Solid State High Frequency Welder Operation Manual: Baoding Tong Ze Electric Co., LTD

Solid State High Frequency Welder
Operation Manual
BAODING TONG ZE ELECTRIC CO., LTD.

China Baoding Tongze Electric Technology Co., Ltd.
Mobile / wechat / WhatsApp:+8613315240123 E-mail：[email protected]
Solid State High Frequency Welder
Operation Manual
Edit: Zhandong Ma
Edition: V1.0
Publishing date: 2015-10-15
Copyright reserved: BAODING TONG ZE ELECTRIC CO., LTD.

Note: the rights of amendment to this manual are reserved. Should any
differences exist between the product and this manual, please contact us
and we will provide relative service.
Technical support Tel: +86312-3188848 Fax: +86312-5936063
Important Note
Thanks for choosing our products. Please note the following points in
order to operate the equipment in a safety, correct and high efficiency way:
1) This manual is only adapted to the solid state high frequency welder
that equipped with old type 3# board.
2) Please read this manual carefully, and adjust, test and operate
according to relative instructions of this manual. Please take the
documents delivery with equipment as standard if have.
3) In order to prevent the device to be destroyed, hot plugging and
touching the chips and components on the PCB is not permitted.
4) Please use qualified instrument and device to test the equipment.
5) Please contact us if any malfunction occurs or needs maintenance.

Contents
1 Brief introduction.............................................................................................................................................. 1
1.1 General.........................................................................................................................................1
1.2 Main features...............................................................................................................................2
1.3 exterior dimension and structure..............................................................................................6
2 Equipment installation...................................................................................................................................... 7
2.1 Environmental requirements.....................................................................................................7
2.2 cooling water requirements.......................................................................................................7
2.3 power net requirement...............................................................................................................8
2.4 power connection wire between switchgear rectifying cabinet and inverter output
cabinet................................................................................................................................................. 9
2.5 connection of control wire....................................................................................................... 10
2.6 Zero-connection requirement of induction heating equipment......................................... 10
2.7 Ground-connection requirement of induction heating equipment.................................... 10
3 Electric principle..............................................................................................................................................13
3.1 Equipment main circuit structure........................................................................................... 13
3.2 3-phase full control bridge type rectifying circuit................................................................. 14
3.3 single phase serial bridge type inverter circuit.................................................................... 15
3.4 output power adjustment......................................................................................................... 18
3.5 rectifying side control............................................................................................................... 19
3.6 Phase-locked loop and phase angle lock.............................................................................20
3.7 Welder protection......................................................................................................................21
4 Operation instruction......................................................................................................................................23
4.1 Brief illustration..........................................................................................................................23
4.2 Functional classification of control board............................................................................. 25
4.3 Function description of 1# board........................................................................................... 26
4.8 Function description of speed power tracking board..........................................................33
4.9 operation procedure................................................................................................................. 34
4.10 Notice....................................................................................................................................... 35
5 Fault instruction.............................................................................................................................................. 37
5.1 nixie tube display of 1# board.................................................................................................37
6 Instruction of important wave form............................................................................................................... 38
6.1 wave form of rectifying part.....................................................................................................38
6.2 wave form of inverter part....................................................................................................... 39
7 main electronic components and test............................................................................................................ 42
8 Appendix..........................................................................................................................................................48
Baoding Tongze Electric Technology Co., Ltd. Tel: +86-312-3188848

1 E-mail: [email protected]
Baoding Tongze Electric Technology Co., Ltd. Tel: +86-312-3188848

2 E-mail: [email protected]
Solid state HF welder Operation manual
1 Brief introduction
1.1 General
High frequency welding is originated in 1950s, which is a new welding technics to

weld steel or other metal material using skin effect and proximity effect produced by
high frequency current. The appearance and mature of high frequency welding
technology directly promote the development of straight seam welding tube industry.
GGP series of solid state HF welder is a kind of high frequency inverter power supply
to change 3-phase power frequency 50Hz AC to be single phase high frequency AC
(100~600kHz), with AC-DC-AC topological structure for the circuit. GGP series of
solid state HF welder adopts high voltage large power MOSFET module as switch
device of inverter. Take MCU system and intelligent CPLD programmable chip as core
to form rectifying and inverter digital control system. GGP series of solid state HF
welder has the advantages of high welding quality, simple and reliable circuit,
convenient commissioning and operation and energy saving, which is the best choice
for enterprises to improve production technics and enhance quality.
GGP series of solid state HF welder includes: switchgear rectifying cabinet, inverter
output cabinet, console (optional), positioning table (optional), water cooling system
(optional)
a. switchgear rectifying cabinet b. inverter output cabinet
1
c. console d. water cooling system
Fig. 1 GGP series of solid state HF welder compositon
1.2 Main features

⑴ technology features
 Perfect structure design
 Independent design of switchgear rectifying cabinet and inverter output

cabinet, connected by soft cable, which is convenient for layout at user’s site.
 The rectifier adopts 3-phase 6-pulse thyristor rectifying. For large power
welder, 12-pulse thyristor rectifying can be selected to eliminate grid side fifth
and seventh harmonic, and grid side harmonic current is the lowest.
 Power combination of the inverter bridge is accomplished by the way of power

unit superposition. Each MOSFET power unit is designed to be
50kW/100kW/150kW and slideway drawer structure, which is convenient for
installation and repair.
 High standard electromagnetism compatibility design, electromagnetism

radiation meets national standard.
 Closed cabinet design, meeting rigor environmental requirements on site.

