INTRODUCTION OFINTRODUCTION OFHYOSUNGHYOSUNG

WELDING MACHINEWELDING MACHINE

Global TopGlobal Top Welding Machine & Solution ProviderWelding Machine & Solution Provider

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Content

1. Hyosung Corp. Profile

2. Welding Machine and Solution

3. Supply Record

* Company Profile

* Digital CO2 Arc Welding Machine

1. ProPAC Model for Shipbuildings and Heavy Industries

2. Specifications of ProPAC Model

3. Special Features of ProPAC Model

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Hyosung is a comprehensive maker of ARC welding machines and SPOT welding machine. As it started welding business on 1978, it was the only company to sign a technical partnership with foreign advanced country.

Based on accumulated technology, it has analyzed the customer’s needs in the field of automobile, heavy industry and shipbuilding industry. It is providing the world’s best customer oriented products and currently leading technological innovation for common growth with its customers.

The inverter controlled CO2 welding machines occupy more than 70% of Korean automobile industry and lately, the top shipbuilding company in Korea has recognized our company’s special function and reliable quality. Our sales record is increasing rapidly. In 2008, we have received more than 10 thousand unit orders and we are the number one company in Korea.

We running after Global Excellence !!We running after Global Excellence !!

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Power &Industrial

Systems PGTextile PG Trading PG

IndustrialMaterial

PG

ConstructionPG

ChemicalsPG

InformationPG

•Power Systems PU• Industrial Machinery PU•Hyosung Ebara PU

•Spandex•Nylon•Polyester•Dyeing

•Steel•Chemical•DigitalMachinery

•Tire Cord•Steel Cord•Bead Wire

•Building•Apartment•Villa

•Pet bottle•TPA•Film

•BankingSolution•Storage

Solution

•Welding Machines•Transformer•GIS•Motor•Steel Tower•Pump

•Nylon Fiber PU•Spandex PU•Polyester Fiber PU•Fabric PU•Dyeing PU

•Steel&Metal Products PU ,Ⅱ•Chemical Products PU•TransWorld PU

•Tire & Industrial Reinforce-ments PU•Technical Yarn PU• Interior PU

•Construc-tion PU•HEEC PU

•PP/DH PU•Packaging PU•TPA PU •Film PU

•Nautilus Hyosung PU•HIS PU •Hyosung Capital PU

* PG : Performance Group* PU : Performance Unit

1-1. Group Structure

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11.0%13.0%

6.0%

12.0%

27.0%

13.0%

18.0%

• Net Sales : $5.6 Billion

• Group Foundation : 1957

• Employees : 6,340 persons

• Headquarter : Seoul, Korea

Power &Industrial

Systems PGTextile PG Trading PG

IndustrialMaterial

PG

ConstructionPG

ChemicalsPG

InformationPG

SpandexSpandexWorld #2(M/S 14%)

•Steel•Chemical•Digital

Machinery

Tire CordTire CordWorld #1(M/S 30%)

••TransformerTransformer(765kV,

2000MVA)

••GISGIS(800 kV

double-pole)World 1st

19.8%

33.9%

15.1%13.8% 12.7%

3.8%0.6%

1-2. Group Revenue

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Hyosung (HK) Ltd.

Hyosung Singapore Pte. Ltd.

Hyosung Chemical Fiber Co., Ltd.Hyosung Spandex Co., Ltd.Hyosung Film Co., Ltd

Hyosung Japan

Beijing Hyosung Computer technology, Co., Ltd.Hyosung Container Co., Ltd.

OpCo GMBH

HICO America Inc.

Hyosung America, Inc.

Hyosung Nantong Transformer Co., Ltd.

Mexico

Panama

Brazil

Taiwan

Barcelona MilanoIstanbul

Moscow

Dubai

Indonesia

Philippines

Hyosung Taiwan

L.A

Scottsville

Scottsburg

Vietnam

Hyosung Steel CordQingdao Co., Ltd.

Baoding Hyosung Tianwei Transformer Co., Ltd.

