PROLOGUE

Firstly thanks for choosing our products.

Please carefully review the manual before operation so as to properly manipulateour

Please carefully check whether the machine is in good condition and in accordancewith packing list after its arrival. If it is damaged during transportation and load, orif parts are missed because of wrong packing or other reasons, please contact ussoon so that we can deal with it in time in case of any lose or inconvenience for you.Our after service phone No. is 86-28-85011951(85012443, 85013964). Please firstcontact the subsidiary company, office and agent nearby so as to serve you faster.

The manual is for installing and debugging, correctly operating, checking andeliminating anomaly, and daily maintenance for user. Please carefully read it beforeoperation and maintenance, and proceed strictly in accordance with the operatingregulations.

The machine should be installed and maintained by professionals. If the user comesacross any technical problems during the operation, please contact out departmentof after-sale service in time.

If there is any omission in the manual, please understand. You are welcome to givevaluable opinions and suggestions to us. We’ll try to supply you with the best andefficient service.

If technical parameters would be improved and the manual would be changed,please forgive our not notifying.

The ownership and interpretation right belong to Chengdu Huayuan ElectricEquipment Co., Ltd. It is forbidden to copy the manual to a third party. Otherwise itwill be regarded as a tort.

Chengdu Huayuan Electric Equipment Co., Ltd

CONTENTS

1. Safety instructions

2. Operating regulations

3. Summary of the machine

4. Structure of the machine

5. Models and technical parameters

6. Use conditions

7. Installation and debugging

8. Electric principle and functions

9. Adjusting operation and connection

10.Welding operation

11.Maintenance

12.Common troubleshooting

13.List of main parts

14.Accessories

Safety Instructions

★ The people is operating or in the vicinity, to have a full understanding of safety

measures .

Please strict accordance with the operating regulations for theinstallation, commissioning, operation and maintenance!

Please wear the necessary protective guard: mask, gloves, hatsand so on!

Rotating components easily hurt, please note fingers, clothing, hair, etc.involved!

Magnetic RadiationWelding current would generate magnetic field when it passes. Beside the welding cable, thereshould be no magnetic sensitive things such as watch, mobile phone, fault detection instrument,steel-made tools and so on. The method of prevent magnetic radiation is as follows. Let the cablepenetrate pipe to decrease the rounding area of cable and to avoid setting work position in it. Thecable connected to work piece should be as short as possible. Try not to work beside the main power.Danger of electric shockAccording to national standard (GB3805-93), the AC/DC voltage for people to bear is very low. Butrequired voltage may cause electric shock even if it is accordant with relative national standards.The operator should wear guard in case of electric shock. Do not make your spare skin touch the workpiece or electrode. Guard clothes and gloves should be dry.During automatic welding, welding wire, feeding wheel and contact tip may cause creepage. Underany condition, the cable for connecting to work piece should be firm and close to welding point. Makethe earthing point of work piece and power ground. Three-phase zero wire is not allowed.Regularly check the earthing clamp and welding cable to keep the machine in good condition. Ifnecessary, change the worn part caused by insulation. It is forbidden to immerse machine head orcable into water or to touch both ends of electrode at the same time. Please tie up safety belt whenworking in a high altitude.Welding dust and gas is harmful.Welding may cause harmful dust and gas. Please keep away from breathing them. When welding forspecial materials like stainless steel, galvanization plate, alloy material with lead and chromic, payattention to keeping ventilated and set another flue. Do not weld in the poisonous and flammable gas.Some protective gas (even inert gases) may make man choke. Please keep air fresh.Arc splash may cause fire.Flammable things should be far away from welding place. If they cannot be moved, cover them by

flame resistant material to avoid fire caused by splash. The operator should protect the collar, cuffand hair in case of hurt by splash. The earthing wire should be connected to work piece. Do notconduct by step, or it may cause fire at the contact.Safe operationWhen checking and repairing the machine, please turn off the input power. For installation it shouldbe based on relative national standard or standard manufacturer commends. Make preparation forunexpected machine injury, electricity injury or scald.

Operating regulationsThe operation and maintenance should accordant with the Operation Manual.

Wrong operation may cause accidents, injure operator or damage the machine.

