I 焊接设备生产制造商

Wuxi Foken Cutting & Welding Equipment Co., Ltd.

Tel: 13812090222

13812096242

Fax: 0510-83291211

E-mail: manager@volcanocn.com

Address: No.25 Tianshun Road, Yangshan Town, Huishan District, Wuxi City, Jiangsu Province, China

Suggestions on Installation and Commissioning of Welding Machine

First, check whether the screws and all contact parts are loose after long-distance transportation.

1. Installation Location of the Main Unit

The welding machine shall be installed outdoors in an environment free from rain, serious dust, flammable and explosive gases. It shall be more than 30CM above the ground, placed stably and fixed firmly.

2. Safety Grounding

There is a grounding mark at the lower front of the main unit. A copper cable with a cross-sectional area of more than 10mm² must be used for reliable connection to the ground. Generally, the grounding resistance is required to be less than 4Ω to ensure safety.

3. Primary Cable

The primary cable of the welding machine shall be connected to the user’s 150A air switch, with a cross-sectional area of no less than 16mm².

4. Control Box

Fix the control box under the gantry welding machine operation box with reliable bolt fastening.

5. Welding Cables

Two copper cables with a cross-sectional area of 95mm² shall be used. Copper lugs at both ends must be crimped with a hydraulic clamp or tinned to ensure good contact. Poor contact may cause overheating under high current, leading to premature cable aging and affecting welding.

6. Insulation

The gantry, wire feeding mechanism and welding wire shall be insulated, with an insulation resistance greater than 1MΩ.

7. 14-Core Connection

The 14-core cable is the control cable between the main unit and the control box. The aviation plug must be tinned and fitted with an insulating sleeve. After soldering, a continuity test shall be carried out instrument by instrument to ensure correctness.

8. Motor Wiring

In the 4-core aviation plug of the control box, terminals 1 and 2 are connected to the armature of the wire feeding motor; terminals 3 and 4 are connected to the excitation of the wire feeding motor.

9. Ground Cable (Negative Pole of Main Unit)

Two copper cables with a cross-sectional area of 95mm² shall be used. Installation shall be the same as Item 5, with reliable connection to the material rack.

Commissioning

Confirm all connections are correct.

Check whether the user’s three-phase 380V power supply is within the ±10% tolerance range.

Check the settings of the main unit switch, which shall be set to “Remote Control” and “Stop” positions.

Check the settings of the control box switch, which shall be set to “Commissioning” and “Stop” positions.

Check the fuses at the bottom of the control box. The fuses for power supply, wire feeding and traveling are 1A, 5A and 5A respectively.

Install a suitable wire spool.

Check the insulation between the wire feeder and the gantry, which shall be greater than 1MΩ.

Turn all knobs on the control box counterclockwise to the minimum.

Switch on the power supply; the main unit fan should start running.

After no-load operation for 5 minutes, set the welding wire selector switch to “Wire Feed In”, slowly rotate the “Welding Wire Voltage” knob, and observe the rotation of the wire feeding wheel. (If the direction is incorrect, reverse the positive and negative poles of the wire feeding motor armature after power off to change the direction.) Meanwhile, feed the welding wire into the welding gun slowly.

Install a suitable contact tip.

Select proper welding parameters:

A. Welding current

B. Welding voltage

C. Travel speed

D. Appropriate welding consumables

E. Base metal preparation, etc.

Set welding current and voltage according to the parameters, and set travel speed on the gantry.

Move the gantry to the arc starting pad and spread welding flux.

Set the control box to welding mode: adjust the switches to “Welding” and “Wire Feed In” positions.

Start the gantry and welding machine simultaneously. The gantry shall travel at the set speed. The welding wire is fed slowly before contacting the workpiece (this speed is adjusted by PCB2 and PW3, usually preset before delivery and requires no adjustment). During this period, the voltmeter indicates DC 58V (no-load voltage). Arc ignition occurs when the welding wire contacts the workpiece. Carefully adjust “Welding Voltage” and “Welding Current” until the required parameters are achieved.

To stop welding, press the stop button.

Cut off the main power supply and the main valve to ensure safety.