* The user needs to prepare three winding power transformer.
 Full digital control system
 3-D rectifier adopts high cost performance MCU controlling to realize precise
synchronism trigger with high control precision and small grid-side non
characteristic harmonic.
 Resonant inverter adopts CPLD to form full-digital control system that is
2
characterized by their automatic constant angle, high phase-lock precise and

wide scope of phase-lock.
 The welder has electronic automatic load matching function with good load
adaptability, high electrical efficiency and high power coefficient.
 The welder has perfect protection function with reliable working and low
failure rate.
 HMI and fault diagnosis system
 Adopt PLC and touch screen to form perfect HMI system.
 Realize integrated automatic control of welder system.
 Fault display and diagnosis system.
⑵ Main Technical Parameter

Table 1- Technical parameter of solid state HF welder
Rated DC Rated DC Electrical

model AC input Frequency scope
voltage current efficiency
3AC380V
GGP60-0.8-H 450V 130A 650~800 kHz ≥85%
50/60Hz
3AC380V
GGP100-0.45-H 450V 220A 400~450 kHz ≥85%
50/60Hz
3AC380V
GGP150-0.4-H 450V 330A 350~400 kHz ≥85%
50/60Hz
3AC380V
GGP200-0.35-H 450V 440A 300~350 kHz ≥85%
50/60Hz
3AC380V
GGP250-0.3-H 450V 550A 250~300 kHz ≥85%
50/60Hz
3AC380V
GGP300-0.3-H 450V 660A 250~300 kHz ≥85%
50/60Hz
3AC380V
GGP400-0.3-H 450V 880A 250~300 kHz ≥85%
50/60Hz
3AC380V
GGP500-0.2-H 450V 1100A 150~200 kHz ≥85%
50/60Hz
3AC380V
GGP600-0.2H 450V 1300A 150~200 kHz ≥85%
50/60Hz
3AC380V
GGP700-0.2-H 450V 1500A 150~200 kHz ≥85%
50/60Hz
3AC380V
GGP800-0.2-H 450V 1800A 150~200 kHz ≥85%
50/60Hz
3AC380V
GGP1000-0.2-H 450V 2200A 150~200 kHz ≥85%
50/60Hz
3AC380V
GGP1200-0.2-H 450V 2700A 150~200 kHz ≥85%
50/60Hz
3AC380V
GGP1400-0.15-H 450V 3100A 100~150 kHz ≥85%
50/60Hz
3
3AC380V
GGP1600-0.15H 450V 3600A 100~150 kHz ≥85%
50/60Hz
3AC380V
GGP1800-0.15-H 450V 4000A 100~150 kHz ≥85%
50/60Hz
Note: Conventional design. Can be customized according to user’s grid and welding
technics.
⑶ Model
GGP□－□－□
application（quenching-C, welding-H）
Working frequency（MHz）
Rated power (kW)
Equipment code: solid state high frequency
Example:
GGP100-0.4-H: rated power 100kW; frequency: 400kHz; H: for welding.
⑷ equipment composition
Solid state HF welder is composed of switchgear rectifying cabinet, inverter output

cabinet, console, positioning table and water cooling system.
 switchgear rectifying cabinet
 One-cabinet design of both switchgear cabinet and rectifying part with

function of switchgear cabinet and rectifying control of solid state HF welder.
 Install incoming switch, incoming ampere meter and switchable voltmeter and
incoming voltage indication light.
 Install 3-phase full-controlled thyristor rectifying bridge to realize power

adjustment of solid state HF welder.
 Install flat-wave reactor, flat-wave capacitor and filter to improve the flat-wave
coefficient.
4
 inverter output cabinet
 The inverter part is composed of MOSFET single-phase inverter bridge

connected in parallel. The power of single-phase bridge is 100kW/50kW; the
inverter bridge adopts the building block method to realize power superposition.
Every piece of bridge plates is designed to be drawer type, which is very
convenient to be installed and repaired.
 Adopt matching transformer to finish power combination. With adoption of

secondary resonance and no welding transformer, tank circuit resonant
capacitor (low voltage) has a resonance with the inductor directly to realize
power transfer through output arm.
 Adopt sealed cabinet with installation of air conditioner.
 console
 The console realizes the function of remote operation and power adjustment
with installation of LCD screen. Having armature voltage and excitation voltage
indication of DC drive and DC voltage and DC current indication of HF welder.
Power closed loop control function is optional.
 The design of console will be different as per different type and quantity of DC
drive matched with.
 positioning table
 2-D positioning table: for induction welding mode and installation and
adjustment of inverter output cabinet. The position of inductor coil can be
adjusted manually.
 3-D positioning table: for induction/contact welding mode, and installation and
adjustment of inverter output cabinet. The position of inductor coil can be
adjusted manually and electrically.
5
 Water-water cooling system
 For water cooling of switchgear rectifying cabinet and inverter output cabinet,
high quality plate-type heat exchanger, water pump and stainless steel pipeline
are adopted, having water pressure and water temperature display and
protection.
 Water-water heat exchanger will be different as per different welder power, for
details please refer to selection guide.
1.3 exterior dimension and structure
The exterior dimension of GGP series solid state HF welder is our standard design
(table 2). For special requirement, non-standard design can be made, but min.
dimension needs to be negotiated by both parties.
Table 2 exterior dimension of GGP series solid state HF welder (L×W×H)
switchgear rectifying inverter output

Power Console (mm)
cabinet (mm) cabinet (mm)
60kW 1500×900×2000 1750×700×1100 850×550×1200
100kW 1500×900×2000 1750×700×1100 850×550×1200
100kw double
1500×900×2000 1750×700×1400 850×550×1200
frequency
150kw 1500×900×2000 1750×700×1100 850×550×1200
200kw 1500×900×2000 1750×700×1400 850×550×1200
250kW 1800×900×2000 1800×700×1600 850×550×1200
300kW 1800×900×2000 1800×700×1800 850×550×1200

400kW 1800×900×2000 2000×800×1500 850×550×1200
500kW 2000×1150×2000 2000×800×1800 850×550×1200
600kW 2000×1150×2000 2000×800×2000 850×550×1200
700kW 2000×1500×2000 2900×1000×2000 850×550×1200
800kW 2000×1500×2000 2900×1000×2000 850×550×1200
1000kW 2000×1500×2000 2900×1000×2000 850×550×1200
1200kW 2000×1500×2000 2900×1000×2150 850×550×1200
1800kW 2100×1700×2000 3500×1200×2500 850×550×1200
6
2 Equipment installation
Before or after unpacking of equipment, the components should be checked to see if

there’s damage or damp during transportation. It should be repaired if such situation
occurs, and operated after the defects eliminated. Please inform us in time in order
not to miss the time of claim.
2.1 Environmental requirements
（1） Indoor installation with good grounding condition. Grounding wire color
should be obviously different from control wires. Sectional area of
grounding wire: >6mm2, grounding resistance: ＜4Ω.
（2） Height above sea level should be no more than 1000m, otherwise rated
value should be reduced to be operated.
（3） Ambient temperature: -10℃~+40℃, otherwise rated value should be
reduced to be operated.
（4） Air relative humidity: ≤85%.
（5） No severe vibration, no conductive dust, no various causticity gas and
explosion gas.
（6） Installation gradient: ≤5°.
（7） Install in the place with good ventilation condition.
2.2 cooling water requirements

