and requests & preparations before operation4.1.1 Wears of safeguards

a) Wear fur gloves and safety shoes to protect the skin and bare parts;b) Wear a shield filter glass that match with different welding current to protect eyes;c) There should be ventilation in the welding place to prevent breathing in deleterious gas .

4.1.2 Checking after connection:a) Check out all the items according to the section 2.3 “Connections of Gas-shieldedWelding”, make sure there’s no error.

b) Check out all the items according to the section 1.6 “Input power condition” to meet all therequests.

4.1.3 Operations of the switches & adjustment of gas fluxFirst, turn on the power switch of distribution box;Second, turn the welding model switch to the “gas-shield” welding model;Third, turn the “welding wire’s type ”switch and the “welding diameter” switch to the right

position to meet the type and diameter of welding wire;Fourth, turn the “Gas-supply” switch to “check” position;Fifth, turn on the gas valve of the cylinder, and then adjust the switch of the flowmeter slowly to

meet the value needed;Sixth, turn the “gas supply” switch to “welding” position.

4.1.4 Installation of the welding wireThe name of operation components please refer to Figure 3 (NB200/315IGBT have nocomponents that in the dotted circle)Methods and requirementsFirst, make sure that the size of the wire feeding slot at the outer side of the wire feeding wheel

fits with the diameter of the used welding wire, otherwise, dismantle the wire feeding wheel andchoose suitble diameter wire, install the wheel and make the slot be at the outer side perfectly;Second, pull down the handle of wire feeder, and then lift the press-arm;Third, install the welding wire reel to the welding wire reel’s axis, adjust the baffle of the

welding wire reel’s axis to be spread，screw down the manual nut. The out end of the wire is below.The welding wire comes out at clockwise rotation;Fourth, let welding wire go through the wire rectification wheel (or guide pipe), wire feeding

wheel slot, then insert into the guide tip;Fifth, press the welding wire with press-arm, and then pull up the handle to press the press-arm,

circumgyrate the handle with suitable strength;Sixth, check up the tip of welding torch, whose aperture diameter should meet the diameter of the

wire;Seventh, press “manual wire feeding” button on the control box of wire feeder, adjust “welding

current adjustment” knob for a right feeding speed. You can loosen the button until there is


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15—20mm wire outside of welding torch.

Figure 3 Installation of welding wire

Figure 3. Installation sketch map of welding wire

4.2 Directions of the basic weldingWelding can be performed by the “arc ending” switch and welding torch switch on the panelin two methods : with arc ending self-lock and acting with the switch on the weldingtorch synchronistically without arc ending function.

4.2.1 Welding operation with arc ending function1) Features instruction:a) The main features of the welding function is the ability to fill up the hollows when endingweld, which can be propitious to connect the start-point and end-point of the welding seamcontinuously;

b)Mainly used in welding middling thickness plate;c) The self-lock will be canceled if the arc is stopped for more than 0.5s.

2) Operation regulationsa)Turn the “arc ending” switch to “yes” position;b)After on standby state, press the welding torch switch, it begins to feed gas and come into thegas pre-flow state . After feeding gas for some time, welding voltage appears, then cominginto the arc starting state and begins to feed wire slowly. After successful arc starting, the wirefeeding speed will become normal, and then welding current appears. Then you can loosen thewelding torch`s switch, welding goes into the self-lock state. Simultaneously, you can adjustthe “welding voltage adjustment” knob and “welding current adjustment” knob for the bestwelding performance;

c)When welding is finishing, press the welding torch switch again, and it come into arc endingadjustment state. Then, set the arc ending voltage and current by adjusting the relative knobson the welding power panel (or adjust them to the needed values respectively in advance,commonly to the 60～70% of the normal welding current ) , thus you can control and adjustthe effect of filling up hollows at the end of welding. Then loosen the welding torch`s switchagain, wire feeding stops immediately, it will come back to burn state, the welding voltagewill decrease and become back burn voltage. When the welding current becomes zero, arcquenches, gas feeding stops, and the welding finishes.

4.2.2 Welding operation without arc ending function (operate with welding torch`s

下搬/上压

抬起/压下

焊枪

接口

手

柄压臂

导向嘴

送丝轮

矫丝轮

矫正手

轮

矫正支座

NB -350IGBT

为焊丝导向管

焊丝

Welding Gun Connector

Handle

Guide Tip

Wire Feeding Wheel

Press Arm

Rectify Wire Wheel

Welding Wire

RectificationSupport Saddle

RectificationWheel

Wire LeadingTube forNB-350IGBT


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switch synchronously)1) Features instruction:a) Press the welding torch`s switch to start welding, and loosen it to stop welding;b) It is suitable for orientation welding and spot welding of thin plate;c) There is no arc ending process.

