Solid State High-frequency Welding Machine

User’s Manual

Baoding ZSHC Electrical Co., LTD.

May 29, 2018

 Catalog
Introduction ................................................................................................................................................... 2
1. Summary ......................................................................................................................................3
2. Composition of the Equipment ..................................................................................................3
2.1 DC Power Unit ........................................................................................................................3
2.2 Inverter Output Unit ............................................................................................................... 4
2.3 Central Control Unit ............................................................................................................... 4
2.4 Water-water Heat Exchange Unit ........................................................................................... 4
2.5 Rectifier isolation transformer ................................................................................................4
3. Main Parameter .......................................................................................................................... 4
4. Control description and procedure ........................................................................................... 5
4.1 Control description ........................................................................................................... 5
4.2 The order of operations .....................................................................................................5
4.3 Notice ................................................................................................................................6
5. Fault display & trouble shooting ...............................................................................................7
5.1、Fault display on the screen & trouble shooting .................................................................... 7
5.2、Power board fault display & trouble shooting ......................................................................7
5.3、Rectifying part fault display & trouble shooting .................................................................8
5.4 Trigger board fault display & trouble shooting ...................................................................... 9
5.5 Other fault display & trouble shooting .................................................................................10
6. Induction coil ................................................................................................................................. 11
7. Impeder .......................................................................................................................................... 13
8. Regular maintenance ....................................................................................................................13
8.1、Maintain by shift ................................................................................................................14
8.2、Maintain by week .............................................................................................................. 15
8.3、Maintain by month .............................................................................................................15
8.4. Maintenance by semi year ................................................................................................... 15
9. Common components information & measurement .................................................................15
9.1 Common components information (attached) ......................................................................15
9.2 Common tools and instruments ............................................................................................ 15
9.3 methods of measurement ...................................................................................................... 16
10. Appendix ...................................................................................................................................... 17
10.1 Welding machine ground laying schematic ........................................................................17
10.2 Machine layout ................................................................................................................... 17
10.3 Machine wiring diagram .....................................................................................................17
10.4 Machine water route drawing ............................................................................................. 17
10.5 Rectifier control schematic .................................................................................................17
10.6 Inverter control schematic .................................................................................................. 17
10.7 The center control unit schematic .......................................................................................17
10.8 Water-water heat exchanger control schematic .................................................................. 17

1
Introduction

We appreciate you purchase the Solid State High Frequency Welding Machine. Before your
operation please read and comprehend the instruction attentively for proper use of the machine. Incorrect
operation will cause abnormal function or breakdown, and cut down its life span. Please keep this
manual carefully together with the equipment in order that it server at any time afterwards.

Safety considerations

Please be familiar with the details of the instruction before installation, circuit connection
operation, preservation to guarantee the appropriate operation. At the same time, please be familiar with
the situation of the cooperated facility and all the attention concerned with safety.

Attention
The user manual may change without priornotice. Manual in Chinese shall prevail.
Around the HF equipment, 10 mm thick 35 KV voltage enduring board should be placed.
Don’t touch the shell while operating.
While power off, the label signed with “Don’t switch while power off and overhaul” must be
hanged on the main power switch.
With the circumstance below 0 ℃ , when the equipment ceases to run, the remained water in it
must be discharged clearly by the compressed air to avoid damaging the element by freezing.
Halt water after 30 min of the welding machine turns off.
Please read the instruction carefully, comprehend every item of the content to ensure the correct
installation, circuit connection and operation.

Dangers
By the side of the solid state HF welder equipment, the breaker that used to protect the circuit and
avoid electric leaking must be applied.
Be sure to connect with the ground wire.
Wiring must be processed by professional electricians.
Begin to operate the equipment after ensuring the power is off.
Don’t touch the switch button by the wet or greasy hands.
Turn off all the power sources before overhaul, then discharge the condenses repeatedly by
discharge stick, before begin to overhaul or change elements of the equipment.

2
1. Summary
QGT-1 Solid State H.F Welding machine is specially designed for straight seam welding of the
steel tube. It is current type parallel step up resonance circuit composed by transistor inverter of module
power unit by IRFP460 and DSEI60-06A fast recovery power components, tank circuit capacitance C
and the inductive coil L. This circuit adapts well to low load impendance of H.F welding. No output
transformer needed. Thus achieves the high efficiency and the whole machine realibility.
The Solid State H.F Welding machine is featured by obvious energy saving, high quality of
welding seam, simple structure, easy maintanence, low failure rate, and low maintanence cost.
The control part of QGT-1 Solid State H.F Welding machine is composed by relay and failure
display LCD.
Multiple and sensitive protection ensures the safe operation of the welding machine.
 Over-current Protection: short circuit of induction coil or mis-operation may cause

over-current, when exceeds the set value, protection occurs immediately.

