Hyundai Dynamic auto 350M Operating instructions

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VER 2. 0

2007. 7

DYNAMIC AUTO

350M/500M

OPERATION MANUAL

HEAD OFFICE: ILSONG BLDG. 16th fl.157-37,

SAMSUNG-DONG, KANGNAM-KU, SEOUL, KOREA

TEL : (+82-2)6230-6062～5 FAX: (+82-2)522-2030

FACTORY : 9-2, SAEUM-DONG, ICHEON-SI, GYEONGGI-DO, KOREA

TEL : (+82-31)636-3100 FAX: (+82-31)636-3957

www.hyundaiwelding.com

- 1 -

TABLE OF CONTE NTS

SE CTION 1 - SAFE TY PR E CAUTIONS - R E AD BE FOR E USING -----------------

2

1-1. Symbol Usage ------------------------------------------------------------- 2

1-2 . Arc Welding Hazards -------------------------------------------------------- 2

1-2-1. Hazard in Welding Power While in Use ------------------------------------ 3

1-2-2. Hazard Around Working Area While in Use --------------------------------- 5

1-3. Additional Symbols For Installation, Operation, And Mai ntenance ----------------- 8

SE CTION 2 - DE FINITIONS -------------------------------------------------

9

2-1. Manufacturer's Warning Label Definitions --------------------------------------- 9

2-2. Manufacturer's Rating Label -------------------------------------------------- 10

SE CTION 3 - INSTALLATION ------------------------------------------------

11

3-1. Specifications --------------------------------------------------------------- 11

3-2. Duty Cycle And Overheating ------------------------------------------------- 11

3-3. Selecting A Location -------------------------------------------------------- 12

3-3-1. Dimension and Weight --------------------------------------------------- 12

3-3-2. Site Selection ---------------------------------------------------------- 12

3-3-3. Transporting Methods ---------------------------------------------------- 14

3-4. Weld Output Receptacles And Selecting Cable Sizes ---------------------------- 14

3-4-1. Weld Output Connections ------------------------------------------------ 15

3-5. Recept acle Information ------------------------------------------------------- 17

3-5-1. DYNAMIC AUTO 350M -------------------------------------------------- 17

3-5-2. DYNAMIC AUTO 500M -------------------------------------------------- 17

3-6. Electrical Service Guide ------------------------------------------------------ 18

3-7. Connecting Input Power ----------------------------------------------------- 18

3-7-1. Electrical Input Requirements --------------------------------------------- 19

SE CTION 4 - OPE R ATION --------------------------------------------------

20

4-1. Front Panel Controls -------------------------------------------------------- 2 0

4-1-1. DYNAMIC AUTO 350M--------------------------------------------------- 20

4-1-2 . DYNAMIC AUTO 500M--------------------------------------------------- 21

SE CTION 5 - SE QUE NCE OF OPE R ATIO N -----------------------------------

22

5-1. Dynamic Auto 350M -------------------------------------------------------- 22

5-2. Dynam ic Auto 500M -------------------------------------------------------- 24

SE CTION 6 - PCB SETTING ------------------------------------------------

25

6-1. DYNAMIC AUTO 350M ------------------------------------------------------ 25

6-2. DYNAMIC AUTO 500 M ------------------------------------------------------ 27

SE CTION 7 - FUNCTION DIAGR AM ------------------------------------------

28

7-1. DYNAMIC AUTO 350M ------------------------------------------------------ 28

7-2. DYNAMIC AUTO 500 M ------------------------------------------------------ 29

SE CTION 8 - M AINTE NANCE & TROUBLE SH OOTING --------------------------

30

8-1. Routine Maintenance -------------------------------------------------------- 30

8-2. Troubleshooting(Dynamic Auto 350M) ------------------------------------------ 30

8-3. Troubleshooting(Dynamic Auto 500M) ------------------------------------------ 34