2)Operation regulations:a) Turn the “arc ending” switch to “no” position;b) After on standby state, press the welding torch switch, it begins to feed gas and come into thegas pre-flow state . After feeding gas for some time, welding voltage appears, then coming intothe arc starting state and begins to feed wire slowly. After successful arc starting, the wirefeeding speed will become normal, and then welding current appears. But you can`t loosen theswitch now.Simultaneously, adjust the “welding voltage adjustment” knob and the “weldingcurrent adjustment”knob for the best performance of welding;c) When welding is finishing, loosen the welding torch switch, wire feeding stops immediately,and become back burn state, The welding voltage will decrease and becomes back burn voltage.When welding current becomes zero, arc quenches, gas sending stops, and the welding finished.

5 . Directions of prolonged output cableThe connection cable on this series of machine is allowed to be lengthened between power sourceand wire feeder, but the below regulations have to be followed.a) The resistance of cable will increase, and the increase of the cable’s voltage drop will makeagainst the welding. Moreover, the smaller cable sectional area is, the greater influence will be;

b)When lengthening the cable, the shorter, the better;c) When lengthening cable, get the cable straight.

6 . Technique conditions6.1 Technical parametersTYPE

PARAMETER NB-200IGBT NB-250IGBT NB-315IGBT NB-350IGBT NB-500IGBT NB-630IGBT

Shield rank IP21SRated input voltage Three-phase power 3~380VAC 50HzRated input capacity 6.7KVA 9.4KVA 13.2KVA 16.5KVA 26.3KVA 36.2KVA

Gas-shieldwelding

Outputcurrent

60～200A 60~250A 60~315A 60～315A 60～500A 60～630A

Outputvoltage

17～24V 17～26.5V 17～29.8V 17～31.5V 17～39V 17～44V

manual welding

Outputcurrent

60～200A 60~250A 60~315A 60～315A 60～500A 60～630A

Outputvoltage

22.4～28V 22.4～30V 22.4～32.6V 22.4～34V 22.4～40V 22.4～44V

Arc ending current 60～200A 60~250A 60~315A 80～315A 80～500A 80～630AArc ending voltage 17～25V 17～28V 17～32V 17～40V 17～40V 17～40V

Duty cycle 60% 60% 60% 100% 100% 100%Rated current 200A 250A 315A 350A 500A 630A

Suited welding wire’sdiameter

Solid 0.8mm1.0mm

Solid 0.8mm1.0mm

Solid 0.8mm1.0mm

Solid 0.8mm1.0mm1.2mm




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Flux-cored1.0mm

Flux-cored1.0mm

Flux-cored1.0mm1.2mm

Flux-cored0.8mm1.0mm1.2mm



Outline(length×width×height)

570×290×530（mm）640×290×530（mm）

640×320×570（mm）

Weight 31Kg 32Kg 34Kg 39Kg 45Kg 54Kg

* Its rated duty cycle is 60％, that means in a 10 minutes working period，the machine will run for6 minutes under rated welding current and rest for 4 minutes. If the Rated duty cycle is 100%,thatmeans in a 10 minutes working period，the machine will run for 10 minutes under rated weldingcurrent without rest. If the machine works over the rated duty cycle, the inner temperature will riseand exceed the fixed threshold. In order to avoid worsening the performance or even burning outthe machine, there is heat protection on this series of welding machine. When the inner temperatureexceeds the fixed, he heat protection begins to work, the overload indicator lamp lights, at this timethe machine has no output. Wait until the temperature is below the fixed and the overload indicatorlamp is turned off, the machine recovers and go on welding.

6.2 Instructions of keywordsDefinition of “yes”/ “no” arc ending:There will normally be a small hole at the terminal of the welding seam unless the welding

current is very small, and this hole is called “arc hole” in jargon. The reason is that condensationshrinking of the melting metals and the pressure of arc. Commonly, the larger welding current is,the larger hole will be. In the welding component, welding bug will appear because of the “archole”. So, make the hole smaller as possible as you can. We call the method of filling the “archole” as “arc hole filling weld”, and the standard current value set is 60～70% of the weldingcurrent.When the welding ends, operate the welding torch switch and change into the arc ending

welding program with lower current than the welding current, we call it arc ending “yes”. Arcending “no” means there is no control program of filling up the arc hole. Operate the welding torchswitch and end the welding with normal welding current.