 Open Circuit: Mis-operation or induction coil is open circuit, protection occurs immediately.

 Wrong phases: Three phase sequence wrong, protection occurs immediately. L5 of MUCK

board is on.
 Temperature protection: the temperature of the vibration device on the moulding board is

once higher than 60 centigrade, protection occurs immediately.

 Water-lack protection: When the water-pressure is not high enough or lower than the preset

value, protection occurs immediately.

 Water-temperature: The water temperature of cycling water is higher than the temperature

rating, protection occurs immediately.

 Working power supply protection: 24V switching power supply is not normal, protection

occurs immediately.
 Power board protection: The supply voltage is lower than 15V, water temperature is too high,

MOSFET tube damage, impulse loss, protection occurs immediately.

 Frequency protection: Bad output leg insulation, arcing, protection occurs immediately.

 Phase lock protection: Tank capacitor damage, bad output leg insulation, protection occurs

immediately.

2. Composition of the Equipment

QGT-1 Solid State H.F Welding machine is composed by five parts:

2.1 DC Power Unit

DC Power Unit includes rectify, flight wave and control parts. 3-phase full-controllable thyristor
rectifying bridge and flight wave reactor, flight wave capacitor, and filter ensure stable DC output and
guarantees high quality welding.
Current meter, voltage meter and control system are equipped in the DC power unit. Thus the
welder is controllable even without central control unit.
Output DC voltage 0-235V is continuously adjustable and has soft start and time constant
setting.

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 2.2 Inverter Output Unit

The inverter part is mainly made up by tank circuit capacitance C and the inductive coil L. Power
components all adopts MOSFET as large power component module type power unit.
LC type oscilation circuit differes to vacuum type, the tank circuit capacitance C and the
inductive coil L produce resonance directly, no output transformer needed, reduce the loss greatly, and
impove the efficiency. (Note: compare to vacuum tube, output efficiency can improve 25%-30%).

2.3 Central Control Unit

Installed with LCD, power and speed adjust module; indicate the output current and voltage of the
DC power unit; armature voltage and current, excitation voltage and current of the DC speed adjust unit.
The pipe line can be completely controlled by the central control unit.

2.4 Water-water Heat Exchange Unit

Composition：Plate heat exchanger, water tank, pump and electrical control part.
Working principle: The internal cooling is called inner water (distilled water), and the external
cooling is called outer water (ordinary water). External and inner water exchange through the plate heat
exchanger to reduce the temperature of the inner water. Thus, the equipment inside is cooled.
Features:
A. Seal circulation, outer water (normal) cools down the inner water (distilled water), no scaling.
B. High efficiency of heat radiation, low cost, applicable to large power H.F equipment.
C. Reservoir is used for outer water.

2.5 Rectifier isolation transformer

It is the input rectifier part of the equipment. It reduces the input voltage from 380V(customized
415V) to 200V to ensure stable power supply, at the same time, to insulate the power grid.

3. Main Parameter

Data Power 100KW 150KW 200KW 250KW

Input Rated Power 150KVA 230KVA 300KVA 380KVA

Input Rated Power 450KVA 600KVA 750KVA 900KVA

Output Rated Power 300KW 400KW 500KW 600KW

Input Rated Voltage 3Phase380V 3Phase380V 3Phase380V 3Phase380V

DC Rated Voltage 0-235V 0-235V 0-235V 0-235V

DC Rated Current 1500A 2000A 2500A 3000A

Frequency Range 250KHZ±30KHZ 250KHZ±30KHZ 200KHZ±30KHZ 200KHZ±30KHZ

Efficiency 85% 85% 85% 85%

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 PowerFactor Full Load＞0.9 Full Load＞0.9 Full Load＞0.9 Full Load＞0.9
Cooling water
0．25MPa 0．25MPa 0．25MPa 0．25MPa
pressure
Inlet Water
＜35℃ ＜35℃ ＜35℃ ＜35℃
Temperature
Complex
Resonance Complex Resonance Complex Resonance Complex Resonance
Resonance

