KUZAY INVERTER WELDING MACHINE

KZY160 / KZY200 / KZY230 / KZY250 / KZY400 / KZY600 INVERTER WELDING MACHINE OPERATING MANUAL

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1. Content

1. Contents2. Electro-magnetic Compliance 3. Safety Rules 4. General info and Cautions 5. Main Features 6. Front and Rear Panel Controls 7. Technical Informations 8. How to Operate 9. Welding Method with Covered Electrode 10.Storage and Transportation Conditions 11.Maintenance and Repair 12.CE Certificate 13. ISO 9001:2008 Certificate 14.Warranty

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2. Electro-Magnetic Compliance (EMC)

Your machine is manufactured with complete compliance to the implementing regulations. Nevertheless, it may produce electro-magnetic fields which can interfere with other systems (Phones, Computers, T.V.’s). To minimize these effects, please read this section carefully. This machine is designed to be used in industrial areas. If you use it in a house or office, please carry out the following precautions:

Check out the electro-magnetic immunity of,

Input & output cables around the machine’s working space Phone and computer cables Radio and T.V. sets Computers and the devices run on computers Safety and control devices for industrial processes Calibration and measurement devices Medical equipment

User has to be sure of all the equipment’s compliancy in his working space. Otherwise extra safety precautions might be needed. The ideal measurements of a working space are determined by the construction of this area and other factors. To reduce the impact of the electro-magnetic waves produced by the machine:

Do the machine’s connection to the mains as explained in the manual. If any electro-magnetic interference occurs, some precautionary measures must be taken, such as filtering the mains.

Output cables ( + /- tips ) should be as short as possible and kept together.

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3. Safety Rules

Caution:

Keep children away from working space. People with cardiac pacemakers, should consult to their doctors before using the equipment.

Electric shocks can cause injuries and death

Electrode and the piece worked on are electrically active when the machine is on. Do not touch on these neither with naked hands, nor with wet clothes. To insulate your hands please wear dry, imperforate gloves.

Light rays can be burning and dangerous

To protect your eyes from flames and light rays, please use a protective mask with appropriate filter. Head mask and filtered glasses should conform to the ANSI Z87 standards.

Gases and fumes can be suffocative and combustible

During welding process, smokes and gases which are a detriment to health can occur. While welding, please keep your head out of the smoke and do not inhale the gases by ensuring there is enough ventilation in your working place.

Welding sparks can cause fire and explosions

If there are any elements that can start a fire in your working area, take them away. If that is not possible, cover them very well. Please keep in mind that; the welding sparks and hot particles come off the welding can pass through even the smallest spaces. Never weld around the hydraulic lines. Always keep a fire extinguisher nearby.

The tube can explode when it is damaged

Only use gas cylinders that inclusive protective gases suitable for the process and regulators that are designed for the chosen gas and the pressure. All the hoses, gears, and the components should be suited to the welding process and kept in good condition.

Electric and Magnetic Fields (EMF) can be dangerous

Electric current goes through a conductive material creates EMF. Welding current generates EMF around the welding machine and the cables. Being exposed to EMF can create some health issues. Therefore please take the advices below into consideration.

Orientate the electrode and the chassis cables together.

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Do not wrap the electrode and the chassis cables around your body. Attach the chassis cable onto the material being welded as close as possible. While welding stay as far as possible from the power units.

4. General Info and Cautions

Do not install, use, or fix the welding machine before reading the manual.

When taking a long break or after the job is finished, cut the machine’s electric connection off the mains.

Do not make any changes in the machine, as it would change the machine’s technical and safety properties and also break the warranty agreement.

During the work ambient temperature should be between -10 0C and +40 0C. Manufacturing firm reserves the right to change and modify the technical

properties without notice.

5. Main Features

In inverter technology, 50 Hz – 60 Hz frequencies are converted in to 20 Khz by IGBT. And later by lowering down the voltage, alternating current transforms in to direct current. Because of this technologic revolution, welding machine’s dimensions got much smaller, became substantially lighter and also works % 40 more efficiently.

KUZAY INVERTER WELDING MACHINE

Has a feature which averts the Peak Flow coming from generator or mains. Due to its constant DC output current feature, it welds high quality. It can easily be converted into the Gas-Shielded Welding Machine by

attaching a TIG Torch (Tube, Hose, Clamp ). With its ability to start at currents as low as 5amp, it enables you to weld really

thin sheets. Igniting the electrode is easy because of its “Hot Start” feature. Can ignite the electrodes continuously at least 20 times in a row. If the electrode sticks to the material, the current lowers down automatically

and the electrode comes off easily. Comparing to the transformer welding machines, it is much smaller and about

%25 lighter. Consumes %35 to %40 less energy compared to the transformer welding

machines.

