MZ-1

Submerged Arc Welding Tractor

(MZ-D Control Box)

OPERATOR’S MANUAL
(PLEASE READ CAREFELLY BEFORE OPERATION)

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO., LTD.

Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

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 Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

Safety Depends on You

Huayuan arc welding and cutting equipment is designed and built with safety in mind. However, your
overall safety can be increased by proper installation and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.

Attention (very important)

1. Don`t let the tractor fall when it is on a slope position.
2. The tractor can`t be used in rain because its protection grade is IP21C.
3. Please don`t wear glove when guiding wire and changing wire reel.

4.across arm
3.box locking 4.across&arm
rotation lift 5. across arm 6.hanging 7.wire
7. 导丝 8.flux 9.welding head 10.head angle
handle lifting lock
lock retraction lock ring guide
架 ring hopper lifting adjustment lock

11.head elevation
11.机头仰角调节
angle adjustment

2.control box
12.wirefeed roller

13.Press wheel and

13.压紧轮及调
adjustment handle
1.wire reel 节手柄

14.上校直轮及
14. Upper corrective
手柄
wheel and handle

15.lower corrective
15.下校直轮
wheel

16.导电杆夹紧件
16.conductive rod
26. wiring board
clamping unit
and cable jacket

17. flux tube

25. clutch

18.conductive rod

24.handle

19. Flux hopper

clamping nut
23.wheel 22.立柱移动调节
22.column moving adjustment 21.conductive tip 20. probe

Diagram 1: Tractor Structure

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Ca ut io ns Arc and arc rays can hurt.

All performing welding workers ought to have health qualification from the authority organization to
prevent you and others from arc radiation and burn. It should be prevented for children to enter into
dangerous area as well.
Be careful reading the following important items and the welder safety byelaw from the authority
organization. Be sure that qualified professionals perform all installation, maintenances and repair
procedures.

1 Electric shock: The welding circuits are not insulated when welding. If you touch the
two output electrodes of the machine with your bare skin at the same time, it will lead
to electric shock, sometimes even fatal dangers. Users need to follow the items below
to avoid electric shocks:
 If possible, lay some insulating materials, which are dry and large enough, in your working field.
Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as possible
as you can.
 Components in the automatic and semiautomatic welding machine such as the welding wire reel,
feed wheel, contact tip and welding head are all electric components. .
 Always be sure the machine has been connected perfectly to the work piece with the work cables

and should be as close as possible to the working area.

 The work piece should be grounded perfectly.
 Make sure that the insulating material of the electrode holder, the grounding clamp, the welding
cable and the welding head are not affected by damp, mildewed or spoilt, and be replaced
momentarily.
 Never dip the electrode in water for cooling.
 Never touch electric components of two welding machines at the same time, because this voltage
is supposed to be two times of welding voltage while the grounding mode is not clear.
 While working high above the ground or other places having the risk of falling, please be sure to
wear safety belt to avoid losing balance caused by electric shock.
2 Arc: Use an arc welding mask to protect your eyes and skin from sparks and the rays
of the arc, pay special attention to the filter glass, which must be conformable to the
national standard.
 Use clothing made from durable flame-resistant material or sailcloth to protect your skin from
hurting by the arc rays.
 Remind other nearby personnel before working lest arc rays hurt them by accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous to health. Avoid
breathing these fumes and gases. While working in limited room, use enough
ventilation and/or exhaust to keep fumes and gases away from the breathing zone, or
use the respirator. Do not weld at the same time when using of degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with these gases to form phosgene, a highly toxic
gas,

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 Some protective gases used in welding might displace the oxygen in the air, and can lead to hurt
or even death.
 Read and understand the manufacturer’s instructions for this equipment, and validate the health
certification of consumptive materials, make sure they are innocuous.
4 Spatter: Spatter can cause fire or explosion.
 Remove fire hazards from the welding area. Remember that spatter from welding
can easily go through small cracks and touch fire hazards. Protect all kinds of lines
going though welding area, including hydraulic lines in the wild.
 Where compressed gases are to be used in the field, special precautions should be used to
prevent explosion.
 When welding stops, make certain that no live part is touching the work piece or the work stage.
Accidental contact can create a fire hazard.
 Do not weld containers or lines, which are not proved to be innocuous.
 It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work
until the proper steps have been taken to insure that there is no flammable or toxic gas.
 Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a cap
over your hair to prevent from burning by spatter. Wear the ear shield when performing sideways
or face up welding. Always wear safety glasses with side shields when being in a welding area.
 The welding cables should be as close to the welding area as possible, and the short, the better.
Avoid welding cables going through the building framework, lifting chains, AC or DC cables of
other welding machines and appliances. The welding current is strong enough to damage them
while having short circuit with them.
5 Cylinder: Damage of it might cause explosion.
 Make sure that the gas in the storage cylinder is qualified for welding, and the
decompression flow-meter, the adapter and the pipe are all in good condition.
 Make sure that the installation of cylinder is by the wall and bundled tightly by a chain.
 Be sure to put the cylinder in the working space with no crash or shake, and far from welding
area.
 It is forbidden to touch cylinder with the welding clamp or the work cables.
 Avoid facing the cylinder while installing the decompression flow-meter or the gasometer.
 When not working, please tighten the valve.
6 Power: (For electrically powered welding and cutting equipment) Turn off input
power before installation, maintenances and repair, so that avoid accident.
 HUAYUAN welding equipment is Ι class safeguard equipment; please install the
equipment in accordance with the manufacturer’s recommendations by specific persons.
 Ground the equipment perfectly in accordance with the manufacturer’s recommendations.
7 Power:(For engine driven welding and cutting equipment)
 Work in ventilated place or outdoors.

 Do not add fuel near to fire or during engine starting or welding. When not working,
add fuel after engine is cooling down; otherwise, the evaporation of hot fuel would
result in dangers. Do not splash fuel out of the fuel tank, and do not start the engine
until complete evaporation of the outside fuel.