Data Power 300KW 400KW 500KW 600KW

Input Rated Power 450KVA 600KVA 750KVA 900KVA

Output Rated Power 300KW 400KW 500KW 600KW

Input Rated Voltage 3Phase380V 3Phase380V 3Phase380V 3Phase380V

DC Rated Voltage 0-235V 0-235V 0-235V 0-235V

DC Rated Current 1500A 2000A 2500A 3000A

Frequency Range 250KHZ±30KHZ 250KHZ±30KHZ 200KHZ±30KHZ 200KHZ±30KHZ

Efficiency 85% 85% 85% 85%

PowerFactor Full Load＞0.9 Full Load＞0.9 Full Load＞0.9 Full Load＞0.9

Cooling water
0．25MPa 0．25MPa 0．25MPa 0．25MPa
pressure
Inlet Water
＜35℃ ＜35℃ ＜35℃ ＜35℃
Temperature
Complex
Resonance Complex Resonance Complex Resonance Complex Resonance
Resonance

4. Control description and procedure

4.1 Control description

Control operation have two sets of controls—internal control and external control. In the internal
control first check the power adjustment potentiometer is in the zero position, the switch is in the internal
control position. Turn on the high frequency welder power, press the reset button, start the main loop
control, start the heating control.
Note: Internal control only used in situations of commissioning, troubleshooting, and invalid
external control. Normally use external control for the welding machine.

4.2 The order of operations

4.2.1 typical indicator descriptions in normal operation:

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 Power distribution
Boot order Rectifying board Trigger board
board

Turn the power on, LED L1，L2，L3，L5，L12， LED LED16、LED17、HFOK、

LED A、B、LED on
press the reset button L20 on DCON on. RESET flash once

LED L1，L2，L3，L5，L12， LED LED16、LED17、

Start main circuit LED A、B、LED on
L20,L4 on HFOK、DCON on

LED L1，L2，L3，L4，L12，
LED LED16、LED17、HFOK、
L20，L11，L14,L15, L21，
Start heating DCOK、DCON、START、 LED A、B、LED on
L22，L23，L24，L25，L26
SYNC on
on. L5 off.

4.2.2 The boot process:

• Check the induction coil and output leg connection is good, check the welded steel pipe and the
induction coil is short circuit, and induction coil loop is open circuit or short circuit.
• Start the water cooling system, check that the water pressure is up to 0.2-0.3Mpa. Check if the
water temperature is below 35℃.
• Check that the potentiometer is at zero positon, switch of rectifier unit is on external control.
After the confirmation, started high-frequency welder, press the reset button, start the excitation control,
start running control, start the main loop, and start heating. Adjust the speed control potentiometer and
heating adjust potentiometer so that the production line meets the desired requirements.
4.3.3 The stop process:
• Press the stop button, the motor stops and welder stops output.
• The stop process must obey the sequence: stop heating—stop main loop—stoop H.F welder.
• In emergency, press the ermergency stop button, operation and heating stop at the same time.

4.3 Notice

• When forwar-reverse switch is on the reverse position, heating will not start.
• Without starting the operation control, heating will not start
• In heating control, main circuit control, and power control, there is interlock protection. Boot
order must be high frequency welder power → main circuit → heating. Stop order must be heating
→ main circuit → high frequency welder.
• Avoid direct main power supply of the DC power unit. This is mainly to prevent the over
voltage shock of the large inductors in a sudden loss of power.
• Multiple protection are adopted for the welder. When a fault occurs, protection circuit actions,
fault indicate LED is on. Please carefully observe the fault led, after the fault analysis, make according
treatment before the turn on the power again. Remember no blind operation to avoid failure to expand.

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5. Fault display & trouble shooting

5.1、Fault display on the screen & trouble shooting

Phenomenon Position Reason

Water pressure relay failure.

