CS-231 USER MANUAL
Contents
1. 1 TORCH BASE MATERIALS CO 2 GAS CO 2 GAS WIRE FEEDING 4 r WELDING CONTROL CABLE R amp WELDING POWER WELDING POWER CABLE TORCH SIGNAL R S TORCH CABLE A WIRE N i 440 380 220 FEEDER i VAC A POWER SOURCE 500 600ADC C02 amp 0 GAS B CONTROL PANEL jo ap AE SS CO 2 GAS CO 2 GAS WIRE FEEDING WE2. tuning QP 041 17 CHUNG SONG INDUSTRY CO LTD 3P Z h NW 2 APPLIED MATERIALS SHAPE and POSTURE 3 MAIN SPECIFICATIONS QP 041 17 CHUNG SONG INDUSTRY CO LTD Set I 95 55 E I I I Start Stop Driving Speed Adjust Travel Direction Weld Not Weld 1 Weld Not Weld 2 1 CARRIAGE 2 POWER CABLE 1 08Q 3C 30M Configuration Model Size WxLxH Weight BODY Driving Motor Division GENERAL Gear Ratio Driving Method BODY Input Power Driving Speed WELDING ANGLE RUNNING ANGLE CLAMPING SLIDE X SLIDE Z SLIDE TORCH 1 BODY CONTROL otandard Supply Scope Composed HER Items for Equipment Warehousing 4 CONTROL PANEL OPERATION EXPLANATION Travel speed display QP 041 17 CHUNG SONG INDUSTRY CO LTD nm min A m 4 4 Carriage BLDC MOTOR 1SET 1PC 1SET 2PCS 3PCS 1PC UI 9 P cm min QP 041 17 z 8 eu h Travel speed volume control e Turn the knob in this direction to slow down CI Turn the knob in this direction to speed up 3 Traveling direction TOGGLE S W This switch selects the direction of carriage 1 Welding Non welding You can select welding non welding function of Torch No 1 2 Welding Non welding You can select welding non welding function of Torc
3. CS 231 USER MANUAL CHUNG SONG INDUSTRY CO LTD MADE IN KOREA H L T 82 55 329 9500 F 82 55 329 9505 MAIL koweld koweld co kr Http www koweld co kr Table of contents 1 Outline and characteristics a a 3p 2 Applicable Materials shape and posture 4p 3 Main specificallOHiS cure aanaju aaa kaka anda jaak OS ta aaa 5p 4 Control Panel Operation Explanation 6p 5 Installation amp Operation semnioeincsusnaakedsnbsHdbueniukaunak unanka at kkik iis 8p 6 Maintenance and checking eeeHHHHHe 9p 7 Breakdown and measures Hee 9p 8 P id LISE eee u EM E E ee 11p 9 Block diagrami m a i 14p 10 Circuit dpi a jk pa REE 15p 11 Assembly plai sence a aaa jaa nt I UU SERI OUS 19p QP 041 17 CHUNG SONG INDUSTRY CO LTD 2 1 OUTLINE and CHARACTERISTICS CS 231 carriage is a 2 pole fillet auto welding machine with 4 rubber wheel drive The machine can operate on I BAR type member without installing any rail and the 2 pole torch provides faster and highly effecient work Built in magnet neodium prevents the carriage from getting out of the welding line The BLDC motor guarantees smooth operation at both low and high speed Torch angle and member height ARM length are easily adjusted and X Z slide supports fine
