GWA Series Variable Frequency Inverter Fixed Type Spot Welding Machine

User Manual

Jiangsu Junye Welding Technology Co., Ltd.

JIANGSU JUNYE WELDING TECHNOLOGY CO.,LTD

Thank you for using the welding equipment from Junye Equipment.

Please carefully read the correct usage methods and precautions of this manual before installing and using the welding machine. If you have any questions, you can directly inquire with our company, and we are happy to answer the questions of our users.

The GWA series frequency conversion fixed-point projection welding machine is a set of advanced welding equipment. The important components of this series of welding machines include inverters, welding controllers, and frequency transformers. It adopts a modular design, selects imported high-power components, and is equipped with our advanced microcomputer multifunctional JY-MF controller. This controller uses a 16-bit high-speed DSP microcomputer as the core, with 2 sets of analog/digital conversion circuits. It can automatically control the power voltage fluctuations and environmental temperature changes to maintain stable output, ensuring the highest quality of our products. This series of welding machines has three memory functions, simple setting and operation, excellent performance, low failure rate, and is durable, making it the first choice to ensure high-quality welding products.

The content of this book strives for accuracy and conciseness. If there are any errors or omissions, our company will revise them as soon as possible to achieve perfection.

Please note

Highly dangerous, handle with care

Be careful not to injure your hand with the electrode

Table of Contents

Table of Contents

1PrecautionsVI

2Features and Applications1

2.1Fixed-point convex welding inverter with frequency conversion: block diagram2

2.2Outline dimension diagram (as per actual)3

3Technical Data4

4Structure Overview5

4.1Body5

4.2Frequency Converter Inverter5

4.3Frequency Converter Welding Transformer5

4.4Electrode Pressure Device5

4.5Airway System5

4.6Upper and Lower Electrode Section5

4.7Cooling Water System5

4.8Inverter Control Box6

5Variable Frequency Drive Controller Description7

5.1Technical Parameters7

5.2Controller Front Panel Description7

5.3Controller Installation Instructions8

5.3.1Enclosure Installation8

5.3.2Installation of power lines and welding transformers8

5.3.3Grounding (must be reliably grounded when installing the controller)8

5.3.4Installation of cooling water pipes8

5.3.5Connection of control lines8

6Safe Operation Specifications9

6.1Before using the controller, please read the following precautions carefully. To ensure the normal operation of the equipment and the personal safety of the operator, please operate according to the requirements.9

6.2In the event of a circuit breaker tripping, the following items must be checked:10

7HMI Interface11

7.1Main Interface Description11

7.1.1Home Page11

7.1.2Login Page11

7.1.3Welding Sequence Page13

7.1.4Welding Settings Page14

7.1.5Monitoring Page15

7.2System Login Instructions23

7.2.1User Access Permissions Overview23

7.2.2User Logout23

7.3Precautions23

8Instructions for Use24

8.1Welder Type and Starting Method24

8.1.1Ordinary Spot Welding24

8.1.2Seam Welding27

8.2Method of Specification Selection28

8.3Current Monitoring30

9Parameter Description32

9.1Welding Machine Installation32

9.2Welding Machine Commissioning and Operation32

10Maintenance and Care of the Welding Machine34

11Failure diagnosis35

12Elimination of welding defects36

13Maintenance and after-sales service of products37

14Appendix38

14.1Appendix 1: Adjustment Method of Pre-tension Time38

14.2Appendix 3: Terminal Block Description39

14.3Appendix 4: Air Circuit Diagram40

14.4Appendix 5: Water Circuit Diagram41

14.5Appendix 6: Vulnerable Parts42

Precautions

■To ensure personal safety and normal use, please readtheseprecautions carefully

1. Ensure the ground wire connection is properly established before operation，otherwise it is easy to get an electric shock!