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 Make sure that all the safeguard equipments, machine cover and devices are all in a
good condition. Be sure that arms, clothes and all the tools do not touch all the
moving and rotating components including V belt, gear and fan etc.
 Sometimes having to dismantle some parts of the device during maintenance, but must keep
safety awareness strongly every time.
 Do not put your hand close to fans and do not move the brake handle while operating.
 Please remove the connection between the engine and the welding equipment to avoid sudden
starting during maintenances.
 When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid
hurt by the hot vapor.
8 Electromagnetic: Welding current going though any area can generate
electromagnetic, as well as the welding equipment itself.
 Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users
should consult one’s doctor first.
 The effect of electromagnetic to one’s health is not confirmed, so it might have some negative
effect to one’s health.
 Welders may use following method to reduce the hazardous of electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding
cable is by your left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.
9 Lift Equipment: carton or wooden boxes package the welding machines supplied by
HUAYUAN. There is no lifting equipment in its wrapper. Users can move it to the
prospective area by a fork-lift truck, and then open the box.
 If having rings, the machine can be transited using rings. While HUAYUAN Welding
Machine Manufacture reminds users, there is possible risk to damage the welding
machine. It is better to push the welding machine moving in use of its rollers unless
special situations.
 Be sure that the appurtenances are all removed off when lifting.
 When lifting, make sure that there is no person below the welding machine, and
remind people passing by at any moment.
 Do not move the hoist too fast.

10 Noise: HUAYUAN Welding Machine Manufacture reminds users: Noise beyond the
limit (over 80 db) can cause injury to vision, heart and audition depending on oneself.
Please consult local medical institution. Use the equipment with doctor’s permission
would help to keeping healthy.

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Catalogue

一． Product introduction---------------------------------------------------6

二． installation----------------------------------------------------------------8

三． Tractor structure and panel introduction--------------------------8

四． Maintenance and repair-----------------------------------------------15

五 Introduction about submerged arc welding materials and

technologies---------17

六． The weld defects and preventions------------------------------------22

七． Machine

diagram---------------------------------------------------------------------22

八． Accessories----------------------------------------------------------------23

九． Appendix ---------------------------------------------------------------------23

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SAFETY
For the electrical wires and terminals inside the Control Box over the safe voltage, only the trained
personnel should open the machine cover to check it.

一、 Product Introduction

1．Introduction on model

model： M Z — 1
Single wire
Automatic Submerged Arc Welding

Name: submerged arc welding tractor

2. Application Field & Condition
1） This welding tractor, assembled with submerged arc welding machine power source, can automatically
weld under flux layer. It is mainly used for welding various steel plate structure with groove or without
groove, such as butt weld, fillet weld and lap weld etc, and these kinds of welding seam can be at
horizontal level or on inclined surface with inclination angle less than 10°with horizontal level. This
machine can weld the steel carbon structure steel, low alloy structure steel, stainless steel, heat-proof
steel and compound steel etc.

2） Environment condition
a. Power supply quality
The waveform of power supply voltage should be actual sinusoid wave, the fluctuation of frequency
can`t exceed its rated value ±1% ； the fluctuation of power supply voltage can`t exceed its rated value
±10%.
b. Environment condition
The ambient air temperature range:
Welding: -10～+40℃；transport and store: -25～+55℃
Relative humidity level: at 40℃, ≦50%, at 20℃, ≦90%
The dust, corrosive gas and materials around working place should not exceed the normal content and
the machine should be used in the place with sea level less than 1000m, dry and ventilation and be
prevented from sunshine and raining.

3． Technical parameters

Item Parameter

The rated supply voltage 1~110V/50Hz (usually supplied by power source)

Suitable diameter of wire φ2.5 3.2 4.0 5.0 6.0mm

Rated welding current 1600A

Rated duty cycle 100%

Welding speed 0～155cm/min

Wire-feed speed 40～2000cm/min (can choose 135～675cm/min)

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Wire feed method constant or alternate wire-feed

Adjustable range of up-down (The tractor’s column) 140mm

Horizontal adjustable range of (The tractor’s head) 93mm

The distance of tractor wheel 300mm

The distance of tractor axes 350mm

Horizontal rotated angle (the head round the ±90 °

column)

Front-back sloped angle (the tractor`s head) ±30°

Left-right sloped angle (the tractor`s head) ±30°

Capacity of flux hopper 10L

Capacity of wire reel 25KG

Protection grade IP21C

Weight (without flux and wire) 52KG

External dimension 1010×580×930mm

4.External Dimension
930

35 0 300
5 80
3 60
10 10

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二、Installation(diagram as below)
断路器
breaker 此处若接触不好，将会有“手动
送丝”正常但启动后不能送丝的
Welding power
3～380V 故障。
source 焊接电源
MZ-1小车
MZ-1 tractor

送丝
行走
1～3

Welding
cable
焊接电缆
弧压采样
控制电缆
Control cable 行走
接地电缆
Earth cable

工件
workpiece

Diagram 2: installation
1. The welding power source should be installed as per the requirements of corresponding instruction

manual.

2. Usually connect one terminal of welding cable with output terminal “+” of power source, connect the

other side with the conductive board of the tractor, and connect one terminal of ground cable with

terminal “－” of power source, connect the other side with workpiece. If the positive pole& negative

pole are connected mistakenly, the manual wire feeding and welding does not work.

If work with DC electrode negative type, the positive& negative line of output terminal should be

exchanged, connect the workpiece to positive pole of power source and connect the tractor with

negative pole. (Meanwhile, exchange the signal wire at the back of tractor voltmeter by professional

person)

3. The multi-core control cable connects the “control” signal output terminal of power source with

control box connector of tractor firmly.

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4. Connect the tractor with ground firmly by copper-core wire ≥Φ1.0mm2

三、Tractor structure and panel introduction

1． Tractor structure (see diagram 1)

1) Wire reel: have welding wire put into wire reel before welding orderly.

2) Control box: during submerged arc welding all control is operated through control box.