The installation, debugging, operation and maintenance should be done by professionals or speciallytrained people. The machine can not be changed without manufacturer’s permission.The operator should master the structure, control, operation of the machine and the safetyinstructions.

When the welding center is working, it should be kept at a certain distance from people or othersubjects, preventing hurting people or damaging the machine. It is forbidden to stand under the beamof welding manipulator. The operator and others are not allowed to stand on the work piece.

Welding center machine should ground well. Cables should be firmly connected. Cable wires and rollliner rubber should be prevented from mechanic, hot source (hot weld) or oil stains in order to keepgood insulation and avoid sudden electric shock.

The control tank and manual control box have electric wiring and connectors which exceeds the safetyvoltage (GB3805-93). Only trained professionals can open the case cover in conduction and repair.Emergency and safety device should be checked every day especially before the welding center startswork. If there is anything abnormal, the trouble should be resolved before operation.

Summary of the machineAutomatic submerged arc welding center belongs to mechatronics. It is widely used in boilers,pressure vessel, petrochemical and mechanical and other industries, particularly for auto weldingprocessing of longitudinal seam and girth seam of shell work piece, and ring seam of axis work piece,and also for resurfacing welding of work piece ( with specialized head) and welding processing oflarge-scale structure piece long seam.

Automatic submerged arc welding center equipment mainly include CZ series welding manipulator,welding turning rolls (ZT series self-adjustable, KT series adjustable), HB series welding positioner,MZ9 series hang submerged arc welding machine and central control system. Generally, weldingmanipulator, welding turning rolls and hang submerged arc welding machine are together used forauto welding of longitudinal seam and girth seam of round shell. Welding manipulator, weldingpositioner and hang submerged arc welding machine are together used for auto welding of ring seam

of axis work piece (flange-cylinder), but not used for welding U-shaped space curve weld.

Welding positioner and welding turning rolls are not only for auto welding but also for positioningwork piece at assembly, fault defection, spray finishing, abrading and manual welding so as to getgood processing position and speed.

Structure of the machine

1. The structure of welding manipulator

CZ series welding manipulator (in boom structure) is composed of base, stud parts (including stud, liftdevice, bracket, slide defending device, counterweight), beam parts (including beam, guide way,supporting boom, drive device), rotation parts (manual or electric), rotation locking device (manual,pneumatic or electric), travel trolley (manual or electric), man-loading device and internal flex beam.Each part is in modular structure. Optional parts can be chosen and assembled by user’s processingcondition and requirement.

Installation base is divided into fixed base (including fix type and fix rotation type) andtravel base (trolley travel type). The fixed base is for fixing the base and the travel base(travel way) is for displaying travel trolley.

The base can be fixed on the ground or on the travel trolley. The base can be set withrotation parts and stud.

The stud has quantities of safety holes. When the beam falls off suddenly, the safety hookwould match with the safety hole so as to prevent human from hurting or the machine fromdamaging. In the stud there is counterweight device which can make the lift and position ofbeam more balanced and reliable.

On the stud there is a bracket which is used for stable lift, fix and speed flex of the beam.The bracket makes lift and self-lock fix through motor, worm reducer, chain and chain

wheel. The beam is driven by AC motor and transmitted by reducer and chain wheel. It applies

transduction with stepless speed adjustment to drive the head travel so as to meet weldingspeed requirement of straight weld.

The wire plate and wiring link can be fixed on the beam. On the front there is a turningbracket which is for hanging, adjusting and fixing the head.

2. The structure of welding turning rolls

It mainly includes ZT series self-adjustable type and KT series adjustable type. It is a welding positionmachine which drives the work piece rotation by friction between roller and work piece. It is mainlyfor loading and driving work piece rotation to get good position and speed for welding processing andassembling.ZT series self-adjustable turning roll is made up of a drive roll and an idler roll (The number of idler rollcan be increased by user’s need.). The drive roll is separate from the idler roll. Their central distancesof rolls are automatically adjusted by diameter of work piece to fit processing requirements. The driveand idler rolls can be added according to different weight and length of work piece so as to improvedriving and carrying capability of turning rolls.

Reducer 1

Fixed support base

Swing arm

Roll

Gear unitMotor

Base

Reducer 2

The drive turning roll is composed of base, roller, roller bracket, driven slowdown device and controlsystem etc.