2. Be aware of the high-voltage section

3. Inverters, variable frequency welding transformers, and primary windings all have high voltages. Therefore, when contacting these electrical circuits, the power must be turned off to prevent electric shock accidents;

4.Before connecting the welding machine power supply, make sure that the start switch (foot switch or button) is not in the operating (on) state;

4.Turn off or disconnect the welding machine power switch before performing any maintenance checks or repairs, and have a qualified technician operate it (especially the inverter, variable frequency welding transformer, and other components that come into contact with high-voltage electricity);

5. Do not use the welding machine in places with corrosive gases or excessive dust, and avoid the control box coming into contact with water or oil;

6. Do not place heavy objects on the control box;

7. Keep the environment as clean as possible, avoid iron filings and excessive dampness from entering, and regularly check for loose areas, such as

Terminal blocks, screws, etc.

Features and Applications

GWAseriesvariable-frequencyinverter fixed-point projection welding machine is a set of advanced welding equipment. It is widely used, with a small transformer volume and high output energy. Its superior performance is due to the frequency of the transformer being increased from50/60Hzto1000Hz, which greatly reduces the weight of the core material. In addition, the rectifying diodes in the transformer's secondary circuit convert electrical energy into DC power for welding use. This greatly improves the secondary circuit inductance value,which is an important factor causing energy loss,and is almost negligible in DC welding circuits, thus reducing production costs to the lowest possible level.

Compared with ordinary AC resistance welding machines, it has the following advantages:

Energy saving: Compared with using power frequency, it can reduce the consumption of electrical energy. With the same weight of transformer, more energy can be output, which can be conveniently used with large automatic welding machines. It is more suitable for welding thick workpieces and highly conductive metals, such as aluminum and all galvanized steel plates. Generally speaking, the systems with small size and light weight can accelerate movement, shorten the working cycle, and are the best matching solutions for welding robots/automatic machinery.

In semi-automatic equipment, one variable-frequency welding transformer can replace many power frequency transformers, reducing the parallel situation in the secondary circuit.

Improve power factor, reduce production costs.

In a secondary circuit with a large opening area, interference can be reduced: welding current is DC, and it will not affect welding when there is inductive/magnetic material in the secondary winding.

Balance the load of the power supply equipment:Variablefrequency inverter fixed-point projection welding machine uses three-phase power and can store energy.

Stronger adaptability to fluctuations and voltage drops in the power grid:Part of the energy is stored in the inverter and supplied to the load, replacing the direct power supply from the power grid to the load.

More precise and rapid current control: Compared to the power frequency system, it can analyze more and more accurate parameters.

More rapid achievement of set current:Variablefrequency can adjust welding current 20 times faster than traditional technology.

More reliable process: Most applications of metal with resistance welding have better results with DC welding.

Variable frequency systems are usually more reliable than traditional technology and can avoid some hazards that may cause damage to silicon-controlled rectifier systems.

Reduce operation costs, including saving each welding energy point and shortening the welding cycle.

The heat regulation of traditional welding equipment is carried out by phase shifting of the main power supply equipment. It is controlled by the variable part in each 50/60Hz main sine curve cycle. Two water-cooled or air-cooled SCR (Silicon Controlled Rectifier) are used as switching components in parallel, to control the output heat of the welding equipment. Resistance welding machines operating at 50/60Hz are usually single-phase and high-power, which may cause some impact on the power supply network, such as unbalanced phases, excessive voltage drop, low power factor, and interference with the operation of other electrical equipment.

An inverter is a device that generates and controls variable frequency energy, replacing SCR for energy conversion and preventing three-phase imbalance. Energy control is achieved by adjusting the pulse width of 1000Hz pulses, and it is equipped with a capacitor bank to store energy and filter out ripple. The primary winding of the welding transformer is supplied with a 1000Hz square wave. The inverter must be water-cooled or air-cooled.

Block diagram of a fixed-frequency inverter spot projection welding machine:

Outline of dimensions and sizes (actual dimensions apply)

Technical Data

Overview of Structure

GWA series variable frequency inverter fixed-point projection welding machine mainly consists of body, variable frequency inverter, variable frequency welding transformer, pressure transmission device, air and water systems, upper and lower electrodes, control box and start switch, etc.

