To operate the welding machine properly, start by rotating the handle counterclockwise to separate the two jaws. The movable clamp is positioned on the outer edge of the eccentric lever's plane. The clamp can only be activated when this plane comes into contact with the ejector pin. Once the jaws are open, step on the pedals to release the clamping force, place the workpiece between the jaws, then release the pedals to secure it in place. When clamping a welded component, make sure to leave an appropriate gap between the pieces based on the size of the weld section. After clamping, pull the handle clockwise to relax it, allowing the ends of the workpiece to touch and press against each other due to the spring force.
Observe the 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. There should be a specific distance between them, which should be adjusted according to the workpiece. When the weld joint is formed, the copper contact of the limit switch will open, and the resulting weld flash should meet the required standards. Press the welding button to activate the welding transformer, supply power to the welding pieces, heat their ends, and apply the forging pressure to complete the upset process. This process stops automatically once the limit switch detects the proper condition.
After welding, step on the pedal again to release the jaws and remove the workpiece. Depending on the requirements of the weldment, decide whether to perform tempering. The tempering specifications—such as energization time and current—are generally lower than the welding parameters. Before starting actual welding, always begin with a low specification and gradually adjust it based on test results. The quality of the weld is determined by how many times the workpiece can be bent after testing under the same conditions.
Take into account the effect of current shunting when welding ring-shaped components; these require slightly higher specifications compared to straight sections of the same size. When adjusting the limit switch screw, always check the relative position of the ejector pin and the switch piece through the inspection window. Ensure the switch piece opens at the end of the welding process, otherwise excessive pressure may cause deformation. Avoid striking the fixture or forcing the workpiece while it’s clamped, as this could damage the machine. Keep conductive debris away from the welding area to prevent short circuits. Regularly clean the jaws and electrode surfaces to remove oxides and slag, ensuring good conductivity.
After finishing the welding operation, loosen the handle clockwise to keep the electrodes at the minimum distance, preventing unnecessary stress on the internal spring. All moving parts must remain well-lubricated for smooth operation. Always turn off the power before stopping the machine or performing maintenance to ensure safety. If any faults occur during welding, stop the machine immediately and repair it before resuming use. Regular maintenance is essential to avoid common issues and maintain optimal performance.
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