Important - Telwin INVERSPOTTER 13500 smart aqua Manuel D'instructions

6.2.2 Adjusting the squeeze force and function (pneumatic clamp only)
The force is adjusted automatically or manually (using the air group pressure regulator).
The automatic (default setting) or manual mode can be set by pressing the "MODE"
key several times (Fig. C-5) until "MAINTENANCE" appears on the display; after this,
use the cursors to move to "AUTO" and select "AUTO" or "MAN" with the encoder.
Press the encoder to confirm the choice made.
Automatic adjustment:
By choosing "AUTO" the user can set the required force value; by pressing the
pushbutton on the clamp, the electrodes squeeze at the force that is set without
emitting current.
In the "AUTO" mode, during the spot welding cycle, the force at the electrodes is
adjusted automatically according to the values set in the spot welding program.
Manual adjustment:
Select "MAN" to set the force value, acting directly on the pressure adjuster (Fig.
B-10): set 3 bar and move the electrodes using the clamp pushbutton, then read the
force value obtained on the display; increase the pressure and repeat the squeezing
operation until the required force value is obtained.
In the "MAN" mode, during the spot welding cycle, following the procedure described
above to adjust the force at the electrodes manually.
Squeeze function:
Squeezes the electrodes at the set force without emitting current.
The electrodes can be squeezed in any spot welding program by following the
procedure below (double click):
Press and release the pushbutton on the clamp, then immediately keep the pushbutton
pressed. The clamp squeezes and keeps the electrodes closed until the pushbutton is
released again. The display shows "SQUEEZING" and the LED on the clamp flashes.
WARNING: using protective gloves can make double clicking to
squeeze difficult. We therefore recommend selecting the squeeze function when
inside the "MAINTENANCE" program.
WARNING!
RESIDUAL RISK! Even in this operation mode the risk of crushing of the upper
limbs is present: take the necessary precautions (see safety chapter).
6.2.3 Automatic setting of the spot welding parameters
The spot welding parameters are set automatically by the machine: "SMART AUTO"
mode. Both plugs of clamp C must be connected to the machine (Fig. F).
6.2.4 Semi-automatic setting of the spot welding parameters (Current, Time)
(Paragraph 4.2.1 and Fig. C)
The spot welding parameters are set by the machine, selecting the thickness and
material (*) of the panels to be welded from the following modes:
- EASY (two equal panels).
- PRO (two equal or different panels).
- MULTI (three equal or different panels).
Spot execution is correct when, during a pull test, the nugget on the welded point is
extracted from one of the two panels.
(*) NOTE: The standard materials available are:
- "Iron" ("Fe" abbreviated): iron panels with a low carbon content;
- "Fe Zn" (abb. "Fz"): galvanized iron panels with a low carbon content;
- "Hss" (abb. "Hs"): steel panels with a high breakage limit (700 MPa max);
- "Boron" (abb. "Br"): boron steel panels.
6.2.5 Manual setting of the spot welding parameters and creation of a
personalised program
The spot welding parameters can be set manually to test weld or to create a
personalised program.
Starting from the "Easy, Pro, Multi" mode, press pushbutton 1 shown in Fig. C for three
seconds to enter the "MANUAL/PROG" mode, then use the same key to select the
parameter to be modified: press and rotate the encoder to modify the value, and press
the encoder again to confirm. In this manner the chosen parameters can already be
used to spot weld, but will not be saved.
To return to the initial mode, press key 1 Fig. C for 3 seconds; "save the program?"
appears. Select "NO" if the new values are NOT to be saved, and press "YES" to save
with name.
The personalised program with its name can be used again at any moment in the
"CUST" mode.
6.3 AUTOMATIC SPOT WELDING PROCEDURE
This function is available with the pneumatic "C" clamp that is supplied with the
machine as standard.
Select the "SMART AUTO" mode using the "MODE" key to enter the preliminary
"ZEROING" procedure.
To zero correctly, keep the clamp push-button pressed for the time necessary following
the indications given on the display, then proceed as follows:
- Place the arm electrode against the surface of one of the two panels to be welded.
- Press the pushbutton on the clamp to:
a) Close the panels between the electrodes.
b) Start the spot welding cycle with the current passage signalled by the LED on
the control panel.
- Release the pushbutton a few moments after the LED has switched off.
- After spot welding, the average spot welding Current (excluding the start and end
slopes), the Force at the electrodes and the spot welding time are displayed.
A "warning" can be added to the displayed values, signalled by the red flashing
LED of the clamp (see TAB. 1), on the basis of the result obtained with the spot
welding.
- When finished working, place the clamp in its support on the trolley.
To zero again, press the "MODE" key repeatedly until "ZEROING" appears on the
display; to exit from this procedure without zeroing, press the "ESC" key.

