Telwin INVERSPOTTER 14000 SMART AQUA 400V Manuel D'instructions page 5

ENGLISH
1. GENERAL SAFETY RULES FOR RESISTANCE WELDING ................................5
2. INTRODUCTION AND GENERAL DESCRIPTION ................................................6
2.1 INTRODUCTION .............................................................................................6
2.2 STANDARD ACCESSORIES ...........................................................................6
2.3 OPTIONAL ACCESSORIES ............................................................................6
3. TECHNICAL INFORMATION .................................................................................6
3.1 RATING PLATE ...............................................................................................6
3.2 OTHER TECHNICAL INFORMATION .............................................................6
3.2.1 Spot welder ............................................................................................6
3.2.2 Cooling system (GRA) ...........................................................................6
4. DESCRIPTION OF THE SPOT WELDER ..............................................................6
4.1 SPOT WELDER UNIT AND MAIN COMPONENTS ........................................6
4.2 CONTROL AND ADJUSTMENT DEVICES .....................................................6
4.2.1 Control Panel .........................................................................................6
4.2.2 Pressure regulator and pressure gauge unit .........................................7
4.3 SAFETY AND INTERLOCK FUNCTIONS ........................................................7
4.3.1 Safeguards and alarms .........................................................................7
5. INSTALLATION ..................................................................................................7
5.1 SETTING UP ..................................................................................................7
5.2 LIFTING PROCEDURES .................................................................................7
5.3 POSITIONING THE SPOT WELDER ..............................................................7
5.4 CONNECTION TO THE MAIN POWER SUPPLY ............................................. 7
5.4.1 Warnings ................................................................................................7
5.4.2 Mains plug and socket ...........................................................................7
APPLIANCES FOR RESISTANCE
PROFESSIONAL USE
Note: In the following text the term "spot-welder" will be used.
1. GENERAL SAFETY RULES FOR RESISTANCE WELDING
The operator should be properly trained to use the spot-welder safely and
should be informed of the risks connected with resistance welding procedures,
of related protection measures and of emergency procedures.
(Only for pneumatic cylinder-operated versions) The spot-welder is provided
with a main switch with emergency functions, fitted with a padlock for locking it
in the "O" (open) position.
The padlock key should be handed over only and exclusively to an expert
operator or to an operator who has been trained for the tasks assigned to
him and has been warned of the possible hazards arising from this welding
procedure and from neglectful use of the spot-welder.
When the operator is absent the switch should be set to the "O" position, the
padlock should be closed and the key removed.
- Electrical installation should be carried out following accident-prevention
legislation and standards.
- The spot-welder should be connected only and exclusively to a power supply
with the neutral conductor connected to earth.
- Make sure the power supply outlet is correctly connected to the earth
protection.
- Do not use cables with worn or damaged insulation or with loosened
connections.
- Do not use the spot-welder in damp or wet environments or in the rain.
- When connecting the welding cables or carrying out any routine maintenance
operation on the arms and/or electrodes the spot-welder should be switched
off and disconnected from the power supply. Pneumatic cylinder-operated
spot-welders should be locked with the main switch in the "O" position and
the padlock closed.
The same procedure should be followed when making connections to the
water supply or to a closed circuit cooling unit (water-cooled spot-welders)
and whenever repairs are made (extraordinary maintenance).
- Do not weld on containers, receptacles or piping that contain or have
contained flammable liquid or gas products.
- Do not operate on materials cleaned with cholorinated solvents or near such
substances.
- Do not weld on pressurised containers.
- Remove all flammable substances from the work area (e.g. wood, paper, rags etc.).
- Make sure there is sufficient ventilation or provide means for removing
welding fumes near the electrodes; a systematic approach is necessary
to evaluate limits of exposure to the welding fumes depending on their
composition and concentration and on the length of exposure.
- Always protect the eyes with suitable eye protectors.
- Wear protective gloves and clothing suitable for resistance welding work.
- Noise levels: If the personal daily exposure level (LEPd) is found to be greater
than 85db(A) due to particularly intensive welding operations, wearing
personal protection devices is compulsory.
- The flowing of spot welding currents generates electromagnetic fields (EMF)
around the spot welding circuit.
Electromagnetic fields can interfere with certain medical equipment (e.g. Pace-
makers, respiratory equipment, metallic prostheses etc.).
Adequate protective measures must be adopted for persons with these types of
medical apparatus. For example, they must be forbidden access to the area in
which spot welding machines are in operation.
