Horizontal 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.