• Base: Box structure composed of steel and I-beam steel welding combination, with goodload-carrying capacity, rigidity and stability.

• Rollers: There are four rollers on drive roll and follower idler roll each other. Four rollers on thedrive roll are simultaneously driving rollers. The rollers have rubber surface and steel-corecombination structure. Steel-core roller is designed in groove surface. It can effectively prevent therubber desquamating.

• Roller bracket: Every bracket is linked by two pieces of curved plates, supporting and linkingrollers. Angle between bracket shaft and rollers on curved plate is 90° in general. It can be adjustedfrom 90°-120° according to specific requirements.

• Driven reducer: Standard drive roll is driven by two motors. After slowdown by two class wormgear, one class gear drives four rollers turning simultaneously.

• Control system: It applies LG-IG5 vector control transducer for stepless speed adjustment. It has

great speed range, high precision, great starting torque, strong driving ability, smooth rotation with

other protecting functions like over-load, over-current, over-voltage, over-heat, under-voltage, free

maintenance and so on. The start, stop, regulation, observe and reverse rotation of roll all proceeds

on control box. The operation is easy and reliable. The linkage connector can be easily connected to

manipulators and welding machine, to make up automatic welding center.

KT series adjustable welding turning rolls are made up of base, roller support base, rollers and

driving system.

Adjust the central distance of roller according to different diameter of work piece. Fix it

through the screw on the base.

The standard device is composed of a drive roll and an idler roll. It is operated by manual control

box of welding center.

The base is formed by combination welding of steel plate and formed steel. It has large loading

capacity of supporting work parts and work pieces.

Roller support base is to connect base and roller. When the diameter of work piece is changed,

the central distance of roller can be adjusted by moving roller support base. When moving roller

support base, loose fixed bolt and bolt on the turning-defending board first, then push or lift

roller support base to proper place, and then fix the fixed bolt and bolt on the turning-defending

board

Roller is fixed inside the roller support base. There are mainly three structures for rollers, rubber

surface with steel core roller (3 to 10 ton), steel and rubber combination roller (20 to 100 ton),

steel roller (over 100 ton). The size of rollers refers to parameter diagram.

Driving system takes three-phase AC as power source. It outputs moment via motor. After

reducing by one class cycloidal pinwheel, one class worm (large-tonnage) or two class worm, it

transfers moment to roller shaft to drive the roller which finally drives work piece.

3. The structure of welding positioner

It is mainly composed of work desk, frame, rotation driving system, reversal drivingsystem.

● Working desk is formed by finish machining of casting. There are many T-shapedgrooves on the desk surface to assemble fixed work piece. There are also plenty ofpositioning lines for positioning the work piece to make work piece shaft coincidewith the desk shaft.

● Frame is formed by deposit welding. It is used for supporting work parts and workpiece. There are many stiffening sibs welding in the frame with large whole rigidityand loading capacity.

● Rotation driving system is make up of AC motor, cycloidal pinwheel ,worm reducerand so on .It drives work desk rotation ±360°around the rotation shaft .The wormreducer has very good self-lock performance.

● Reversal driving system outputs moment through AC motor , reducer two class bycycloidal pinwheel and driver fan-shape gear fixed on the desk profile by straightgear to driver the desk reversing from 0°to 120°.The worm reducer has very goodself-lock performance.

Models and technical parameters1. Model definition

Model Definition of Welding Manipulator

CZ- B×A –XYZ Man-loading sign，“0”non loading,“1”man-loading

Rotation sign“0”non“1”manual“2”electricTravel sign“0”non“1”manual“2”electric

Flex route (m)Lift route (m)Manipulator code

Model Definition of Welding Turning Roll

ZT-[ ]t Loading capacity（ton）

Code of self-adjustable welding turning rolls

KT-[ ]t Loading capacity（ton）

Code of adjustable welding turning rollsModel Definition of Welding Positioner

HB-[ ] Loading capacity（No.×0.1=ton）

Code of pedestal type welding positioner

2. The components, models and technique parameters

The components and models: CZ-3×3-010, ZT-10t, MZ9-1250 Handing submerged ArcWelding machine and accessories.Instructions: CZ-3×3-010 indicates: the lift travel of beam is 3 meters, and flex travel is 3meters. It is the welding manipulator with fixed manual rotation.MZ9-1250 indicates: Hanging Submerged Arc Welding head (electric three-dimensional head, smallregulation of travel is 100×100×100mm), with ZD5-1000 Submerged Arc Welding power source.

