ＮＡＳ

ＴＯＡ

DC INVERTER TRANSFORMER

ＨＦＴ－９０Ｃ－６Ｂ
ＨＦＴ－９０Ｃ－３Ｂ

INSTRUCTION MANUAL

Rev. 1.0

Before using this welder, please go through this manual

carefully.
 For safety, a qualified operator should perform installation, maintenance and repair of
this welder or the one who is familiar with the machine.
 For safety, an operator who understands the contents of this manual fully and is
capable of handling the machine as such should operate the welder.
 After going through this manual, please keep it together with the maker's quarantine
paper at any position where related persons can take out and see anytime.
 Please enquiry your dealer, our sales offices for more information.
 Our address and telephone number are given on this manual.
 Reproduction without permission prohibited.

2012.10

NAS TOA WELDING TECHNOLOGIES CO.,LTD.

 Contents
1. To use it safely...............................................................................................................................................................................1
1.1 Perusal of manual.................................................................................................................................................................. 1
1.2 Attention symbol ................................................................................................................................................................... 2
2．Electric shock.................................................................................................................................................................................3
3．Scattering and noise ................................................................................................................................................................... 4
4．Fire, explosion, and burn ...........................................................................................................................................................4
5．Caught between electrodes...................................................................................................................................................5
6. Scope .................................................................................................................................................................................................. 6
7. Directions..........................................................................................................................................................................................6
8. Transportation ................................................................................................................................................................................8
9. Connection .......................................................................................................................................................................................8
9.1 Fixation...................................................................................................................................................................................8
9.2 Mounting of secondary conductor ............................................................................................................................9
9.3 Connection of cooling water piping..........................................................................................................................9
9.4 Connection of power cable and signal cable .....................................................................................................10
10. Symptom and treatment in case of the trouble.........................................................................................................10
11. Maintenance check ..................................................................................................................................................................11
11.1 Daily checkup .................................................................................................................................................................11
11.2 Regular Inspection (Every three months).........................................................................................................11
11.3 Check of abnormal.......................................................................................................................................................11
12. Guarantee.....................................................................................................................................................................................12
13. Repair..............................................................................................................................................................................................12
14. General specification...............................................................................................................................................................13
15. Dimension .....................................................................................................................................................................................14
16. Electric circuit drawing ..........................................................................................................................................................15
17. Cooling water circuit drawing..............................................................................................................................................15
1. To use it safely

Please guard the following to avoid an important

Warning accident resulting in injury or death.

● Never use this welding machine for any purpose other than welding.
● This welder has been carefully designed and fabricated to assure safe operation.
However, users are requested to observe safety precautions hereof.
Failure may cause serious trouble that may lead users or other people to death or serious
injury.
● For construction of power source at input side, selection of installation site, handling, storage
and piping of high pressure gas, storage of products after welding
and disposal of waste, users shall comply with the law and company standard.
● The welding machine and peripheral area shall be protected so that people will not carelessly
step in.
● Any one who has a pace-maker for heart disease implanted shall keep away from the
welding machine or welding site unless he gets doctor's permission. The welding machine,
while welding, generates magnetic field to near-by area,
having an adverse effect on the pace-maker function.
● This welding machine must be installed, inspected for maintenance and repaired by a qualified
operator or a person who is familiar with the welding machine, for safety.
● This welding machine must be operated by an operator who has gone through this manual
carefully and has sufficient knowledge and technique to handle the machine.
● Please surely install the case and the cover, and tighten the eyebolt firmly when you lift up
the welding machine with the crane.

1.1 Perusal of manual

● Before using the machine, please go through the operation manual carefully.
● Notes shown in this manual are used to prevent harm and the damage to you and other
people beforehand by safely using the equipment.
● This welder has been carefully designed and fabricated to assure safe operation.
However, the users are requested to observe safety precautions hereof.
Failure may cause serious trouble that may lead users or other people to death or serious
injury.

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1.2 Attention symbol

● Mishandling of the machine may cause danger or injury to the user in various levels.
This operation manual classifies such dangers into three divisions as follows and expresses
its level of danger with warning symbols as follows.

Attention
symbol Signal term Contents

For a dangerous imminent situation in which the death

Danger or the serious illness is caused if you do not evade.

For a dangerous situation in which the death or the

Warning serious illness might be caused if you do not evade.

When only a dicey situation and a material trouble that

Attention might cause the trouble of a slight injury or inside extent
might occur if you do not evade.