IMPORTANT:

For good automatic spot welding results, repeat zeroing when:
- The electrodes are replaced;
- The electrodes are cleaned (advisable after approx. 30 spots);
- The arm is changed;
- The welding style is changed.
WARNING: during zeroing the clamp carries out a special spot
welding cycle where current is issued and the electrodes are closed several
times. Respect all the indications given in the "GENERAL SAFETY" paragraph
OF THIS MANUAL!
6.4 SEMI-AUTOMATIC OR MANUAL SPOT WELDING PROCEDURE
Operations valid for all tools, starting from the "Easy, Pro, Multi" modes:
- Select the panels to be welded (material and thickness) using the encoder.
- Look at the pre-set spot welding parameters (Fig. C-1).
- If required, personalise the spot welding program (see paragraph 6.2.4).
6.4.1 PNEUMATIC CLAMP
- Select continuous or pulsed spot welding (Fig. C-2).
- Place the arm electrode against the surface of one of the two panels to be welded.
- Press the pushbutton on the clamp to:
a) Close the panels between the electrodes.
b) Start the spot welding cycle with the current passage signalled by the LED
on the control panel.
- Release the pushbutton a few moments after the LED
- After spot welding, the average spot welding Current (excluding the start and end
ramps), and the Force at the electrodes are displayed.
A "warning" can be added to the displayed values, signalled by the flashing red
LED on the clamp (see TAB. 1), on the basis of the result obtained with the spot
welding.
- When finished working, place the clamp in its support on the trolley.
WARNING: presence of dangerous voltage! Always check the integrity
of the clamp power cable; the protective corrugated conduit must not be cut,
broken or crushed! Before and while using the clamp, make sure the cable
remains away from moving parts, heat sources, cutting surfaces, liquids, etc.
WARNING: the clamp holds the transformation, insulation and
rectifying sets necessary for spot welding; if there are any doubts on clamp
integrity (because of falls, violent knocks, etc.), disconnect the spot welder and
consult an authorised technical service centre.
6.4.2 STUDDER GUN
WARNING!
- To fix or remove the accessories to or from the gun chuck, use two fixed head
spanners in order to prevent the chuck from rotating.
- When working on doors or bonnets, you must make the earth connection
on these parts so as to prevent current from passing through the hinges,
and in any case the connection must be near the area being spot welded (if
the current has to travel long distances this will reduce the efficiency of the
weld).
6.4.2.1 Connecting the earth cable
a) Remove all traces of dirt, paint, etc. from an area on the plate that corresponds to
the contact surface of the earth bar, then take the completely clean plate as close
as possible to the point where working is to be carried out.
b1) Fix the copper bar to the cleaned panel surface using an ARTICULATED
GRIPPER (welding model).
In alternative to method "b1" (difficult to carry out) use:
b2) Spot weld a washer to the surface of the previously prepared panel; move the
washer through the copper bar slit and lock it with the supplied clamp.
Spot welding the washer for fixing the earth terminal
Fit the relative electrode (POS. 9, Fig. I) to the gun chuck and insert the washer
(POS.13, Fig. I).
Place the washer in the selected area. Place the earth terminal in contact in the
same area; press the gun pushbutton, activating welding of the washer to be fixed as
described previously.
Spot welding screws, washers, rivets
Fit the gun with the correct electrode, insert the element to be spot welded and place
it against the panel at the required point; press the gun pushbutton: release the
pushbutton only after the set time has passed (LED
Spot welding panels on one side only
Fit the electrode to be used onto the gun chuck (POS. 6, fig. I), pressing on the surface
to be spot-welded. Press the gun pushbutton, and release it only after the set time has
passed (LED switches off).
WARNING!
Maximum thickness of panel that can be spot welded, on only one side: 1+1 mm. This
type of spot weld cannot be used on body supporting structures.
Some essential precautions must be taken to obtain correct results when spot welding
plate:
1 - The earth connection must be impeccable.
2 - The two parts to be spot welded must be cleaned from all traces of paint, grease,
oil.
3 - The points to be spot welded must be in contact with each other, without gaps; if
necessary press with a tool, not the gun. Pressure that is too strong causes bad
results.
4 - The piece to be machined must not be thicker than 1 mm.
5 - The electrode tip must have a diameter of 2.5 mm.
6 - Tighten the nut that locks the electrode well and make sure the welding cable
connectors are locked.
7 - When spot welding, lightly push the electrode (3-4 kg). Press the pushbutton, and
only move yourself and the gun away from the workpiece when the spot welding
time has passed.
8 - Never stand more than 30 cm away from the earth fixing point.
Contemporaneous spot welding and traction of special washers
To do this fit and lock the chuck (POS 4, Fig. G) against the body of the extractor
(POS.1, Fig. I), connect and fully tighten the other extractor terminal to the gun (Fig. I).
Insert the special washer (POS. 14, Fig. I) into the chuck (POS. 4, Fig. I), locking it with
the relative screw (Fig. I). Spot weld it in the relative area, adjusting the spot welder as
if spot welding normal washers and begin traction.
When finished, rotate the extractor by 90° to detach the washer, which can be spot
welded again in a new position.
- 9 -
has switched off.
switches off).