3、Main technical parametersMain technical parameters of welding manipulator

SpecificationsParameters

2×2 2.5×2.5 3×3 4×4 5×5 6×6 7×7

Lift route of beam 2m 2.5m 3m 4m 5m 6m 7m

Lift speed of beam 80-800mm/minFlex route of beam 2m 2.5m 3m 4m 5m 6m 7m

Flex speed of beam 150-2000mm/min (frequency conversion with stepless speed regulation)Travel speed oftrolley

150-2000mm/min (frequency conversion with stepless speed regulation or manuallytravel)

Stud rotation range ±360°

Stud rotation speed0.03-0.75rpm（frequency conversion with stepless speed regulation or manually

rotation）Totalloadbeamallows 100kg 200kg(for man-loading type400kg） 400kgHeight of travel

trolley275 275 275

Height of rotationdevice

130 130 130

Basic height ofmanipulator

3270 3770 4470 5470 6470 7570 8570

Flexcapacityof beam

amax 3350 3850 4450 5450 6450 7500 8500

amin 1350 1450 1500

Heightof beam

bmax 2450 2950 3550 4550 5550 6550 7550bmin 450 550 550

Gauge of trolley W 1500 1800 2070Electric condition Three phase-380V

The above are standard specifications of manipulator. The beam can be extended by 0.5-3m orshortened by 0.5-2m regarding special request.

Main technical parameters of adjustable welding turning rollsParameters

Models

Loadingcapacity

(t)

Linespeed

mm/min

Power(kw)

Applyingof

diameter/mm

Roller size andstructure

The dimension/mmDrive, Idler Weight

（t）length

width

height

KT-3t 3 70～1200 2×0.18 120～2200φ300×110

Rubber roller16001450

430360 560 0.60

KT-5t 5 70～1200 2×0.25 150～2200φ300×110

Rubber roller18001650

430360 560 0.80

KT-10t 10 70～1200 2×0.37 150～2800φ350×118

Rubber roller19101910

730600 580 1.20

KT-20t 20

70～1200 2×0.55300～3600

φ350×175Steel andrubber

combinationroller

22402240

860600 580 1.70

KT-30t 30

70～1200 2×0.75300～3600

φ425×198Steel andrubber

combinationroller

23002300

950520 680 2.40

KT-40t 40

70～12002×1.10 300～4000

φ425×198Steel andrubber

combinationroller

24502450

950520 680 3.00

KT-50t 50

70～1200 2×1.50300～4500

φ425×198Steel andrubber

combinationroller

31002660

1100600 800 3.50

KT-60t 60

70～1200 2×1.50300～5000

425×198Steel andrubber

combinationroller

32002760

1100600 800 3.90

KT-80t 80

70～1200 2×1.50800～6000

φ580×280Steel andrubber

combinationroller

31003100

1300950 1070 5.10

KT-100t 100

70～1200 2×1.50800～6500

φ600×300Steel andrubber

combinationroller

33003300

1420980 1120 6.30

KT-200t 200

70～1200 2×3.00800～6500

φ650×300Steel andrubber

combinationroller

36003600

16101010 1210 12.80

KT-300t 300

70～1200 2×5.501000～7200

φ800×350Steel andrubber

combinationroller

44004400

18401220 1620 18.40

Main technical parameters of self-adjustable welding turning rollsParameters

Models

Loadingcapacity(t)

Linespeed

mm/min

Power

(kw)