Power supply, load inductor and copper strip adopt water cooling method, and the
quality of cooling water will directly affect the operation reliability. It is suggested
analyze and test the cooling water, the result should meet the following conditions. It
should be solved by purification method if differences existed.
⑴ Mechanical property: transparent and not turbid without deposit (screen mesh
dimension 0.38mm), total solid content is no more than 250mgL.
⑵ Chemical property:
PH value 6~8
Chlorid no more than 100mg/L
Nitrite (NO2-) no more than 0.04mg/L
7
Fe no more than 0.3mg/L

Mn no more than 0.05mg/L
S no more than 250mg/L
⑶ Conductivity: no more than 600μs /cm
⑷ Water inlet temperature: no less than 5℃, no more than 35℃. Fogging
coatings on the surface of water cooling component should be avoided for high
ambient temperature.
⑸ Water inlet pressure: 0.18~0.25Mpa (approximately 1.8~2.5kg/cm2).
2.3 power net requirement
The power net voltage should be sine wave and harmonic distortion is no more than
5%. The power net input is line voltage 380V AC, continuous fluctuation range of
power net voltage is no more than ±10%, power net frequency change is no more
than ±2% (i.e. between 49~51Hz), the unbalancedness of 3-phase should less than
±5%.
The power supply incoming line adopts copper core cable to connect. The contact of
the joint should be in good and reliable condition. Increase the contact area and
decrease contact resistance as far as possible.
There’s no phase sequence differentiation requirement for power supply incoming line,
but it is better connect as per positive sequence (when positive sequence, 1# board
displays number and there’s no radix point at the bottom right; and there’s radix point
when negative sequence) so as to check synchronization relationship between trigger
pulse and power supply incoming line when maintenance. Power supply incoming line
A, B and C should connect yellow, green and red, and clearly marked.
The wire of power supply incoming line should be pressed firmly by screw, and the
nominal current of wire is no less than the max DC current in Table 1.
Power supply incoming line is no less than the value listed in Table 3.
8
Table 3 power supply incoming line and load connection copper strip sectional area
Power 3-phase line incoming copper strip sectional area
60 kW 75 mm2
100 kW 120 mm2
150 kW 185 mm2
200 kW 2 pcs of 120 mm2 or 1 piece of 240 mm2
250 kW 1piece of 300 mm2 or 2 pcs of 185 mm2
300 kW 1 piece of 300 mm2 or 2 pcs of 185 mm2
400 kW 3 pcs of 150 mm2 or 2 pcs of 240 mm2
2.4 power connection wire between switchgear rectifying cabinet and inverter
output cabinet
Copper wire is adopted for connection between switchgear rectifying cabinet and
inverter output cabinet. Please refer to the mark inside the cabinet when connection.
The contact of the connection should be in good condition, and increase the contact
area and decrease contact resistance as far as possible.
Please refer to Table 4 for correspondence relationship between copper wire
specification and equipment power.
Table 4 correspondence relationship between copper wire specification and equipment
power
Total area of anode plastic Total area of cathode plastic

Rated power( kW) 2
copper wire (mm ) copper wire (mm2)
9
60 kw 50 mm2×2 50 mm2×2
100 kw 70 mm2×2 70 mm2×2
150 kw 70 mm2×3 70 mm2×3
200 kw 70 mm2×4 70 mm2×4
250 kw 70 mm2×5 95 mm2×4
300 kw 120 mm2×3 120 mm2×3
400 kw 120 mm2×4 120 mm2×4
500 kw 120 mm2×5 150 mm2×4
600 kw 120 mm2×6 120 mm2×6
700 kw 120 mm2×7 150 mm2×6
800 kw 120 mm2×8 150 mm2×6
1000 kw 120 mm2×10 185 mm2×6
1200 kw 120 mm2×12 185 mm2×8
1800 kw 120 mm2×18 185 mm2×12
2.5 connection of control wire
According to external terminal instruction of external control function of this manual,

connect external control wire and check if the connection of outside lead is correct or
not and the connection point is loose or not as per electric drawing.
2.6 Zero-connection requirement of induction heating equipment
The power supply of equipment is 3-phase 4-wire system, for null line, copper wire
that not less than 2.5mm2 should be used and connected with “N” on terminal block, to
meet the requirement of single phase 220V operation power supply.
Special note: Zero-connection and earthing should not be connected in parallel.
2.7 Ground-connection requirement of induction heating equipment
In order to ensure normal working and security of operator, and considering the
equipment shielding needs, the equipment should adopt single ground-connection
system, which is composed of earthing electrode and grounding line. The total
resistance of grounded circuit should be less than 4Ω.
10
Special note: equipment ground-connection system should not share
ground-connection system with large power equipment such as electric welder or