3) Box locking handle: loosen the handle, control box can be turned right or left.
4) Cross arm rotation& lift lock: loosen the handle, the cross arm can rotate around the column ±90°, and
adjust the height of the head to meet the different welding position requirements.
5) Across arm retraction lock: loosen two nuts fixed in across arm lock, the across arm can be moved
forward and backward, then lock the across arm in the required position.
6)Hanging ring: to lift the tractor.
7) Wire guide unit: pass the wire through the location hole on the top of wire guide unit before sending it
to conductive rod.
8) Flux hopper: Store the flux. adjust the switch below the hopper to control the flux flow.
9)welding head lifting adjustment: adjust handle to regulate the wire extension to meet the height change
of workpiece.
10) Head angle adjustment: loose this handle, the head can rotate around the cross arm to ±30°
11) Head elevation angle: it can adjust the elevation angle range ±30°by loosening head with the K6 inner
six-corner spanner.
12) Wire feed rollers: This wheel is a wearing part. See the appendix figures.
13) Press wheel and adjustment handle: adjust the press strength of the wire by this handle.
14) Upper corrective wheel and handle: correct the straightening strength of wire.
15) Lower corrective wheel: work with upper corrective wheel.
16) Conductive rod clamping unit: to connect welding cable and conductive rod firmly. Please check the
joint connection condition regularly.
17) Flux tube: the flux flows to the welding area through this tube.
18) Conductive rod: customer can choose different length of conductive rod to change the length of
electrode and meet the different workpiece welding requirements. Customers can change its length by
themselves.
19) Flux hopper clamping nut: clamp the flux hopper and adjust the extension length of electrode to meet
the different welding positions of butt weld, fillet weld.
20) Probe: instruct and guide the welding arc moving along with required track.
21) Conductive tip: It belongs to wearing part and is used for conducting electricity. Notes: the
corresponding conductive tip should be selected to match with different diameter wires. If the aperture
become big and there is unstable arc appearing, then the conductive tip must be changed.
22) Column moving adjustment: adjust it to align the wire to weld seam.
23) Wheel: tractor travels depending on these wheels, the distance of wheel is 300mm and wheel width is
30mm.
24) handle: for moving the tractor.
25) clutch: urn on this switch and tractor travels automatically while welding. Turn off this switch to move
the tractor to the welding position manually.
26)Wiring board and cable jacket: connect the cable of power source with wiring board firmly and pack it
by cable jacket.

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 Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
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2、the function of tractor control panel

2.1 power on and off:

Power switch:
1. press the switch, the power is
电源开关：
off.
1. 按下关闭电源
2. Rotate the switch clockwise,
2. 顺 时 针 旋 转 开 启 电
the power is on.
源

2.2 ammeter display and the adjustment of welding current:

2.2.1 when the pass is pressed, it displays the preset current value stored inside the pass. No matter
whether the welding is under going, and the encoder is under adjusting (at this time it is invalid to adjust
welding current encode value). The pre-display indicator is on.
2.2.2 when the pass is not pressed, the welding current encoder is under adjusting, the welding current
preset value is pre-displayed, and the pre-display indicator is on. No matter whether the welding is under
going, if the welding current encoder is adjusted during welding, the welding current will be displayed
after stopping adjusting for 5 seconds. If the control box is locked, it is invalid to adjust encoder.
2.2.3 when the pass is not pressed, and the welding current encoder is not adjusted, the start button is
pressed, the welding current is displayed and welding indicator is on.
2.2.4 Except above situations, pre-display welding current preset value, and pre-display indicator is on.

Ammeter

焊接电流指示
Welding current indicating
Pre-display 预显电流指示
current indicating

Adjusting encoder
of welding current

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2.3 Voltmeter display and the adjustment of welding voltage:

2.3.1 when the pass is pressed, it displays the preset voltage value stored inside the pass. No matter
whether the welding is under going, and the encoder is under adjusting (at this time it is invalid to adjust
welding voltage encode value). The pre-display indicator is on.
2.3.2 when the pass is not pressed, the welding voltage encoder is under adjusting, the welding voltage
preset value is pre-displayed, and the pre-display indicator is on. No matter whether the welding is under
going, if the welding voltage encoder is adjusted during welding, the welding voltage will be displayed
after stopping adjusting for 5 seconds. If the control box is locked, it is invalid to adjust encoder.
2.3.3 when the pass is not pressed, and the welding voltage encoder is not adjusted, the start button is
pressed, the welding voltage is displayed and welding indicator is on.
2.3.4 Except above situations, pre-display welding voltage preset value, and pre-display indicator is on.

voltmeter

焊接电压指示
Welding voltage indicating
Pre-display 预显电压指示
voltage indicating

Adjusting encoder
of welding voltage

2.4 walking speed display and walking speed adjustment:

2.4.1 when the pass is pressed, it displays the preset walking speed stored inside the pass. No matter
whether the welding is under going, and the encoder is under adjusting (at this time it is invalid to adjust
walking speed encode value). The pre-display indicator is on.
2.4.2 when the pass is not pressed, the walking speed encoder is under adjusting, the preset valve of
walking speed is pre-displayed, and the pre-display indicator is on. No matter whether the welding is
under going, if the walking speed encoder is adjusted during welding, the walking speed will be displayed
after stopping adjusting for 5 seconds. If the control box is locked, it is invalid to adjust encoder.
2.4.3 when the pass is not pressed, and the walking speed encoder is not adjusted, the start button is
pressed, the walking speed is displayed and welding indicator is on.
2.4.4 Except above situations, pre-display walking speed preset value, and pre-display indicator is on.

