1. Brief introduction and working principal of the QGT-1 Solid State HF Welder
QGT-1 series solid state H.F welder is specially designed for straight seam welding. It adopts high power components of US IR IRFP460 MOSFET and Germany IXYS Company DSEI60-06A rapid recovery diode. The high power capacitor C and inductor coil L compose current-mode parallel upper-voltage resonance circuit, which doesn’t need output transformer. Thus, it not only improves the efficiency, but also increases the reliability of the welder.
The solid state H.F welder has such distinct features as energy-saving, effective welding, simple structure, easy maintenance, low failure rate, low maintenance cost etc.
2.Supply list
| DESCRIPTION |
COMPOSITION |
QTY. |
QGT-1-1000KW
Solid State H.F Welder (one unit) |
DC Power Unit |
1 |
| Inverter Output Unit |
1 |
| Central Control Unit |
1 |
| Water-water Heat Exchange Unit |
1 |
| Rectifier Isolation transformer |
1 |
| 3D Adjustable Table |
1 |
| Output Leg |
1 |
3. Performance introduction
3.1 DC Power Unit
|
DC Power Unit includes rectify, flight wave and control parts.
|
- Independent current & voltage display and control system — the welder is controllable even without central control unit.
- Low Ripple Fiter — Reduces AC line harmonics and DC Ripple, ensure the weld quality.
- SCR Power Supply — Provides constant output power for consistent weld quality.
- Rectifier Circuit — 6 pulse Retification.
- Simens PLC — easy to control and diagnose.
|
| Power factor |
0.9 |
| Power distribution capacity |
1500KVA |
| Input voltage |
380/50 Hz 6% linear |
| Ripple coefficient |
＜1% |
| PLC type |
SIEMENS |
| Dimensions |
123cm(L)158 cm(W) 223cm(H) |
| Working temperature |
-5℃ to +50℃ |
| Operating humidity |
≤85% |
3.2 Inverter Output Unit
|
The inverter part is made up by parallel MOSFET power transistor modules, which is easy for maintainance.
|
- Stable DC output — enhanced by 3-phase full-controllable thyristor rectifying bridge, flight wave reactor, filter capacitor, and filter reactor.
- Independent current & voltage display and control system — the welder is controllable even without central control unit.
- Compact, sealed and internally water cooled cabinet
- Automatic load matching system — enables the welder to run at optimum efficiency with +/- 1% frequency stability.
|
| Rated output power |
800KW |
| Output frequency |
200KHZ |
| Dimensions (without output leads) |
378cm(L)107 cm(W)260 cm(H) |
| Efficiency |
＞85% |
3.3 Central Control Unit
|
Installed with LCD, power and speed adjust module, the pipe line can be completely controlled by the central control unit.
|
Dispay and alarm — the output current and voltage of the DC power unit; armature voltage and current, excitation voltage and current of the DC speed adjust unit. |
| Dimensions |
111cm(L) 132cm(W) 135cm(H) |
3.4 Water-water Heat Exchange Unit
|
Composition：Plate heat exchanger, water tank, pump and electrical control part.
|
- Closed loop circulation, outer water (normal) cools down the inner water (distilled water), no scaling.
- Heat exchanger fins — High efficiency of heat radiation, low cost, applicable to large power H.F equipment.
- Stainless steel water pump and copper pipe — less polution of the loop.
- Stainless steel water tank with level switch — easy to check water level.
|
| Distilled water |
＜35℃ |
| Cooling water pressure |
0.15-0.3Mpa |
| Cooling water flow |
＞50m³/h |
| Cooling system |
Over-temperature protection for cooler |
| Resonance method |
Series‐parallel
Complex resonance |
| Dimensions |
166cm(L) 110cm(W)185 cm(H) |
3.5 Rectifier isolation transformer
|
It is the input rectifier part of the equipment. It reduces the input voltage from 415V to 200V to ensure stable power supply, at the same time, to insulate the power grid.
|
| Dimensions |
230cm(L) 220cm(W) 220cm(H) |
4. Features of solid state H.F welder
There are good reasons why solid state welders have displaced vacuum tube welders in the pipe and tube industry. These include higher efficiency, higher reliability, improved safety, and more installation flexibility.
4.1 Simple circuit and flexible installation
Using series-parallel complex resonance circuit, the power only needs to connect main circuit cable between rectifier power supply and the transformer and inverter unit. The installation only needs 2-3 days under good support of the user.
4.2 Complete protection and easy maintenance
Equipment has perfect failure alarm and fault display system. Once there is a failure, the LCD can show the fault location clearly, so that maintenance personnel can quickly find out the cause of the failure and troubleshoot.
Protection measures as follows:
- Current protection： Once coil short circuit or over-current caused by disoperation occurs，the device will automatically stop and display the fault.
- Open-circuit protection：Once open-circuit caused by disoperation occurs, the device will automatically stop and display the fault.
- Lack Phase protection: Once any phase of the three-phase power supply loses, the device will automatically stop and the LED of the rectify unit lights up.
- Wrong Phase protection: Once wrong wiring occurs, the equipment cannot start.
- Module board protection:
a.Once the temperature of the oscillation component on module board is above 60 ℃, the device will automatically stop.
b. Once the working voltage of module board is lower than the setting value, the device will automatically stop.
c. Once the trigger pulse loses, the device will automatically stop.
d. Once MOSFET damaged，the device will automatically stop.
- Water pressure protection: Once the water pressure is insufficient or lower than the setting value, the device will automatically stop and display the fault.
- Water temperature protection: Once the temperature of circulating water is higher than the setting value, the device will automatically stop and display the fault.
- Frequency Protection：Once frequency is too high or too low, the inverter trigger unit LED lights up and the rectify unit is switched off.
4.3 Small harmonic interference, no pollution to the power grid
With the transformer, RC and LC filter network, the harmonic of solid state H.F welder is small.When solid state H.F welder operates at full power, the power factor can reach 0.9 or more.
4.4 High efficiency, power saving and less cooling water
Compared with the vacuum tube welder, the solid state H.F can save 25%-30% power.It doesn’t’ need reservoir for out water, thus, the cooling water consumption reduces by 70%.
4.5 Less welding spatter, good welding quality
The power supply waveform of solid state H.F is stable, and the steel tube weld tends to be a straight line. The tests of drawing, flattening, flaring, water pressure and other performance are qualified.
5. Warranty Period
12 months from the date of the equipment is qualified to be commissioned by the Seller’s technician at the Buyer’s site. Or 18 months from the date of the equipment leaves the factory of the seller, which first comes, first serves.
Diana Wei
Tel: +86-312-2090169 E-mail: sales@zhuosihengchang.com
Wechat: 1332739751 Whatsapp:86-13323224636
Website: www.metalinductionweld.com
