Crossbar automatic welding machine

operating instructions
JIN SHI

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
Installation requirements: placed on indoor hard ground,
(such as cement floor).
1、 Compressed air intake pipe access position: The intake
pipe is inserted into the position marked in 3 on the right
figure. On the right figure 1: clamp the main pressure gauge
0.4-0.6Mpa; 2: support pipe cylinder pressure gauge,
pressure adjustment range: 0.2-0.3Mpa

(Method of adjusting the pressure: As shown in Figure 4,

the plastic knob is pulled up, and then the pressure is
increased clockwise, and vice versa.) The scale looks at the
value of the inner ring of the table. ）

2、 Power supply voltage requirements: three-phase

four-wire, voltage range: 220V±10%, frequency of
60Hz±1%. The imbalance of the three-phase
voltage ≤5%.
3、 Power inlet: The input line is: three-phase
four-wire, three fire wire diameter ≥ 16mm2
copper wire, ground wire ≥6 mm2. The wiring
location is shown in Figure 2

(The three fire wires must be connected to the

A/B/C terminals of the input box, the line
sequence is not divided, and the zero wire is
connected to the terminal post marked N on the right.) Cover the hood after
connecting the wires. To prevent electric shock. 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).

The factory plant should be equipped with a four-wire leakage protector

at the power supply of the equipment: (current ≥60A).

4、 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.
5、 Mixed gas ratio: 80% (Ar) + 20% (CO2).
6、 Shielding gas tubing method: The
trachea shown in Figure 3 is:
protective gas interface, these 2
tracheas are connected to the outlet
of the pressure reducing filter on the
cylinder. Air flow is adjusted to: 15-
25ML.

7、 Resize: Position as shown in Figure 4

(on the slide plate).
Loosen the screws showing the location of the diagram,Put the round tube
that needs to be weldedPlaced inOn the bracket,Push the skateboardTo the
right position, the two ends of the round tube are far away from the
casting tooling＜50mm, ensure that the workpiece can be taken out after
welding, the distance is too far to clamp the round pipe and casting.

8、 Mounting the wire tray: As shown in Figure 5 on the right: the wire pad is loaded into the
pan shaft, and the small shaft on the pan shaft is inserted into the small hole in the wire
disc, and the outer baffle is locked. Prevent the ribbon from falling out. Note that the wire
comes out from the lower end, and the wire is sent to the entrance of the welding torch
through the wire feed wheel, and the pressure handle is pressed. Send the wire out of the
torch by pressing the manual wire feed button on the front panel of the welder.

10, electricity, gas are ready, start the power-up operation:

After the power switch on the control panel is turned on, the control box touch screen lights up after a
few seconds to display the power-on screen. Figure 7 shows:

Press the corresponding button at the bottom of the boot screen to enter the corresponding
screen.

Open the front panel door of the cabinet, and the front panel of the welder has a digital display, as
shown in Figure 6:

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, the welding voltage, the size of the current and the 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. Hand soldering/gas brazing: Select

switch: This switch must be pressed down.

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.
 11. After the compressed air is
connected, the boxes and welding
torches at both ends are retracted,
the welding torch is at the upper
end, and the support frame is
supported. The positioning
cylinder protrudes and the
positioning tip into the positioning
disc groove.

Put the casting and the tube into the mold, enter the manual screen, press the "Clamp/Enter the
Gun" button, clamp the cylinder action, clamp the tube and the casting, and the welding gun
falls.

A. Adjust the position of the casting mold at both ends with a

horizontal ruler, so that the mold at both ends is symmetrical
on the same plane, and the mold is tightened.

B. Adjust the height of the support pipe frame, the two rubber
wheels are slightly attached to the pipe, a little lower, and the distance
is uniform. This is shown in Figure 8.

C, adjust the angle of the welding torch: the welding wire

probes out of the conductive nozzle about 15mm, adjusts the
angle of the welding torch by adjusting the clamp gun fixture, and adjusts the buckle to the
appropriate position as shown in Figure 9: The position of the
welding torch is not fixed and unchanged. Its position
should be adjusted appropriately according to the welding
effect. The angle adjustment of the wheel buckle welding
torch is shown in Figure 10:
12. Introduction to the function of the front panel of the control
box: as shown in Figure 11

A, welder A and welder B twist switch: control the opening and

shutdown of the welding machine, when dialed to the ON position, the welding machine is turned
on, and when the OFF position is turned off. Normal operation in the ON position. If you just want
to see if the operation of the equipment is not welded, then you can dial the switch to the OFF
position.

B. Remote control socket: This socket is connected to the foot switch cable. If the foot pedal switch
device does not work, you can unplug the plug, directly short the 2 pins inside the seat, see if it can
work, if normal, it means that the foot switch is broken or the line is broken.