Applyingof

diameter/mm

Roller size andstructure

The dimension/mmDrive, Idler

Weight（t）lengt

hwidt

hheight

ZT-5t 5 70～1200 0.75 300～3300φ300×110

Rubber roller21001600

700500 850 1.25

ZT-10t 10 70～1200 0.75 300～3300φ300×110

Rubber roller21001600

700500 850 1.42

ZT-20t 20 70～1200 1.5 500～4500φ350×118

Rubber roller23501720

740480 980 1.90

ZT-30t 3070～1200 1.5

500～4500

φ350×175Steel and rubber

combinationroller

25201840

830530 980 2.50

ZT-40t 4070～1200 1.5

700～4700

φ350×175Steel and rubber

combinationroller

28202140

850580 1030 3.20

ZT-50t 5070～1200

2.2 900～5200

φ425×198Steel and rubber

combinationroller

34002480

1000630 1200 4.20

ZT-60t 6070～1200 2.2

900～5200

φ425×198Steel and rubber

combinationroller

34002480

1000630 1200 4.70

ZT-80t 8070～1200 3.0

1000～6800

φ510×280Steel and rubber

combinationroller

39003000

1400980 1600 7.00

ZT-100t 10070～1200 3.0

1000～6800

φ510×280Steel and rubber

combinationroller

40003100

1400980 1600 8.10

Main technical parameters of welding positioner

Models HB-5HB-10

HB-20 HB-30 HB-40 HB-50 HB-80 HB-100

Loading capacity(t) 0.5 1.0 2.0 3.0 4.0 5.0 8.0 10.0

Diameter of work

desk800 1200 1400 1600 1800

Rotation speed

（r/min）0.065-1 0.045-0.65 0.035-0.5

Reversal speed

（r/min）0.75 0.37 0.25

Reversal angle 120°

Max distance of

gravity center(mm)250 300 400

Max excentricity

(mm)250 300 250

Input capacity

(KVA)4 6 8

Dimension

（mm）

H 780 1098 1195 1445 1675 1675 1790 2000

L 1130 1500 1700 1890 1900 1900 3000 3900

W 910 1100 1185 1280 1330 1330 1930 2400

D 95 163 165 185 93 93 205 205

Weight (t) 0.5 1.3 1.5 3.0 3.8 3.8 5.6 7.5

Electric conditions Three phase-380V

Use conditions Ambient temperature condition on operation: -10℃~40℃

Voltage: 380V±10% (when the frequency is rated)

Frequency: 50/ 60Hz±10% (when the voltage is rated)

The machine should be used at the environment where is ventilated, dry, moisture-proof, and far

from severe shock and vibration.

Installation and debugging

1. Points of installation and operation of welding manipulatorThe main installationThe manipulator is partly packed when it leaves factory. It will be installed at user’s place. The usershould make installation preparation in advance according to our basic picture of installation. At thescene of installation, user should supply responding rods and people.● Installation of slide block and stud: The slide block, stud, chain and counterweight should be

adjusted in the right place before leaving factory. If the slide block moves abnormally up anddown, it just needs to adjust and lock the holding eccenter on the slide block.

● Installation of beam and stud: After installing stud vertically, the beam is inserted into theholding eccenter on the slide block from the end and back to the last limit, Then adjust theeccenter to make the front-end of bear a bit tip-tilted . More the beam onto the front limit tocheck if the beam is horizontal. If it is tip-tilted or droop. Adjust the eccenter to keep a good level.

● Installation of beam and track: The beam is delicately matched with track. If there is any shake,adjusting the eccenter can eliminate the clearance.

● After adjustment, all the eccenters should be locked and fixed.● Installation of chain wheel and chain: Keep the chain tightened .Adjust the relative position of

chain wheel and chain to make the beam well engaged during the flex process. Then fix it.● Route switch and mechanic block should be properly installed to make life and flex route a little

longer than the rated value. This is to make the installation stable and reliable.● Examine if there is fit clearance, disturbance and abnormity among each moving part and system.

After final adjustment, every action should be flexible and stable.

Points of electric connection● Electric connection should proceed according to relative figures.● There should be no abnormity effecting conduction in the electric parts. It should be fixed tightly.

Especially the positive and negative cable connectors should be tightly fixed.

● The terminals should be tightened to fix nuts.● All contact pins and picks should be properly and tightly inserted into connection terminal.

Points of running debugging

● Single conduction checking: Correct the rotation direction of each motor to make sure knob andkey switch connected in the right way.

● Whole run checking: Make the electric system reliable, running part flexible and mechanicassemble delicate.

