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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
- 2 -
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
- 4 -
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
- 5 -
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
- 6 -
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
- 8 -
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
- 9 -
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
- 10 -
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
- 12 -
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
- 13 -
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
- 14 -
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
- 15 -
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
- 16 -
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
- 17 -
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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