Body

The body reinforced structure is reasonable, making the body both light and rigid. The upper cantilever of the body is equipped with a pressure transmission device and upper electrode part, and an electromagnetic valve is installed on the upper extension arm. The lower extension arm is equipped with lower electrodes, which can be adjusted in height. There is an in-out water distributor at the lower left side of the body. A variable frequency welding transformer is installed inside the body. The bottom support of the body has ground mounting holes for fixing the body during installation.

Variable frequency inverter

Variable frequencyinverter is the main power drive component of this machine. It converts three-phase50/60Hz380VAC power input into a high-voltage DC power supply, which is connected to capacitors for filtering. After that, thevariable frequencyinverter outputs an appropriate amount of1KHz PWMsquare wave based on the control input settings and feedback current. This is then output through avariable frequencywelding transformer to output low-voltageDC highcurrent for welding.

Variable frequencywelding transformer

There are various specifications ofvariable frequencywelding transformers available for selection. Current measurement is carried out using sensors in the secondary circuit. The primary of the transformer is equipped with a temperature-sensing switch, and a rectifier group is installed on the secondary. All coils and rectifier elements are water-cooled. The operating frequency is 1000Hz, greatly reducing the weight of the core material.

Electrode pressure unit

The electrode pressure device is mainly composed of cylinders, cylinder bases, electrode drive shafts, and electrode connections, etc. The electrode drive shafts are made of heat-treated die steel and are rolled by ball bearings for friction, which is wear-resistant and has good followability.

Airway System

The movement of the welding machine electrode and the pressure applied to the welding piece are achieved by the airway system. The GWA series variable frequency inverter fixed-point projection welding machine selects high-quality imported pneumatic components, including pressure gauges, water filters, solenoid valves, and flow control valves, etc. The installation of flow control valves in the airway allows for adjustable downward pressure speed of the electrode, reducing the vibration caused during downward pressure.

Upper and Lower Electrode Section

The electrode part consists of electrode connection seat, electrode base, electrode arm, electrode rod, and electrode head, etc. The electrode rod and electrode base can be connected to cooling water, and their rear ends are connected to the secondary winding of the welding transformer with soft copper strips and conductive copper plates.

Cooling Water System

The cooling water passage includes the secondary winding of the frequency conversion welding transformer, inverter, upper and lower electrode bases, upper and lower electrode handles, and upper and lower electrode heads. After passing through the Y-type water filter, the cooling water is cooled through a分流器分流器 to the secondary circuit.

Inverter Control Box

The welding controller uses a microcomputer program for control, with a touch screen for adjustment, and is equipped with a silicon-controlled rectifier (SCR) drive board, a multi-functional protection and phase loss detection board, and a function control board, among other components. The direct-read operating system is easy to operate, can store welding parameters, and in addition to the basic common setting parameters, it also has weld point counting and weld point setting. Weld point counting is the counting that occurs after each welding operation of the spot welder, which adds1to the count, allowing for calculation of the number of weld points for easy management; weld point setting allows the user to pre-set the required number of welding points. When the spot welder reaches thesetpoint, the spot welder automatically stops working. This feature is convenient for users to schedule inspections or maintenance of the electrodes to ensure welding quality.

The automatic diagnostic function measures input current, voltage, frequency, cooling water flow, and other data before each welding operation, and during welding, it measures the conduction state of the SCR and IGBT to ensure that the spot welder operates normally.

The control box is equipped with an inverter module, which replaces the SCR for energy conversion and does not cause three-phase imbalance.

Variable Frequency Controller Description

TechnicalParameters

Table 51 Counting Parameters

Controller Front Panel Instructions

Panel52Front Panel Description

Installation Instructions for Controller

Cabinet Installation

Install the controller in an environment with a temperature of 5-45°C, away from direct sunlight;

Lightning protection should be provided for the controller input power in accordance with relevant regulations and laws;

Avoid water, oil stains, and metal dust from entering the interior of the box; Note: The controller box is equipped with mounting holes for on-site installation and fixation. It is not recommended to drill holes in the box yourself.

If drilling is necessary, ensure that the metal shavings are completely cleaned up, otherwise the leftover metal shavings may damage the internal components.