What is the slow wire feeding speed of arc striking?To get stable arc striking, decrease the feeding speed and let it below the normal wire feeding

speed, this control process is called the control of slow wire feeding of arc striking. The slowdownspeed is called the slow wire feeding speed of arc striking.

What is burn-back time?After welding, wire feeder is not stop even if the welding torch switch is shut down because of

inertia. So there will be some more wire drive out from the torch, thus the wire will adhere to theworkpiece, or it will cause difficulty in arc striking next time. In order to avoid this defeat, it isnecessary to deal with it inside the welding machine, so that after shutting down the welding torchswitch, the output voltage will still exist for a short time to burn the wire. This process time isburn-back time. This time varies because of differences in welding conditions, the resistance ofwelding feeding tube and the length of output cable.

6.3 Examples of welding conditionData in table 1, table 2 is the reference value under the standard condition.When welding, please correct the values according to workpieces and the welding position to get

the right welding conditions.

Table 1:


15

Thickness

(mm)

Length(mm)

Wirediameter(mm)

Weldingcurrent(A)

Weldingvoltage(V)

Weldingspeed

(cm/Min)

Stickout(mm)

Gas flow(L/ Min)

Ttypewelding

Slow

speed

1.0 2.5～3 0.8 70～80 17～18 50～60 10 10～151.2 3～3.5 1.0 85～90 18～19 50～60 10 10～151.6 3～3.5 1.0,1.2 100～110 18～19.5 50～60 10 10～152.0 3～3.5 1.0,1.2 115～125 19.5～20 50～60 10 10～152.3 3～3.5 1.0,1.2 130～140 19.5～21 50～60 10 10～153.2 3.5～4 1.0,1.2 150～170 21～22 45～50 15 15～204.5 4.5～5 1.0,1.2 180～200 23～24 40～45 15 15～206 5～5.5 1.2 230～260 25～27 40～45 20 15～208, 9 6～7 1.2,1.6 270～380 29～35 40～45 25 20～2512 7～8 1.2,1.6 300～380 32～35 35～40 25 20～25

Highspeed

1.0 2～2.5 0.8 140 19～20 150 10 151.2 3 0.8 140 19～20 110 10 151.6 3 1.0, 1.2 180 22～23 110 10 15～202.0 3.5 1.2 210 24 110 15 202.3 3.5 1.2 230 25 100 20 253.2 3.5 1.2 260 27 100 20 254.5 4.5 1.2 280 30 80 20 256 5.5 1.2 300 33 70 25 25

Putupweld(thinplate)

Slow

speed

0.8 0.8 60～70 16～17 40～45 10 10～151.2 0.8 80～90 18～19 45～50 10 10～151.6 0.8 90～100 19～20 45～50 10 10～152.3 0.8 100～130 20～21 45～50 10 10～15

1.0,1.2 120～150 20～21 45～50 10 10～15

3.2 1.0,1.2 150～180 20～22 35～45 10～15 10～15

4.5 1.2 200～250 24～26 40～50 10～15 10～15

Highspeed

2.3～3.2 1.2220 24 150 15 25

300 26 250 15 25

Cornerweld

Slow

speed 1.6 0.8 65～75 16～17 40～45 10 10～15

2.3 0.8 80～100 19～20 40～45 10 10～15

3.2 1.0, 1.2 130～150 20～22 35～40 15 10～15

4.5 1.0, 1.2 150～180 21～23 30～35 15 10～15


16

Table 2:

7. working principle7.1 Summarize of working principle

The inputed three-phase AC 380VAC50Hz(60Hz) is rectified and supplied to the IGBT inverter toproduce 20 kHz AC. This AC is transformed by the high–frequency transformer and rectified; then goesinto the output of DC power.7.2 Main electric elementary diagram

Please refer to appendix 1.8. Troubles and troubleshooting8.1 Please check with multimeter if there are any troubles:

Three-phase power should be 380±50VAC, check if there is phase lack or exceeding voltagefluctuation;

Whether the fuse on the back panel of the welding machine is melted;Whether the three-phase power switch at the switchboard is damaged; Whether the fuse and

electrical power wire are installed reliably, Otherwise it will cause phase lack or they are not connectedtightly, so the welding machine will work abnormally.

The control cable of the wire feeder is easy to be broken, check the related pins of the twoconnector plugs with six pins at the ends of the control cable to be conductive, whether the weldingcable is connected reliably, and the workpiece is connected tightly.

Whether the welding torch switch and the wire connected are damaged or open circuit; whether thenozzle, conduct tip , conduct tip’s seat and shunt are burned out and damaged.