4. 2011 sheet 1 of 2 QP 041 17 CHUNG SONG INDUSTRY CO LTD ISP 10 Circuit diagram RLY_TORCH lt PD7 T2 PF7 AD C7 TDI RED TTL TKD_ITL eK CN4 A dl AJ 5 Y1 is OUT XTAL1 Tm a XTAL2 PG3 TOSC2 PGATOSC1 D D P PCO IPCI rin is Ls ip in FNDO FND1 PEO SS PB1 SCIO PE2 MOSD PES MISO PBA QCO PBS OC1A PBE OC18 FEL DIR PET OCZ CAC ISP SCK 1 AI PDO EN UP SW IPC2 iPCa PDOSCLANTO PFO ADCO T PDA SDAANTT PFA ADC1 T T PDARXD1ANT2 PF2 ADC2 PDX TXD4ANT3 PFS ADC3 PDAIC1 PFA AD CA TCI El Pp amp xckct PFS ADCSITMS RLY TORCH gt POSTI PFB AD C amp TDO FND2 FND3 Mili b e El po 0 PED PDIRXD PGXALE PET PDOITXD PGi RD PE2 XCKOJAINO POOR PE3 OC3A AINT PEA DC3BANTA PES OC3C INTE PEB T3 INTS 5 SEL SEN L vec DC 24V JRST xd pa PES INT u28 3 R GND D PE ICP3 Q o swt DIR SW GND Eu RUN SW C15 VEC WEC C16 C17 C18 C19 GND GND U2C PU U2D TS11CS513A_ 20 CPU0I SY E A m 0l HH II sa A BAA AS E U3D USF Ji b GIN J2 O sO m DUN m p OQ MA MOT RUN PB5 RUN a D gt MOT RUN GND 3E C13 PBS OCRIB MMA PM PB DIR 13 502 DIR itle T 11C 513A Bize Document Number Rev 20 Date
5. 7WC TC T03 CLAMP FIXED KNOB AL6061 2 7WC TC T04 CLAMP FIXED BOLT 1 S45C 2 7WC TC 05 CLAMP INSULATION BAKELITE 2 CP BODY 05 MAGNET N D 2 25X40X10 P ZZ 05 GEARHEAD d 1 1 5042 400 M 1 Z 15 SCALE 1 None PROJECTION F gt DRAWING CHECKED REVIEWED APPROVED Parts List CS PART NO DESCRIPTION MATERIAL Q T COMMENTS 100B BD P04 ROLLER BEARING SUJ2 4 688 23 BD 01 BODY BASE AL6061 1 23 BD 02 BACK PLATE AL6061 1 23 BD 03 BOTTOM COVER SUS 1 23 BD 04 SIDE PLATE R AL6061 1 23 BD 05 SIDE PLATE L AL6061 1 23 BD 06 BOTTOM BRACKET AL6061 1 23 BD 08 WHEEL SHAFT S45C 2 23 BD 09 WHEEL SHAFT BUSH U AL6061 2 23 BD 10 SHAFT HOUSING BRACKET AL6061 2 23 BD 11 WHEEL SHAFT BUSH D AL6061 2 23 BD 13 SUPR CASE 1 AL6061 1 23 BD 14 AH 21011 S45C 2 M 1 Z 26 23 BD 15 AH 21012 S45C 2 M 1 Z 30 23 BD 17 CHAIN SPROCKET BUSH R AL6061 2 23 BD 19 MAGNET CASE 1 AL6061 2 23 BD 19 UPPER GUIDE ROLLER BUSH SS400 4 23 BD 20 UPPER GUIDE ROLLER BUSH 2 SS400 2 23 BD 21 UPPER GUIDE BRACKET 1 AL6061 2 23 BD 22 UPPER GUIDE ROLLER SUS 2 23 BD 24 SENSOR COVER AL6061 1 23 BD 28 HANDLE BRACKET 2 AL6061 1 23 BD 29 HANDLE BRACKET 1 AL6061 1 23 BD 31 SPATTER COVER 2 AL6061 1 23 BD 3
6. hionday November Z9 20 b QP 041 17 CHUNG SONG INDUSTRY CO LTD 16 10 Circuit diagram 4 3 2 1 D D c C DC 24V DC 24V DC 24V L AC220V CN2 1 R1 B C2 K AC220V A RIM bf EARTH nou P GND D1 D EARTH P GND ite T511C5514A Bize Documert Number Rev B POWER 18 Date Monday November 28 2011 pheet 1 of 1 i taa QP 041 17 CHUNG SONG INDUSTRY CO LTD 17 11 Assembly plan 300 H 405 W I BAR 2POLE WELDING CARRIAGE JH GENERAL SPECIFCATION gt HA 9 APE Kg B 4WHEEL 21012 SY A SAA 0 S F X ROLLER SUS 3331 XI 2 DIMENSION 270 L X 405 W X 300 H 8 Kg FUST 01060 mm mint5 WHEEL 850 BODY FH DE 24V 12W 5000RPM 23101 400 1 SPUR GEAR 2 1 SLIDE As Atot OLS Hel 0r50mm 5 A 0 6 J c 0 20 GUIDE mm 5 270 L DATE UNIT mm SCALE 1 None PROJECTION EO DRAWING CHECKED REVIEWED APPROVED TITLE BODY PART I BAR
7. INDUSTRIES CO LTD QP 041 17 CHUNG SONG INDUSTRY CO LTD 20P