160 V – 230 V Electrode range: 1.6 mm – 2.4 mm – 3.25 mm ISO 9001 and CE certificates for safety and reliability 2 year warranty on parts and labor

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6. Front & Rear Panel Controls

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Welding Current Control Knob

Thermal Protection Indicator Light

Power Indicator Light

Negative (-) Output Terminal

ON / OFF Switch BUTTON

Power Cable

Ventilation Duct

Positive (-) Output Terminal

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7. Technical Information

KZY 160A KZY 200A

System Voltage 230 V – 1 Phase

230 V – 1 Phase

Input Power 3.6 KVA 4.4 KVA

Frequency 50 / 60 Hz 50 / 60 Hz

Open Circuit Voltage 55 V DC 56 V DC

Welding Current Range 5 A – 160 A 5 A – 200 A

Protection Rating IP 21 IP 21

Electrode Diameter 1.6 – 2.5 – 3.25 mm

1.6 – 2.5 – 3.25 – 4 mm

Fuse Value and Type 25 A Time-delay

25 A Time-delay

Rated Outputs % 40 160 A% 60 140 A% 100 110 A

% 40 200 A% 60 160 A% 100 140 A

Dimensions ( H-W-L ) 245× 155 × 365 mm

245× 155 × 365 mm

Weight 5.5 kg 6 kg

KZY 230A KZY 250A

Input Voltage 280 V ± %15 V 1 phase

280 V ± %15 2 phase

Input Power 5 KVA 5 KVAFrequency 50/60 Hz 50/60 HzRated Outputs (%40 250 A)

(%60 210 A)(%100 180 A)

(%40 250 A)(%60 220 A)(%100 190 A)

Welding Current Range 5 A – 230 A 5A – 250 AMax. Open Circuit Voltage 68 V DC 68 V DCFuse Voltage & Type 25 A ( Time-

delay )25 A ( Time-delay )

Protection F FDimensions ( H-W-L ) 365 × 165 ×

255 mm365 × 165 × 255 mm

Weight 8.4 kg 8.5 kg

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KZY 400A KZY 600AInput Voltage 380 V ± %15 V 2 Phase 380 V ± %15 V 2 PhaseInput Power 10 KVA 15 KVAFrequency 50/60 Hz 50/60 HzRated Outputs (%40 390 A)

(%60 320 A) (%100 280 A)

(%40 500 A)(%60 400 A)(%100 370 A)

Welding Current Range 20 A - 400 A 20 A – 500 AMax Open Circuit Voltage

80 V DC 85 V DC

Fuse Voltage & Type 32 A ( Time-delay ) 40 A ( Time-delay )Cooling 160 × 160 mm 220 V Fan

12 V 2 DC Fan220 × 220 mm 220 V Fan12 V 3 DC Fan

Protection F FDimensions ( H-W-L ) 490 × 290 × 430 mm 490 × 290 × 560 mmWeight 12 kg 16 kg

8. How to Operate

Do not place or run the machine on a surface tilting level is more than 15’. Always run the machine in a well ventilated environment. When machine is

running do not cover it with anything. Dust and dirt might infiltrate into the machine. You should keep it at minimum

level. The machine has IP 21 protection rating. Keep it as dry as possible. Never run the machine under direct sunlight or in a place there is water splash

risqué. Run it away from radio controlled devices. Please read the “Electro-magnetic

Compliance” section. Do not run the machine if the ambient temperature is outside the range of -10

and +40 0C and if the ambient air humidity is above %70. People who are not authorised with electrical equipment should not open the

chassis cover and interfere with the workings of the machine. When the machine runs, its internal parts get heated. This machine is

protected against overheating by means of Thermal protection. When this protection steps in, Temperature warning lamp switches on. When the temperature drop down to the safe working levels, the warning signal turns off.

Stop running the machine if, insulation burnt is smelled or over-trembling is felt or flame and/or smoke are seen on it or loud noise is heard. Then make a detailed inspection.

If the current circuit gets locked or if voltage is noticed on the chassis, stop the machine and make a detailed inspection.

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Do not let connection contacts get over heated.

9. Welding Method with Covered Electrode

Determine which one of the pole is suitable for the used electrode. You can find this info on the electrode box.

Mount the electrode into the electrode holder. Attach the clamp pliers to a clean and rust-free part of the working

piece. Plug in the power cable to the socket. Turn on the machine with on / off button. Adjust the suitable welding current value depends on the electrode

diameter, type, position etc. Start welding by following the usual welding procedure.

10. Storage and Transportation Conditions

The machine should be stored in rooms which its ambient temperatures between -10 0C and +40 0C and the ambient air humidity is below %70.

Ensure there is no burning, conductive gases or similar conditions in the room. Store the machine in its packaging. In long distance transportations, package the machine well against

mechanical damages.

11. Maintenance and Repair

Maintenance should be done only by the authorised staff.

Check the connections and isolation of the power and energy lines. Change the loose connections.

The dust accumulated inside the machine should be cleaned regularly by air-pressure. This procedure can be practiced twice a month.

If the machine is affected by the water and moister, it should be wicked and its isolation should be checked.

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12. CE Certificate

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13. ISO 9001:2008 Certificate

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14.Warranty

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