2. Points of installation and operation of welding rolls.

Installation Points● Please read the operation manual carefully before installation.● It is forbidden to slant and upend the machine.● It should be lifted and installed by lifting lug on the base.● The machine takes three-phase 380V power as its source. The three-phase inlet wire should get

through air switch to ensure safe operation.● The drive and idler rolls should be parallel vertical in high level to prevent work piece shaft

moving caused by wrong installation.● Please connect the ground wire well at the grounding sign on the control box of turning rolls

before operation.● The standard components of the machine contain no conduction device. It should be equipped by

the user according to the actual welding processing situation. The user can equip it when theordering the machine.

Operation points● When lifting the work piece, it is forbidden to hit rubber wheel and other parts badly in case of

any damage for the rubber wheel and other parts.● Please lubricate the relative parts of machine before operation regarding maintenance. It is not

allowed to operate without lubricating.● Each cable should be fixed and connected to keep good conduction.

3. Points of installation and operation of hanging machine head

● For adjustability, the hanging head can be divided into 2D adjusting head and 3D adjusting head.For precision adjustment, it can be divided into manual adjusting head and electric adjustinghead. For size, it can be divided into standard head and mini head. The mini head for 3D electricadjustment is equipped when it needs to enter into cylinderφ500-800. When welding cylinderoverφ800, 2D adjustable head is suitable. And choose manual or electric adjustment if necessary.

● The machine head is composed of wire feeding device, precision device, wire reel, wire frame, fluxhopper, wire feeding pipe and so on.

● The wire feeding device of each head is the same, including feeding motor, reducer, wire feedingwheels, pinch roller, pressure adjusting handle, idler wheel, adjusting wheel and handle etc.

● Precision device is divided into four kinds, 2D manual, 2D electric, 3D manual and 3D electric.

They are separately combined by two or three manual or electric support plate.● The block is made up of frame, lead screw, feed rod, moving block, adjusting handle (manual),

support plate motor, chain wheel and chain, mounting plate, travel switch and so on.

● Manual adjustment can be done by driving screw through handle turning. Electric adjustment canbe done by electric switch controlling motor movement to drive screw. It is to fine-tune theposition of nozzle at the process of welding to prevent welding slanting.

● One end of the precision device (block) is connected to wire feeding device through hex bolts. Theother end is fixed on the mounting plate by bolts. And the mounting plate can be divided intofixed type (with 3D adjusting head, welding on the supporting boom of manipulator) androtatable type (with 2D adjusting head, fixed on the supporting boom of manipulator in boltconnection through rotating lock-in device).

For 3D electric adjusting head, set the wire reel on the end of beam when it needs to enter cylinder

below diameterф600, and wire checking device and feeding pipe should be added. Meanwhile,increase the power of feeding motor to feed wire smoothly.

Electric principle and functions

Electric control includes main circuit, control circuit and welding control circuit.

1. Main circuit principle and functions

Three-phase four-wire power inlet line L1, L2, L3 and PE are connected to upper end of gas

switch QF by winding. The gas switch has functions of overflow and overload.

The outlet line of gas switch U1, V1 and W1is connected to upper end of relay KM1 and

edge of control transformer TC.

After point start button SB2 (local control) or SB3 (remote control), relay KM1 pulls in. KM1

outlet line U2, V2 and W2 is separately connected to the inlet end of transducer and upper

end of recycle relay KM2.

By switch of KA1, KA2, KA3, KA4 and KA5, transducer U separately drives beam lift motor,

beam flex motor, turning roll motor, trolley travel motor and stud rotation motor (hanging

in the air).

Relay KM2 works. Recycle motor works (hanging in the air).

2. Control circuit principle and functions

After shutting off the gas switch, control transformer TC is conducted and the power yellow

indicator lamp HL1 on the main control box turns on.

Point start button SB2 (local control) or SB3 (remote control). Relay KM1 pulls in and makes

self-protection. Main circuit and control circuit are conducted. Each control part stays in

working state. And the indicator lamp HL2 (remote control) turns on. Speed digital meter PV

display responding digitals, which indicates that the manipulator starts working.

When the beam moves up and down/ right and left along the stud, the end is set with

travel switch. When the beam moves to the limit, responding switches SQ1, SQ2, SQ3 and

SQ4 work and break responding control circuit. Then the beam has to move in the opposite

direction. Meanwhile, the ends of beam up and down/ right and left are all set with limit

block in case of sliding or falling off. Moreover, falling defending device is set on the bracket.