power machine. Grounding line should be far from large power equipment power line
and keep a regular check.
⑴earthing electrode requirement
earthing electrode can adopt galvanized angle steel and requirements are as
follows:
① the length of earthing electrode is 2.5m galvanized angle steel (45×45mm) at
least 3 pieces.
② horizontal or triangle embedded in vertical.
③ space between the angle steel is 2.5m～3m.
④ Embedding depth ≥ 0.6m.
⑤ vertical earthing electrode connection: galvanized flat steel can be welded
together. It should be firm and reliable if using screws to connect earthing electrode
outlet line and grounding line net. Corrosion preventing treatment should be done for
the connect point.
⑥ in order to increase the conductivity of earthing electrode, resistance reducing
treatment can be done to the soil environment. Lime, salt, water and wood carbonic
can be mixed together as per certain proportion to pour.
⑵ Grounding line
The grounding line is connected by galvanized flat steel that not less than 4×40mm.
Lapping welding method should be adopted for connection to earthing electrode.
There’re grounding bolts at the lower part behind the equipment. A3 steel lug plate is
welded on galvanized flat steel and fixed on grounding bolts.
⑶ equipment grounding drawing
11
⑷ Grounding wire distribution (for reference)
12
3 Electric principle
3.1 Equipment main circuit structure
Equipment main circuit structure is shown in Fig. 2 and Fig. 3., the rectifier adopts
3-phase bridge type thyristor full control rectifying circuit. DC side adopts capacitor
filter to meet the working requirements of serial resonance inverter (voltage type
inverter). The inverter adopts large power single phase H bridge inverter structure; the
tank circuit is serial resonance structure. As the voltage type inverter over current
protection is very important, our company adopts unique and reliable current
protection circuit to ensure a safety and reliable operation of inverter.
Fig. 2 full solid state induction heating power supply topological structure diagram
Fig. 3 full solid state induction heating power supply main circuit diagram
13
3.2 3-phase full control bridge type rectifying circuit
Output voltage of 3-phase full control bridge type rectifying circuit: Ud
=1.35Ulcosα
AC line incoming current of power supply: I1＝0.816×Id
Grid-side power coefficient of power supply: λ＝0.955×cosα
Ud、Id —— output DC voltage, current average value
Ul、I1 —— AC line voltage and phase current
α—— thyristor trigger delay angle
λ——network side power coefficient
under the condition of given rectifying bridge input line voltage Ul, change the thyristor
trigger delay angle α can change output DC voltage. Generally the traditional
induction heating power supply adjusts DC voltage by adjusting of rectifying trigger
angle, and adjusts the equipment output power. Rectifier circuit structure and trigger
pulse is shown in Fig.4. Rectifier network side AC voltage/current and DC voltage
wave is shown in Fig. 5. The advantage that choosing thyristor rectifying for the power
supply but not diode rectifying is power supply can realize soft start and soft turn off,
decreasing voltage and current impact. Faults can be eliminated rapidly when occurs.
Ld 1
0.5
usa T1~6 0
0.075 0.08 0.085 0.09 0.095 0.1
1
usb Ud U0 0.5
usc Cd RL 0
0.075 0.08 0.085 0.09 0.095 0.1
L 1
0.5
0
0.075 0.08 0.085 0.09 0.095 0.1
1
Fig. 4 3-phase thyristor rectifying circuit structure and trigger pulse
14
400 400
is is
200 us 200 us
0 0
-200 -200
-400 -400
0.08 0.085 0.09 0.095 0.1 0.105 0.11 0.115 0.12 0.08 0.085 0.09 0.095 0.1 0.105 0.11 0.115 0.12
600 Ud 600 Ud
U0 U0
400 400
200 200
0 0
0.08 0.085 0.09 0.095 0.1 0.105 0.11 0.115 0.12 0.08 0.085 0.09 0.095 0.1 0.105 0.11 0.115 0.12
α=00 α=300
Fig. 5 rectifier wave for different trigger angle
3.3 single phase serial bridge type inverter circuit
Serial resonant inverter is also called voltage resonant inverter, the structure is shown
in Fig. 6, the output voltage of serial resonant inverter is a similar square wave. As the
circuit works near the resonant frequency, oscillating circuit has the minimum
impedance to fundamental wave, so the load current iH is close to sine wave.
Meanwhile in order to avoid direct connection of upper bridge arm and lower bridge
arm of inverter, conversion should follow the rules of turn off first and start secondly,
enough dead zone time should be left between turn off and start.
S1 S2
L
uH
R
uH iH
0
t
Cd C iH
S4 S3
0
t
Fig. 6 serial resonant inverter structure and wave
There are four working status in the working process of serial resonant inverter, which
is shown in Fig. 7:
15
⑴ status 1:
S1 and S3 are on, S2 and S4 are off. The voltage of C1 and C3 is zero, voltage of C2
and C4 is DC bridge voltage Ud, freewheeling diode D1, D2, D3 and D4 are in the off
status. Resonant inverter working status is shown in Fig. 7 (a). C1, C2, C3 and C4 are
absorption capacitor of power switching device S1, S2, S3 and S4 (including junction
capacitance of switching device with equal capacitance value). D1, D2, D3 and D4 are
antiparallel fast recovery diode of power switching device. Cr is resonant capacitor, Lr
and Rr are equivalent inductance and resistance of inductor and heated workpiece. L0
is equivalent lumped inductance of DC line and stray inductance of components. Cd is
DC filtering capacitor.
Fig. 7 serial resonant inverter working status
⑵ status 2:
The pulse of S1 and S3 are turned off at the time of t0, S1 and S3 are rapidly turned off
under the condition of small load current and zero voltage. Meanwhile capacitor C1
and C3 are charged, capacitor C2 and C4 start to discharge to keep continuous flow of
load current. During this time, load current continuous keep the same direction.
Because of charging and discharging of absorption capacitor, the terminal voltage of
switching device S1 and S3 start to rise from zero, the terminal voltage of switching
device S2 and S4 start to drop. At the time of t1, voltage of absorption capacitor C1, C2,
C3 and C4 are all Ud/2, load terminal voltage is zero. At the time of t2, capacitor C1 and
16
C3 are charged to Ud, capacitor C2 and C4 are discharged to zero. In the following
short period of time, the energy saved in stray inductance L0 continuously charge C1
and C3 to make the voltage is a little higher than DC power supply voltage Ud, then
oscillating and attenuation to be stable value Ud. 于 As the current is very small when
switching device is turned off, the energy saved in stray inductance L0 is also very
small, so the voltage of capacitor C1 and C3 rises not much. Resonant inverter working
status is shown in Fig. 7 (b).
⑶ status 3:
At the time of t2, as load current has not been commutated, it will continue to flow
through diode D2 and D4. Although trigger pulse of S2 and S4 comes at t3, as load
current has not been commutated, there will be no current in switching device S2 and
S4. Resonant inverter working status is shown in Fig. 7 (c).
⑷ status 4:
The load current starts to commutate at t4, diode D2 and D4 are turned off, and load
current begins to flow through S2 and S4. As conversion occurs between fast recovery
diode and switching device in the same bridge arm, there’s no reverse recovery
problem of diode, and because both ends voltage of S2 and S4 are zero, it is obviously
that S2 and S4 are zero voltage switching (ZVS) and zero current switching (ZCS).
Resonant inverter working status is shown in Fig. 7 (d).
Serial resonant inverter can work at resistance, capacitive and inductive state, seen
from the above inverter conversion process, the ideal working state of serial resonant
inverter is small inductive quasi resonant.
500
1000 1000
UH IH UH IH
UH UH UH
IH IH IH
P s1
P s4 Ps1
-1000 -1000 Ps4
-500
5.7 5.72 5.74 5.76 5.62 5.64 5.66 5.68 5.6 5.62 5.64 5.66 5.68
(a) -4 (d) -4 (a) -4
x 10 x 10 x10
500
Us1 1000 1000
Us1 Is1 Us1 Us1