Rockhill

Chongqing GuangzhouGuangdong

Zuhai

Charlotte

Hyosung Luxembourg

Hyosung Brazil

Hyosung USA (Utica plant)Decatur

1-3. Overseas Business Network

Hyosung New Delhi Office

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Changwon Plant

TR, GCB/GIS, Motor, Panel, Pump

Chochiwon Plant

Welding M/C, T/L Tower

Head Office

Plant

Factory 4

Factory 2 Distribution / Mold Transformer

Factory 1 Power Transformer GIS • GCB 266,920

48,380

Factory 3 Motor / Reducer / Ind. Machinery 324,252

Electrical Panel 30,578

Chochiwon Welding machine 120,547

Ebara Pump 48,203

Product Area (m2)

Manufacturing Sites

1-4. Facilities

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Power &IndustrialSystems

PG

Power Systems PU

Industrial Machinery PU

Hyosung-Ebara PU• Welding Machines

• Power Transformer

• Gas Insulated Switchgear

• Electrical Panel

• Transmission Line Tower

• Substation Project

• Engineering & Service

• Total Employees : 2,700

• Engineer : 1,280

- Electrical Engineers : 768

- Mechanical Engineers : 512

• R & D : 160

• Electric Motor

• Industrial Machinery

• Gear Reducer

• Wind Tower

• Pump

1-5. Power & Industrial PG

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DescriptionDescriptionDescription

• Welding Machines (In Korea)

• UHV Power Transformer

• Distribution Transformer

• MV / LV Switchgear

• Gas Insulated Switchgear &

Gas Circuit Breaker

• Transmission Line Steel Tower

• Electric Motor

• Power & Industrial Pump

• Welding Machines (In Korea)

• UHV Power Transformer

• Distribution Transformer

• MV / LV Switchgear

• Gas Insulated Switchgear &

Gas Circuit Breaker

• Transmission Line Steel Tower

• Electric Motor

• Power & Industrial Pump

HYOSUNG SUPPLIES

• Arc Welding Machines - SCR- INVERTER- PULSE

• Resistance Welding Machines- SPOT- PROJECTION- SEAM- ROBOT SEAM

DOMINANT MARKET SHARE

MARKETSHARE

MARKETMARKET

SHARESHARE

• 52%

• 57%

• 52%

• 31%

• 71%

• 25%

• 50%

• 55%

• 52%

• 57%

• 52%

• 31%

• 71%

• 25%

• 50%

• 55%

1-6. Power & Industrial PG in KOREA

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Welding MachineWelding Machine

&&

SolutionSolution

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� CO2/MAG Welding Machines

� Pulse MIG Welding Machines

� TIG Welding Machines

� Air Plasma Cutter

� Spot Welding Machines

� Special Spot Welding Machine

� Fuel Tank, Shock absorber Seam,

3-phase Projection

� Robot Welding System

� Gentry Type Welding System

� A variety of special automatic

Welding System

22--1. Product Range of Welding Machine1. Product Range of Welding Machine

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1978.07 Signed a technical partnership for ARC Welding machines with an

American company, HOBART BROTHERS CO.,LTD.

1989.04 Signed a technical partnership for ARC, SPOT Welding machines with a

Japanese company, JAPAN OSAKA DENKI CO.,LTD.

1990.08 Manufacturing of Thyristor controlled CO2 ARC and SPOT welding

machines.

1992.02 Manufacturing of Inverter controlled MIG/MAG welding machines.

1994.04 1st extension of a technical partnership with OSAKA DENKI CO.,LTD

(Added Welding Automation.)

1994.06 Acquired ISO 9001 certificate for all the products in line/

Completion of the Jochiwon factory.

1997.10 Proclaimed the CE mark for Portable TR and Multi TR .

1999.04 OEM exports of Stationary TR and Multi TR. OSAKA DENKI.

2000.08 Acquired ISO 14001 certificate.

2-2. History (Welding Machine Division)

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2000.10 2nd extension of a technical partnership with OSAKA DENKI

CO.,LTD (Added Special Resistance Welding Machine)

2002.10 Took over a technical partnership with DAIHEN.

2003.11 Acquired the Chinese Compulsory Certificates(CCC) for CO2 ARC

welding machines and resistance welding machine.

2005.04 Started delivering the ship products for three Hyundai companies

(Heavy industry, Mipo Dockyard, Samho heavy industry)(SCR 600A)

2005.07 Proclaimed the CE compliance for CO2 ARC welding machines,

3 phase Projection 300KVA, Seam 200KVA

2005.09 Termination of a technical partnership with DAIHEN(OTC)

2006.03 Completed development of ProPAC model for special ships, started

mass production. Signed a contract with Hanjin industry’s Philippine

SUBIC YARD (SCR 600A)

2-2. History (Welding Machine Division)

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Transformer winding machine Test Bench

SPOT Special Machines Line

2-3. Manufacturing Line

a vacuum copper wire

pouring equipment

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PCB Automatic Insertion Machine Accessories automatic insertion Feeder

PCB automatic inspection machine PCB Automatic inspection JIG

2-4. Production Lines (Printed Circuit Board)

