To operate the welder, begin by turning the handle counterclockwise to separate the two jaws. The moving clamp is positioned on the outer edge of the eccentric on the joystick. The clamp will only activate when the plane of the eccentric comes into contact with the ejector. Ensure proper positioning before proceeding.
Next, step on the pedals to open the jaws, then place the workpiece between them. Release the pedals to allow the jaws to clamp the workpiece securely. When clamping a welded piece, leave an appropriate gap between the workpieces based on the size of the weld joint. After clamping, pull the handle clockwise to release it, ensuring that the ends of the workpiece make full contact and are pressed together by the spring force.
Observe the relative position of the ejector pin and the switch piece of the welding limit switch (also known as the upset switch) located at the top of the fixed fixture. The distance between these components should be set correctly so that the workpiece can trigger the switch during the welding process. Once the weld joint is formed, the copper piece of the limit switch will open, and the weld flash should meet the required specifications.
Press the welding button to energize the welding transformer, heating the end of the workpiece. The upsetting process will occur under the top forging force, and the limit switch will control the timing of the operation. After the welding is complete, step on the pedal again to loosen the jaws and remove the workpiece.
Depending on the specific requirements of the weldment, decide whether tempering is necessary. The tempering specification (including energization time and current) should be lower than the welding specification for the same section.
When starting the welding process, always begin with a lower specification and gradually adjust based on test results. The quality of the weld can be assessed by bending the workpiece multiple times after test welding. Be aware of potential current shunting, especially when welding annular parts, which may require a slightly higher specification compared to straight sections.
When adjusting the limit switch, carefully observe the position of the ejector and the switch piece through the inspection window. The switch piece should open at the end of the welding cycle; otherwise, it may become deformed due to excessive pressure.
Avoid striking or forcefully pressing the fixture surface during operation, as this can damage the welder. Do not place conductive debris near the machine, as it could cause short circuits. Regularly clean the jaws, electrode surfaces, and any welding slag to maintain good conductivity and performance.
After completing the welding, loosen the handle clockwise to bring the electrodes to their minimum distance, preventing fatigue damage to the internal spring. Keep all moving parts well lubricated for smooth operation. Always turn off the power supply when the welding is finished, or before maintenance or repairs to ensure safety.
If any faults occur during welding, stop the machine immediately and perform maintenance. Confirm that the welder is functioning properly before resuming operations. Regular checks and proper maintenance are essential to prevent common issues and ensure long-term reliability.
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