Us1
Is1 Is1 Is1
Is1
0 0 0
5.7 5.72 5.74 5.76 5.62 5.64 5.66 5.68 5.6 5.62 5.64 5.66 5.68
(b) -4 (e) -4 (b) -4
50 x 10 x 10 x10
17
（a） small inductive （b）resistance （c）small capacitive
Fig. 8 test wave of inverter working state

Fig 8 is the simulation and measured waveform of serial resonant inverter at inductive,
resistance and capacitive state. From the above waveform we can see that under the
small inductive state, whether load voltage current waveform or component voltage
current waveform is ideal. But under the state of non- zero voltage switching, even the
inverter works at resistance state of power coefficient is 1, because switching device
conversion loses zero voltage switching conditions, from the waveform we can see
that there’s larger peak current of the component when turned on, and because
reverse recovery current of diode and discharging current of capacitor save large
power in line stray inductance and lead to line high frequency surge oscillating. Under
the capacitive state, the inverter has worse conversion condition, not only switching
loss of component increases greatly, but also higher surge impact voltage will threat
the safety of switching component. The equipment is only allowed to work at small
inductive state but not pure resistance or capacitive state.
Seen from the above analysis we can know that, under suitable working mode, the
switching loss of serial resonant inverter is very small, so it can work under higher
working frequency. That’s the reason why at present serial resonant inverter receives
more attention in semi-conductor high frequency induction heating power supply.
3.4 output power adjustment

Output power can be formulated as follows:
Pout=UdId=Ud2/R
Ud ——average of rectifying bridge output DC voltage
18
Id ——average of rectifying bridge output DC current

From the power expression can know that for given load, the load impedance
basically does not change when resonant, so output power of high frequency welder
can be adjusted by adjusting rectifying bridge output voltage Ud, and rectifying output
voltage is adjusted through controlling rectifying thyristor phase-shift angle.
U,I,P (%)
100
80 U
I
60
40 P
20
Rref* (%)
0 10 20 30 40 50 60 70 80 90 100
Fig. 9 welder power adjusting curve

3.5 rectifying side control
Welder rectifying side control circuit takes MCS-51 series of MCU as core, matching
with peripheral circuit to form rectifier double closed loop PI adjuster, constant power
control, fault protection and thyristor trigger etc.
According to the above, change full control rectifying bridge thyristor trigger delay
angle α can control rectifying output DC voltage average, and then control equipment
output power. As PI adjuster is none-static-error adjuster, so the given is equal to the
feedback in static state. When the equipment load changes, to be the feedback signal
through sampling voltage and current at double closed loop PI adjuster, closed loop
adjust the voltage and current to ensure voltage and current output value will not
exceed the setting limitation value, to achieve precise voltage limited and current
limited effect. Double closed loop PI control can decrease the influence that grid
voltage fluctuation to the power supply, and is very important to the application site of
instable grid voltage.
In order to trigger the thyristor reliably, the rectifier adopts high frequency modulation
19
of trigger pulse with the pulse width of 120 degree, and reduce the pulse transformer
volume. Trigger pulse front edge peak current can reach to 1A, the tail of the trigger
current extent is more than 300mA, which can trigger thyristor with any specification
and no need to considerate its trigger current dispersivity.
3.6 Phase-locked loop and phase angle lock

Serial resonant inverter always hopes to working under small inductive quasi resonant
status, i.e. working frequency is always higher than load natural resonance frequency.
As the differences and changes of the load, the electricity parameter of load coil will
change, which will make the inverter deviate from the optimal operating point, not only
increase MOSFET turn off current on inverter bridge and lead to increased turn loss,
but also the inverter power capacity can not be fully utilized. So the inverter control
circuit needs to set phase lock control circuit to realize phase-locked frequency
automatic tracking, i.e. phase locking.
Fig. 10 phase-locked loop diagram
20
Fig. 11 welder resonant inverter control diagram
3.7 Welder protection

The protection function of the welder is mainly for each abnormal situation and fault of
the power supply, except the general protection of control power supply fault and
under water pressure protection, there are mainly AC over current protection, DC over
current protection, loss of lock protection and heating plate temperature protection.
(1) AC over current protection
The short circuit of power supply rectifying side or abnormal working of control circuit
may lead to AC over current protection. Over current protection circuit monitors
3-phase line incoming current, when the current exceeds the setting value, 3-phase
thyristor rectifier control circuit protection turns off, meanwhile the integration fault
indication light is on, the nixie tube displays the fault reason. If rectifying SCR is bad,
AC main circuit breaker will also tripped and cut the connection to the electric grid.
(2) DC over current protection
The short circuit of welder output load or abnormal working of inverter control circuit
and driving circuit may all lead to DC over current. As voltage type inverter DC side is
large capacitor, DC over current protection has a great harm and easily leads to
damage of MOSFET.
Hall current test circuit installed at welder DC side, when test that DC current is large
21
than setting threshold value, blockade inverter MOSFET driving pulse to protect the
welder.
(3) Loss of lock protection
The welder load has terrible conditions, short circuit between inductor coil turns,
arcing and grounding fault often occur, sometimes inductor open circuit and short
circuit may happen. The occurrence of the above problems to the load will lead to
severe fluctuation of tank circuit natural resonance frequency, and cause inverter
working state abrupt change to threat the safe and reliable operation of the
component.
Loss of lock protection circuit collects load voltage and current phase value, to make a
comparison with given threshold signal at actual time. When phase value exceeds
setting threshold value, protection circuit judges it as tank circuit fault, further to
realize loss of lock protection function. Protection circuit should detect this fault
precisely and rapidly to avoid the protection not timely or error protection.
(4) Temperature protection
Inverter switching component of the welder has a severe heating problem, so water
cooling method is widely applied. Fixed temperature test switch on each inverter
bridge board and the switch will do the protection when the temperature of the board
exceeds 55℃.
When temperature protection actuates, please check whether the water pipe is
blocked or water pressure is too low.
22
4 Operation instruction
4.1 Brief illustration
Fig. 12 switchgear rectifying cabinet (front)
Fig. 13 switchgear rectifying cabinet (back)
23
Fig. 14 control part of switchgear rectifying cabinet
Fig. 15 main loop of inverter output cabinet
24
Fig. 16 control part of inverter output cabinet
4.2 Functional classification of control board
Brief introduction of control board function