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◆ CO2/MAG Welding Machine

- Inverter Control

- Thyrister Control

◆ Pulse MIG Welding Machine

◆ TIG Welding Machine

◆ DC Arc Welding Machine

◆ Plasma Air Cutter

:1 500 Sets/ Month

Pulse MIG Welder TIG Welder

CO2/MAG/MIG Welder

- Thyristor Control

CO2/MAG/MIG Welder

- Inverter Control

DC Arc Welder

2-5. Arc Welding Machines

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◆SPOT Welding Machines

- Portable Spot TR

- Multi Spot TR

- Stationary Spot Welder

- Inverter Spot Welder

◆ SeamWelding Machines

◆ Robot Seam Welding Machines

◆ Projection Welding Machines

Portable Spot TR. Inverter Spot 1Φ Projection 3Φ Projection

2-6. Resistance Spot & Special Welding Machines

Robot Seam

Seam Welding Machine

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CCC (China) CE (Europe)ISO 9000

2-7. Quality Assurance

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INVERTER

ROBOT TR

Stationary

Multi&Portable

TIG/PLASMA

PULSE(MIG)

INV(MAG)

SCR(CO2)

(Products)

(Business Area)

Vehicle Shipbuilding Railroad carElectronics

Chemistry

A

R

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P

O

T SPOTPROJECTION

SEAM

SPOT

VERY USEFUL USEFUL

SPOT

2-8. Applicable Industries

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1) Annual Supply : 15,000 EA

6. Medium & Small shipbuildings

5. SPP Shipbuilding

4. Hanjin Heavy Industries

3. Hyundai Samho Heavy Industries

2. Hyundai Mipo Dockyard

1. Hyundai Heavy Industries

Name

Shipbuilding Company

World

Ranking

8006004

3,2001,9001

2007

(EA)

2008

(EA)

7 500 500

9 3,000 5,000

8 100 700

- 8,000 5,000

2) Supply Record (’07 ~ ’08)

* Samsung Heavy Industries (2nd Ranking)

* STX Offshore & Shipbuilding (5th Ranking)Inverter CO2 600A - 100% supplied

3. Supply Record

※ Hanjin Heavy Industries Subic Shipyard : 1,500 EA (2009)

Introduction to

Digital CO2 ArcWelding Machine

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▣ Abbreviation of ProProfessional PPerfect AArc welding CControl, and

an implied model name of worldwide top class welding machine that is a perfect product to accomplish zero defects reflecting Hyosung's management philosophy.

▣ Improving arc stability and Weldability.

◇ Stabilization of output voltage with input voltage change

◇ Stabilization of wire feed rate with input voltage change

◇ Adoption of waveform control technique similar to inverter control technique

▣ Multi-functional welding machine

◇ CO2 and MAG welding

◇ SMAW

◇ Gouging

▣ Various Functions for Energy Saving

◇ Reduce Electric Power loss of transformer

◇ Saving Electric Power for Cooling Motor

◇ Saving CO2 gas

1.2 Specialized to shipbuildings and heavy industries

1.1 ProPAC is?

1. ProPAC Model for Shipbuildings and Heavy Industries

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1. ProPAC Model for Shipbuildings and Heavy Industries

▣ Small, Lightweight, and High Power

◇ Optimal design and manufacturing of Transformer and Reactor.

◇ Lightweight high power welder compared to competitors.

▣ Developing high power weldier suitable for shipbuilding and steel

structure

◇ Suitable for long cable and Single cable usage.

◇ Use of control technique (C.T.E Control) to prevent welding defects at Tack weld

during Fillet welding.

◇ Making output power stable in spite of input voltage change leads to prevent

welding defects.

◇ Preventing power loss due to low Arc Time of welder.

◇ Multi-functional welder with CO2/MIG, Gouging, Manual welding(SMAW).

◇ Saving Shield Gas (CO2).

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Items Specification Remarks

Rating

Rated input 220V, 380V, 415V, 440V

Capacity

350A 50~350A, 14~36V

500A 50~500A, 14~42V

600A 80~600A, 14~52V

Rated Duty Cycle

350A 100% at 270A, 60% at 350A SMAW 60% at 350A

500A 100% at 389A, 60% at 500A SMAW 60% at 500A

600A 100% at 600A, 60% at 720A Gouging 100% at 600A

Function

Welding method CO2/MIG, SMAW, Gouging Multi-functional Welder

Welding wire Solid or Flux wire

Wire diameter 1.2 / 1.4 / 1.6mm

Feed motor control DC - 24V

Q’ty of PCB 1 EA (Digital PCB)

Self-

Protecting

Secondary Cable short

sensing Installed

Secondary overcurrent

350A Cut off more than 400A for 1 sec. Cut off power automatically

when overcurrent exist500A Cut off more than 600A for 1 sec.