Water pressure water cooling Heat exchanger is lack of water, pump can't work
failure system properly.
Relay KA8 no suction
Water temperature is higher than 35
water cooling
Temperature failure Thermodetector works improperly.
system
Relay KA9 no suction
power board
see power board, trigger board, rectifying board
Welder failure trigger board
fault display & trouble shooting
rectifying board

5.2、Power board fault display & trouble shooting

5.2.1 Power board fault display instruction

Note: Any of the above fault can led to stop protection and show “welder failure” on the touch screen.
5.2.2 Power board fault trouble shooting
If the power board fault occurs, first, check if the alarm displayed. The alarm has 4 types: Mosfet destory,
no impulse, over temperature, and working power failure. See above figure. If other components fault,
check one by one with the multimeter. Change the component when find out.
5.2.2.1 Power board fault and repair
There are 5 indicate LEDs on the two sides of the power board. Normally only 1 green LED is on on
each side. When fault occurs, green LED is off, red LED is on.
“Working power fault” LED on—power supply for the power board voltage is less than 15V—check the
power supply voltage of the power distribution board.

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“Temperature is too high” LED on—the temperature of the aluminum bar for the Mosfet cooling is too
high-- inspect if the water channel is smooth.
“Impulse loss” LED on—No impulse input on the power board—check the horn plug cable in the AC
main cable output side, and the output cable of the trigger board is well plugged in.
“Mosfet fault”—one or more Mosfet destroy—check the components appearance of the power board.
Normally, if the power component is broken, it is featured by shell broken. And check by multimeter
other components are ok. The fast recovery diode and large power absorb resitance are to check one by
one. When find broken, change it. Remove the power board for maintanance if necessary. Details are
referred to “Power board change instruction” and common component measuremnt.
5.2.2.2 Power board change instruction
Make sure the power supply is off, the water pump stops before remove the power board!!
Remove the inlet and outlet of the power board. Take measures to prevent the leaking water dripping on
the power board. Unplug the impulse and power cable on the sides of the power board. Loose the fixed
screw on the DC main bus, then loose the 2 fixed screws on the tank circuit. In this remove process, 2
persons should coperate to prevent power board to fall. Then change a good power board. In the
installation, first tighten the screw on the DC main bus not too tightly, fix the 2 tank circuit screws, then
tighten the screw on the DC main. After change, check if the cable on the 2 sides of the power board are
plugged in and locked. Check the water channel is correct and fixed. When no mistake, the welder can
start to work.

5.3、Rectifying part fault display & trouble shooting

5.3.1 Wrong phase fault

Phenomenon Trouble shooting

LED L17 on the Check if the sequency of the three phase input power is right.
rectifying board of
DC power unit is on

5.3.2 Over current fault

Phenomenon Trouble shooting

LED L18 or L16 on 1. Check if the rectifying SCR is damaged (refer to 9.3.4).
the rectifying board 2. Check if the flat wave reactor burned.
of DC power unit is 3. Check if the inverter unit power components are broken.
on. 4. Check if the resistance of the inductor is loose.
Note: Any of the above fault can led to stop protection and show “welder failure” on the touch screen.

5.3.3 Full load when start welder

Phenomenon Trouble shooting

Rectifying board in the DC 1. Check if the power adjust potentiometer is broken.

power unit indicates normally. 2. Check the rectifying board is broken.

8
 5.4 Trigger board fault display & trouble shooting

5.4.1 Tigger board fault display instruction

9
5.4.2 Phase lock fault

Phenomenon Trouble shooting

LED HF or LF is on. 1. Tank capacitor matching is improper. Adjust it.

2. Arcing between induction coil and pipe.
3. Capacitor is broken.
4. Bad insulation of output leg.
5.4.3 Frequency fault

Phenomenon Trouble shooting

LED FBHL or FBHH 1. Induction coil arcs.

is on. 2. Bad insulation of output leg.

5.4.4 Power board fault

Phenomenon Trouble shooting

LED MOD is on. See Power board fault display & trouble shooting

5.4.5 Over voltage fault

Phenomenon Trouble shooting

LED GY is on. 1. Check the coil

2. Weld moulding open corner (VEE) angel is too small.
3. Arcing in weld VEE.

5.5 Other fault display & trouble shooting

5.5.1 Tank fault and trouble shooting

Cooling water fault will lead to output leg burn to red or capacitor damage.
Capacitor damage can lead to tank fail to resonance. Remove the capacitor and check one by one.
5.5.2 Motor drive power fault and trouble shooting
Switching power supply is applied for perfect protection and hard to damage for the working power.
Only if high voltage, the power may destroyed. Once destroyed, there is no indicated LED on. Over
current protection will also make the power stop. Find the over current reason and after trouble shooting,
supply power then the welder works normally.