Installation of power lines and welding transformers

Power Cable: Connect the power cable to the input terminal of the controllerA,B,C;

Welding Transformer: Connect the transformer to the output terminal of the controllerR,S;

Grounding (It is necessary to ground reliably when installing the controller)

Grounding Wire: Connect the grounding wire to the grounding busbar inside the controller;

Wiring connection: The specification should be>=25 square millimeters and must be greater than half the specification of the power cable;

Install cooling water pipes

Cooling water hose: If cooling water is to be provided, use a hose with an aperture of 9.5mm (3/8 inch);

Cooling water requirements: Inlet temperature: 10-35℃, maximum pressure: 0.3Mpa;

Cooling Water Instructions: Use clean water or industrial water for cooling; do not use water with electrolytic properties (such as highly acidic or alkaline water). The circulating cooling water must be completely changed every 6 months, or 5-10% of the water must be changed frequently. If the ambient temperature is low and freezing may occur, be sure to drain the water in the controller when the controller is not working.

Control Line Connection

Control Line Instructions: Signal line diameter ≥0.2mm; power line diameter ≥0.5mm; it is recommended to use shielded cables;

Connection Instructions: When connecting signal lines, be sure to keep them away from power cables to avoid interference with the control signal transmission.

Safe Operation Regulations

Before using the controller, please read the following precautions carefully,Operate according to the requirements to ensure the normal operation of the equipment and the personal safety of the operators.

Before powering on, check the cables and grounding wires for tightness and damage; the cabinet shell must be securely grounded;

The water-cooled controller must be connected to the cooling water before use, and it must be ensured that there is sufficient flow and pressure of the cooling water; the working condition of the water cooling system must be checked regularly (at least once a month) to ensure that the water flow is unobstructed and there is no leakage.

When powering on, the display panel must be switched to the monitoring page, monitor the capacitor voltage, and wait until the capacitor voltage reaches about 550V (indicating normal operation of the controller) before leaving the power-on switch. If an abnormal capacitor voltage is detected on the monitoring page, the power should be turned off immediately;

It is strictly prohibited to open the controller box when in use, and it is prohibited to touch any part inside with your hands to avoid electric shock (there is approximately 550V high voltage);

After powering on, if the fault light indicates a fault, the fault code must be checked through the display panel, confirm the fault and eliminate it before use. If the fault cannot be resolved, please contact the equipment manufacturer;

Before use, it is necessary to confirm that the relevant parameters of the equipment are normal (such as whether the current welding method is the required method, whether the selected specification is the required specification, etc.), to avoid incorrect operation due to incorrect parameters;

Welding work should be carried out according to the welding technology requirements, and the welding sequence, welding current, and other relevant parameters must be set in accordance with the welding process requirements.

After the power is disconnected, the internal high voltage needs several minutes to be fully discharged. Do not touch any internal parts immediately. Wait until all the indicator lights on the circuit board are off, and the capacitor voltage is confirmed to be safe with a voltmeter before performing maintenance or other operations.

When checking the internal wiring of the box, it is imperative to turn off the power and ensure safety before proceeding. Non-professionals are strictly prohibited from opening the cover.

It is strictly prohibited to touch the components on the control panel with bare hands, as this may cause static damage to the components; it is strictly prohibited to touch the IGBT directly, as this may cause static damage to the components.

In the event of a fuse tripping, the following items must be checked:

Check for any leakage in the transformer;

Check for any short circuits in the connecting cables;

Check for any damage or tears in the cables;

Check for faults inside the inverter controller (contact the equipment manufacturer).

HMI Interface

Main Interface Description

Main Page

Click to enter the production counting interface。

Figure71Main page

Loginpage

Figure 72Loginpage

UserName: Displays the current logged-in user.

Operator,Technician,Administratorlogin passwords are initially set to 111, 222, and 333 respectively.

After entering the password, you must click "Login" to log in.

Set the logout time, if the login time exceeds the logout time, it will automatically log out.

Welding Sequence Page

< span id=0> figure 73 welding timing

Set welding timing-related parameters.

Welding Settings Page

Set welding control parameters.