8. 2POLE TORCH iam PROJECT I BAR WELDING CARRIAGE TYPE CS 231 DWG No CS 231 A001 CHUNG SONG INDUSTRIES CO LTD QP 041 17 CHUNG SONG INDUSTRY CO LTD 18P 11 Assembly plan PANEL 1 TORCH X amp Z SLIDE KIT BODY 2 TORCH X amp Z SLIDE KIT DATE UNIT mn BODY PART SCALE 1 None PROJECTION TITLE I BAR 2POLE ASS Y iam VED PROJECT I BAR WELDING CARRIAGE TYPE CS 231 DWG No CS 231 A002 CHUNG SONG INDUSTRIES CO LTD QP 041 17 CHUNG SONG INDUSTRY CO LTD I9P 11 Assembly plan Parts List CS PART NO DESCRIPTION MATERIAL Q T COMMENTS 5 BD 03 HANDLE COVER RUBBER 1 5 BD 04 GRIP BRACKET SS400 1 5 BD 14 WHEEL 2 RUBBER 4 650 5 BD 14 WHEEL 1 AL6061 4 5 PN 53 TOGGLE SWITCH COVER RUBBER 3 gyds 5 PN 55 PUSH BUTTON COVER 1 RUBBER 1 BLACK 5 PN 56 PUSH BUTTON COVER 2 RUBBER 1 ORANGE 5 PN 57 VOLUME KNOB PLASTIC 1 F9 5 PN 58 FUSE PLASTIC 1 F8303 584 5 PN 59 POWER CONNECTOR PLASTIC 1 SCK 20 3P 5 PN 62 TOGGLE SWITCH PLASTIC 3 WIT 2216 2c 5 PN 65 PUSH BUTTON E 2 SP 103C 5 SD HD KNOB PLASTIC 4 7W PN 97 2PIN TORCH CONNECT PLASTIC 2 7WC TC TORCH CLAMP L AL6061 2 7WC TC T02 TORCH CLAMP U AL6061 2
9. 3 SLIDE ROLLER BUSH 2 SS400 1 23 BD 34 SLIDE ROLLER SUS 1 23 BD 35 SLIDE ROLLER BUSH SS400 1 23 BD 36 SLIDE ROLLER HOUSING AL6061 1 23 BD 37 WHEEL SLIDE BSAE AL6061 1 23 BD 38 SLIDE ROLLER KNOB AL6061 1 23 BD 39 HEATING SPACE AL6061 5 23 BD 40 HEATING COVER B S 1 23 BD 66 CLAMP BOLT S45C 1 23 BD P01 SHIHE SELAH M10 45L SUS 1 23 BD P02 STRIPPER BOLT 2 SCM435 1 8X25L 23 BD P03 STRIPPER BOLT 1 SCM435 2 8X45L 23 BD POS DU BUSH i 2 52d08X6L 23 P06 SLIDE ROLLER SHAFT BEARING STEEL 2 6000 23 BD P08 SHAFT BEARING S45C 6 688 23 BD P10 SENSOR_PSN17 5DN PLASTIC 1 23 PN 01 PANEL 2POLE S541 2 3 1 23 PN 02 NAME PANEL FRAME S541 3 1 23 PN 03 NAME PANEL 2pole AL6061 1 23 PN 04 CONNECT PLATE AL6061 1 23 PN 63 MAIN PCB PLASTIC 1 23 SD 41 Y SLIDE BRACKET 2 AL6061 4 23 SD 42 SLIDE SUPPORT AL6061 4 23 SD 43 SLIDE BAR 55400 8 23 SD 44 SLIDE BOLT L S45C 4 23 SD 45 X SLIDE FLANGE AL6061 4 23 SD 46 Y SLIDE BRACKET 1 AL6061 4 23 SD 47 Y SLIDE COVER 2 AL6061 4 23 SD 49 SLIDE FIXED BRACKET L AL6061 1 L TYPE 23 SD 50 Z SLIDE FIXED BRACKET 1 AL6061 1 I TYPE 23 SD 51 TORCH CLAMP BRACKET AL6061 2 23 SD 52 ARM AL6061 2 23 SD 53 ARM CLAMP AL6061 2 23 SD 54 Z SLIDE FIXED BRACKET L AL6061 1 L TYPE 23 SD 55 SLIDE FIXED BRACKET I AL6061 1 I TYPE DATE 2011 11 25 UNIT mm ASSEMBLY TITLE I BAR 2POLE ASS Y cs PROJECT AUTO CARRIAGE TYPE CS DWG No 001 CHUNG SONG
10. LDING CONTROL CABLE T amp WELDING POWER WELDING POWER CABLE N TORCH SIGNAL R S i i 4L10 380 220 i VAC 9 L a TORCH CABLE POWER H SOURCE H OE 500 600ADC EON e V C02 GAS POWER CABLE i 12 220VAC B 69 50 60Hz VE TIOVAC 50Hz 2 TORCH BUYER S OPTION EARTH CABLE DATE 2011 11 25 UNIT mm SYSTEM LAYOUT SCALE 1 NONE PROJECTION 0 TITLE DRAWING CHECKED REVIEWED APPROVED CS 231 ASS Y PROJECT AUTO CARRIAGE TYPE CS 231 DWG NO 001 CHUNG SONG INDUSTRIES CO LTD QP 041 17 CHUNG SONG INDUSTRY CO LTD 13P 10 Circuit diagram J1 1 A 2 3 C 4 D 5 E 6 F DIG1 7 G DIG2 8 H DIG3 NM GND J2 EN_UP_SW EN PUSH SW o SI 0 Q gt Q N GND GND EN DN SW Cs GND itle TS11CS511A ize Document Number Rev A DIS amp SW 11 Date Monday November 28 2011 heet 1 of 1 2 QP 041 17 CHUNG SONG INDUSTRY CO LTD 14P 10 Circuit diagram DC 24V DC 24V vec 5 R1 p P GND In D1 NM GND vec CN2 WELD COM OO DC 24V 3 NED Come 4 c 5 c F SETO EXT STOP 9 GND TORCH1 TORCH2 CS K2 a SW2 3 ME i WELD COM2 DC 24V DC 24V 1 C4 SW1 4 3 le an WELD COM1 RLY TORCH RLY_TORCH RLY_TORCH gt ite TS11CS513A Dize Document Number Rev B POWER 20 Date Monday November 28