If lift chain breaks or lift reducer is damaged, the lift chain has no full for safety hook and

the relief spring pull makes the safety hook insert into safety hole of the stud so as to keep

people and equipment in safe way.

Control object selection switch SA6 (local control)/ SA5 (remote control) select the drive

object of transducer U. The potential device RP (remote control) is used to adjust speed of

the selected object. Turn the selection switch SA5 or SA6, the responding relay KA1, KA2,

KA3, KA4, KA5 work and switch the control object of transducer (beam lift, beam flex, roller

rotation, trolley movement and stud rotation).

Selection switch SA5 (remote control) is to select the working pattern of drive object of

transducer U. When it turns to Manual, the moving direction of transducer drive object can

be controlled by turning SB5 and SB6 (local control) or selection switch SA5 (remote control).

When it turns to Auto, transducer drive object is conducted to welding machine. Press the

Start Button, the drive object moves in the pre-set direction.

The one end of crossing plate of the head is connected to welding head, and the other end

is fixed on the beam end of manipulator. It has electric and manual adjustment. Manual

plate adjusts the position of head by hand wheel. Electric plate drive motor M7 and M8

belong to servomotor and rectify into 24C power by UR2. It makes moving precision

adjustment up and down/ right and left by selection switch SA9 and SA10 on the remote

control box (SA9 is right/ left switch and SA10 is up/down switch).

Adjusting operation and connection1. Introduction of panel of main control tank● “Power indicator” HL1 is to show if the main control box is conducted or not.● “Beam Up”SB4 is inching button which is used for controlling upward movement of

beam near by.● “Beam Down”SB5 is inching button which is used for controlling downward

movement of beam near by.● “Control Object” selection switch SA5 is used for selecting control object of

transducer.● “Backward/Reversion”SB7 is inching button which cooperates with SA5 to make

negative/movement of transducer drive object.● “Forward/Rotation” SB6 is inching button which cooperates with SA5 to make

positive movement of transducer drive object.● “Sudden Stop” SB1 is pressed before the system power cuts. (When power turns on

again, turning an angle is necessary to open it.)● “Near control/Remote control” SA3 is to selection control position (transduction drive

object). When it turns to “Near Control”, transducer control object can be onlyoperated on the main control box. When it turns to “Remote Control”, it can be onlyoperation on the manual control box.

● “Power” SA1 is toggle switch which is used for controlling the conduction of controlsystem.

升降 伸缩 台车 滚轮 回转 电源指示灯

停止

降/退/反转

等速送丝

变速送丝

工作

升/进/正转

Chengdu Huayuan Electric Equipment Co.LTD

近控

远控

1

3

5

1

4

6

1

2

Lift Flex Roll Boom Rotation Power indicator lamp

Drop/Backward/Reverion

Stop Work

Rise/Forward/Rotation

CON.VOLT. Near control

Remote control VARI.VOLT.

2. Introduction of panel of manual control box● “Control Object” selection switch SA4 is to select the transduction drive object.● After “Electric plate up / down” selection switch SA8 inches, the plate moves in the

responding direction (right or left).● “Speed Adjustment” potential device RP is to adjust the speed of transduction drive

object. The speed would be increased by clockwise adjustment.● After “Beam UP/Down” selection switch SA2 turns up or down, beam is up or down in

the travel range.● After “Turning direction” turns up or down, transduction drive object moves in the

responding direction.● For “Control Pattern” selection switch SA7, when it turns to “Manual”, the moving

direction of transducer drive object can be manually controlled; when it turns to“Auto”, the transducer drive object is controlled by welding starting circuit in thepre-set direction.

● “Digital Meter” 1 is used to show welding voltage. “Digital Meter” 2 is to showwelding current. “Digital Meter” 3 is to show the frequency of transducer.

3. Introduction of air connecting parts on the lower end of control tank (If the connection plate has

some instruction, please refer to the figure!)

4. Introduction of left side of air connecting parts in welding box

“1” to 26 core socket, pinhead of main control tank

“2” to 20 core socket, pinhead of manual control box

1

2

5. Introduction of right side of air connecting parts in welding box

“1” to 4 core socket, pinhead of feeding motor

“2” to 4 core socket, pinhead of crossing plate

“3” to 12 core socket, pinhead of arc welding rectifier

Welding operation

The user presets the required welding current and voltage according to his welding processing

technique.