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Walking speed

行走速度指示
Walking speed indicating
预显行走速度指示
Pre-display walking speed indicating

Adjusting encoder
of walking speed

2.5 function selection:

2.5.1 CV/CC selection: press the CV/CC characteristic selection button, the current welding characteristic is
changed from CV to CC, or from CC to CV. It records the current welding characteristic automatically.
When the power is restarted after power off, the working status keeps the same. If the controller is locked,
it is invalid to press the CV/CC characteristic selection button.
2.5.2 the selection of walking direction: press the button, the current welding direction is changed from
left to right, or from right to left. It records the current welding direction automatically. When the power
is restarted after power off, the working status keeps the same. The walking direction cannot be locked.
2.5.3 the selection of walking mode: press the button, the current walking mode is changed from
automatic type to manual type, or from manual type to automatic type. It does not record current welding
mode. When the power is restarted after power off, the walking keeps the automatic status. The walking
mode cannot be locked.
2.5.4 the selection of wire diameter: press the button, t he current used wire is changed from 3mm to
4mm, and the like.
CV/CC characteristic Walking
Walking mode
特性选择
selection 行走方向
direction 行走方式

Wire diameter
丝径选择
selection

2.6 storage use:

2.6.1 pass display: when the pass is pressed, it displays the selected pass number.
2.6.2 pass selection/storage/use: press the pass selection button, the pass displays the current pass
number. No matter whether the welding is under going, the indicator displays the pre-display, ammeter

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displays the pre-display current stored inside the pass, voltmeter displays the pre-display voltage stored
inside pass, walking speed display displays the pre-display walking speed stored inside the pass, it is invalid
to adjust encoder. If the pass selection or use or storage button is not pressed within 5 seconds, the pass
display is closed, above display displays normally. If the pass selection button is pressed, the current pass
number plus 1, it displays the storage parameter in next pass. If the use button is pressed, the parameter
inside the pass will be selected as the current welding parameter. If the storage button is pressed, the
current welding parameter is stored inside this pass.

Pass selection

storage

use

2.7 operation:
2.7.1 start button: press the start button, welding starts.
2.7.2 stop button: press the stop button, welding stops.
2.7.3 manual wire-back button: press the button, wire-back starts in 5S.
2.7.4 manual wire-feed button: press the button, wire-feed starts in 5S.

start stop 手动退丝

Manual wire-back 手动送丝
Manual wire-feed

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Remark:
If user chooses the CC function, besides the control box selects the CC, the function switch of
power source is placed on SAW and CC function.
If user chooses the CV function, besides the control box selects the CV, the function switch of
power source is placed on SAW and CV function.

3、build-in function:
3.1 locking function of welding parameters:
When the adjustment of welding parameters on panel is prohibited, this function can be used.
Firstly test the welding, select wire, welding characteristic, welding speed, then open the locking function
on main control board, the parameters cannot be adjusted on panel, but welding is normal. If the
welding parameters need to be adjusted, then close the locking function.

Locking function is closed(ex-factory status) locking function is opened

3.2 speed-up function of wirefeeding:

The ex-factory set of control box has the speed-up function of wirefeeding. After manual wirefeeding
for 5s continuously, it will be reverted to the Maximum wirefeed speed. When the speed-up function is
locked, there will be no maximum speed appearing in manual wirefeed and wire-back.

The prohibiting function of wirefeed speed-up is closed(ex-factory status) the prohibiting function of wirefeed speed-up is opened
4、the selection of welding power source and wirefeeder:
The new ex-factory welding system has completed the set of parameters, it can work after power on,
there is no need to have following set.
If change the control board of control box or change welding power source, the abnormal welding
may appear due to the improper parameters set, the parameters can be reset through following methods.
3.1 press the manual wirefeed button and manual wire-back button simultaneously, after 10 seconds
except the current is displayed, other digital display and indicator is off, the control box enters adjusting
mode.
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3.2 Ammeter displaying number 2 means that the power source used is ZDE AC/DC square wave arc
welding rectifier. Number 5 means that the power source used is ZD5 series DC arc welding rectifier.
Number 7 means that the power source used is ZD7 series DC arc welding rectifier. To select it through
rotating welding current encoder, after finishing press the storage button.
3.3 Ammeter displaying 630 means that the power source is 630A, 800 means the power source is
800A, 1000 means the power source is 1000A, 1250 means the power source is 1250A, 1600 means the
power source is 1600A. To select it through rotating welding current encoder, after finishing press the
storage button.
3.4 Ammeter displaying number 14 means that the wirefeed motor is 14r/min, 47 means wirefeed
motor 47r/min. To select it through rotating welding current encoder, after finishing press the storage
button.
3.5 All digital display and indicator is on, power off the power source.
3.6 start the power source, press the CV/CC characteristic selection button, if it can be adjusted, then
the set successes. To select proper wire and characteristic, adjust the welding power source, welding
voltage, welding speed to proper range, then the welding can start.
四、Maintenance and Repair
When the equipment occurs any problem, please check it as below steps.
First step: confirm the trouble causes
Please refer to below table 2-common trouble and solution.
Second step: external checking
Please refer to below checking & repairing 1: the methods of inspection motor
If the problem cannot be solved as per above mentioned solution, please contact local distributor or
inform our Huayuan service department.
Table 2 Common trouble and solution
Trouble Checking items Trouble analyzing and conlusion
A. To measure the resistance between the Check and repair welding/control cables
7 and 8 lines of the welding control cables, If control cable is no problem, the power
GZ1 the value ought to be about infinite. source is under trouble
Indicator and all If the fuse is damaged, change a new fuse
display does not B. check fuse
1.5A，Φ5×20
work when turn C. open the machine cover, test the line J2 The switch of power source is damaged, or
on the machine 14 and 15 OF MZDAP1, No 110V voltage the connection is under trouble
D. control board MZDAP1 or MZDAP2 is
Change control baord
damaged
A. welding wire contact workpiece normal
GZ2
B. button is damaged change
Press manual
B. control board MZDAP1 is damaged change
wirefeed switch,
Check the wirefeed motor as per checking
no reaction D．wirefeed motor is damaged
& repairing 1
GZ3 A. button is damaged change
Press manual
wire-back
B. control board MZDAP1 is damaged change
button, no
reaction
GZ4 A. button is damaged change
Cannot start B. control board MZDAP1 is damaged change
GZ5 A. button is damaged change

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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
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Cannot stop B. control board MZDAP1 is damaged change

GZ6
Cannot switch MZDAP2 is damaged change
wire diameter
A. incorrect wire or characteristic is
Check welding parameters set
GZ7 choosen
Welding is B. improper welding power source and
reset
abnormal wirefeed motor is set
C．control board MZDAP1 is damaged change