Figure74Welding SettingsPage

Pulse Start: When in continuous state, if pulse start is enabled, it will work continuously after receiving the first start signal until the second start signal is received; if disabled, the machine will start working when the start signal is closed and stop working when released.

Welding Machine Type: Spot Welding, Seam Weld Selection.

Continuous Welding: Selection between continuous welding and spot welding.

Transformer Turns Ratio: Transformer primary-secondary turns ratio.

Monitor page

< Span ID=0> Figure75 Monitoring Interface

Welding current and count monitoring data.

Semi-automatic:Press and hold0.5seconds to switch between semi-automatic and automatic modes.

Workpiece number setting: Set the required workpiece number.

Welding count: Displays the number of welds completed, with the count increasing by 1 for each welding, and the welding count can be reset.

Grinding Count Setting: Set the grinding count.

Grinding Count Display: Display the number of grindings and can be reset accordingly.

Semi-Automatic:Press and hold0.5seconds to switch between semi-automatic and automatic modes..

Current Position: Display the current position of the motor.

Manual Speed: The speed during manual operation.

Automatic Speed: The speed during automatic operation.

Ascend: You can ascend when the indicator light turns green.

Descend: You can descend when the indicator light turns green.

Current Pressure: Display the current pressure value.

Torque Speed: Set the torque speed.

Current Temperature:Display the current temperature value..

Origin Calibration: Press and hold for 3 seconds to complete origin calibration.

Current Position: Display the current position.

Current Pressure: Display the current pressure.

Calibration Pressure: Set the pressure value that meets the requirements.

GraphiteCollision Position-Workpiece Thickness-Torque Start Interval=Torque Start Position

Initial Position: Select an appropriate location for position teaching.

Workpiece Allowable Error: The allowable error value of the workpiece,Press for 1 secondto teach.

Pre-pressure Time:Time required to apply a certain pressure to the workpiece by the electrode before welding.

Current Temperature: Displays the current temperature.

Welding Time：The time required to complete one discharge.

Delay Spraying：Thetime ofdelay spraying.

Pressure Holding Time：The time for pressure maintenance.

Spraying Time：Set thesprayingtime.

GraphiteCollision position - workpiece thickness - start interval of torque = start position of torque

Initial position: Select an appropriate position。

Welding pressure: Welding pressure value.

Workpiece allowable error: Workpiece allowable error value，Press for 1 secondto perform position teaching。

Workpiece Temperature: Display the workpiece temperature value.

Pre-pressure Time:Apply a certain pressure to the welding part before weldingforthe requiredtime.

Hold Time:Time to maintain the pressure..

Delayed Water Spraying: The time for delayed water spraying.

Maximum temperature limit: The highest allowable temperature value.

Minimum temperature limit: The lowest allowable temperature value.

Insulation time: The set insulation time.

Spraying time: The set spraying time.

Protection Time: Set the protection time.

GraphiteCollision Position-Workpiece Thickness-Torque Start Interval=Torque Start Position

Initial Position: Select a suitable position.

Welding Pressure: Welding pressure value.

Workpiece Allowable Error: Workpiece allowable error value,Press for 1 secondPosition Teaching.

Record relevant data.

Specifications 1 to Specification 24.

System Login Instructions

User Permission Introduction

If you need to change permissions, then first go to the "Password Settings" page, enter the corresponding user number at the "User Number" field, and then enter the corresponding user's password at the "User Password" field. The user number can be "Operator," Technician," Administrator," with the initial passwords being "111, 222, 333," respectively. For example, if you enter Operator in the "User Number" field and enter the password for "User Operator," the system will be in the "User Operator" state. If the password is entered incorrectly, the prompt information shown in the following figure will appear.

The system is in the "User Operator" state, and can only view all pages. It cannot modify parameters. In the "User Technician" state, the system can view all pages and modify all parameters. In the "User Administrator" state, the system can view all pages, modify all parameters, and also modify all passwords.

User Logout

Click the "click" "“"Logout User"””" button, and the system will be in a state without a user.

Precautions

Do not change any parameters during the welding process; be sure to keep the password for "User 3" properly.