Things must be done.

Compulsory For example, grounding work.

Things must not be done.

Prohibited

● Serious injury as described above means loss of sight, injury, burning (high or low
temperature), electric shock, fracture of bone or intoxication which may cause after-effect
or hospitalization or long term care at hospital.
Medium level of injury means injury, burning or electric shock which do not require
hospitalization. Material damage means damage of estate or breakage of machine or devices.

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2．Electric shock

To avoid electric shock, please observe the following

Warning precautions without fail.

※ Touching the energized area other than secondary conductor may

cause electric shock or burning.
※Touching your hands to both ends of the secondary conductor may
cause critical electric shock.

〔General work〕
● Never touch the energized area other than secondary conductor.
● Do not use a cable of insufficient capacity, damaged or the one having bare conductor.
● Tightly connect the cable joints and insulate.
● Do not use the welding machine with its cover or case dismounted.
● Use cable, pneumatic hose, water hose which are sufficiently pressure-tight ones.
● Use cooling water of 5000Ω-cm or more of resistance with less deposits.
● When working at high place, be certain to tie a life rope around you.

〔Installation・Maintenance・Check〕
● The grounding work shall be performed according to the law (Electrical Equipment
Technical Standard) by a qualified engineer.
● Before installing or inspecting for maintenance of the welding machine, be sure to turn off
the switch in the distributor box and all the power sources at input side and wait for 5
minutes.
Even though the input power source are turned off, the condenser may have charge.
Be certain to start the work after confirming there is no charged voltage in the condenser.
● Perform periodic inspection and repair damaged part as soon as it is found.

〔Welding operation〕
● Do not use torn or wet gloves.Always use dry, insulated gloves.
● When the welder is not used, please turn off all the power sources of all the machines and
devices.

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3．Scattering and noise

To defend you and other people from scattering and the

Attention noise generated when welding, use the defense tool
such as the cover curtains.
※The scattering sparks may hurt your eyes or burn your skin.
※Noise may cause hearing trouble.

● Wear goggles to protect your eyes from scattering sparks.

● Wear protective gloves, long sleeve working wear or leather apron.
● Install a protective curtain around the welding spot so that scattering sparks will not hurt
people near-by.
● Use sound-proof materials if welding noise level is high.
● It impairs one's vision because of scattering generated when welding and it causes the burn.
Wearing such as protective glasses, protection cap, gloves, and flame resisting work clothes
is necessary for the worker in preparation for scattering generated by the welding.
● A welding machine and a surrounding noise level are measured in the welding work place.
Please do the ear cap if it is necessary. A big noise might cause aural abnormality.

4．Fire, explosion, and burn

Observe the following precautions to avoid fire,

Warning explosion or bursting.

※Spatter or heated base metal immediately after welding can cause fire.
※Insufficient connection at cable joint may cause fire due to heating by
welding.

● Remove any flammable items in the welding area so that spatter will not come in contact
with such flammable items.
If unremovable, then cover it with a non-flammable material.
● Do not weld in the presence of flammable gas.
● Do not bring heated base metal just after welding close to any flammable items.
● Please do not touch by bare-handed the metal immediately after the welding.
● When welding a ceiling, floor or wall, remove any flammable items located in a hidden area.
● Precisely tighten the cable joint section and insulate.
● Install a fire extinguisher near the welding area for safety.
● Scattering is generated by the welding. Please do not bring anyone other than the worker to
this vicinity.

4
5．Caught between electrodes

Never insert your hand or finger into a space between

Warning electrodes.

※Do not insert a part of your body, such as arm, hand or finger,
otherwise, you will be caught by the electrodes and have serious injury
or fracture of bone.

● Never insert your hand or finger into a space between electrodes.

● Before turning on the power switch or supplying compressed air, first make sure that there is
no danger around the welding machine.
● When the welding machine is not used, be sure to turn off all the supplies, such as the power,
compressed air and cooling water.

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6. Scope
This transformer is only for the DC inverter. Please do not connect with the AC inverter and the
controller of the single-phase alternating current. It overheats and burns.

7. Directions
(1) Don't operate beyond the rating.
Ratings of the transformer are as follows.
The transformer overheats when using it exceeding ratings and it damages it.
・Rated capacity 90kVA
・Maximum welding current 18,000A
・Maximum welding time 0.5second
・Rated duty factor 10%
※About the duty factor

T2：Cycle time of welding one point

T1：Weld time

T1
Duty cycle＝ ×100 〔％〕
T2
(2) It is necessary to construct grounding.
When construction is imperfect, it causes the electric shock.