11. RIAGE Check if CO Gas is properly Supplied Start Welding Work Start the Welding Work by pressing the Driving Start BUTTON after switching ON the Welding Speed Switch of the Control Board Press the STOP BUTTON Switch 2 if Welding Work of the Materials is finished Confirm the Welding End QP 041 17 CHUNG SONG INDUSTRY CO LTD 7P 6 Maintenance and checking The auto carriage should be regularly maintained and repaired to use it safely for a long time 1 ls there much dust on the control panel Control box torch adjustment switch should be kept clean and wipe floating matters off Be sure to clean around control box 2 Aren t deposits stuck to Remove deposits and sputters from tip nozzle guide roller driving wheels magnets and slide adjustment part They may cause problems for travelling carriage safely 3 Are the screws in torch clamps and guide rollers loose The loose screws may cause bad travelling or uneven bead and therefore all the screws should be tightened Especially floating matters such as dust should be wiped off well 4 Isn t there any damage on connecter power cable and torch cable Check if connectors are loosely connected or damaged Or are cable hose and torch disconnected or damaged 5 Isn t there any abnormal noise or overheating Check the wheel motor and welding torch 7 Breakdown and measures If there is any problems with auto carriage check instruction
12. e The switch on welding machine is change the crater switch to off mode on mode QP 041 17 CHUNG SONG INDUSTRY CO LTD 9P _ lt HM ra i ALC uw 8 Part List CS NO DESCRIPTION MAT REMARK BODY PART Ca pow ama aa ws joo RW aa 1 fpoovecrrommare j wx Tas x ovem aa C G wansi j s mem C 5 fomen saer cove j mem 15 jwensmersusa f see C 161 Jwensmeersusa f so m jm r se C 2 pooma wes C 25 were j ser Tan 24 faner sacer j Aa C 2 wem see Tan s af wem Tan sensor 3 SON ioc wer pcsmusmuss MOTOR j fiwon wc moz moror sacer 1 ser Y 7 SLIDE PART QP 041 17 CHUNG SONG INDUSTRY CO LTD 10 QP 041 17 CHUNG SONG INDUSTRY CO LTD 1 L a mo m 4 sasc 2 QLA M12 S45C 28 ZLM M12 CS 20S SLIDE BOLT R SLIDE BUSH 5 100B 100B AL6N01 30 D DESCRIPTION EA _ 2 II N a A IN Un i 0 IZ sue covery s jwarsuxsor af sse pe sunnum fanc saoe sor cove j mss 7 s jwersuxsmeer fa 7 jwersuoc
13. h No 2 6 Start switch Push button Black Push this switch to start operation of the Carriage Stop switch Push button Red CHUNG SONG INDUSTRY CO LTD 6P 5 INSTALLATION AND OPERATION 1 WELDING PREPARATION At first tools for WELDING such as POWER SOURCE and WIRE FEEDER are needed Welding Power Source 35 440 380 220V AC for the Driving and Control of CS 4A TYPE is needed CO Gas Tank for Welding is needed TORCH for CO Auto Welding is needed Basic Preparation Tools of Welding Works are basically needed 2 CONNECTING METHOD of CARRIAGE WELDING TORCH CONDUIT