Checking and Repairing 1: the methods of inspecting motor

Warnings
The checking and repairing issue must be done by our Huayuan professional person. For your safety please
read carefully the safety notes.
A. Checking method: to make sure if the wire feed motor and walking motor can be
revolved when the DC voltage is supplied directly.
Checking Requirement: a DC current battery, electrical wires.
Checking steps:
 Pull out the plug of the wire feed motor or walking motor.
 Supply a 12VDC between the No.1 and 2 terminals of the motor with the wire.
 Check whether the outside wire around motor is in trouble: if motor run at a low rate, change
the wires of No.1 and No.2, the motor run in reverse. It shows the motor works well, or that be
in trouble.
B. If the wire feed motor has fault, replace it.
Required tool: inner six-corner spanner M6; straight screwdriver 150mm
 Use inner six-corner spanner M6 to remove the head
 Loose motor clamping nut, take the motor down
 Remove the two guide line on the back of motor, pay attention to its direction and mark it.
 Test the naked motor by use of checking method A, and confirm if the motor has fault again. If
the motor works well, that means the guide line connected to motor is short circuit, please
repair or change it.
 If confirm the motor is broken, replace it by a new motor.
 Install the motor and screw down the nut.
 Connect the two guide line as the mark.
C. If the walking motor has fault, replace it.
 Turn the tractor 90°.
 Remove the bottom base by straight screwdriver.
 Remove 4 pcs M6 screws by M6 spanner.
 Remove motor installation plate, and take down motor.
 Remove the two motor lines and pay attention to the direction and mark it.
 Test the naked motor by use of checking method A, and confirm if the motor has fault again. If
the motor works well, that means the guide line connected to motor is short circuit, please
repair or change it.
 If the motor is broken, replace it by a new motor.

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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

 Connect the two motor lines

 Install the motor into machine by M6 spanner
 Install the bottom base

五、Introduction about submerged arc welding materials and technologies

1. Welding flux
The function of welding flux is to ensure a good welding seam shape, besides its molten slag
covering the molten pool can prevent oxygen, nitrogen in air from entering molten pool. The welding
flux has a metallurgical reaction with liquid metal, which can remove the impurities in metal like oxygen,
hydrogen, sulfur, phosphorus, and add to the required alloy, then a welding seam metal with good
mechanical property or special property can be obtained.
According to the alkaline level, welding flux can be divided into alkaline flux, acid flux and neutral
flux. According to the chemical property, it can be divided into oxidizing flux (inclusive of SiO2,MnO or
Feo largely), weak oxidizing flux and inert flux (inclusive of Al2O3, CaO, MgO, CaF2, but almost no
SiO2,MnO or Feo).
Table 4 Common welding flux usage and matched wire
Suitable
Welding Welding flux
Usage Matched wire current
flux type granularity(MM)
type
HJ130 Low carbon steel, common low 0.45～2.5 H10Mn2 AC/DC
alloy steel current
HJ131 Ni alloy 0.3～2 Ni wire AC/DC
current
HJ150 Roller surfacing 0.45～2.5 2Cr13、3 Cr2W8 DC
current
HJ172 High Cr iron steel 0.3～2 Steel wire DC
current
HJ173 Mn-A1 high alloy steel 0.25～2.5 Steel wire DC
current
HJ230 Low carbon steel, common low 0.45～2.5 H08MnA、H10Mn2 AC/DC
alloy steel current
HJ250 Low alloy high tensile steel 0.3～2 Steel wire DC
current
HJ251 Heat resistant steel 0.3～2 Cr-Mo steel wire DC
current
HJ260 Stainless steel, roller surfacing 0.3～2 Stainless wire DC
current
HJ330 Low carbon steel and common 0.45～2.5 H08MnA、H10Mn2 AC/DC
low alloy steel current
Mn-Mo、Mn-Si and Ni high AC/DC
HJ350 Low alloy and high tensile steel 0.2～1.4
tensile steel wire current
HJ430 Low carbon steel and common 0.45～2.5 H08A、H10MnA AC/DC
low alloy steel current

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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

HJ431 Low carbon steel and common 0.45～2.5 H08A、H10MnA AC/DC

low alloy steel current
HJ432 Low carbon steel and common 0.2～1.4 H08A AC/DC
low alloy steel(thin plate) current
HJ433 Low carbon steel 0.45～2.5 H08A AC/DC
current
H08MnAH10MnMoA AC/DC
SJ101 Low alloy structural steel 0.3～2
H08Mn2MoA、H10Mn2 current
H08MnA 、 H10Mn2 、 AC/DC
SJ301 Common structural steel 0.3～2
H08MnMoA current
2.Welding wire
The applied welding wire in submerged arc welding is different for different types of welding
metals. Usually, there are carbon structural steel, alloy structural steel, high alloy steel, various
nonferrous metal welding wires and special alloy wires used for surfacing. The allied welding wire
surface should be smooth enough, so that it can be feed smoothly. It is better to choose the wire coated
with copper, which can not only prevent rust, but also improve the contact status between wire and
conductive tip. If there is oil stain and rust on wire, it must be cleaned, or they will be brought into
welding seam and cause blow holes, and affect mechanical property of welding seam.
Table 5 steel wire diameter and allowed deviation（mm）：
Wire diameter（mm） 2.0 2.5 3.0 3.2 4.0 5.0 6.0 6.5 7.0 8.0 9.0
Allowed deviation -0.12 -0.16 -0.20
general precision
Allowed deviation high -0.06 -0.08 -0.10
precision
Table 6 current range for various diameter wires
Wire diameter 2.0 2.5 3.0 4.0 5.0 6.0
（mm）
Current 200～400 250～450 350～600 500～800 700～1000 800～1200
range(A)
3.Parameters of affecting welding seam shape size
A. Welding technology parameters
1)Welding current
Welding current I increases, productivity improves, and deposition R, molten depth H enlarges. If I
is too large, it will cause burning through and overlarge heat-affecting zone. If I is too small, it will
cause insufficient molten depth and deformed welding seam. Under normal welding conditions and
no change made to other conditions, welding seam molten depth H is almost direct ration to welding
current I. H=Km X I
Km is proportion coefficient, it changes with the change of current type, polarity, wire diameter
and welding flux chemical composition.