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5.5.3 Cooling water fault and trouble shooting
Usually, the problem is water pipe jam caused by bad water quality or debris. So, check periodically and
change water pipe when necessary.
5.5.4 Welder works normally, speed is low
⑴ Coincide the moulding open corner (VEE) with demand: the open corner of the ordinary carbon steel
is 3-5。
⑵ The outsider diameter circular section surface of the axial magnet should be 75% times the inside
diameter circular section surface. Does the axial magnet have any crack? Does it locate in the most
suitable place? The water cooling of the axial magnet should be increased appropriately.
⑶ Has the squeeze roller been adjusted in place?
⑷ Does the width of the band steel meet the needs? (narrow width can influence the speed) The
empirical factor multiplied is differently adopted, when the company calculates the welding line
quality and the welding speed, and can also save the material.
⑸ Steel strip moulding, the appearance before entering the squeeze roller:

Correct. The inside bead and the outside bead coherent, welding speed is stabile.

Wrong. The inside bead is high, influencing the welding speed.

Wrong. The outside bead is high, influencing the welding speed.

6. Induction coil
The material, shape, manufacture process of the induction coil can influence directly the welding
efficiency of the steel tube.
The induction coil has the meticulous and precise manufacture process. Usually the induction coil is
made in advance. Thus, they can elaborate the functions of every parts of the facility and improve the
welding efficiency.
Solid state HF induction welder is different from the valve tape HF welder. The vacuum HF welder
has output welding transformer. The induction coil is installed on the secondary side of the welding
transformer. It is easy to match and not rigorous on the demand for induction coil. For there is one more
grade on welding transformer coupling, the efficiency is obviously low.

The solid state HF welder, besides the working volt of the complete appliance is low, its channeling
capacitance resonates directly with the induction coil welded on the steel tube. For there is no welding
transformer, having one less grade coupling, the efficiency is obviously higer.
That would ask for the induction coil to be strict and standard in manufacture to match. By the
reason that the electric pressure is low, the gap between the inside diameter of the induction coil and the
outside diameter of the welded steel tube (VEE) may reduce properly to improve the welding efficiency.
The benefit from the strict and standard manufacture of the induction coil is far higher than the
manufacture cost of the induction coil.

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 Skeleton map of induction coil A and induction coil B.
water cooling water cooling

copper pipe expansion copper pipe expansion

copper pipe: 6-12mm

copper pipe 8-10mm

insulator ，
polyethylene tube or belt binding
copper beltδ: 2-3mm, wide: 15-30mm

insulation

Type A Type B

Type A: According to the diameter of the steel tube, inside diameter of the induction coil, outside
diameter bilateral clearance, make carefully the clamping fixture on which use the copper pipe to twine.
Type B: Firstly twine the copper strip on the clamping fixture, the twine the copper pipe on the copper
strip, finally weld the copper pipe and strip together.

· Add the insulating barrier, poly silk fluoride strip or pipe. When twining the poly silk fluoride strip or
pipe, twine tightly and then twine with fiber glass strip, and put into the insulated paint, finally bake
it for preparation afterwards.
· Using the square copper pipe or rectangle copper pipe takes an advantage of the round pipe.

Φ50mm,δ:2.5mm and below steel pipe inductor standard

Outer Diameter Unilateral clearance

Width of the Turn of the
Induction coil of between the
induction coil induction coil
copper pipe coil and pipe
Φ15-16 3-4mm 18-20mm 3
Φ19-22 4-5mm 20-25mm 3
Φ25-30 4-5mm 25-30mm 3
Induction coil
Φ32-35 4-5mm 32-35mm 3
type A
Φ36-40 4-5mm 36-40mm 3
Φ41-45 4-5mm 40-45mm 3
Φ46-50 4-5mm 48-52mm 3

Below Φ50mm,δ:2.75-3.75mm specifications of copper pipe induction coil

Unilateral clearance
Outer Diameter of Width of the Turn of the
Induction coil between the
copper pipe induction coil induction coil
coil and pipe
Induction coil Φ32 4-5mm 73mm 2

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 type B Φ38 4-5mm 87mm 2

Φ42 4-5mm 87mm 2

Φ48 4-5mm 103mm 2

※ Outer diameter of copper pipe: Outer diameter of steel pipe (VEE)

※ Unilateral clearance between the coil and pipe: The dissimilarity between induction coil inner
diameter and welded steel pipe outer diameter divided by 2.
※ Width of the induction coil: the distance between the first turn and the last turn.