ATTENTIONS:This welding machine adopts large capacity,high voltage and electrolytic capacitor filter, it can not

be opened until the three-phase power is shut down more than 10 minutes.

Thick-ness(mm）

Wirediameter(mm)

RootgapG（mm）

Weldingcurrent(A)

Weldingvoltage（V）

Weldingspeed(cm/Min)

Wire out(mm）

Gasflux(L/Min)

Itypebuttwelding

Slow

speed

0.8 0.8 0 60～70 16～16.5 50～60 10 101.0 0.8 0 75～85 17～17.5 50～60 10 10～151.2 0.8 0 80～90 17～18 50～60 10 10～151.6 0.8 0 95～105 18～19 45～50 10 10～152.0 1,1.2 0～0.5 110～120 19～19.5 45～50 10 10～152.3 1,1.2 0.5～1 120～130 19.5～20 45～50 10 10～153.2 1,1.2 1～1.2 140～150 20～21 45～50 10 ～

1510～15

4.5 1,1.2 1～1.5 170～185 22～23 40～50 15 156 Face 1.2 1.2 ～

1.5230～260 24～26 40～50 15 15～20

Inside 1.2 1.2 ～1.5

230～260 24～26 40～50 15 15～20

9 Face 1.2 1.2 ～1.5

320～340 32～34 40～50 15 15～20

Inside 1.2 1.2 ～1.5

320～340 32～34 40～50 15 15～20

Highspeed

0.8 0.8 0 89 16.5 120 10 151.0 0.8 0 100 17 120 10 151.2 0.8 0 110 18 120 10 151.6 1,1.2 0 160 19 120 10 152.0 1,1.2 0 180 20 80 15 152.3 1,1.2 0 200 22 100 15 203.2 1.2 0 240 25 100 15 20


17

8.2 Common troubles and troubleshooting

Troubles Reasons Troubleshooting1． Turn on power,the indicator lampdoesn’t light, thedigital meter doesn’tlight.

1．Phase lack；2．Power switch is damaged；3．Power control fuse (3A) is melted；

1．Check the three-phase power；2．Replace input power switch；3．Replace Power control fuses；

2．Welding machinedoes not work， theundervoltageindicator lamp lights

1．Phase lack；2．Three-phase power is under voltage；

1. Check the three-phase powerto make sure it meet therequirements of the machine；

3. There is no outputvoltage and thereis noise inner themachine

1．The fast recovery diode of the maincircuit is damaged；

1.Check and replace the damagedfast recovery diode;

4．Welding machinedoesn’t work，overheat indicator lamplights

1．The temperature is too high；2．When welding，cooler fans rotateslowly or don’t work, which leads tobad cooling；3．Temperature relay is damaged；

1．Welding machine will becomenormal after rest for some time；2. Check the fans power orchange cooling fans；3．Replace temperature relay；

5 ． Welding wirefeeder works, butthere is no wirefeeding or thefeeding isn’tstable.

1． Wire press wheel is not pressedtightly；2．The type of wire feeding slot doesn’tmatch the welding wire；3． The tip is jammed because of thespatters；4．The wire feeding wheel is abraded；5．The wire feeding tube of the weldingtorch is jammed；6． The curving semidiameter of thewelding torch cable is too small；

1．Press tightly；2. Replace wire feeder wheelslot；3．Clean the spatters in the tip；4．Change wire feeding wheel；5．Blow off the dust with the drycompressed air or replace a rightone with the same type；6. Make the curvingsemidiameter of welding torchcable over 300mm；

6．The feeder don’twork after pressingdown the torchswitch or there is noopen circuit voltage

1．The control cable of the wire feederis broken；

2．Short circuit of welding gun switch;3．The PCB is broken；

1．Replace the control cable；2 ． Check control wire of thewelding torch switch；3．Repair or replace the PCB；

7．Many pores in thewelding seam

1．CO2 gas is not pure；2．The gas flow is not enough；3．There is rust or oil in the weldingseam；4．The wind is strong when welding；5．The path of CO2 is jammed or airleak；6．Valve doesn’t work；

1．Use pure CO2 gas；2．Adjust the gas flow；3．Clean the welding seam；4．The precaution against windshould be adopted；5．Check the path;6．Check the voltage 24VDC ofthe valve winding；


18

7．The nozzle is distorted； 7．Replace the nozzle；

8．Current /voltageis out of control

1 ． Control cable of wire feeder isbroken；

2．Current /voltage adjust potentiometeris damaged；3．The PCB is damaged；

1．Replace the control cable；2．Replace the potentiometer；3．Repair or replace the PCB；

