Pole automatic welding machine

operating instructions
JIN SHI

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Thank you very much for purchasing the products of Golden Lion welding
machine.
◆ Please read this manual carefully and keep it properly before use for future
reference.

Renqiu Jinshi Welding Machine

Manufacturing Co., Ltd
Address: Renqiu City Xinzhongyi Industrial Zone
Tel:0317-2926890 Website:www.jinshihanji.com
1、 Installation requirements: placed on indoor hard ground, (such as cement
floor).
1、 First adjust the level of the main body of the pole, and then install and fix the
end of the pipe platform on the main structure to adjust the level, and then
place the loading rack in a suitable position, adjust the position of the moving
 end of the feeding rack according to the length of the pipe and fix it. Hang the
disc on the tooling, clamp the disc, manually insert the tube into the disc first,
adjust the support frame on the tube platform, so that the center height of the
tube is consistent with the center height of the disc, so that the tube can be
smoothly penetrated into the disc. After adjustment, it is fixed with expansion
bolts.
2、 Compressed air intake pipe access position: intake pipe inserted to the right
Figure 1: Pressure gauge 0.6-0.7Mpa; (Method of adjusting the pressure: As
shown in Figure 1, the plastic knob is pulled up, and then the pressure is
increased clockwise, and the reverse decreases.) The scale looks at the value
of the inner ring of the table. ）
3、 Power supply voltage requirements:
three-phase four-wire, voltage range:
220V±10%, frequency of 60Hz±1%. The
imbalance of the three-phase voltage
≤5%.
4、 Power inlet: The input line is:
three-phase four-wire, three fire
wire U/V/W wire diameter≥ 70mm2
copper wire, ground wire ≥6 mm2. The
wiring location is shown in Figure 2:

Important: Firewire and Zero wire cannot be connected to the wrong

position, the wrong line is connected, and the equipment will burn out.
Here is the high voltage, pay attention to safety).

5、 Flue gas ---- can be harmful to health, keep the head out of the flue gas
and avoid inhaling welded fumes.
When welding, use ventilation or suction devices to maintain air
circulation in the working environment.
6、 Mixed gas ratio: 80% (Ar) + 20% (CO2).
 7、 Welding shielding gas
tubing method: The gas
tank shown in Figure 3
is:
When the gas is first injected, the
gas in the gas tank should be discharged,
and the gas detector switch of the
welding machine should be turned on to allow the gas to be discharged from the welding torch

8, add hydraulic oil: high-quality wear-resistant hydraulic oil #46, about: about 30KG, look at the
oil gauge scale, > 2/3 scale,

2、 Operation steps: Electricity and gas are ready, start the power-on operation:

1、 After the compressed air is connected, the welding torch and the protective door rise to
the uppermost end, and the clamped cylinders at both ends are retracted. The other
cylinders are returned to their original positions.
2、 First close the
leakage protector,
and then close the air
one by one, there are
switches behind the
welding machine,
and also close one by
one, the welding
machine gets
electricity, the
current, voltmeter
display, the fan turns.
Then press the power
switch on the
operating box to the ON position, and the touch screen will light up after a few seconds to
display the boot screen. The front panel of the welder is displayed as shown in Figure 4:

A, the left side of the digital display shows the welding current, the adjustment current knob can
change its number, the right is the welding voltage, the same adjustment voltage knob can
change its voltage value, welding voltage, the size of the current and welding speed are related,
the faster the welding speed, the corresponding voltage and current should be larger, not the
bigger the better. Relationship between voltage and current: voltage U = 14 + 0.05I. For
example: the welding current is 200A, then the welding voltage U = 14 + 0.05X200 = 24V, in
general, the welding voltage is 1--2V higher

B. Manual wire feeding button: Press and hold this button, the wire feeding motor rotates the
wire feeding, release stops, and the welding wire needs to be rotated.
 C, control switch: select "on", if you select "off", the welding torch switch can not be opened, the
welding machine has no current output.