Instructions for Use

Welding machine type and start-up method

The ZMF series controller can work in two modes: ordinary spot welding and seam welding. In ordinary spot welding, there are single-point welding and continuous welding modes. The welding start can be initiated through the start pin or the standard pin.

Ordinary spot welding

Single-point welding, pulse start

The controller is in single-point welding, pulse start mode (pulse start:1; continuous/single point:0; standard terminal start:0), when a pulse start signal is given, and the signal length exceeds the start signal filtering time, it enters the welding process. After the welding is completed, it automatically stops, as shown in Figure 61.

Figure81Single-point welding, pulse start timing

Single-point welding, non-pulse start

The controller is in single-point welding, non-pulse start mode (pulse start:0; continuous/single point:0; standard terminal start:0), when a start signal is given, and the signal length exceeds the start signal filtering time, it enters the pre-pressure time, at which time the gas valve opens and outputs. If the start signal is maintained until the end of the pre-pressure time, it enters the welding process, and the gas valve closes and stops outputting after the welding is completed; if the start signal is not maintained until the end of the pre-pressure time, it does not enter the welding process, and the gas valve closes and stops outputting, as shown in Figure 62.

Image82Single-point Welding, Non-Pulse Start Sequence

Continuous Welding, Pulse Start

The controller is in continuous welding, pulse start mode (Pulse Start:1；Continuous/Single-point:1；Standard Terminal Start:0), when a pulse start signal is given, and the signal length exceeds the start signal filtering time, the welding process will begin. After one welding is completed, the welding process will enter the rest period at the end of the maintenance time, and the exhaust valve will close the output. Then, it will automatically enter the second welding, third welding, and N welding processes, until the welding end signal is detected. After receiving the welding end pulse signal, continuous welding will end, and the exhaust valve will close the output, as shown in Figure 63. It should be noted that the pre-pressure time is ignored for the second and subsequent welding processes.

Image83Continuous Welding, Pulse Start Sequence

Continuous welding, non-pulse start

The controller is in continuous welding, non-pulse start mode (pulse start:0; continuous/single point:1; standard terminal start: 0) when a start signal is given. If the signal length exceeds the start signal filtering time, it enters the pre-pressure time, at which point the gas valve opens and outputs. If the start signal is maintained until the end of the pre-pressure time, it enters the welding process. If the start signal is not maintained until the end of the pre-pressure time, it does not enter the welding process, and the gas valve closes the output. At this time, if the start signal is maintained, after one welding is completed, it will enter the rest time at the end of the maintenance time, during which the gas valve will close the output, and then automatically enter the second welding, third welding, N welding process. When the start signal disappears, continuous welding ends, and the gas valve closes the output, as shown in Figure 64 as shown. It should be noted that the pre-pressure time is ignored for the second and subsequent welding processes.

Figure84 timing diagram of continuous welding, non-pulse start

Single-point welding, standard terminal start

The controller is in single-point welding mode, with the specification terminal start mode (Continuous/Single Point: 1; Terminal Select Specification: 1; Specification Terminal Start: 1;Double Specification DoubleValve: 0) when the specification terminal detects a valid specification number, the signal length exceeds the filtering time, and then enters the welding process. The welding stops automatically after completion, as shown in Figure 65.Attention: In this mode, if the value of the Double Specification DoubleValve is 1, then when specification 1 is started, only valve 1 operates, and when specification 2 is started, valve 2 operates. This function is used for applications where two start signals correspond to two valves.

Figure 85 Single-point welding, specification terminal start

Seam welding

Seam welding pulse start

The controller is in the seam welding mode with pulse start mode (pulse start:1；standard terminal start:0）. When a pulse start signal is given, and the signal length exceeds the start signal filtering time, it enters the seam welding pulse cycle for periodic welding until an end signal is received. After receiving the welding end pulse signal, the seam welding pulse cycle ends, and the gas valve closes the output, as shown inFigure 66.