9. Wire feedingstarts withoutpressing down thewelding torch switch

1．The wire connecting welding gun isshort circuit；2．Control cable of the wire feeder hasshort circuit；

3．The manual button of wire feeding isdamaged；

1．Repair or change welding gun；2 ． Repair or change controlcable；3．Change the manual button ofwire feeding；

10．The current isn’tstable, and there istoo much spatter

1．Welding criterion is wrong；2．The quality of wire is bad；3．There is rust or oil on the weldingdevice or wire；4．Too much fluctuation of distributionvoltage；5． The stick out of the wire is toolong ；6．Choose wrong position of the wirediameter select switch；7．The type of wire feeding slotdoesn’t match the welding wire；8．Problems in the protective gas；9．Incorrect type of the tip or theaperture of the tip becomes too big;10．Too much feculency in the wirefeeding tube ， the resistance of thefeeding wire is too large；11．The ground cable becomes loose；

1．Adjust the welding criterionagain；2．Change wire；3．Clean the welding device andwire；4． The fluctuation of the linevoltage can’t exceed ±15%；5．The stick out should be about10 times than the wirediameter；6．Take a right position of wirediameter select switch；7． Replace wire feeding wheelslot；8．Use the purer gas；9．Replace tip；10．Clean the wire feeding tube；11．Fix the cable connected to theground tightly；

11．Gas heater frosts

1. The input power fuses of the heater(5A) is burned ；2. The resistance wire of the heater isbroken ；

1. Replace the fuse with the sametype；2. Repair or replace the heater；

ATTENTION:Only qualified technicians are allowed to perform troubleshooting work on the machine.If for anyreason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact our service department for technical assistance.


19

9. Packing list (another packing list for aluminum welding)

1. NB-IGBT power source 12. Wire feeder 13. CO2 gas flowmeter 14. Composite cable(gas tube, control wire and welding cable are include)10m5. Ground line 1.8m6. Welding torch with 3m cable 17. Operation manual 18. Conformity certificate 19. Guarantee card 1


20

QF1

C5

V2

SKM**GB128D

V3

SKM**GB128D

R1

100K/2W

R2

100K/2W

C10

C6

TM1

TA2

V4

V5

C2

C9

C1

C8

C3

L1

L2

C7

40n×2

L3

FU1

1.5A

EV1

风扇

C4

＋15V 1

Out 3

-15V 2

0V 4

TA1

TC118V

18V

36V

17V

380V

220V

190V

过热

欠压

2838

3937

电源

29

HL2

HL1

HL3

KT1

3635

RP3

4.7K 收弧电流

RP2

10K

收弧电压

5856

5554

30 31 32 80.

81.

44

5251

5049

PV1

69.

70 71 72

G2

E2

G1

E1

G4

E4

G3

E3

2425

G1

G2

G3

G4

G1

G2

G3

G4

E1

E2

E3

E4

E1

E2

E3

E4

1 2 3 4

5 6 7

8

9 10 11

27

13

14 15

16

1718

19

20 21

22

2324

25

AP1

NB-IGBT系列主电路图

ZX7-AP4

79 68.

6745

27V

27V

8V

26V

4746

加热器电源

RT1

RA10K

RB

390/2

SB1

SB2

DA

1N4007

DB

1N4007

RC4.7K

RP5

5KRP4

5K

焊接电压

焊接电流A -+

MG1

YV1

12

64

53

7753

66.

8342

78

送丝机

42

SA1

检气43

82

R4

RP1

30K

电弧特性

4041

6261.

SA4

SA5

63

手工焊气保焊

丝径选择

SA3

焊丝选择

65

SA2

收弧有无

64

PA1

73 74 75 76

V1

+-

3334

引弧成功信号

5960.

29

84

57

L4

26


21

The final explanation rights reserved to Huayuan Company!If there is any changes in the user’s manual, forgive not to inform separately!

Chengdu Huayuan Electric equipment Co.,Ltd.

Address: Wuhou National Science Park, Chengdu, ChinaPostcode: 610045

Telephone:0086-28-85365838Fax:0086-28-85033444

E-mail: [email protected] [email protected]://www.hwayuan.com

mailto:[email protected]

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Documents

OPERATOR’SMANUALen.hwayuan.com/.../3cde4ec2-02c7-4136-a4e5-d786e1bf387f.pdf2015/10/29 · PARAMETER NB-200IGBT NB-250IGBT NB-315IGBT NB-350IGBT NB-500IGBT NB-630IGBT Shieldrank