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(WTr) (Manual) HFGT-80G 【Rev1.0】
(WTr) (Manual) HFGT-80G 【Rev1.0】
TOA
DC INVERTER TRANSFORMER
HFGT-80G-A
HFGT-80G-B
INSTRUCTION MANUAL
Rev. 1.0
2013.02
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1.To use it safely
● 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.
● 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
● 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
〔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 noise
Attention 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.
※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.
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5.Caught between 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.
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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 80kVA
・Maximum welding current 16,000A
・Maximum welding time 0.5second
・Rated duty factor 10%
※About the duty factor
T1:Weld time
T1
Duty cycle= ×100 〔%〕
T2
(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.
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(10) Please attach a cover to the input part.
When it touches the input terminal, it causes the electric shock.
(11) Abnormal circumstances must turn off power after stopping driving.
It causes the electric shock and a fire when keeping driving like abnormality.
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8. Transportation
(1) This transformer is 10kg. When carrying, be careful not to suffer an injury.
(2) Do not give diode stack the impact. The transformer 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 14mm. The bolt must not hit the bottom of the tap.
Tap M8 depth14mm
Tap M6 depth12mm
Output terminal
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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 connect the diode and the transformer with the series route about piping. Please
supply cooling water to the diode cooling water entrance. When water is supplied oppositely,
the transformer overheats and the diode might be damaged.
(5) The cooling water gateway size is PT1/8(Rc1/8).
Water in
Water out
Input terminal M6
Earth terminal M6
Thermostat terminal M3
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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.
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.
Tester
Normal value
+ Red, - Black 5Ω
+ Black, - Red ∞
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②Thermostat check
Please apply the tester to the thermostat terminal, and measure resistance.
Tester
Normal value
0Ω
100Ω
Electric wire
Input terminal (U.V)
The insulation resistance
tester of the DC 500V
Normal value
Red
50MΩ or more
Black
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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"
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14. General specification
HFGT-80G-A
Model
HFGT-80G-B
Rated primary voltage 1φ AC600V±10%(Rectangle wave)
Input
Rated frequency 1800Hz
Secondary no-load voltage 11.1V
Turn ratio 54
Rated capacity (at 50%duty
80kVA
factor)
Output Maximum welding current 16,000A
Rated duty factor 10%
Maximum welding time 0.5second
Maximum capacity 178kVA
Withstand voltage AC2500V-1minute
Class of insulation Class F
Thermostat(Diode stack abnormality
Security function
temperature detection)
Cooling water flow rate 3L/min
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15. Dimension
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16. Circuit drawing
Input Output
Earth
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