Figure86Seam Welding Pulse Start Timing

Non-pulse seam welding start

The controller is in the seam welding mode with non-pulse start mode (pulse start:0；standard terminal start:0）. When the start signal length exceeds the start signal filtering time, it enters the pre-pressure time, at which time the gas valve opens the output. If the start signal is maintained until the end of the pre-pressure time, it enters the welding process. If the start signal is not maintained until the end of the pre-pressure time, it does not enter the welding process, and the gas valve closes the output. At this time, if the start signal is maintained continuously, it enters the seam welding pulse cycle for periodic welding until the start signal ends. After the start signal ends, the seam welding pulse cycle ends, and the gas valve closes the output, as shown inFigure 67.

Image87Non-pulse Seam Welding Timing Sequence

Specification Selection Method

The specification selection method includes panel selection specification and terminal selection specification. When selecting the panel specification, the specification number entered in the specification input box on the display screen is the current working specification; when selecting the terminal specification, the value represented by the detected specification terminal is the current working specification. There are two modes for specification terminals, namely 1234 mode and 1248 mode, for detailed information seeTable 6.1 and Table 6.2:

Table 81 Specification Terminal 1248 Mode

Table 82 Specification Terminal 1234 Mode

Note:

● Indicates an effective terminal; ○ Indicates an invalid terminal

This background color indicates that the feature is optional and available on some models

Current Monitoring

The current monitoring function is used to detect the actual current during the welding process and compare the feedback current value with the set reference value and over/under limit values. When the measured current value exceeds the allowable error, the controller will issue an alarm or a warning. If the measured value is below the allowable error range, a counter will be started and compared with it; if it is allowed to re-weld, the controller will re-weld the weld point once. For each welding pulse, the current monitoring function can be set separately. When the measured current value exceeds the current set error, an alarm or warning signal will be generated. For the three welding processes of preheating, welding, and tempering, current reference values, over-limit values, allowable under-limit values, and alarm under-limit values are set separately. As shown in Figure 6.8:

Image8888Illustration of Current Monitoring Threshold

Preheating (welding or tempering) reference values: An actual current reference value can be set, and parameters such as current over-limit and under-limit values are based on this reference value.

Current over-limit value: For current I (current during preheating, welding, or tempering), there is an over-limit range relative to the current reference value. When the actual current exceeds this range, the controller will issue an alarm. At this point, the controller may only issue an alarm without interrupting the welding process, or it may interrupt the welding process. This function can be set through the dip switch S6 on the mainboard.

Current under-limit value: The measured current value has a low limit error relative to the reference current value, which is the alarm under-limit value. When the current measurement value exceeds the allowable alarm range, an alarm will be issued. At this time, it may interrupt the welding or not interrupt the welding and restart the next one.

Current Allowance Deficit Value: An allowable deficit value can be set relative to the current reference value, which is also a percentage. Between the allowable deficit and the alarm deficit, a parameter can be introduced: the consecutive deficit points, which allows for a continuous n points to be located between the allowable deficit and the alarm deficit. If the point count exceeds n, an alarm will sound and the welding process will end.

Consecutive Deficit Points: When the actual current value falls within the range between the current alarm deficit and the current allowable deficit, an additional welding attempt is allowed. If the next attempt still falls within this range and does not exceed the "consecutive deficit points" limit, another welding attempt can be made, until the set value of the consecutive deficit points is reached. If the next point is still deficit, the controller will issue an alarm.

Parameter Description

Welding Machine Installation

The welding machine should be placed on a solid and stable ground surface and be fixed with foot bolts.

将

Insert the plug of the start switch (foot switch or button) into the foot switch socket at the bottom front of the control box on the right side of the welder body;

Connect the inlet and outlet pipes to the cooling water inlet and outlet of the water-cooled分流器 on the lower left side of the body, and tighten the pipe joints to prevent leakage; the inlet and outlet pipes cannot be reversed;

Before connecting the air intake, it is necessary to clean the airway to prevent metal fragments or other impurities from remaining in the airway; connect the outlet of the air compressor to the air intake on the right side of the welder body using the air intake;

The installation is complete at this point.

Welding Machine Adjustment and Operation

Note: Ensure the welding machine is properly wired before connecting the water and gas lines, then connect the power supply.