D: Self-locking/non-self-locking switch: Select the non-self-locking state

E, gas detection / welding switch: when testing the gas flow, the switch to the gas detection state,
solenoid valve open, the welding gun has gas out, adjust the gas flow and then dial to the
welding state, normal work selection:
welding state.

F, alarm: This alarm is in the case of

opening the welding gun switch, there
is no current output is not welded when
the alarm is issued.

3, after the power switch is closed, the oil

pump motor rotates, pay attention to the direction of motor rotation, rotate according to the direction
indicated by the motor, the direction is not right, the power is cut off, change the motor input three-
phase line, any two can be swapped. Enter the manual screen of the touch screen, press the "through
the tube in" or "through the tube back" button, the cylinder action, look at the fuel gauge pressure ≤
2MPa, as shown in Figure 5: (In general, the pressure factory is adjusted, no need to adjust. ）

4, hang the disc, enter the manual screen in the

touch screen, press the "clip disc" key, the disc is
clamped, and then manually put the round tube
into the disc, press the "tooling forward push"
key, the tooling platform enters the welding
position, pay attention to the probe shown in
Figure 6, adjust the probe position, let the probe
light on, (if the probe does not probe the tooling, in automatic operation, the clamping cylinder at
both ends does not move, the cylinder is not clamped. ）

5. Press the "left and right clamping tube" key, clamp the tube tightly left and right , adjust the
distance from the edge of the tube to the first disc through the adjustable cylinder in Figure 7, and lock the
nut after adjustment.
 Tighten the tightening bolts of Figure 7 as well.

6, left and right clamp cylinder adjustment, the welding torch down, adjust the angle of the welding
torch, the welding torch up and down to adjust the adjustable cylinder nut, left and right to adjust the
large bolt of the clamp gun fixture, the welding wire probe out of the conductive nozzle distance: 15-
18MM, the angle of the welding gun and the disc is about 45 °.

7, pay attention to the carbon

brush and copper plate should
be pressed to the pipe and
disc, the contact is tight. If the
contact with the ground wire is
not good, it will burst the wire
and the welding quality will be
poor.

8. Adjust the angle of the welding torch, open the gas detection switch on the front panel of the
welding machine one by one, let the gas be released from the welding torch for a while, and
discharge the air in the gas tank. If it is not discharged, the gas in the gas tank contains too much air,
and the weld bead has pores during welding. Leave it for a while before hitting the switch to the
welded state.

9. Adjust the parameters and close the welding machine switch, as shown in Figure 8: welding torch
switch control knob

10. Press
the
 emergency stop switch to return each
station to its original state: The action steps
are as follows:

A, first hang the disc, the sleeve is placed, press the start button,
the disc is clamped, the pipe cylinder action pushes the pipe
into the disc, the pipe is in place After the probe detects the
signal, the cylinder stops, and then the cylinder is
automatically returned with delay, while manually rotating
the cylinder, finding the hole, pressing the pin key, inserting
the pin into the hole. (If you do not press the latch key,
pressing the start key again does not work, the device does
not move, you must press the latch key to do it). After the
cylinder is rewinded into place, the feeding automatically
begins - pushing the tube.

B, press the start button again, the tooling platform is pushed

forward, pushed to the welding position, after the probe
detects the signal, the cylinder action at the left and right ends, the clamping pipe - the welding
torch falls - start spot welding--- spot welding is completed - automatically pulling the pin —
Tooling platform exits. At the same time, weld welding began inside.

C. After the tooling platform exits, it starts to put the disc, sleeve, press the start button, and begin to
automatically clamp the disc - through the tube - latch, waiting for the welding inside to be
completed. Welding completed - automatic unloading, welded workpiece along the unloading
rack fell into the manual testing platform, unqualified welding, qualified products into the
material frame.

D. After the welding is completed, press the start button again, repeat the action of the B-C step, and
cycle the welding.