Name function Position
Switchgear
Rectifying control, PI adjuster, over current protection, self check,
1# board rectifying
sending all sorts of control signal.
cabinet
Switchgear
2# board DC protection, having interface with PLC and 1# board. rectifying
cabinet
Inverter control, having frequency automatic tracking, dead zone Inverter
3# board formation, inductive angle adjustment, tank circuit voltage output
protection and loss of lock etc. cabinet
Inverter
5# board MOSFET driving and test output
cabinet
Inverter
9# board AC protection, having interface with PLC and 2# board. output
cabinet
25
Switchgear
10# board Test signal isolation function. rectifying
cabinet
Voltage Switchgear
feedback Provide isolated DC voltage signal to 1# board. rectifying
board cabinet
Power
Switchgear
supply
Provide driving power supply to 5# board. rectifying
distribution
cabinet
board
Switchgear
Speed power
Realize synchronization adjustment of speed and power. rectifying
tracking board
cabinet
4.3 Function description of 1# board
Fig. 17 1# board
26
Function description of Indication light of 1# board

Name function
LED1 Heating indication, light is on means heating
Proportional integral indication, light is on: adjuster is proportion state; light is
LED2
off: adjuster is proportion-integral state.
LED3 Lack of phase, light is on means lack of phase.
Line incoming over current indication, light is on means line incoming over
LED4
current
Function description of potentiometer of 1# board

name function
Power network voltage phase lock adjustment potentiometer, important
RW21
parameter, user should not change it
Initial phase angle adjustment, DC voltage will increase when unti-clockwise
RW22
adjustment
Filter time adjustment of power given signal, unti-clockwise adjustment to
RW31
extend start time.
RW32 Voltage outer loop magnification adjustment, user should not change it
RW33 Current inner loop magnification adjustment 1, user should not change it
RW34 Current inner loop magnification adjustment 2, user should not change it
Current feedback magnification adjustment, for current limiting setting, current
RW35
will increase when unti-clockwise adjustment.
Over current protection adjustment, for over current protection setting, current
RW36
Voltage feedback magnification adjustment, for voltage limiting setting, voltage
RW37
Over voltage protection adjustment, for over voltage protection setting, user
RW38
should not change it.
RW40 Voltage signal treatment.
Function description of 1# board test point

CK0 Control power ground.
CK21 Phase lock ring control electrical level, the normal is stable 2.5V voltage.
Potentiometer given measuring, indicating the input of power given
CK31
potentiometer.
CK32 Output value of adjusted voltage ring (0～－10V)
CK33 Output value of adjusted double closed loop, to AD conversion chip (0～10V)
Measuring point of 3-phase line incoming current, which is used for measuring
CK34
DC voltage and current formation, to judge the conducting state of six MOSFET.
Measuring of input current feedback, which can be changed by adjustment of
CK35
RW35.
CK36 Measuring of input current, which can be changed by adjustment of RW36.
27
Measuring of DC voltage feedback, which can be changed by voltage feedback

CK37
board or RW37.
Fig. 18 2# board
Function description of 2# board

Name Function
Light on indicates DC over current of bridge A. RW1 adjusts DC over
LED1, RW1
current threshold of bridge A. clockwise adjustment to increase threshold.
Light on indicates DC over current of bridge B. RW2 adjusts DC over
LED2, RW2
current threshold of bridge B. clockwise adjustment to increase threshold.
Light on indicates DC over current of bridge C. RW3 adjusts DC over
LED3, RW3
current threshold of bridge C. clockwise adjustment to increase threshold.
Light on indicates DC over current of bridge D. RW4 adjusts DC over
LED4, RW4
current threshold of bridge D. clockwise adjustment to increase threshold.
28
Fig. 19 3# board
Function description of 3# board

Name Function
RW1 Over frequency protection set value
RW2 Over voltage protection set value
RW3 Phase lock voltage set value
RW4 Separate excitation given frequency
RW5 Lower limit frequency adjustment
RW6 Upper limit frequency adjustment
RW7 Over frequency protection comparison value
RW8 High loss of lock protection set value
RW9 Low loss of lock protection set value
RW10 Dead zone setting
RW11 Spare
29
RW13 Inverter angle adjustment

RW14 Spare
RW15 Open protection set value

Name function
LED1 Reset indication light, light on is reset.
Loss of lock protection open indication. Light off when not heating, light on after
LED2
heating means loss of lock protection has already opened.
LED3 Spare.
LED4 Normal indication of 3# board. Light on means 3# board is normal.
Phase lock indication. Light off when not heating, light on after heating means
LED5
equipment is in phase lock working state.
Loss of lock protection indication. The light should be on after LD5 is on, light off
LED6
after LD5 is on means loss of lock protection.
LED9 Low loss of lock protection indication. Light on means low loss of lock protection.
High loss of lock protection indication. Light on means high loss of lock
LED10
protection.
Over frequency protection indication. Light on means equipment phase lock
LED11
frequency is over high.
LED12 External protection indication. Light on means 2# board or 9# board protection.
Tank circuit over voltage indication. Light on means tank circuit voltage is over
LED13
high.
3 ＃ board power supply under voltage indication. Light on means 3# board
LED14
power supply voltage is too low.
Function description of 3# board test point