600A Cut off more than 700A for 1 sec.

Overheat Sensor Installed

Cost Saving

Function

Transformer power saving Installed (30±1sec.)M/S contact point protection

during Tack weld

Fan power saving Installed

Co2 Gas saving Installed

2. Specification of ProPAC Model

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Duty Cycle

Welding Method

Input Power

2. Specification of ProPAC Model

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1) Stabilizing output voltage

Feedback control of output current and voltage is used to stabilize

output with input voltage change.

For stabilizing output voltage in the case of insufficient or excessive

output occurs compared with setting value, changing duty cycle(phase

angle) enables voltage to be constant and results in stable output.

2) Stabilizing Wire feed rate

Controlling wire feeding in a constant speed with input power change keeps

arc stability and output current constantly.

3. Special Features of ProPAC Model

3.1 Output power stability with input power voltage change

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( WFS stability with cable length)

▣ Stabilizing feed rate with long cable usage

Change of control cable length and/or load

current of feed motor can lead voltage

drop occurs in the control cable and

resulting in feed rate drops.

▣ Preventing welding wire slipping

*. Responding time and life

1) Relay : Responding time -- 30mS, Contact point life -- 100,000 times

2) MOS-FET: Responding time -- 0.2 ㎲, Contact point life -- Semi-permanent

*. Calculation of wire slipping length

Condition)1.2mm 350A WFR 15.8m/min

1) Relay : Responding time - 30mS � max. 7.8mm

2) MOS-FET: Responding time - 0.2 ㎲ � 0.000005mm

In order to prevent wire slipping after

welding, fast responding (150,000 times

faster than common relay) MOS-FET is used

to stop wire in the shortest time and can

be used semi-permanently.

WFS Stabiltiy with Cable Length

75%

80%

85%

90%

95%

100%

5m 30m 60m 90m 120m

Cable Length(m)

WF

S S

tab

ility

(%)

Hyosung

A Company

B Company

� voltage is compensated for the amount

of voltage drop and the range of feed rate

change is minimized, and finally output

current will be stabled.

3. Special Features of ProPAC Model

3.2 Stability of Wire Feed Speed

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Long cable usage can cause malfunction of welder or unstable output due to magnetic

field(Noise) around Single Cable. However, ProPAC Model is designed not to be affected by

Noise with 120m Single Cable, therefore stable welding can be performed.

◇ Calculation of output power in shipyard

1) Welding Condition : FCW(1.4mm) 450A

-.Suitable welding voltage: 0.05 × 450A ＋ 18V = 40V

2) Voltage drop with cable length

Shipyard condition

-. Single Cable 60sq 50m ＋ Extension Feeder 30m : Total 80m

-. Voltage drop on cable : 12V

3) welding power demand : 52V

※ Since it is maximum output power condition, input voltage

drop will cause output voltage drop

※Think about…

3.3 Stable welding power with 120m long cable length

3. Special Features of ProPAC Model

▣ High power welding in shipyard

▣ Stable welding with 120m long cable usage

Since ProPAC 600 model has a higher power, 600A 52V (100% Duty Cycle), compared to

competitor, long cable can be used without the lack of power.

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▣ In order to obtain the effect of electrical reactor, direct reactor used subsidiary coil was designed and, as a result, the optimum arc stability is realized.

(SCR ProPAC Current/Voltage Waveform) (Inverter UR Model Current/Voltage Waveform)

Welding Waveform of ProPAC Model similar to waveform control of Inverter

Welding Current Waveform

Welding Voltage Waveform

3.4 Control technique for Arc Stabilizing

3. Special Features of ProPAC Model

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3.5 Constant Thermal Energy (C.T.E control) Technique

CConstant TThermal EEnergy control technique is applied to supply thermal energy constantly even with wire stick out length change, and then penetration and bead width will be uniform.

- Constant Thermal Energy (C.T.E) Technique is patented as a unique technology of Hyosung.

Tack welding

Conventional welder

Tack welding

C.T.E Controlled welder

ARCLENGTH

3. Special Features of ProPAC Model

▣ Arc stability on uneven surface

Constant Thermal Energy is supplied to the different stick out length at tack weld and on uneven surface, therefore arc stability is improved, spatter is reduced, and finally the best quality of weld is made.

▣ Conventional welder

Changes welding current and arc length with wire length change, therefore penetration and bead width would be also changed.