For thick wire submerged arc welding, Km≈1mm/100A. For thin wire submerged arc welding,

Km≈1.3mm/100A.

2)arc voltage
Arc voltage is direct ration to arc length. If no change made to other conditions, with the increase
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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

of arc voltage welding seam molten width increases apparently, but molten depth and excess weld
metal decreases a little.

3)welding speed
Welding speed has a great effect on molten depth and width. When the welding speed is low(eg.
Single wire submerged arc welding speed is less than 670mm/min), with the increase of welding
speed, arc column inclines, and this is beneficial for backward flowing of molten metal, molten depth
increase a little, but usually the increase of welding speed can reduce molten depth, width and excess
weld metal. When welding speed increases to a certain level, molten depth and width will reduce
greatly due to the decrease of energy input.
B. Welding technology
Both the inclined angle of welding wire and workpiece angle have a great effect on welding seam
shape.
The inclination direction of wire includes forward and backward inclination. If the inclination
direction and angle is different, the force and heat function of arc to molten pool is different, thereby
it has a different effect on welding seam shape. When welding wire inclines backward at a certain
angle, the arc force to push the metal in molten pool backward is reduced, the metal on the molten
pool bottom become thick, so molten depth reduces, but the pre-heat effect of arc to base metal
forward increases, so molten width enlarges.
Inclination welding of workpiece includes upslope welding and downslope welding, which have a
different effect on welding seam shape. When it is upslope welding, it is easy to occur overlarge
excess weld metal, undercut on both sides, deformed welding seam etc. In practice, upslope welding
should be avoided as much as possible. The effect of downslope welding is contrary to upslope
welding. When the inclination angle is less than 6°～ 8°, the molten depth and excess weld metal all
reduce, molten width increases a little, welding seam shape is improved. But if welding angle is too
big, it will cause incomplete fusion, welding bead and other flaws.
C. Structure
1) Groove shape
Under same conditions, if groove width and depth is increased, then molten depth will decrease a
little, and excess weld metal, deposition ratio reduces greatly.
2) Welding seam gap
For butt welding, the change of welding seam gap can be used to adjust excess weld metal and
fusion ratio. Too large gap will cause solder skips easily.

Table 7 the influence of welding seam gap to butt welding seam size（wire Ф5mm flux HJ330）：
Plate parameters Molten depth Molten width reinforcement Fusion ratio%
thick （mm） （mm） （mm）
ness Welding Arc Weldin gap（mm）
(mm current voltage g speed 0 2 4 0 2 4 0 2 4 0 2 4
) （A） （V） （cm/
min）
12 700～ 32～34 50 7.5 8.0 7.5 20 21 20 2.5 2.0 1.0 74 64 57
750 134 5.6 6.0 5.5 10 11 10 2.0 - - 71 61 46

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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

20 700～ 36～38 20 10 9.5 10 27 27 27 3.0 2.0 2.5 60 57 52

750 33.4 11 11.5 11 23 22 22 3.5 2.5 1.5 63 58 49
134 6.5 7.0 7.0 11 11 10 2.5 - - 72 61 45
30 700～ 40～42 20 10.5 11 10.5 34 33 35 3.5 3.0 2.5 61 59 55
750 33.4 12 12 11 30 29 30 3.0 2.0 1.5 67 63 69
134 7.5 7.5 7.5 12 12 12 1.5 - - 77 72 60
4.butt joint single side welding
For automatic submerged arc welding, a groove can be made or not on workpiece. A groove does
not only ensure molten depth, sometimes also meet other technology purposes. Butt joint single
welding can take following methods: weld on welding flux backing plate, weld on permanent backing
plate or locking bottom, weld on temporary backing plate and impending welding etc.
1) weld on welding flux copper backing plate. It takes copper backing plate with groove, to which
welding flux is filled. During welding the welding flux plays the role of backing plate, also
protecting copper backing plate, which will be avoided to get direct effect of arc. Groove plays the
role of shaping back welding seam.
2) Weld on permanent backing plate or locking bottom plate. When welding workpiece is allowed to
keep permanent backing plate, the workpiece under 10mm in thickness can adopt permanent
backing plate single welding method. The workpiece above 10mm in thickness can adopt locking
bottom welding method.
3) Impending welding. When the workpiece is well assembled and has no gap, it can adopt
impending welding without backing plate. When this method is used for single side welding,
workpiece can be fused completely. Usually molten depth does not surpass two-thirds of plate
thickness, or it is easy to weld through. This method is only suitable for welding the joint which is
not required to fuse completely.
4) Weld on welding flux backing. For this welding method, the quality of welding seam shape mainly
depends on the backing strength, evenness of welding flux, and the evenness of welding seam
assembling.
Table 8 welding conditions of butt joint single welding on welding flux backing：
Plate Assembling Wire Welding Arc voltage Welding Granularity of
thickness gap diameter current （V） speed welding flux
（mm） （mm ） （mm） （A） （cm/min） backing
2 0～1.0 1.6 120 24～28 73 fine
3 0～1.5 1.6 275～300 28～30 56.7 fine
2.0 275～300 28～30 56.7
3.0 400～425 25～28 117
4 0～1.5 2.0 375～400 28～30 66.7 fine
4.0 525～550 28～30 83.3
5 0～2.5 2.0 425～500 32～34 58.3 fine
4.0 575～625 28～30 67.5
6 0～3.0 2.0 475 32～34 50 Normal
4.0 600～650 28～32 67.5
7 0～3.0 4.0 650～750 30～34 61.7 Normal
8 0～3.5 4.0 725～775 30～36 56.7 Normal
5.Butt joint double-side welding
1) Impending welding. No gap or a very little gap less than 1mm is left during assembling workpiece.
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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