Name Function
CK1 Over frequency protection voltage set point.
CK2 Over voltage protection test point.
CK3 Phase lock voltage PS value. 9.7V.
CK4 Pulse signal measuring point.
CK12 Low loss of lock protection voltage measure point.
CK13 High loss of lock protection voltage measure point.
CK14 Over frequency protection voltage measure point.
CK16 Open protection voltage measure point.
30
Fig. 20 5# driving board

Name function
The bridges that connect positive pole and negative pole are called positive
bridge and negative bridge. Positive bridge and negative bridge belong to one
LED51 group, the light of driving board are all off when the group of bridge is normal.
When fault happens, light is on means 5# board is normal, light is off means 5#
board has fault.
31
Fig. 21 9# board

Name function
Light is on means AC over current of bridge A. RW1 adjusts AC over current
LED1、RW1 threshold value of bridge A. Threshold value increases when clockwise
adjustment.
Light is on means AC over current of bridge B. RW2 adjusts AC over current
LED2、RW2 threshold value of bridge B. Threshold value increases when clockwise
adjustment.
Light is on means AC over current of bridge C. RW3 adjusts AC over current
LED3、RW3 threshold value of bridge C. Threshold value increases when clockwise
adjustment.
Light is on means AC over current of bridge D. RW4 adjusts AC over current
LED4、RW4 threshold value of bridge D. Threshold value increases when clockwise
adjustment.
32
4.8 Function description of speed power tracking board
Fig. 22 speed power tracking board
Function description of Indication light of speed power tracking board

Name function
+15V power supply indication. Light is on means +15V power supply is
LED1
normal.
-15V power supply indication. Light is on means -15V power supply is
LED2
normal.
LED3 Matching light load indication, light is on means normal.
LED4 Matching heavy load indication, light is on means normal.
LED5 Light is on when speed feedback value is more than 0.7V.
LED6 Manual indication, light is on means manual state.
LED7 Automatic indication, light is on means automatic tracking state.
33
Function description of potentiometer of speed power tracking board

Name function
RW1 Voltage input signal calibration adjustment.
RW2 Current input signal calibration adjustment.
RW3 Speed input signal calibration adjustment.
RW4 Power signal calibration adjustment.
Note: it takes 100kW welder as the above example, which is a little different
from other power grade circuit board for the installation position, but control
boards specification is exactly the same.
4.9 operation procedure

⑴ start-up procedure
① switchgear rectifying cabinet is powered on. Check line incoming voltage value
of voltage meter on the panel, and should accord with power net requirement of Part 2
of this manual. Check if there’s abnormal inside the cabinet or not.
② connect cooling water system, hydraulic pressure relay normally open point is
closed, check whether water pipe in rectifying cabinet and inverter cabinet is normal
or not, check water inlet pressure and outlet water flow smooth condition, which
should accord with cooling water pressure and water quality requirement in Part 2 of
this manual.
③ check tank circuit and inductor coil, check if there’s short circuit between the
heated and inductor coil, and if the inductor coil is open circuit or not.
④ unticlockwise adjust power regulating potentiometer to the minimum, press
control power supply box button, the light is on, 1# board and PLC start to self check,
indication light of 3# board and power supply driving board is on. When self check is
over without fault, integral fault indication light is off, 1# board nixie tube flashes to
display “1”, then the PLC on the console displays system state.
⑤ check whether power regulating potentiometer has already been adjusted to
the minimum or not, press main loop box button, main contact switches on, main loop
box indication light is on, 1# board nixie tube still flashes to display “1”.
34
⑥ press heating start button, heating relay turns on, 1# board display “H”, DC
voltage meter and DC current meter has slight display. Clockwise adjust power
regulating potentiometer on the panel slowly, then DC voltage meter and DC current
meter increase linearly, adjust power regulating potentiometer to required power.
⑵ stop procedure
The stop procedure is contrary operation of start-up procedure, following points
should be noted:
① after pressing stop heating button, power output is soft stop, so there’s soft
stop time from pressing stop heating button to final output power is zero. It is better
that the interval time between stop heating and stop main loop be more than soft stop
time.
② stop process: stop heating→stop main contactor of main loop→stop control
power supply→stop external switch cabinet power supply, as there’s interlock control
among heating control, main loop control and control power supply operation, try to
avoid stop external power supply directly.
4.10 Notice
① when changing specification of the pipe, the matching of inductor and

workpiece should be paid strict attention. If there’s big difference for the specification
of changing heated workpiece, it is better change the matched inductor to improve

equipment efficiency and output ability.
② regularly check if the water pipe leaks or not.
③ regularly check if the indication light and meter on the panel is normal or not,
including DC voltage meter, DC current meter etc.
④ keep clean of each part of control circuit and components inside the cabinet,
and smooth of cooling water pipe.
⑤ multi-protection measures have been taken, when there’s fault, protection

circuit is active, fault indication light on the panel is on. Please observe the displaying
35
content carefully and analyze reason of the fault, power on will be permitted only after
the fault is eliminated.
⑥ the equipment is designed with internal/external control transfer switch. For
internal control, power regulating is accomplished by potentiometer on the panel, and
internal heating start/stop is for the control. For the external control, power regulating
is accomplished by external potentiometer, and external heating start/stop is for the
control.
⑦ the type of adjuster selected by 1# board S201 short circuit block is
proportion/proportion-integral, under proportion mode, LD2 indication light is on,

proportion state is test condition. When normal working, adjuster should be switched
to be proportion-integral (PI) state to ensure equipment having constant power output

and precise voltage limiting and current limiting function.
36
5 Fault instruction
5.1 nixie tube display of 1# board
Nixie tube display state instruction-rectifying board nixie tube display

display meaning measures
Check if control power supply is lack of phase or not
Lack of phase, 3-phase Check if control power supply fuse melts or not
0 unbalance, too low line Check if power grid voltage is unbalanced or not
incoming voltage Check if power grid voltage is too low (line voltage is
less than 340V)
1# board powers on and self check without any fault,
1 Wait for heating
waiting for heating start (normal state)
Check if line incoming current exceeds allowable
Line incoming over
2 value or not
current
Check if current transformer is damaged or not
Replace ADC0804 chip
Power on self check A/D Replace DG212 chip
3
initial value too large Check if R202 and C205 is separately 10K and
180P
Test if 2#, 9# and 3#板 is alarming or not
4 Integration protection
Test if MOSFET and diode is damaged or not
Test if 151 wire to GND wire is short circuit or not
5 Power on heated Test if the corresponding contact to 151 wire on
heating relay is good or not.
6 Power on reset Test if 152 wire to GND wire is short circuit or not
H heating Normal working
37
6 Instruction of important wave form