▣ Constant Thermal Energy (C.T.EC.T.E) Control

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▣ Waveform Control Technique with own improved start technique is preventing from arc start failure and performing smooth arc during welding start.

Conventional Model New developed ProPAC Model

3.6 Arc Start Waveform Control Technique

Arc Start WaveformControl Technique

3. Special Features of ProPAC Model

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▣ Unique Burn-back Control Technique is improving arc start success by minimizing ball size of wire end point.

Conventional Model

3.7 Arc Start Finish Control Technique

FLUX

1.4Ø

SOLID

1.2Ø

New developed ProPAC Model

3. Special Features of ProPAC Model

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3. Special Features of ProPAC Model

3.8 Durability

▣ 100% Duty Cycle at 600A

▣ Cover Panel

Transformer in ProPAC 600 is powerful to

give 100% Duty Cycle at 600A.

Protect connectors from the rust due to

salty wind especially at near the ocean.

Rusted connector can rise the contact

resistance and result in power loss and

equipment’s life cycle.

Cover Panel

� The life cycle of welder is increase due to low load factor

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▣ When welding equipment stops, the type of malfunction is indicated to user by alarm on welder.

3.9 Convenient Equipment Maintenance

Diagnosis Causes Lamp Indication

1. Initializing Failure

CT Failure, Voltage out-put phenomena, or Torch detection error during self-analyzing mode at power on

-Possible to check abnormality of key components

on welder during operation

Twinkle twice quickly and twice slowly

2. Overheating

Inside temperature rises

-Cut off the output power automatically by thermal sensor

Lamp on continuously

3. Over currentOver current flows due to abnormality

more than (CO2:700A, GOUGING:750A)

Blinking slowly at an interval of 2 sec.

4. Control Cable Short

Short between cables due to physical damages of secondary control cable or electric leakage etc.

- When short is detected by power monitoring circuit, power to control cable is cut off to protect PCB completely from burn out.

Blinking slowly at an interval of 0.5 sec.

3. Special Features of ProPAC Model

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3.10 Saving Energy

During idle, the power to transformer is cut off to reduce the

possibility short by impurities.

*. Calculation of Power Cost

1) Reducing Transformer Power Cost (based on core loss 1.2kW)

: USD 128 saving/year

Reduced the incidence of defect of welder by protecting impurities invasion such as dust and salt-

corrosion at transformer and semiconductor’s contact point.

2) Reducing Fan Motor Power Cost (based on 150W)

: USD 17 saving/year

Ave. Welding Current FAN Operating time Remarks

600A 7 min Max.

300A 4 min

- 1 min Min.

▣ Power saving with Fan Motor operating time

※Based on Arc Time 22%, Power Cost ￠6 / ㎾h

Basis (2007 annual industrial standard)

Basic value : 10MH/day, 20days/month

3. Special Features of ProPAC Model

▣ Saving power on Transformer

When it is idle for 30 sec., the power is cut off automatically

to save electric power loss.

▣ Safe from Electrical Hazard

� Fan Motor malfunction reduced by 78% (based on ARC Time 22%)

▣ Reduce the incidence of defect of welder

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A device is added to save the gas that is spouted

2~3 times more than setting amount At start of

CO2/MAG welding,

� Saving the gas consumption

*. Calculation of gas saving cost*. Calculation of gas saving cost● Gas loss for 1 time : 0.45 ℓ/time

( loss /time : (30-15) ℓ x 60% = 9ℓ/min.) ※Gas loss rate (welding time 27sec. basis)

0.45ℓ÷(6.75ℓ+0.45ℓ) = 6.25% Loss

● Annual loss amount : 28,512 ℓ = 28.5 ㎥

* Annual saving cost : USD 15 / year

* Saving cost for 8 years: USD 120 / welder

※ Basic condition* Welding time : 2 times/min., 264 times/day* Basic : ARC time 22%, 10MH/day, 20 days/month

* CO2 unit price : ￠30 /kg, ￠54 /㎥

※ Power cost saving

* Power cost : USD 91 / year, welder

* Gas cost : USD 15 / year, welder( 6.25% saving)

* yearly saving cost/welder : USD 106 saving◆ Saving cost for 8 years : USD 848 / welder

※ Average welder replacing period : 8 years basis

※ Saving cost of welding machine

SavingEffect

Gas F

low

Rate

(l/m

im) Without Gas Saving

Circuit

With Gas Saving Circuit

Peak phenomena CUT

Time (sec)

3. Special Features of ProPAC Model

3.10 Saving Energy

▣ Gas Saving Function

End of Document