SE CTION 9 - E LE CTR ICAL DIAGR AM -----------------------------------------

36

9-1. DYNAMIC AUTO 350M ------------------------------------------------------ 36

9-2. DYNAMIC AUTO 500 M ------------------------------------------------------ 37

SE CTION 10 - PAR TS LIST -------------------------------------------------

38

10 -1. Main Assembly-Dynamic Auto 350M ------------------------------------------ 3 8

10 -2. Main Assem bly-Dynamic Auto 500M ------------------------------------------ 40

VER 2. 0

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SE CTION 1 - SAFE TY PR E CAUTIONS

- R E AD BE FOR E USING

1-1. Sy m b o l Us a g e

Th e sy m b o l s s h o w n b e l o w a r e u s e d t h r o u g h o u t t h i s m a n u a l t o c a l l a t t e n t i o n t o a n d i d e n t i f y

p o s s i b l e h a z a r d s . W he n y o u s e e t h e sy m b o l , w a t c h o u t , a n d f o l l o w t h e r e l a t e d i n s t r u c t i o n s to

a v o i d t h e h a z a r d .

This safety alert symbol is used with the signal words DANGER and WARNING to

call attention to the safety statements.

DANGER statements identify procedures or practices which must be followed to avoid

serious personal injury or loss of life.

WARNING statements identify procedures or practices which must be followed to avoid

minor personal injury or damage to this equipment.

statements identify special instructions necessary for the most efficient

operation of this equipment.

1-2 . Ar c W e l d i n g H a z a r d s

Means Danger! Warning! Watch Out! There are possible hazards with this procedures!

The possible hazards are sho wn in the adjoining symbols.

This group of symbols means Danger! Warning! Watch Out! possible ELECTRIC

SHOCK and HOT PARTS hazards. Consult symbols and related instructions below for

necessary actions to avoid the hazards.

VER 2. 0

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1-2 -1. H a z a r d s i n W e l d i n g Po w e r So u r c e W h i l e i n Us e

DANGE R

E LE CTR IC SHOCK c a n ki l l .

Touching live electrical parts can cause fatal shocks or severe burns. The electrode

and work circuit is electrically live whenever the output is on.

The input power circuit and m achine internal circuits are also live when power is on.

In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and

all metal parts touching the welding wire are electrically live. Incorrectly installed or

improperly grounded equipment is a hazard.

•Do not touch live electrical parts.

•Wear dry, hole-free insulating gloves and body protection.

•Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent

any physical contact with the work or ground.

•Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

•Use AC output ONLY if required for the welding process.

•If AC output is required, use remote output control if present on unit.

•Disconnect input power or stop engine before installing or servicing this equipment.

•Properly install and ground this equipment according to its Owner's Manual and national, state, a nd

local codes.

•Always verify the supply ground-check and be sure that input power cord ground wire is properly

connected to ground terminal in disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

•When making input connections, attach proper grounding conductor first-double-check connections.

•Frequently inspect input power cord for damage or bare wiring-replace cord immediately if damaged-

bare wiring can kill.

•Turn off all equipment when not in use.

•Do not use worn, damaged, undersized, or poorly spliced cables.

•Do not drape cables over your body.

•If earth grounding of the workpiece is required, ground it directly with a separate cable-do not use

work clamp or work c able.

•Do not touch electrode if you are in contact with the work, ground, or another electrode from a

different machine.

•Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit

according to this manual.

•Wear a safety harness if working above floor level.

•Keep all panels and covers securely in place.

•Cla mp work cable with good metal-to-metal contact to workpiece or workcable as near the weld as

practical.

•Insulate work clamp when not co nnected to workpiece to prevent contact with any meta l object.

•Do not connect more than one electrode or work cable to any single weld output terminal.

VER 2. 0

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DANGE R

H OT PA R TS c a n c a u s e s e v e r e b u r n s .

•Do not touch hot parts bare handed.

•Allow cooling period before working on gun or torch.

DANGE R

M AGNE TIC FIE LDS c a n a f f e c t p a c e m a k e r s .

•Pacemaker wearers keep away.

•Wearers should consult their doctor before going near arc welding, gouging, or spot

welding operations.