This spot welder conforms to technical product standards for exclusive use
in an industrial environment for professional purposes. It does not assure
compliance with the basic limits relative to human exposure to electromagnetic
WELDING FOR INDUSTRIAL
INDEX
page
5.5 PNEUMATIC CONNECTION ...........................................................................7
5.6 COOLING SYSTEM ASSEMBLY (GRA) .........................................................7
5.7 PNEUMATIC CLAMP CONNECTION .............................................................8
5.8 CLAMP "C": CONNECTION TO THE ARM ....................................................... 8
5.9 CONNECTING THE STUDDER GUN EARTH CABLE ...................................8
6. WELDING (Spot welding) .....................................................................................8
6.1 PREPARATORY OPERATIONS ......................................................................8
6.1.1 Main switch in the "O" position and padlock closed! ..............................8
6.1.1.1 Adjusting and fixing in place of the "C" clamp arm ....................8
6.1.1.2 Adjusting clamp "X" (optional) ...................................................8
6.1.2 Main switch in the "I" position ................................................................8
6.2 ADJUSTING THE SPOT WELDING SETTINGS .............................................8
6.2.1 Adjusting the force and squeeze function (pneumatic clamp only) .......8
6.2.2 Automatic setting of spot welding parameters (Current, Time) ..............8
6.2.3 Manual setting of spot welding parameters and creation
of a customised programme ..................................................................8
6.3 SPOT WELDING PROCEDURE .....................................................................8
6.3.1 PNEUMATIC CLAMP ............................................................................8
6.3.2 STUDDER GUN ....................................................................................9
7. MAINTENANCE ..................................................................................................9
7.1 ROUTINE MAINTENANCE .............................................................................9
7.2 EXTRAORDINARY MAINTENANCE ...............................................................9
7.2.1 Interventions on the GRA ......................................................................9
7.2.2 Replacing the internal battery ................................................................9
AND fields in the domestic environment.
The operator must adopt the following procedures in order to reduce exposure
to electromagnetic fields:
- Fasten the two spot welding cables (if present) as close together as
possible.
- Keep head and trunk as far away as possible from the spot welding circuit.
- Never wind spot welding cables around the body.
- Avoid spot welding with the body within the spot welding circuit. Keep both
cables on the same side of the body.
- Connect the spot welding current return cable to the piece being spot welded,
as close as possible to the welding joint.
- Do not spot weld while close to, sitting on or leaning against the spot welder
(keep at least 50 cm away from it).
- Do not leave objects in ferromagnetic material in proximity of the spot
welding circuit.
- Minimum distance:
- d= 3cm, f= 50cm (Fig. M);
- d= 3cm, f= 50cm (Fig. N);
- d= 30cm (Fig. O);
- d= 20cm (Fig. P) Studder.
- Class A equipment:
This spot welder conforms to technical product standards for exclusive use
in an industrial environment and for professional purposes. It does not assure
compliance with electromagnetic compatibility in domestic dwellings and in
premises directly connected to a low-voltage power supply system feeding
buildings for domestic use.
RESIDUAL RISKS
RISK OF UPPER LIMBS BEING CRUSHED
Both the operating method for the spot-welder and the variability in shape
and size of the piece being welded make it impossible to provide integrated
protection against the danger of the upper limbs being crushed: fingers, hands,
forearm.
The risk should be reduced by appropriate preventive measures:
- The operator should either be expert or trained in resistance welding
procedures using this type of appliance.
- There should be risk evaluation for every type of job to be done; equipment
and masking should be provided to support and guide the work-piece (unless
a portable spot-welder is used).
- Whenever the shape of the piece allows it, adjust the electrode distance so
that the stroke does not exceed 6 mm.
- Do not allow more than one person to work on the same spot-welder at the
same time.
- Unauthorised persons should not be allowed in the working area.
- Do not leave the spot-welder unattended: in such a case it should be
disconnected from the power supply; for pneumatic cylinder-operated spot
welders turn the main switch to "O" and lock it with the supplied padlock,
take out the key and leave it with the person in charge.
- RISK OF BURNS
Some parts of the spot-welder (electrodes arms and nearby areas) may
reach temperatures of over 65°C: suitable protective clothing must be worn.
- RISK OF TIPPING AND FALLING
- Place the spot-welder on a level horizontal surface that is able to support
its weight; confine the spot-welder to the support surface (when required
in the "INSTALLATION" section of this manual). Otherwise with inclined
or uneven floors or moveable supporting surfaces there is the danger of
tipping.
- Never lift the spot-welder unless explicitly required by the "INSTALLATION"
section of this handbook.
- IMPROPER USE
It is dangerous to use the spot-welder for any other purpose than that for
which it is designed (spot resistance welding).
PROTECTIONS
The safeguards and moveable parts of the spot-welder casing should all be in
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