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Mastering the Operation of Your Resistance Welding Machine: A Step-by-Step Guide


Here we provide you with a comprehensive guide on how to operate your resistance welding machine. This guide will help you understand the important aspects of installation, part identification, grade adjustment, and various remarks to ensure a smooth and efficient operation. Let's dive right in!

Functions of the Resistance Welding Machine

Look at the photo provided to familiarize yourself with the machine. It will give you a visual reference for the components discussed in the manual.


Components of the Resistance Welding Machine

Referencing the exhibit numbers mentioned below, please consult the corresponding part photos to identify the different components of your resistance welding machine.


1. Travel switch mandrel2. Stop nut of the machine head
3. Electrode stroke adjusting nut4. Electrode vertical jackscrew
5. Electrode horizontal jackscrew6. Up electrodes clamp holder vertical jackscrew

The Sketch Map of Grade Adjustment

Please refer to Photo 1 for the grade adjustment process. The following instructions will help you navigate the sketch map effectively.


(Photo 1)

Check Photo 1: The two endpoints of the insert handle AB correspond to 1 and 2, respectively.


(Photo 2)

Check Photo 2: Take grade 1 as a sample. Grade 1 corresponds to the position of three insert handles: 1, 2, 2. The subprime (secondary) no-load voltage for grade 1 is 1.76 V.

Additional Vital Considerations

Here are some important remarks to keep in mind while operating your TL-75 resistance welding machine:

1. Power Supply Wiring:Ensure that the power supply wiring is at least 25 mm² or larger.
2. Initial Adjustment:During the initial adjustment, use grade 1. You can make further adjustments as necessary in subsequent stages.
3. Prewelding Current:The prewelding current should be lower than the welding current. Typically, the prewelding current should not exceed 3000 units.
4. Maximum Output Voltage:The welding current reaches its maximum output voltage of around 6000 units. To choose an appropriate welding current, consider a range between 3000 and 6000 units, with a current amendment range of 20 to 100 (higher grade, smaller parameter value).
5. Ground Wire Connection:Ensure the ground wire is properly connected before operating the machine. We recommend connecting the wire under the transformer stand.
6. Machine Head Adjustment:After adjusting the machine head limit nut (stop nut), it is essential to readjust the travel switch screw.
7. Power-On Password:The power-on password for your resistance welding machine is 666666.
8. Compressed Air Pressure:Set the compressed air pressure to match the stable value of your air source. Please do not exceed the air source's stable value, as it may result in unstable pressure during operation.

Advantages of the Machine

With over 20 years of experience, we have developed a cutting-edge resistance welding machine with several advantages. Our "correcting force freely adjust" plug-in machine is known for its easy setup, precise control, and stable welding quality. Thanks to its superior performance, the product pass rate can reach an impressive 99.9%. Customers have praised its ability to save raw materials while delivering excellent welding quality.

Specification and Use Scope

To ensure proper usage, it's essential to understand the specifications and use scope of your resistance welding machine. Refer to the table below for the model, diameter range, power, adjustable level of output voltage, and required air pressure.
Model Diameter Power Adjust Level of Output Voltage Air Pressure

ModelDiameterPowerAdjust Level of Output VoltageAir pressure
TL-25 KVAΦ4~Φ8380 V/50 Hz8 Level0.6~0.8 MPa
TL-50 KVAΦ8~Φ15
TL-75 KVAΦ8~Φ19
TL-100 KVAΦ10~Φ26

Installation of the Equipment

Proper installation is crucial for the efficient operation and safety of your welding machine. Follow these steps:

1. Power Inlet:Ensure the voltage is single-phase 380 V and the power cord CSA matches the welding machine's capacity.
2. Earth Wire:Ground the machine holders to ensure equipment and personal safety.
3. Cooling Water:Some components, such as the sold mask transformer, electrode, and Cu strip, may become hot during production. Ensure a steady supply of cooling water. Connect the waterway in series, with one for the water inlet and the other for the water outlet.
4. Air:Use dry compressed air for the air inlet, maintaining a pressure of approximately 0.6~0.8 MPa. Add an appropriate amount of lubricant to the atomized lubricator.
5. Others:Position the three handles of the sold mask transformer on "1" during installation.

Equipment Commissioning

Once the installation is complete, follow these steps to commission and fine-tune your welding machine:

Coarse Adjustment:

Ⅰ. Electrode Concentricity Adjustment:
a. Set the machine to "Commissioning" mode.
b. Fix the electrode and clamp: Place the electrode inside the clamp holder, with the Al electrode (titanium alloy electrode) on the left and the Cu electrode on the right (approximately 3-6 mm out of the clamp holder). Compress the horizontal jackscrew to secure the upper and lower electrodes in the clamp.
c. Adjust the upper electrode's levelness: Use a vernier caliper or a flat surface tool to ensure the upper electrode's levelness. If needed, adjust the four top jackscrews under the adjustable clamp holder.
d. Adjust the lower electrode's straightness: Use a self-made rod (matching the electrode's hole diameter) to adjust the straightness of the lower electrodes. Lock the bolt in the middle of the holder clamp.
e. Adjust the upper electrode's straightness: Place a self-made rod on the lower electrode and press the "compress" button on the adjustment page. This allows free adjustment of the upper and lower electrodes by moving the upper electrode backward and forward. Ensure the upper electrode remains secure after compression and lock the upper electrode's holder bolt with a wrench.