Ab o u t Pa c e m a k e r s

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following

the above procedures is recommended.

DANGE R

•Electromagnetic energy can interfere with sensitive electronic equipment such as

computers and computer-driven equipment such as robots.

•Be sure all equipment in the welding area is electromagnetically compatible

•To reduce possible interference, keep weld cables as short as possible, close

together, and down low, such as on the floor.

•Be sure this welding machine is installed and grounded according to this manual.

•If interference still occurs, the user must take extra measures such as moving the

welding machine, using shielded cables, using line filters, or shielding the work area.

VER 2. 0

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1-2 -2 . H a z a r d s Ar o u n d W o r k i n g Ar e a W h i l e i n Us e

W AR NING

NOISE c a n d a m a g e he a r i n g .

Noise from some processes or equipment can damage hearing.

•Wear approved ear protection if noise level is high.

DANGE R

BUILDUP OF GAS c a n i n j u r e o r k i l l .

•Shut off shielding gas supply when not in use.

•Always ventilate confined spaces or use approved air-supplied respirator.

DANGE R

FUM E S AND GASE S c a n b e h a z a r d o u s .

Welding produces fumes and gases. Breathing these fumes and gases can be

hazardous to your health.

•Keep your head out of the fumes. Do not breathe the fumes.

•If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

•If ventilation is poor, use an a pproved air-supplied respirator.

•Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.

Always have a trained watch person nearby. Welding fumes and gases can displace air and lower

the oxygen level causing injury or death. Be sure the breathing air is safe.

•Do not weld in locat ions nea r degreasing, cleaning, or spraying operations. The heat and rays of the

arc can react with vapors to form highly toxic and irritating gases.

•Do not weld on coated metals, su ch a s galva nized, lead, or cadmiu m pla ted st eel, unless the coa ting

is removed from the weld area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing these elements can give off toxic

fumes if welded.

VER 2. 0

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DANGE R

CYLINDE R S c a n e x p l o d e i f d a m a g ed .

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can

explode. Since gas cylinders are normally part of the welding process, be sure to

treat them carefully.

•Protect compressed gas cylinders from excessive heat, mechanical shocks, sla g, open flames,

sparks, and arcs.

•Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent

falling or tip ping.

•Keep cylinders away from any welding or other electrical circuits.

•Never drape a welding torch over a gas cylinder.

•Never a llow a welding electrode to touch any cylinder.

•Never weld on a pressurized cylinder-explosion will result.

•Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific

application; maintain them and associated parts in good condition.

•Turn face away from valve outl et when opening cylinder valve.

•Keep protective cap in place over valve except when cylinder is in use or connected for use.

•Read and follow instructions on c ompressed gas cylinders, associated equipment.

W AR NING

AR C R AYS c a n b u r n e y e s a n d s k i n .

Arc rays from the welding process produce intense visible and invisible (ultraviolet

and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

•Wear a welding helmet fitted with a proper shade of filter to protect your face and

eyes when welding or watching.

•Safety gloves must be worn.

•Face protection must be worn.

•Use protective screens or barriers to protect others from flash and glare; warn

others not to watch the arc.

•Wear protective clothing made from durable, flame-resistant material (leather and

wool) and foot protection.

VER 2. 0

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W AR NING

FLYING M E TAL c a n i n j u r e f a c e .

•Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As

welds cool, they can throw off slag.

•Wear approved safety glasses with side shields even under your welding helmet.

DANGE R

W E LDING c a n c a u s e f i r e o r e x p l o s i o n .

Welding on closed containers, such as tanks, drums, or pipes, can ca use them to

blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece,

and hot equipment can cause fires and burns. Accidental contact of electrode to

metal objects can cause sparks, explosion, overheating, or fire. Check and be sure

the area is safe before doing any welding.

•Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause

fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,

overheating, or fire. Check and be sure the area is safe before d oing any welding.

•Protect yourself and others from flying sparks and hot metal.

•Do not weld where flying sparks can strike flammable material.