When welding circular weld: Move the welding head (welding torch) to the welding position by

manipulator and set the running speed of work piece.

When welding longitudinal weld: First adjust the position of work piece to make welder located

in highest or lowest point, and then set beam flex and moving speed of trolley well.

Turn Manual/ Auto switch on the manual control box to “Auto”. Choose drive object and

direction. Press Welding button and start welding.

Notes: The operation of welder and other welding machine is shown in relative Operating Manual.

In order to make manipulator matched with machines from other factories, there is matching

connector in the control system. The connector working pattern and position is shown in relative

principle figure.

MaintenanceMaintenance of welding manipulatorPoints of maintenance● Each open moving part: Track and roller, chain wheel and chain, guide screw and

nuts should be regularly lubricated. Close moving parts, rotary table and bearingshould be regularly poured with lubricating oil to keep the movement flexible anddecrease abrasion.

● Regularly check and clear track/slide block, guide screw/nuts, chain/chain wheel toprevent dust scattered flux and other things so as not to effect the flexibility. It’sforbidden to hit and wear each movement face.

● Regularly check guide screw, spiral wire, chain and other key parts. If there is anyproblem, maintain or change them in time. The life drive device belongs to wearingparts. It should be removed and checked at least every one year .The problem should

1

2

3

be solved in time.● Regularly check each moving switch and block to see if they are loose or damaged.

Keep the movement reliable.● The fuse of circuit should be used strictly in /accordance with rules. Its specifications

can not be freely changed. If it is broken, it should be changed immediately afterfinding out the cause and trouble shooting.

● Regularly check the circuit connector to keep connection stable and reliable.● Sweep the control box and manual control box by compressed air every three months

to keep relay, button and switch clean and well conduction.● After operation ends, drop the beam of manipulator to one third of heights from stud

to the ground and keep the right side of beam parellel with the left side.

Lubricating period of key partsNo. Lubricating parts Kinds of lubricant Lubricating method Lubricating period

1 Beam and stud track Ca-lubricant 3# Laying on Once a month2 Chain and chain wheel Ca-lubricant 3# Laying on Once a month3 Rotary table Machine oil 30# Pouring in the hole Once a month4 Worm reducer Machine oil 30# Pouring in the hole Once half a year5 Planetary reducer Ca-lubricant 3# Laying on Once a month6 Moving reducer Machine oil 30# Pouring in the hole Once a year8 Each moving support Ca-lubricant 3# Laying on Once a month9 Guide screw Ca-lubricant 3# Laying on Once a month

Common troubleshootingNo. Troubles Causes Troubleshooting

1

After

conduction, it

doesn’t work

when pressing

Start button

1. The three-phase inlet wire is not

correct.

2. Control fuse is broken.

3. The Button Sudden stop is not

replaced.

4、Something wrong with contactor

1. Check and eliminate the

trouble

2. Change the fuse

3. Replace the button Sudden

stop

4. Change the contactor

2

The beam can

not rise or

drop.

1. Phase is missing.

2. Problem with the travel switch

3. Problem with the lift motor

4. Problem with control circuit

1. Find out the cause and

solve it

2. Change the travel switch

3. Change the motor

4. Check the control circuit

3After the

power is on,

1. The parameters of transducer

are not correctly set.

1. Reset the parameters

2. Check the responding

control object

of transducer

doesn’t work.

2. Something wrong with control

circuit

3. Problem with transducer

control circuit

3. Change the transducer

4The welder

cannot start.

1. Problem with arc welding

rectifier

2. Problem with control box

Refer to operating manual of

Arc Welding Rectifier

Accessories Our welding manipulator, welding power source, hanging machine head, welding turning rolls,

welding positioner, flux recycle and feeding and flux pad make up automatic welding center,

controlled by centralized control system and operated remotely by manual control box.

Selective accessories are designed and manufactured for the whole machine by our company.

They are very reliable and convenient.

The equipment can be matched with those from other manufacturer. It has connector for them.

If the user needs to make changes of the ordered machine, please supply written instructions to

us before placing order changing it. The change should get our confirmation. Otherwise, the user

would be responsible for the result.

HB-10H