Ⅱ. Adjust the Horizontal Distance between Cu and Al Electrode:
Adjust the horizontal distance between the electrodes by manipulating the bolts of the promoting air cylinder. Follow these steps:
a. Set the machine to adjust gear and loosen the power shut-off adjustment bolt to disable its functionality.
b. On the adjustment page, select the "forward" button to position the Copper electrode at the forward finished position.
c. Slowly rotate the travel switch screw forward until it just touches the switch point (you will hear a touch sound). Continue rotating the screw half a turn.
d. Lock the screw to fix the nuts.

Ⅲ. Adjust the Weld Plug Depth (adjusted by right electrode push forward stroke):
The plug depth is determined by the right electrode's push-forward stroke, which can be adjusted using the stroke adjust nut of the electrode. The initial distance can be determined based on the necessary depth of the workpieces (refer to the distance shown in photo 1, ensuring that the conical surface of the copper head fully inserts into the aluminum tube). Fine-tune the plug depth based on actual welding results. Maintain a gap between the left and right electrodes after the right electrode finishes pushing forward.


Fine Adjustment

After completing the coarse adjustment, proceed with the fine adjustment process, which involves welding and inspecting the results to make necessary adjustments. Follow these steps:
1. Adjust Promoting Air Pressure: Set the promoting air pressure to 0.25-0.45 MPa and the compressing air pressure to 0.5-0.6 MPa.
2. Synchronize Depressed Cylinders: Adjust the two shut-off valves of the compressing air cylinder to ensure smooth and synchronous movement of the depressed cylinders.
3. Adjust Promoting Air Cylinder: Adjust the two shut-off valves of the promoting air cylinder to facilitate smooth forward and backward movement.
4. Parameter Primary Setting (Reference): Set the current to 4:3-7:30, promoting delay time to 1-3 seconds, welding delay time to 1-3 seconds, and hold time to 0.1-1 seconds.
5. Switch to "Welding" mode.
6. Place and weld the Cu and Al pipe, inspect the welding condition, and adjust bolts, electric current, air pressure, and other parameters to achieve a uniform and smooth appearance.
7. Inspect the welding surface with joint pliers. If the connection is imperfect, adjust the electrode position, current input, shut-off valve position, or promoting air pressure.
8. After adjustment, secure the bolts of each shut-off valve.

Operation Interface

1. Main Interface:You can perform an output zero-clearing in the main interface. This is necessary when the weld times reach the preset output value. Clearing the output allows the machine to continue working smoothly.
2. Adjust Interface:To access the adjusted interface, turn the switch on the operation panel and press "Manual" on the home page. You can fine-tune various settings for electrode concentricity and tube expansion (if applicable) within the adjusted interface. Use the dialogue boxes labeled "Compressing press," "Compressing Loose," "Forward push," "Forward back," "Expanding push," and "Expanding back" to make the necessary adjustments. Refer to the equipment testing details for precise instructions.
3. Weld Parameter Setting Interface:On the homepage, you can enter the parameter setting interface by pressing "Parameter." This interface is designed for adjusting machine parameters during welding. Let's explore the specifications:

1. Parameter Specification:

Delay forward:This sets the waiting time for the copper electrode to move forward to the aluminum electrode after clamping the workpiece tightly. Ensure this value is not smaller than 3 to avoid loose clamping.
Delay welding:Determines the waiting time before welding. Set a value larger than 3 to prevent die striking fire.
Pre-welding time:Specifies the time for low current workpiece preheating.
Pre-weld current:Sets the electric current value for low current preheating.
Output set:Pre-set the number of workpieces to be welded. The machine will automatically stop when the upper limit is reached.
Tube expanding delay forward:Determines the waiting time of the punch pin before expanding.
Tube expanding time:Sets the time required for the expanding process.
Over-weld protection:Protects electrode dies during adjustment and welding. Pre-set parameters cannot be modified.
Welding current:Specifies the current value for high current welding.
Protect time:Determines the duration the electrodes remain tightly pressed after welding.

2. Operation

If you need to modify the pre-set specification for different welding workpieces, follow these steps:

● Press the relevant parameter specification value.
● Make the desired modification.
● Press ENT to confirm the input.
● Use CLR to delete an input if needed.
● Press ESC to exit the input mode.

Equipment Maintenance and Fault Resolution

After completing your work, it's crucial to maintain the equipment and address any potential faults. Here are some maintenance tips and common fault resolutions:

1. Equipment Maintenance:
● Clean the surroundings and turn off water, electricity, and gas.
● Place a dry cloth between the upper and lower electrodes to prevent dust accumulation and oxidation.

2. Common Faults and Resolutions:Refer to the table below for common faults, their causes

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1Pipe skids during welding1. Incorrect pipe outer diameter2. Insufficient press pressure3. Worn-off electrode1. Change the pipe2. Increase press pressure3. Repair or change the electrode
2Electrode sparks during welding1. Improperly adjusted delay time2. Insufficient propellant pressure1. Re-adjust the delay time2. Re-adjust the pressure
3Electrode acts un-smoothlyExcessive electric corrosion in the electrical relay's contactor, causing solenoid valve issuesChange the electrical relay
4Cu&Al pipe too hot1. Improper adjustment of electrode's horizontal clearance2. Unadjusted outage top threadRe-adjust the electrode's horizontal clearance and outage top thread


By following these instructions for installation, commissioning, and fine adjustment, you can maximize the performance and efficiency of your equipment. Remember, regular maintenance and periodic inspections will ensure long-term reliability and optimal results. Should you have any further questions or require assistance, please consult this manual or contact our customer service team.