•Remove all flammables within 10.7 m of the welding arc. If this is not possible, tightly cover them

with approved covers.

•Be a lert that welding sparks and hot materials from welding can easily go through small cracks and

openings to a djacent areas.

•Watch for fire, and keep a fire extinguisher nearby.

•Be aware tha t welding on a ceiling, floor, bulkhead, or p artition can cause fire on the hidden side.

•Do not weld on closed containers such as tanks, drums, or pipes.

•Connect work cable to the work as close to the welding area as practical to prevent welding current

from traveling long, possibly unknown paths and causing electric shock and fire hazards.

•Do not use welder to thaw frozen pipes.

•Remove stick electrode from holder or cut off welding wire at c ontact tip when not in use.

•Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes,

and a cap.

•Remove a ny combustibles, such as a butane lighter or matches, from your person before doing any

welding.

VER 2. 0

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1-3 . Ad d i t i o n a l Sy m b o l s Fo r In s t a l l a t io n , Op e r a t i on , An d M a i n t en a n c e

DANGE R

FIR E OR E XPLOSION ha z a r d .

•Do not install or place unit on, over, or near combustible surfaces.

•Do not install unit near flammables.

•Do not overload building wiring - be sure power supply system is properly sized,

rated, and protected to handle this unit.

• Manufactures will not take responsibility on machine and related accident if

user change the design & function

☞ It must be kept original condition as supplier's design.

☞ Do not operate the machine without all the protective guards in the

closed position.

☞ Never attempting to repair, adjusting, clean, or lubricate and moving parts

while machine in motion.

VER 2. 0

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SE CTION 2 - DE FINITIONS

2 -1. M a n u f a c t u r e r ' s W a r n i n g La b e l De f i n i t i o ns

1

2

1. Electricity, Electrical Hazard

•Disconnect power supplies before opening control box or servici ng electrical unit.

☞ Electric power must be checked before connection.

☞ Place must be enough space to handle the working job for safety purpose.

2. HOT PARTS can cause severe burns.

•Do not touch hot parts bare handed.

•Allow cooling period before working on gun or torch.

Do n o t r e m o v e o r p a i n t o v e r t h e l a b e l .

VER 2. 0

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2 -2 . M a n u f a c t u r e r ' s R a t i n g La b e l

VER 2. 0

- 11 -

SE CTION 3 - INSTALLATION

3 -1. Sp e c i f i c a t i o n s

Model Dynami c Auto 350M Dynamic Auto 500M

TYPE HD-CV350 HD-CV500

Rated Input Power 18KV A,16KW 30KVA, 25.5KW

Input Voltage 3

Φ 2 20/380/440 ± 10%

Frequency 50/60Hz 50/60Hz

Rated Welding Current 350A 500A

Rated Welding Voltage 36V 42V

Output Current Range 40A-350A 50A-500A

Output Voltage Range 14V-36V 15V-42V

Max. Open-Circuit Voltage DC 60V 66V

Duty Cycle 50% 60%

Temperature 160℃ 160℃

Weight 130Kg 180K g

3 -2 . Du t y Cy c l e a n d Ov e r h e a t i n g

CAUTION

E x c e e d i n g Du t y Cy c l e R a t i n g s w i l l c a u s e t h e r m a l o v e r l o a d p r o t e c t i o n

c i r c u i t t o b e c o m e e n e r g i z e d a n d sh u t d o w n o u t p u t u n t i l u n i t h a s c o o l e d t o

o p e r a t i n g t e m p e r a t u r e .

The duty cycle is the percentage of a ten minute period that a welding power source can be operated

at a given output without causing overheating and damaging the unit.

This unit is rated at 60 %, 100% duty cycle for 350, 500, 600 amperes; therefore, this unit can be

operated continuously without causing damage to the unit.