The welding machine operates according to the program:

- Select the appropriate specifications based on the material and thickness of the workpiece (refer to the controller's operating instructions);

- Place the function selection knob in the "Test" position, press the foot switch to the lower electrode, and the welder operates according to the program, but no welding current passes through;

- The program performs each action several times;

Note: The welding quality of the workpiece is directly related to the welding current, welding time, electrode pressure, and other welding process specifications. Therefore, appropriate adjustments should be made according to the specific situation during welding, and the adjustment of the welding current and electrode pressure should be carried out synchronously.

Normal welding of the welder:

- After the operation is completely normal, place the function selection switch to the "welding" position to start welding;

- You can follow the operation method of trial welding;

Electrode trimming:

-The electrode head must be kept clean. After a certain period of use, if the electrode shows wear or surface damage, it can be smoothed with copper wire brush, high-quality fine file, or sandpaper. The specific method is as follows:

Place the fine grain file saw between the on/off levels, adjust the function selector to the "valve" or "grinding" position, press the foot switch all the way down to hold the electrode, and rotate the file back and forth horizontally. After the contact surface between the two electrodes is flattened, release the foot switch and reset the upper electrode;

- Use fine sandpaper to flatten the electrode contact surface to ensure good contact between the electrode and the workpiece.

- When the electrode is severely worn, it must be trimmed with machine tools or other tools.

Note: The electrode, electrode holder, locating pin (block), fuse, etc. are consumables. The welding machine should have an adequate stock during production and use to meet production needs.

After use:

Attention: When the ambient temperature is below 0℃ in winter, after using the welding machine, the water in the cooling water pipe must be drained and the remaining water inside the cooling water pipe must be blown away with compressed air to prevent the water pipes from freezing.When using an industrial refrigeration water tank, the cooling water temperature should be adjusted appropriately according to the ambient temperature and usage frequency, especially in summer, the water temperature should not be too low to minimize condensation in the cooling circuit due to the low temperature of the cooling water. Condensation in the cooling circuit is prone to damage transformers and controllers, and the cooling water should be turned off in time when the machine is stopped.

Maintenance and Maintenance of Welding Machines

Attention: It is necessary toturn off the main power supplywhen performing maintenance and maintenance to avoid danger!

Fault diagnosis

Fault codes, causes, and solutions are listed below:

Elimination of Welding Defects

Product maintenance and after-sales service

The maintenance of this product should be carried out by professionals. The company will not bear the consequences of any misuse.

After the product is delivered to the user, the user is responsible for the installation. The company can provide comprehensive technical support if needed.

This product is warranted for one year and lifetime technical support is provided.

This manual is for reference only, and the actual product should be taken as the standard.

Appendix

Appendix 1：Method of adjusting pre-compression time

Pre-compression time is the interval from the start of the upper electrode workingto the start ofelectrical welding, which is also the time for the pressure to gradually increase to a stable state. Therefore, the setting of the pre-compression time has a direct impact on the welding effect.

1. For ordinary workpieces, the pre-compression time should be set appropriately. After the upper electrode tightens the workpiece, the pre-compression time ends and

electrical welding begins;

ρAttention: When adjusting the pre-compression time, the following methods can be used to check whether the pre-compression time setting is appropriate:

Set the pre-pressure time;

Place an insulating plate between the upper and lower electrodes, set the single/two-stage switch at the bottom, lower the upper electrode to securely hold the workpiece, and press the foot switch;

Observe the flashing time of the welding indicator light on the panel, if the welding indicator light flashes after a relatively long time after the upper electrode tightens the workpiece;

Then the pre-pressure time setting is too long; if the upper electrode does not tighten the workpiece, and the welding indicator light has already flashed;

The pre-pressure time is too short; the setting should be changed if the pre-pressure time is too long or too short.

2. For thicker workpieces, the pre-pressure time should be extendeduntil the pressureis stable before welding begins.

Appendix 3:Wiring Terminal Description

Appendix 4：Air Circuit Diagram

Appendix 5：Waterway Map

Appendix 6：Wear Parts

1. Electrode

Technical Requirements:Remove burrs,Not specified chamfer is 1X45°;

Graphite surface antioxidant treatment;