(3) Please drain it in the cold district.

The hose is damaged by water freezing. Please exhaust the water that remains inside the
transformer. Please blow in compress air to the water supply entrance and push water out.

(4) Please remove it when water splashes to the transformer.

When water is infiltrated internally, transformer and welding controller might be damaged by the
insulation failure.

(5) Please secure cooling water the regulated flowing quantity.

The coil and the diode might be damaged when used below regulated flowing quantity.

(6) Please cut power off when you do the check and the repair work of this device.
Please work after it cuts power off when you exchange the power cable and the transformer.
It causes the electric shock and the injury.

(7) Please do not touch the transformer case while energizing.

Please do not touch it because the case is a high temperature. It causes the burn.

6
(8) Please do not voltage test and insulation resistance test.
The diode might be damaged.

(9) Please fix the power cable to the input cover.

When the connection and fixation are imperfect, it causes the electric shock and generation of
heat and a fire.

(10) Please connect the thermostat.

Because abnormality of overheating cannot be detected if the thermostat is not connected, the
coil and the diode might be damaged.

(11) Please do not close the cooling water circuit rapidly.

Parts and tubes of the cooling water circuit might be damaged by the water hammer. Please do
the prevention countermeasure when there is a water hammer.

(12) About cooling water

Please use the cooling water of resistance 5000Ω-cm or more. Please use it after confirming
chemical resistance when you add the medicine to cooling water.

(13) Please cool the secondary conductor connected with the output terminal.
When the secondary conductor is not cooled, the coil and the diode might be damaged by
generation of heat of the secondary conductor.

(14) Please attach a cover to the input part.

When it touches the input terminal, it causes the electric shock.

(15) Abnormal circumstances must turn off power after stopping driving.
It causes the electric shock and a fire when keeping driving like abnormality.

(16) Please do not overhaul and do not repair.

It causes the injury and the electric shock and a fire, etc. when there is incompleteness in the
overhaul and the repair.

Attention of input frequency setting

The rated frequency of this product is 【 1000Hz 】.

Please match the output frequency of the resistance welding controller

to the frequency of the welding transformer.

when it makes a mistake in the setting of the frequency ,the transformer

might be damaged and the controller malfunction

7
8. Transportation
(1)This transformer is 22kg. When carrying, be careful not to suffer an injury.
(2)Do not give cover the impact. The cover might be damaged.
(3)Please protect it so that the wound should not place to the output terminal.

Plastic cover

Output terminal

9. Connection
Please do the following connection before it is use.
9.1 Fixation
There is a tap in 16 places in all in the aluminum frame. Please fix two sides with eight points
the bolt when you mount the transformer in the welding gun and the device. The tap depth of
the aluminum frame is 19mm. The bolt must not hit the bottom of the tap.

Please fix the transformer in opposite respect when installing it in the welding gun.

Bracket

8
9.2 Mounting of secondary conductor
Please fix to M8 volt eight places when you mount the secondary conductor in the output
terminal. The tap depth of the output terminal is 18mm. The bolt must not hit the bottom of the
tap.
Tap M8 depth18mm

9.3 Connection of cooling water piping

1). Please connect the cooling water piping so that the water leak should not happen.
2). Please connect so that neither garbage nor the foreign body may enter in piping.
3). The water supply pressure is 0.5MPa less than. When water leaked by damaged piping, it
becomes the cause of the electric shock and a fire.
4). Please pour cooling water into the diode and the transformer individually. When water is
poured in the series route, the diode might be damaged by the transformer's overheating.
5). The cooling water gateway size is PT1/8(Rc1/8).

Diode Cooling
cooling water water

Transformer
cooling water

The cooling water gateway

position is asymmetry.

9
 9.4 Connection of power cable and signal cable
1). The customer must prepare the input side cover. The cover obtained when our company
ships it doesn't have neither strength nor insulation for the primary side protection and do
not use it, please.
2). Please confirm a power supply shut down when you connect the power cable.
3). The power cable must use the one of sectional area 38mm2 or more.
4). Please tighten the connection so that there is not loosening.
5). The pressure terminal must use the one that suited the current capacity and the size of the
terminal screw. (Input terminal M6, Earth terminal M6, Thermostat terminal M3)
6). Please fix the power cable and the signal cable for the thermostat so that the outside power
should not hang in the input terminal and the thermostat terminal of the transformer.
7). Please connect two power cables and one earth cable with the input terminal and the earth
terminal in the input side case.