C, emergency stop switch: if you encounter a problem and need the device to stop immediately, you
need to press this switch, the touch screen automatic screen will display "emergency stop" or
"STOP" words. Rotate it clockwise to reset and lift the stop state. If the emergency stop switch is
in the closed state, the foot switch cannot be started, and the emergency stop must be lifted.
Reset the switch.

D, power switch: ac220V input power switch of the control box, the power switch to the ON position,
AC220V electricity to the control box power supply, if this switch is broken, the control box has no
electricity, the equipment can not
work.

13. Introduction to the

internal functions of
the control box:

1):DC24V switching power

supply: power to touch screen, PLC controller and driver. Normally, the green light is on.

2): 24V relay: control the welding machine, clamping valve,

positioning valve, motor enablement. The coil of the relay is
controlled by the PLC output. Press the buttons in the manual
screen to correspond to their corresponding relay actions.

3), drive: as shown in Figure 13, under normal circumstances, the

drive on the label 3 green light is on, if the red light is on,
indicating the drive failure. Figure 1, toggle switch: 1/5/6/8
ON,: look at the driver side marking figure: subdivision: 3200 Current: 2.69A If the
position of the toggle switch is not correct, the actual rotation angle is inconsistent with the
angle displayed on the screen. Figure 2, resistance: 1W/2KΩ, if the resistance is bad, the
driver does not alarm, the motor does not rotate.

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 output signal: control relay,

Y0/Y1--- driver PUL-/DIR-Y2--- enable
relay

Y3 --- positioning relay; Y4 –

Clamping relay; Y5 —Welding relay

14. Figure 14: Auto Screen

Introduction:

Auto Screen: Mainly shows the process of action.

1. "Start Key" button: You can press this button when starting

2. "Emergency Stop Key" button: You can also press this button when the emergency stops.

3. "Parameter Settings" button: Press this key to enter the parameter settings page.
4 "Total Zero" button: Press the total number of processes to clear zero.

5 "Back Key" button: Click to exit this screen.

6. "Manual Screen" button, press this key to

enter the manual screen.

7. Clamping /welding
machine/positioning/enabling: four indicator
lights, the corresponding light of the
clamping cylinder action turns 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.

15, Figure 15, manual screen function introduction:

Pages for single station operations

1. "Forward" and "Reverse" buttons: Press it with your hand, the motor will turn, and stop
when it is released.

2.“ Clamp/Gun" button: Press it with your

hand, clamp the cylinder action, and then press
the reset.

3. "Welder" button: Press it with your hand,

the welder turns on, and then press the welder
to close.

4.“ Station Zero" button: Press it by hand, and

the number of degrees displayed by the motor
rotation will be cleared to zero. (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, "enable" button: press this key, the motor is powered off, the drive red light is on, the hand can
turn the shaft, and then press the reset, the motor is charged, the drive is green on, and the shaft
cannot be rotated by hand.

16, Figure 16, parameter screen function introduction:

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

2) Delayed soldering: Delayed start welding, the set 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 customer
requirements.

4) Welding speed: the speed at

which the motor runs during
the welding process.

5）. Return Speed: The speed at which the motor is reversed when not welded.

6）. Return 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.
(365 -5=360°) Sets the angle negative.

7) , "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. The high-level screen is shown in Figure 17

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.

17. Operation steps:

Everything is ready to go and get to work:

A: Put the casting on the mold at both ends, put the tube in the middle, step on the foot switch, the
workpiece clamping, the welding gun in place, if the clamp is not in place or not correct, you can
use the hammer to hit it, so that the workpiece is in place, (if not in place, it may lead to weld bead
offset, welding is not good. The position of the welding torch is unreasonable, and the position of
the welding torch can be adjusted. ）

B: After the workpiece is clamped, and then step on the foot switch, the equipment will begin to
automatically rotate and weld. At this time, the station angle on the auto screen begins to change
in degrees. After the degree changes to a set angle, the welding is automatically stopped, the gun
is withdrawn, the workpiece is released, returned to the initial state, and the workpiece is removed
to prepare for the next weld. In the event of an abnormal situation during the welding process, the
emergency stop switch can be pressed. (In any case, you can press the emergency stop switch, and
after pressing it, it will return to the initial state, but the welding angle is not cleared, and the
manual screen can be cleared by pressing the station clearance key to restart the welding.)
）

18. Fault phenomenon and solution

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)
The touch screen 24V power supply line is broken or the contact is poor, 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.

19. Maintenance of equipment:

A: Clamp gun fixture, welding slag, clean more than 2 times per shift.

B: The entire equipment should be

regularly inspected for dust removal, once
a month.

C: The workbench is cleaned more than 2

times per shift.

D: The rails and drive shafts are oiled

periodically, at least once every 2 days.

E: Fixing parts and fixed mold screws are

regularly checked and tightened. Once a
week.

F: The wire feeding mechanism checks the dust removal regularly, once a week.

G: When the wire is found to be not smooth, the conductive nozzle should be replaced in time.
The wire feed wheel is slippery, the wire feed is unstable, and the wire feed wheel is replaced.