7. Impeder
The cross-sectional area of the impeder should be 70%-75% of the pipe inner diameter
cross-sectional. If lower than 70%, efficiency will obviously reduce. The impeder used in H.F pipe
welding has high initial permeablility. UA ≥ 800 saturation flux density Bs value greater than 3000GS,
the Curie temperature as high as possible and low loss as high as possible. In operation, impeder cooling
should be adequate to prevent broken magnet or ineffective when temperature exceeds the Curie point.
The length and position of the impeder both have the effect on welding efficiency. The impeder
total cross-sectional area and length should adjust to the welding pipe diameter. Usually, when welding
large diameter pipe, the impeder length should be less. But the VEE shaping side should exceed the
squeezing roll central line.

8. Regular maintenance
Regular maintenance is vital to welder long term and stable operation. After the welder came into use,
regular maintenance should be applied. The solid state H.F welder adopts three phase controllable
rectifying, achieves DC electric, then through inverter unit to get H.F AC electric, and through capacitor
resonance to produce large current. Without proper maintenance, it is easy to cause person and
equipment accident. With good maintenance can extend the life span of the welder. So, staff need to
learn how to use and maintain the welder properly.
Besides the working voltage of the complete appliance is low, tank capacitance of the all-transistor
solid state HF induction welder resonances directly with the induction coil welded on the steel tube, so
the efficiency is high. That would demand the operator to have specific general electrical knowledge.
And the operator should have the habit of maintaining and safeguarding the equipment. That will assure
the normal operation of the equipment. Keep the equipment in the good situation, save a large quantity
of electrical energy, and can bring a high output, good quality and economic benefit. On the contrary, the
incorrect employment can cause a subpar functional mode of the equipment; appear an unnecessary
malfunction or even an outage. Sometimes cause the electrical element to be damaged. That would
influence the output and the quality of the equipment, make economic loses. So, we demand
safeguarding and maintaining periodically the equipment, extend effectively the useful time of the
element to guarantee the normal operation of manufacture.

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 Organization and plan of maintenance
Maintenance should have progressively the organization and maintenance. Depending on the
different situation, the parts of the equipment should be maintained shift, weekly, monthly, semi-yearly,
etc. Pay more attention to the parts which are easy to make troubles, such as AC contactor, Medium relay
contactor is easy to burn out to cause bad contact. Vibration at work, nut is easy to loose and poor
contact, which needs the regular inspection. It’s very important to the equipment maintenance that we
collect the original record of the technical data. The collection of the data can make the staff comprehend
abundantly every fields and periods of the equipment. Grasp the operation rule of the equipment to make
them run well. Provide the dependable basis for the economic technical check.
• Keep good contact on the interface of the output plate and its holder.

• Keep good contact on the interface of the holder and the induction coil.

• Induction coil needs an insulating treatment.

• While taking over to the next shift, the staff must do cleaning to the equipment before handing over.

• The overtaker must inspect if there is any flexibility on every interfaces before his starting machine,

clean the interface of housing pin, then inspect if there is any water-clock phenomenon on every water

way. If we confirm that all is in the normal situation, then start the machine.

• The mechanical adjustment of the forming section must be in the right place. Don’t produce any burr

into induction coil.

• While starting the machine, open the device of attracting water vapor and iron dust. (We suggest the

user to install the device. That would be helpful to keep the device in the good functional mode in the

long term, and keep the workshop in good surroundings).

8.1、Maintain by shift

• Staff on duty of solid state HF induction welder must work seriously, hold fast to his position.
• Examine the temperature of entrance & exit of cooling water every other hour, look over if there is
any abnormal phenomenon on the flow rate.
• Look over if it is abnormal in transformer every other hour.
• Record the indications of every instrument once an hour.
• Before duty shifting, cleaning the equipment and make hand-over records. The overtaker mu
st comprehensively inspect the appearance; do the necessary tests when power cut.

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8.2、Maintain by week

• Check every contactor, relay, wire connecting terminal and wire joining to assure they are not in the
flexible state.

• Check entirely the cooling water pipe to assure they are not in the bursting danger and handle it in
time.

• Clean the equipment cabinets once, use the compressed air to dust suction, blow off the moisture
content of the compressed air and then dust suction the equipment. Some parts need a cloth to wipe
the dust, some place with a hair brush to brush the dust.