Input terminal M6

Earth terminal M6

Thermostat terminal M3

10. Symptom and treatment in case of the trouble

Symptom Cause Treatment
No output Disconnection of power cable Power cables are exchanged.
voltage Damaging of coil Transformer are exchanged.
No weld current The energizing signal from the welding Confirm the output of the
controller has not come out. welding controller.
Disconnection of load cable Load cables are exchanged.
Loose connection of load conductor Correct the joint of the load.
No polarity of Breakdown of diode Transformer are exchanged.
output terminal
Cooling water Blocking of cooling water passage Transformer are exchanged.
doesn't flow.
Water leak Damage of cooling water circuit parts Transformer are exchanged.
Thermostat point Breakdown of thermostat Transformer are exchanged.
of contact Operation of thermostat by overheat Pour cooling water of
doesn't operate. regulated flowing quantity.
Smoking and Output frequency setting defect of Use is discontinued and
nasty smell welding controller ,Over load, cooling transformers are exchanged.
water shortage, and breakdown, etc.

10
11. Maintenance check
Please work after it cuts power off when you check.
11.1 Daily checkup
・Are there an abnormal sound and a smell?
・Does the joint of the secondary conductor and the cable overheat?
・Is there a leakage of cooling water?
・In the cold district, water might freeze inside the transformer. Please exhaust the
water that remains inside the transformer. Please blow in compress air to the
water supply entrance and push water out.

11.2 Regular Inspection (Every three months)

・Please increase and tighten the bolt of the secondary conductor mounting in the
transformer. Please blow in compress air to the water inlet, and remove the
scale of the cooling water circuit.

11.3 Check of abnormal

①Diode check
Please measure resistance with an analog tester.
※Measurements of a digital tester are not correct.

Tester
Normal value

＋ Red, － Black ５Ω

＋ Black, － Red ∞

②Thermostat check
Please apply the tester to the thermostat terminal, and measure resistance.

Tester

Normal value

０Ω

11
 ③Earth resistance check
Please measure the earth resistance with the tester.

Tester

Normal value

100Ω

④Insulation resistance test

・ Please measure between primary and secondary windings by using the
insulation resistance tester of the DC 500V about the insulation resistance.
・Please connect (＋) and (－) of the output terminal with the electric wire before it
measures. The diode might be damaged if it doesn't connect it.

Electric wire

The insulation resistance

tester of the DC 500V

Normal value

50MΩ or more

12. Guarantee
The device is guaranteed for one year after purchase day.
However, the one due to trouble in the articles of consumption and handling is
excluded.

13. Repair
Please consult the shop that purchases it according when it is not possible to repair
after it confirms it to "Symptom and treatment in case of the trouble"

12
14. General specification
Model HFT－90C－6B HFT－90C－3B
1φ AC600V±10% 1φ AC300V±10%
Rated primary voltage
Input （Rectangle wave） （Rectangle wave）
Rated frequency 1000Hz
Secondary no-load voltage 10.7V
Turn ratio 56 28
Rated capacity (at 50%duty
90kVA
factor)
Output Maximum welding current 18,000A
Rated duty factor 10%
Maximum welding time 0.5second
Maximum capacity 193kVA
Withstand voltage AC2500V－1minute
Class of insulation Class F
Thermostat（Diode stack abnormality
Security function
temperature detection）
Cooling water flow rate (Transformer) 3L/min

Cooling water flow rate (Diode stack） 3L/min

Temperature of cooling water 30℃ or less

Maximum hydraulic pressure 0.5MPa or less（The dewfall is improper）

Ambient temperature 5℃～40℃
Use
Humidity 30%～95%RH
conditions
Altitude 1000m or less
Input terminal size M6
Earth terminal size M6
Thermostat terminal size M3
Connection
Output terminal size M8
Transformer fixation tap size M10
Cooling water gateway size PT1/8 (Rc1/8)
Dimension 130 (W) × 190 (H) × 338(L)
Mass 22kg
Body color Beige

13
15. Dimension

14
16. Electric circuit drawing

Input
Output

Earth

17. Cooling water circuit drawing

15