For the 1st side welding, the molten depth usually should be less than half of workpiece thickness,
and the molten depth for opposite side welding is required to reach 60% to 70% of workpiece
thickness, so that the workpiece is molten completely.
2) Weld on welding flux backing. For the 1st side welding, the most economic welding method is
reserve a gap but no groove opened, and the selected welding parameters must ensure that the

molten depth is more than 60% ~ 70% of workpiece thickness. For the opposite side welding,
its welding parameters can be the same as that of the 1st side welding, so that the workpiece can
be molten completely.
Table 9 welding conditions of butt joint impending & double-side welding without groove
Plate Wire Workpiece front-side welding Workpiece opposite-side welding
thickness diameter parameters parameters
（mm） （mm） Welding Welding Welding Welding Welding Welding
current voltage current voltage current voltage
（A） （V） （A） （V） （A） （V）
6 4 380～420 30 58 430～470 30 55
8 4 440～480 30 50 480～530 31 50
10 4 530～570 31 46 590～640 33 46
12 4 620～660 35 42 680～720 35 41
14 4 620～660 37 41 730～770 40 38
15 5 680～720 34～36 63 850～900 36～38 43
17 5 800～850 35～37 60 900～950 37～39 43
18 5 850～900 36～38 60 900～950 38～40 40
20 5 850～900 36～38 42 900～1000 38～40 40
22 5 900～950 37～39 53 1000～ 38～40 40
1050
6.Fillet welding
1) Boat-shape welding
The both sides of workpiece for fillet welding is placed under 45°with vertical line, this is the best
condition for welding seam shape. This kind of welding method requires that the assembling gap

of joint is no more than 1 ~ 1.5mm, or the measure must be taken to prevent the los s of liquid
metal.
2) Horizontal fillet welding
When the boat-shape welding is unsuitable for some workpieces, it can take horizontal fillet
welding. The corresponding position of welding wire and welding seam has a great effect on the

quality of horizontal fillet. Usually the inclination angle of welding wire within 20°~ 30°, the

actual position of welding wire should be decided as per joint state. The cross section of each

single pass horizontal fillet is not more than 40 ~ 50mm², that is, when the welding foot length is

more than 8x8mm, it will cause metal spillover and undercut.

六、The weld defects and preventions

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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

1. The main welding defects and reasons

 Blow hole

a) Moisture, filth and oxidizing iron scrap in the flux, etc. all can cause blow holes in welding seam.

b) The insufficient covering of welding flux during welding causes the exposure of arc, which have
air involved in and causes the blow hole.

c) The molten slag is too viscous;

d) The arc magnetic blow causes the blow hole, which is usually produced at the end welding area
of thick plate.
e) The welding position is polluted by iron rust, oil stain or other filth.

 Crackle

a) Solidification crackle: For welding steel, the impurities such as the sulfur, phosphorus etc in the
welding seam causes solidification crackle while the welding seam solidifies.

b) Hydrogen-caused crackle: This kind of crackle is mostly formed in the heat-affect zone of welding
the low-alloy steel, middle-alloy steel and high-carbon steel.

 Slag inclusion

Slag inclusion caused in submerged arc welding is related to not only the slag detachability of welding
flux, but also the assembling state of workpiece, and welding technology parameters.

2. Prevention methods
Please take the following methods according to the quality demand of welding.

 Remove and clean oil, rust, moisture and other impurities on the surface of wire and on the both

sides of welding seam within the range of 20mm.

 The flux must be dried according to its operation regulation, store them under about 50°C

temperature for stand-by.

 The reclaimed flux must be prevented from pollution of the oxide, slag, water dust etc.

 the granular size of the flux must be suitable, the powder and dust should be cleaned up.

 The workpiece assembling gap for impending welding is not more than 0.8 ~ 1.0mm.

 When arc magnetic blows, the welding starts from the earth line side, and earth line must be

connected reliabely.

七、Machine Diagram
1. Machine Schematic Diagram

2. Machine Wiring Diagram

八、Accessories
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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

 MZ-1 tractor 1 set

 Conductive tipΦ2.5 Φ3.0 Φ4.0 (Φ3.2 Φ4.0 Φ5.0 orΦ4.0Φ5.0 Φ6.0) each 1
 Flux tube 2 pcs
 Welding control cable 15m
 Welding cable 15m
 Work cable 3m

九、Appendix
1、welding head
1 2 3 4 5 6

10 7

11
8
20
12 9
21

13

19

14

15

16 17

18

No. Name Specification Qty ERP Code

1 Welding gun holder Part of head, clamped to motor 1 203090000006
GB/T 70.1-2000 M8×75，for clamping the head to
2 Inner hexnut 1
motor and adjust the angel of head
3 Wire guiding plate For limiting the wire position when the wire feeds 1 212010600054
into wire feed system
4 Fixing axis of press wire rolls For fixing the press wire rolls and straighten rolls 2 204700000019
and straighten rolls holder holder. Press wire roll and straighten roll holder
should be able to revolve around the axis.
5 Axis-used elastic ring A type GB/T 894.1-1996 φ10 2
6 Locking hand wheel holder Support locking hand wheel, screw the two M6 2 212010600033
nuts down
It is used to adjust the top tight force of press wire
7 Elastic locking hand wheel roll, and it Can`t exchange with fixed locking 1 212010600029
hand wheel when using
8 Cap nut GB923-1988 M6 2 108020000048
9 Press wire rolls & straighten Supporting press wire rolls and straighten rolls 2 212010600028
rolls holder
10 Wire feeding rolls Connect with output axis of wire feed motor, 1 212010600023
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Chengdu huayuan electric equipment co., ltd MZ-1 Submerged arc welding machine
(MZ-D control box)

supply the wire feed force.