8.3、Maintain by month

• Inspect carefully the equipment cabinet. Check the connective parts and screw on every post head,
controlled silicon, contactor, relay to make sure if they are firm.

• Inspect the contact terminal of the air-break switch. Find if there is burn somewhere, we must use
the file instead of abrasive cloth to polish them.
• Check whether the water-pressure relay is sensible or not. Inspect the wiring of the button switch to
be not loose.
• Clean regularly filtering net to keep filtering effective.

8.4. Maintenance by semi year

• Check the insulator degree of low voltage 380V circuit.

• Repeat to inspect the items of the monthly maintenance.
• Clean the cable ditch in the concealment and the top of the equipment cabinets.

9. Common components information & measurement

9.1 Common components information (attached)

Appendix 1:IRFP460
Appendix 2:DSEI60-06A

9.2 Common tools and instruments

9.2.1 Common tools

In addition to electrical tools, 25W soldering iron (such as TLN-25), tin absorber, welding wire, mix files,
side cutting pliers should be equipped as common tools.
9.2. Multimeter (such as FLUKE 17B)
Mainly used in circuit measurement. In general, semiconductor devices is measured by analog

15
multimeter. Digital multimeter is used for signal measurement. In induction heating equipment,
capacitors and inductors are of large share. Digital multimeter should have enough range to measure.
9.2.3 Clamp ammeter
Large clamp ammeter can measure more than 1000A currents, and there is more than one level of
switching.
Small clamp ammeter measurement below 40A current, multi-function of AC and DC current.
MOSFET tube can be measured.
9.2.4 Signal generator (for example EE1640C)
Sine wave, square wave, triangle wave signal generator can be used as load signal source when
commisssiong. Its figures show should be at least 6 bits to meet 400KHZ requirements.
9.2.5 Dual trace oscilloscope (such as Tektronix TDS1012 100MHZ)
It is essential tools for commissioning and maintenance. It is mainly measures MOSFET tube’s gate
drain waveform, gate sourcing waveform, voltage feedback waveform, observes the drain-source voltage
drop, and if there is burr on the waveform, and so on. Best select more than 20MHZ oscilloscope.
Two point in selecting the oscilloscope:
 Double trace detectors should same grouding, otherwise it will cause a short circuit.
 Maximum measuring voltage must comply with the oscilloscope specification requirements.

9.3 methods of measurement

9.3.1 Diode
Analog multimeter, red pen is positive, black is negative. The diode cathode connects with red table pen,
black pen to the anode of the diode, resistance should be around 20 ohms (use X1), contrary to measure
resistance is infinite, the diode is good.
9.3.2 Transistor
Transistor can be considered equivalent to 2 diode docking. The measurement refer to diode, PNPN and
NPN polarity is reversed.
9.3.3 resistors, capacitors
Resistance can be measured directly by a digital multimeter. The other are outside observation
Capacitor is to check for short circuit by a multimeter. The other are outside observation.
9.3.4 SCR
SCR is very common in the electrical components. There are three groups of SCR to form the rectifier
voltage regulator to achieve power adjustment. To judge its quality is often measured with a multimeter
resistance gear cathode and gate resistor, usually dozens of ohm. Measured with a digital multimeter to
diode, polars are inconnected. Using analog multimeter’s resistance gear measure the resistance between
the cathode and the anode, usually a few hundred ohms.
9.3.5 MOSFET tube
460 MOSfet seen from the front, three pin from left to right followed by a gate, drain, source. MOS
quality can be measured by DT9205A digital universal meter. Fingers don't contact the three pins. On
reliable grounding metal platform, short circuit the three pins, then use multimeter to measure drain and
source pins, resistance should be diode feature (200MΩ tap); then with thumb and index finger pinch

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the gate and drain, meanwhile measure the drain and source, resistance should be 4MΩ around
(200MΩ tap). With this method also can rough measure MOS tube parameter’s consistency.

10. Appendix

10.1 Welding machine ground laying schematic

10.2 Machine layout

10.3 Machine wiring diagram

10.4 Machine water route drawing

10.5 Rectifier control schematic

10.6 Inverter control schematic

10.7 The center control unit schematic

10.8 Water-water heat exchanger control schematic

Updated: Tuesday, June 23, 2015

Baoding ZSHC Electrical Co., LTD.

[email protected]
www.zhuosihengchang.en.alibaba.com

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