VER 2. 0

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3 -3 . Se l e c t i n g a Lo c a t i o n

3 -3 -1. Di m e n s i o n s a n d W e i g h t

MODEL

Dimension(mm)

Weight (Kg)

DWH

Dy namic Auto 350M 650 445 800 130

Dy namic Auto 500M 675 495 970 180

3 -3 -2 . Si t e Se l e c t i o n

CAUTION /

Select an installation site which provides the following:

1. Correct input power supply (see unit nameplate)

2. Shielding gas supply (if applicable)

3. Water supply (if applicable)

4. Adequate ventilation and fresh air supply

5. No flammables

6. A clean and dry area

7. Proper temperature that avoids extremes of heat or cold

8. Proper airflow around unit

VER 2. 0

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W AR NING

Fi r e o r E x p l o s i o n c a n r e s u l t f r o m p l a c i n g u n i t o n o r o v e r c o m b u s t i b l e

s u r f a c e s ; Re s t r i c t e d Ai r f l o w c a n c a u s e o v e r h e at i n g a n d p o s s i b l e d a m a g e

t o i n t e r n a l p a r t s .

•Do not locate unit over combustible surfaces.

•Maintain a t least 300mm of space from rear of unit, 300mm from sides.

•Do not place any filtering device over the intake air passages that provide airflow for cooling this

part.

W a r r a n t y i s s u b j e c t t o b e i ng v o i d e d i f a n y t y p e o f f i l t e r i n g d e v i c e i s u s e d a t i n t a k e a i r

p a s s a g e s .

VER 2. 0

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3 -3 -3 . Tr a n s p o r t i n g M e t h o d s

W AR NING

This unit is equipped with t wo eyelets for carrying purposes.

•Do not touch live electrical parts.

•Disconnect input power conductors from de-energized supply line before moving

welding power source.

•Falling equipment can cause serious personal injury and equipment damage.

•Move unit with hand cart of similar device of adequate capacity.

•If using a fork lift vehicle, place and secure unit on a proper skid before

transporting.

Be sure unit is lifted and transported safely and securely.

3 -4 . W e l d Ou t p u t R e c e p t a c l e s An d Sel e c t i n g Cab l e Si z e s

▲

AR C W E LDING c a n c a u s e E le c t r o m a g n e t i c In t e r f e r e n c e .

To reduce possible interference, keep weld cables as short as possible, close

together, and down low, such as on the floor. Be sure this welding machine is

installed and grounded according to this manual. If interference still occurs, the

user must take extra measures such as moving the welding machine, using

shielded cables, using line f ilters, or shielding the work area.

VER 2. 0

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3 -4 -1. W e l d Ou t p u t Co n n e c t i o n s

To obtain full rated output from this unit, it is necessary to select, prepare, and install proper weld

cables. Failure to comply in any of these areas may result in unsatisfactory welding performance.

This value shall relate to the minimum fitting range for welding cables according to table1

M i n i m u m r a n g e o f s i z e

( m m

2

)

R a t e d c u r r e n t i n A

( 6 0 % d u t y c y c l e )

R a t e d c u r r e n t i n A

( 10 0 % d u t y c y cl e )

up to 10 101 100

10 to 16 139 135

16 to 25 190 180

25 to 35 243 225

35 to 50 316 285

50 to 70 403 355

70 to 95 498 430

95 to 120 587 500

120 to 150 689 580

150 to 185 797 665

Table 1 - Relation between size range and rated current

1. The Current is rated for 60% and 100% duty cycle

2. Welding cables, the coverings of which are not capable of withstanding a

conductor temperature of 85

℃, will be damaged if the coupling devices

are used at the rating given above at an ambient air temperature of

40

℃.

A. W E LD Ca b l e Se l e c t i o n

Use the following guidelines to select weld cables:

1. Use the shortest possible cables, and place ca bles close together.

Excessive cable lengths may reduce or cause unit overload due to added resistance.

2. Use weld cable with an insulation voltage rating equal to or greater than the maximum open-circuit

voltage (OCV) of the welding power source.

3. Select welding cable size according to maximum weld output and total length of connecting cables

in weld circuit. For example, if a 7.5mm electrode holder or torch cable is used with a 7.5m work

able

4. Do not use damaged or frayed cables.

VER 2. 0

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B. W e l d Ca b l e c o n n e c t i o n s

W AR NING /

ARCING can burn skin or damage electrical connections.