6.1 wave form of rectifying part
⑴ rectifying bridge output wave form
Rectifying bridge SCR Rectifying bridge SCR principle drawing
Rectifying bridge SCR passing through instrument Rectifying bridge SCR passing through instrument
transformer sampling wave form (normal) transformer sampling wave form (abnormal)
Note: measuring point: on 1# rectifying board, two ends of resistor R332.
Actual output wave form of rectifying SCR (normal) Actual output wave form of rectifying SCR (abnormal)
38
Note: measuring point: rectifying bridge output, two ends of freewheeling diode.
Note: For normal working 3-phase 6-pulse rectifying bridge, its DC output wave form is
300Hz pulse waveform. Observe its DC waveform can judge the working state of rectifier:
please check rectifying bridge and its trigger pulse if following situation occurs:
 DC current is large after start heating, till 1# board gives an alarm.
 DC voltage can not reach above 350V after start heating
 DC flat wave reactance gives out heat and abnormal sound; DC

electroanalysis capacitor leaks to be damage
Test rectifying output by oscillograph, when abnormal waveform in above figure

appears (DC output is short of wave tip). Please check: whether SCR is damaged or
not, pulse transformer is damaged or not, the gate of SCR is open circuit or not.
⑵correct waveform of SCR trigger pulse and measuring method
6 trigger pulse waveforms of SCR rectifier are 9.6kHz modulate 120 degree width
strong triggering waveform. Mutual difference of 6 trigger pulse waveforms is 60

degree.
Measuring point: pulse transformer 3 feet is negative, 5 feet is positive.
6.2 wave form of inverter part
⑴ 5# board output MOSFET driving waveform
39
Driving pulse waveform Driving pulse waveform (dead zone)
Normal driving pulse waveform (negative pressure) wrong driving pulse waveform (no negative pressure)
Measuring point: two ends of MOSFET pulse wire
⑵ inverter output waveform
（a）inductive angle is too large （b）inductive angle is large
40
（c）suitable angle （d）small angle
Measuring point: two ends of inverter output bridge board
41
7 main electronic components and test
42
43
44
45
46
47
8 Appendix
Please refer to attachment for electric drawing.
48
BAODING TONG ZE ELECTRIC CO., LTD.
Telephone：+86312-3188848
Customer phone：+8613315240123
E-mail：[email protected]
E-mail：[email protected]
Url：www.zgtzdq.com
Address：Dazhuze Industrial Area, Baoding, Hebei Province, China
49

Solid State High Frequency Welder Operation Manual: Baoding Tong Ze Electric Co., LTD

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Solid State High Frequency Welder

BAODING TONG ZE ELECTRIC CO., LTD.

Solid State High Frequency Welder

Publishing date: 2015-10-15

Copyright reserved: BAODING TONG ZE ELECTRIC CO., LTD.

that equipped with old type 3# board.

according to relative instructions of this manual. Please take the

documents delivery with equipment as standard if have.

3) In order to prevent the device to be destroyed, hot plugging and

touching the chips and components on the PCB is not permitted.

4) Please use qualified instrument and device to test the equipment.

5) Please contact us if any malfunction occurs or needs maintenance.

Baoding Tongze Electric Technology Co., Ltd. Tel: +86-312-3188848

Baoding Tongze Electric Technology Co., Ltd. Tel: +86-312-3188848

High frequency welding is originated in 1950s, which is a new welding technics to

a. switchgear rectifying cabinet b. inverter output cabinet

c. console d. water cooling system

Fig. 1 GGP series of solid state HF welder compositon

1.2 Main features

 Perfect structure design

 Independent design of switchgear rectifying cabinet and inverter output

 Power combination of the inverter bridge is accomplished by the way of power

 High standard electromagnetism compatibility design, electromagnetism

 Closed cabinet design, meeting rigor environmental requirements on site.

 Full digital control system

 Resonant inverter adopts CPLD to form full-digital control system that is

characterized by their automatic constant angle, high phase-lock precise and

 HMI and fault diagnosis system

 Adopt PLC and touch screen to form perfect HMI system.

 Realize integrated automatic control of welder system.

 Fault display and diagnosis system.

⑵ Main Technical Parameter

Rated DC Rated DC Electrical

Rated power (kW)

Equipment code: solid state high frequency

GGP100-0.4-H: rated power 100kW; frequency: 400kHz; H: for welding.

Solid state HF welder is composed of switchgear rectifying cabinet, inverter output

 switchgear rectifying cabinet

 One-cabinet design of both switchgear cabinet and rectifying part with

 Install 3-phase full-controlled thyristor rectifying bridge to realize power

 inverter output cabinet

 The inverter part is composed of MOSFET single-phase inverter bridge

 Adopt matching transformer to finish power combination. With adoption of

 Adopt sealed cabinet with installation of air conditioner.

 Water-water cooling system

1.3 exterior dimension and structure

dimension needs to be negotiated by both parties.

Table 2 exterior dimension of GGP series solid state HF welder (L×W×H)

switchgear rectifying inverter output

250kW 1800×900×2000 1800×700×1600 850×550×1200

300kW 1800×900×2000 1800×700×1800 850×550×1200

Before or after unpacking of equipment, the components should be checked to see if

2.1 Environmental requirements

2.2 cooling water requirements

Fe no more than 0.3mg/L

2.3 power net requirement

when negative sequence) so as to check synchronization relationship between trigger

nominal current of wire is no less than the max DC current in Table 1.

Power 3-phase line incoming copper strip sectional area