Third, the internal function of the control box is introduced: as shown in

the figure on the right

1):DC24V switching power supply: power supply to touch screen, PLC controller and relay.
Normally, the green light is on.

2): 24V relay: control welding machine, clamping valve, positioning valve, etc. The 13 pins of the
relay coil are controlled by the PLC output. Press the buttons in the manual screen to
correspond to their corresponding relay actions.
3), driver: under normal circumstances, the green light on the driver is on, if the red light is on, it
means that the driver is faulty, if the resistance of the connection: 1W/2KΩ is bad, the driver
does not alarm, and the motor does not turn.

4), PLC controller: enter the written program, it controls the equipment to run in order, under
normal circumstances, power and RUN lights. X0—X7: Input signal: X0: Start signal --- foot
switch socket, X1: emergency stop signal--- emergency stop on and off.

Y0—Y5,Y0-Y7 output signal: control relay, Y0/Y1--- driver PUL-/DIR- other outputs connected
to the corresponding relay.

Fourth, the touch screen screen introduction

(1) Figure 10: Auto Screen Introduction: Auto Screen: Mainly shows the
process of action.

1. "Start" button: You can press this button at startup.

2. "Emergency Stop" button: You can also press this button when the emergency stop is stopped.

3. "Enter Parameter Screen" button: Press this key to enter the parameter setting page.

4 "Daily Output Zero" button: Press the daily output to zero.

5 "ESC" button: Click to exit this screen.

6. "Enter Manual Screen" button, press this key once to enter the manual screen.

7, X2/ X6 / X4 / X7: these four indicators, the corresponding four limit probes, the probe
detected the signal, the corresponding light turned green.

8, rotation angle: the number of

degrees of rotation when
displaying welding, parameter
setting page: how many degrees
of rotation angle parameters are
set here.

9, lift the alarm key: after the

number of clearances arrives,
the alarm alarm, if you do not
press this key, the device does
not start, you must press this
key to start the device.
 Figure 11: Manual screen function introduction: Page for single station
operation

1. "Forward", "Reverse", "Through the pipe into the cylinder" "Through the pipe exit
cylinder" button: press it with your hand, the motor will turn, and stop when it is released.

2. Round "Do not select welding function" button: press it by hand, turn green to display
"Select welding function", press it again, reset, and cycle the display.

3. Other buttons: press it with your hand, the corresponding function will act, and then press the
reset.

4.“ Angle Zero button: Press it by hand, and the number of degrees displayed by the motor
rotation will be zeroed. (Note: This rotation angle is not the "0" displayed, but the degree
display should be pressed once,
otherwise the boot device cannot
rotate one turn.) ）

5. "Auto Screen" and "Parameter

Setting" buttons: Press this key to enter
the corresponding screen.

Figure 12: Introduction to the

function of the parameter
screen:

1) Delayed rotation: Wait until the time set is up, the rotating motor will act.

2）. Delayed welding: Delayed start welding, set the time is a little shorter than the time of delay
rotation.

3) Welding angle: the number of degrees required for welding a week, in order to make the weld
at the joint beautiful, the
welding angle should be
set a little more: for
example, 365 ° is set
according to the
requirements of the weld.

4) Welding speed: the speed

at which the motor runs
during the welding
process.

5）. Air shift, reverse speed:

the speed at which the
motor is reversed when
 not welded.

6）. Reverse angle: In order to return to the starting point after welding from the starting point,
the extra degrees set by the welding angle must be returned to return to the starting point.
(90+365 -95-=360°) The inversion angle is set to a negative value.

7), set the alarm time: (unit: seconds) After the number of clearances arrives, the alarm time of the
alarm is set to a little longer.

8), set the number of clearances: according to the actual situation of welding, set the appropriate
number of times.

9) , "Advanced screen" key: press this key, enter the advanced screen, will pop up the
conversation box, you need to enter the password: there is no special situation, do not need to
enter this screen.