•Do not touch live electrical parts.

•Shut down unit before marking any weld output connections.

•Do not change position of the welding cable connectors while we lding.

•Be sure the connectors are secure in receptacles before welding

▲Connect end of electrode holder cable to POSITIVE(＋) weld output receptacle

as follows: align keyway, insert plug, and rotate plug clockwise until it is

securely seated in receptacle.

▲Connect work cable connector to NEGATIVE(－) weld output receptacle as

follows: align keyway, insert plug, and rotate plug clockwise until it is securely

seated in receptacle.

Welding TorchBase Metal

For Electrode Negative / Straight Polarity connections, reverse cable

connections to weld output receptacles ; electrode becomes negative.

VER 2. 0

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3 -5 . R e c e p t a c l e In f o r m a t i o n

3-5 -1. DYNAM IC AUTO 3 5 0 M

So c k e t Pi n Nu m b e r So c k e t In f o r m a t i o n

Fr o n t v i e w o f W i r e f e e d e r so c k e t

R e c e p t a c l e

Socket A 46 Signal of output voltage

Socket B 47 Signal of output current

Socket C 44 Voltage, Current COM3

Socket D 48 Voltage, Current COM1

Socket E 43 Sol. valve

Socket F 42

Wire start command

(Welding start-Torch on)

Socket G 45 Command of Inching function

Socket H 41 Motor (＋)

Socket I 40 Motor (－)

3 -5 -2 . DYNAM IC AUTO 5 0 0 M

So c k e t Pi n Nu m b e r So c k e t In f o r m a t i o n

Fr o n t v i e w o f W i r e f e e d e r so c k e t

R e c e p t a c l e

Socket A 76 Signal of output voltage

Socket B 53 Signal of output current

Socket C 73 Voltage, Current COM3(-15V)

Socket D 68 Gas Check Switch - Option

Socket E 74 Sol. valve

Socket F 62

Wire start command

(Welding start-Torch on)

Socket G 65 Command of Inching function

Socket H 59 Motor (+), Common(0V)

Socket I 112 Motor (-24V)

VER 2. 0

- 18 -

3 -6 . E l e c t r i c a l Se r v i c e Gu i d e

ITEM Dynamic Auto 350M Dynamic Auto 500M

Input Voltage 3Φ 220V/380 V/440V ±10 %

Equipment Capacity at Rated Output 18KVA 30KVA

Max Recommended Standard Fuse

or Circuit Breaker Rating In Amperes

50A 10 0A

Min Input Conductor Size 14mm

2

22mm

2

Min output Conductor Size 38mm

2

80mm

2

3 -7 . Co n n e c t i n g In p u t Po w e r

W AR NING

Check a fter remove of input power.

•Do not touch live electrical parts.

•Shut down welding power source, removing fuses from fuse

box, or shutting off and red-t agging circuit breaker or other

disconnecting device.

VER 2. 0

- 19 -

3 -7 -1. E l e c t r i c a l In p u t R e q u i r e m e n t s .

Operate the welding power source from a three-phase 50/60 Hertz, AC power supply. The input

voltage must match one of the electrical input voltages shown on the input data label on the uni t

nameplate. Contact the local electric utility for information about the type of electrical service available,

how proper connections should be made, and inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical

power from the welding power su pply whenever it is necessary to inspect or service the unit.

This unit is equipped with a three-conductor that is connected at the

welding power source end for three-phase electrical input power.

•Do not connect an input (black) conductor to the ground terminal.

•Do not connect the ground (Protective Earth(PE)) conductor to an input line terminal.

1. Connect end of PE c onductor to a suitable ground. Use a grounding method that complies with all

applicable electrical codes.

2. For Three-phase electrical input power : connect ends of Black input conductors to a de-energized

line disconnect switch.

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Hyundai Dynamic auto 350M Operating instructions

Hyundai Dynamic auto 350M Operating instructions

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