11 Wire feed rolls ring For fixing the wire feed rolls position on the axis 1 212010600022
12 Nut assembly parts GB/T 9074.14 M5×20 1
13 Head press wire rolls Supply the press force to wire 1 212010600027
14 Head corrective wheel Supply corrective force together with corrective 1 212010600038
bearing and wire feed rolls
15 Electrode board At the cable connection place, screw down nut. 1 203090000008
16 Conductive rod head For guiding the wire and conduct electricity 1 212010600042
17 Lengthened Conductive rob Lengthen conductive rod, used for conducting 1 203080200035
Ⅱ
18 Conductive tip wearing part, used for conducting 1 106050000063
19 Cap nut GB923-1988 M8 1 108020000047
20 Fixed locking handle wheel For adjusting the straightening force 1 203090000009
21 Wire-straightening bearing GB/T 276-1994 6300 1 108050000020
2、horizontal adjustment part

1 3

4
2

6
5

9 8

No. Name Specification Qty ERP code

1 Column base For fixing the column 1 2030900001
GB/T 73-1985 M8x10 is used for preventing the
2 fixed nut column rotation, the nut should be screwed down 1 108010500023
when using
3 Protection shield 3 Move with column together 1
For connecting protection shield 1 and 2. It can 2
4 Protection shield 2
move flexibly
5 Protection shield 1 Fixed protection shield, for limiting the position of 2
shield 2
- 25 -
 1 2 3 4 5 6 7 8

9
8
7
6

Handle
D1
SK1-1 SK6-3
J3-12
D
42

Rear wheel
SK4-1 1 激光指示器 SK1-2 SK6-4
控A J2-7
Front wheel

启动信号 J3-11
1
41
SK4-2 2 NC 行走电机
MG1

3、Electric diagram
SK2-1 SK7-1
3

A
SK4-3

-
+
J2-1 J1-3
电源给定
3 45
行走电机
SK4-4 4 NC SK2-2 SK7-2 J55ZYT54P×216
J1-4
46
SK4-5 5
控B J2-8
启动信号 SK2-3 SK7-3
5
Horizontal adjusting handle

MZDAP1 J3-10
SK4-6 6
压 J2-6 40
弧压信号（－） 引弧成功 SK2-4 SK7-4
6
FU1 J3-9
110VA SK4-7 7
J2-9 39
1.5A 14 ～110V电源 主控板 MG2 送丝电机
110VB SK4-8 8 SK3-1 SK8-1
J2-10

-
+
15 J1-2
44
C SK4-9 9 NC
送丝电机 SK3-2 SK8-2 J70ZYT53PX216
Chengdu huayuan electric equipment co., ltd

J1-1 C
C SK4-10 10 NC
43
SK5-2 SK10-2
SK4-11 11 J3-8
J2-3
11 38
电流信号 SK5-3 SK10-3
ND SK4-12 12 J3-7
J2-4
force for tractor.
For moving tractor

12 37
SK7-3 SK3-3 通信 SK5-5 SK10-5
position of the head

J2-5 J3-6
弧压信号（+）
Passive moving wheel

16 36
SK5-6 SK10-6
编码器 显示 按键 J2-2
47
J4-1 J4-2 J4-3 J4-4 J4-5 J4-6 J5-1 J5-2 J5-3 J5-4 J5-5 J5-6 J5-7 J5-8 J3-1 J3-2 J3-3 J3-4 J3-5

- 26 -
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

DJ1 DJ1 DJ1 DJ1 DJ3 DJ3 DJ3 DJ3 DJ3

DJ2 DJ2 DJ2 DJ2 DJ4 DJ4 DJ4 DJ4 DJ4

B

17 18 19 20 21 22 23 24 25 26 27 28 29 30

J2-5 J2-6 J2-3 J2-4 J2-1 J2-2 J1-7 J1-8 J1-5 J2-6 J1-3 J1-4 J1-1 J1-2
SA2 SA3 SA4 SA5

SA1
Rotating this handle can adjust the horizontal

There is a keyway in it which supplies the moving

13
MZDAP2
启动 停止 手动 手动
2
2
2
2

电源开关
面板 退丝 送丝
(MZ-D control box)

A
MZ-1 Submerged arc welding machine

212010100001
102010500731
212010100001
212010100029

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

FU1
13
fuse
14
差模(并绕) 共模(反绕)

D L1 L2 SK1 D
引脚 1 2
2 1 线号 42 41 MG1 D1
42
4、wiring diagram
46 45
SK5
29 27 25 23 引脚

5
4
3
2
1
45 43 14 1 16 11 3 41 39 37 35 33 31 21 19 17 2 3 5 41
46 44 22 20 18 30 28 26 24 线号

9
8
7
6
15 5 6 12 47 42 40 38 36 34 32 38 37 36 行走电机
IOIO
J3 J4 J5 J55ZYT54P×216
J1 J2
SK2
1 引脚 1 2 3 4
3 2
线号 45 46 39 40
4

MZDAP1 SK3
MG2
2 1 引脚 1 2 3
线号 43 44 16 43 44
3
Chengdu huayuan electric equipment co., ltd

C
主控板 送丝电机
C

J70ZYT53PX216
16
SK4

引脚 1 2 3 4
1 2
线号 1 NC 3 NC
3 4 5 6
引脚 5 6 7 8
4.2mm6芯胶壳(座) 4.2mm6芯胶壳(头) 4.2mm4芯胶壳(座) 4.2mm4芯胶壳(头) 10 8 9 10 线号 5 6 7 8
11 12 引脚
31 33 35 35 33 31 7 8 8 7 9 10 11 12
32 34 34 32 13 15 15 13 线号 NC NC 11 12

- 27 -
DJ3 DJ4 DJ1 DJ2 XS1

13 15
31 32 33 34

SA2 SA3 SA4 SA5 SA1

急停开关
B B
启动 停止 手动退丝 手动送丝
35 35 35 35 7 8

引脚 1 2 3 4 5 6 7 8 9 10 11 12
线号 远控A H D L 远控B 弧压 ～110V ～110V NC NC I END

30 28 26 24 22 20 18
J1 29 27 25 23 J2 21 19 17

MZDAP2
(MZ-D control box)

面板
A A
MZ-1 Submerged arc welding machine

1 2 3 4 5 6 7 8
The final explanation right is reserved to Huayuan Company!

If there is any change in the manual, please forgive not to inform separately!

Address: Wuhou National Science Park, Chengdu, China

Postcode: 610045

Telephone:0086-28-85365838

Fax: 0086-28-85033444

E-mail: hy_sales@126.com hwayuansales@163.com

http://www.hwayuan.com