Pulse and angle parameters have been set at the factory and cannot be changed, unless the
position of the dip switch on the driver has changed, not the original toggled position, these
two parameters need to be modified.

Fifth, fault phenomena and solutions

A, there are stomata: is the gas protection is not good,

1) Check whether the cylinder is out of gas. Check the air flow, whether the gas flow is small,
adjust the atmospheric flow.

2), press the manual gas detection switch on the front plate of the welding machine, whether the
solenoid valve is open, it is not opened, it may be that the welding machine control board
is broken or the solenoid valve line is broken, and the solenoid valve is broken.

3) Check where the trachea is leaking.

4), the welding torch distance is too far, the gas protection is not good, adjust the welding torch
distance.

B, the weld bead is narrow and high, the molding is not good: the welding voltage may be low,
the welding voltage may be raised, or the gun is far away, the adjustment is closer, or the
welding machine control board is broken.

C, weld leakage: may be too high welding voltage or weld bead deviation, reduce the welding
machine voltage and adjust the welding torch position.

D, the weld bead molding is not good: adjust the current, voltage, and the position of the
welding torch are not good, may be the ground wire contact is not good, or the welding
machine control board is broken. Conductive nozzles are heavily worn and replaced.
E, welding machine out of the wire, out of the air, not welding:
 1) Check whether the ground wire is disconnected.
2), the welder control board is broken.
F, the touch screen is not displayed, the black screen: 1) the touch screen is bad, replace; 2)
Touch screen DC24V power supply line is broken or the contact is bad, reconnect it. 3) The
24V switching power supply in the control box is broken, replace.
G, the touch screen has a display, the alarm appears, the screen can not be operated, as
shown in Figure 18:

1) The data cable behind the screen is in poor

contact, re-plug or replace the data cable

2), replace the data cable is not good to

change the touch screen.

H, the pipe cylinder is not materialized after returning: check whether the back-in-place signal
probe X4 is on, if the light is on, see if the corresponding light in the automatic screen turns
green, does not turn green, may probe ring.

Probe light is not lit: 1, may be the probe distance is far (> 4mm,) did not detect the object, adjust
the probe position can be. 2. Poor contact with the appropriate probe line or bad probe, replace.

The cylinders at both ends of the tooling platform pushed to the welding position do
not move, do not clamp the tube: see if the probe X2 in Figure 6 probes the platform
and whether the light is on. The inspection method is the same as above.

J. If during the welding process, the alarm on the welding machine has been alarming, then there is a
problem with the welding machine:

1, there is no welding wire, or plugged wire. 2, the ground line is not in contact with good.

3, the problem of the welding machine itself, replace the welding machine.

K, press the start switch, the device does not move:

1. The contact contact of the starting switch is poor, and the switch is replaced. 2. The switch wire
is in poor contact or the wire is broken, and it is replaced.

3. The emergency stop switch is locked by pressing. Rotate clockwise to unlock. 4, the number of
clearances arrived, the alarm was not cleared.

Press "Dismiss Alarm Key".

Sixth, the maintenance of the equipment:
A: Clamp gun fixture, welding slag, clean up in time for each shift.

B: The entire equipment should be regularly dedusted and inspected once a month.

C: The bench is cleaned more than 2 times per shift.

D: The rails and drive shafts are oiled periodically, at least once every 2 days.

E: Left and right clamp cylinder fixing bolts and fixing die screws are checked and tightened
regularly. Once a week.

F: The wire feed mechanism at the top checks the dust removal regularly, once a week.

G: The welding gun nozzle is often applied with anti-plugging paste, so that the welding torch is
not easy to get welding slag.

H: When the wire is found to be not smooth and the welding is burst, check the conductive nozzle
in time, and replace the wire feeding hose and serious wear in time. The wire feed wheel is
slippery, the wire feed is unstable, and the wire feed wheel is replaced.