CABLE of AUTO CARRIAGE should be connected to the WIRE FEEDER CONNECTOR for TORCH S W which come out of the WELDING TORCH should be connected to the MAIN CABLE CONNECTOR of the BODY CONTROL CABLE should be connected to the CONTROL BOX CONNECTOR of the BODY OPTION CONTROL POWER SOURCE CABLE should be connected to the POWER SOURCE 3 WELDING PROCESS Switch ON the PRIMARY SIDE DISTRIBUTION BOARD of WELDING POWER SOURCE Switch ON the CONTROL POWER SOURCE of FRONT PANEL of WELDING POWER SOURCE Equip the WIRE FEEDER with WIRE and feed it to the end of TORCH Set the AUTO CARRIAGE at the WELDIING START POINT Adjust the Target Angle and Position of the TORCH with the TORCH ADJUSTMENT SLIDER Fine Adjustment of the Angle and Position is possible with Screw Type Set the Welding Condition that should be fit for a Work to the CAR
14. own af azo s s ET s o pee TORCH CLAMP PART 2 fonaa soor A wma Ts s powwawweo aso Ts 3 TKS ao Ts 3 uwenepsor j sec CS x s 3 etawr veo esos ea GUDIE ROLLER PART persoum j 8 C s j see Un ON l Ul V P lt HM A cs wo Jpeseaenon ea mar REMARK an ea suoeeraceera a sof 7 as fouero fas 7 r us _ j ee jewxsoumcows HANNE ss SUB GUIDE ROLLER PART as pomer j seo L pouneem aar s m E w opm pemmem gt ms Panza a sar o e panem ea S wr o ar s s rocci wren come a moss s ss pusk porron cowna unser poc s_ _s6_fpusHeurroncover2 1 Roeser forane jou ipee ajas p ruenc ens 88e Ts 5 women sus fm Cs Af rasne Weme Puwsumow z exe Dp TORCH conne a sos kiss U1 U1 U1 FEE JI Uu ON QP 041 17 CHUNG SONG INDUSTRY CO LTD 12 P 9 Block Diagram CS 231
15. s as follows 1 Power display light of CONTROL Panel is not turned on Cause Repair measure Bad control cable CABLE change connection disconnection fuse change Control box fuse disconnection if it still makes troubles contact After sales team 2 ARC is not generated though welding button is pressed Cause Repair measure Non welding is selected on Selected weldin welding non welding switch 9 Loose contact of wire Remove slag check earthing Bad welding start button Check and repair the button wiring Check if stop sensor works 3 Carriage does not travel though welding start button is pressed QP 041 17 CHUNG SONG INDUSTRY CO LTD 8P Mm MW NW Check and repair motor driving part Bad welding start button switch Cases ano a lC Wi Check if stop sensor works Bad main PCB change refer to After sales service 4 Torch targets wrong position Cause Repair measure Targeting position of torch clamp Check and tighten screws and Is loose change them if damaged 5 Slide is hard to adjust Cause Repair measure Deposits or dust are on slide part Clean slide part and spread around oil 6 Carriage stops during automatic welding Cause Repair measure Carriage has obstacles in the running Remove obstacles stop sensor operation 7 ARC does not disappears even though stop switch is pressed Cause Repair measure bad welding stop button switch check the switch and change it with a new on
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