Routine Maintenance - Telwin INVERSPOTTER 14000 SMART AQUA 400V Manuel D'instructions

- When the work has been completed, return the clamp to its housing on the trolley.
WARNING: Dangerous high voltage! Always check that the clamp power
cable is intact and in good condition; the protective corrugated tube
must never be sheared, broken or crushed! Before and during use of the clamp,
always check the cable is kept well away from all moving parts, heat sources,
sharp surfaces, liquids, etc.
WARNING: the clamp contains the transformation, insulation and
straightening units needed for spot welding operations; if there is any
doubt concerning the integrity of the clamp (due to a fall, violent impact etc.)
disconnect the spot welder and contact the authorised servicing centre.
6.3.2 STUDDER GUN
WARNING!
- To fit or remove the accessories on the gun chuck use the two fixed hexagon
wrenches to stop the chuck turning.
- When working on doors, bonnets or boots, it is mandatory to connect the earth bar
to these parts to prevent current flowing through the hinges, and in any case in the
proximity of the area being spot-welded (if the current has to travel long distances
this will reduce the efficiency of the weld).
Connecting the earth cable:
a) Strip the sheet as close as possible to the point where you intend to work, to
achieve a surface which corresponds to the contact surface of the earth bar.
b1) Fasten the copper bar to the surface of the sheet metal using an ARTICULATED
CLAMP (welding model).
An alternative option to the "b1" procedure (difficult to put into practice) is as
follows:
b2) Weld a washer to the surface of a suitably prepared sheet; thread the washer
through the copper bar slit and block it in place using the clip delivered with the
machine.
Spot-welding the earth terminal fastener washer
Assemble the relative electrode on the gun chuck (POS.9 Fig. 1) and insert the washer
(POS.13, Fig. I).
Position the washer in the chosen position. Connect the earth terminal in the same
area; press the gun button and weld the washer to be fastened as described above.
Spot-welding screws, washers, nails, rivets
Fit the gun with the appropriate electrode, insert the piece to be spot-welded and place
it on the desired spot on the sheet; press the button on the gun: only release the button
when the set time has elapsed (LED
Spot-welding from one side only
Assemble the relative electrode on the gun chuck (POS.6 Fig. 1) pressing on the
surface to be spot-welded. Press the gun button; only release the button when the set
time has elapsed (LED will switch off).
WARNING!
Maximum thickness of the sheet to be spot-welded from one side only: 1+1 mm. This
type of spot welding on chassis bearing structures in not permitted.
In order to achieve correct sheet metal spot welding results, it is necessary to adopt
some essential precautionary measures:
1 - An impeccable earth connection.
2 - The two parts to be spot-welded must be stripped of all varnish, grease, oil etc.
3 - The parts to be spot-welded must be in contact with each other, with no air gap;
where necessary press together using a tool, not the gun. Excessive pressure
can lead to undesired results.
4 - The thickness of the upper piece must not exceed 1 mm.
5 - The electrode tip must be 2.5 mm in diameter.
6 - Firmly tighten the nut that blocks the electrode, check that the welding cable
connectors are blocked correctly.
7 - Position the electrode using light pressure (3÷4 kg) when ready to spot weld.
Press the button and allow the set spot welding time to elapse; only then retract
with the gun.
8 - Never retract more than 30 cm from the earth fixing point.
Simultaneous spot welding and drawing of special washers
This function is performed by assembling and firmly tightening the chuck (POS.4, Fig.
I) on the extractor body (POS.1, Fig. I), then connect and firmly tighten the other
extractor terminal to the gun (Fig. I). Insert the special electrode (POS.14 Fig. I) on the
chuck (POS.4 Fig. I) and block in place with the relative screw (Fig. I). Spot-weld it in
the desired position, regulating the spot welder for washer spot welding operations,
and start the traction phase.
When completed, rotate the extractor by 90° to remove the washer which can then be
spot-welded again in a new position.
Heating and upsetting sheets
In this operating mode, the TIMER is disabled by default: select welding time and "inf"
= Infinite Time will appear on the display.
The length of operations is therefore set manually according to the length of time for
which the gun button is pressed.
The current intensity is automatically adjusted according to the thickness of the
selected sheet metal.
Heating sheet metal
Assemble the carbon electrode (POS. 12, Fig. I) on the gun chuck and block in place
with the ring nut. Use the carbon tip to touch the previously stripped zone and press
the gun button. Start working from the outside inwards, with circular movement so that
the sheet metal heats up; it will then harden and return to its original position.
In order to prevent the sheet metal from hardening too much, work on small areas at a
time and immediately wipe the area with a damp cloth so it has time to cool down.
Upsettin sheet metal
When using the relative electrode in this position, sheet metal that has localised
deformation can be flattened.
Jogged spot welding (Patching)
This function is ideal for spot welding small sheet metal rectangles to cover holes
generated by rust or other causes.
Assemble the relative electrode (POS. 5, Fig. I) on the gun, tighten place with the ring
nut. Strip the work area and check that the piece of sheet metal to be spot-welded is
clean with no traces of grease or varnish.
Arrange the piece and position the electrode, then press and hold the gun button;
proceed at a steady pace following the work/stand-by intervals of the spot welder.
N.B.: Apply light pressure (3÷4 kg) during this operation, following an ideal line of 2÷3
mm from the edge of the new piece to be welded.
will switch off).
To achieve the best results:
1 - Never retract more than 30 cm from the earth fixing point.
2 - Use cover steel sheeting with a maximum thickness of 0.8 mm; stainless steel is
highly recommended.
3 - Proceed at the pace imposed by the spot welder. Move forward during the stand-
by phase, and stop during the spot welding phase.
Using the supplied extractor (POS.1, Fig. I)
Coupling washers and traction
This function is carried out by fitting and firmly tightening the chuck (POS 3, Fig. I) on
the electrode body (POS. 1 Fig. I). Hook on the spot-welded washer (POS.13 Fig. I)
as illustrated above and start the traction phase. When completed, rotate the extractor
by 90° to remove the washer.
Coupling and traction of rivets
This function is carried out by fitting and firmly tightening the chuck (POS 2, Fig. I)
on the electrode body (POS. 1 Fig. I) Insert the spot-welded plug (POS.15-16 Fig. I)
on the chuck (POS.1 Fig. I) as illustrated above, whilst pulling the terminal towards
the extractor (POS.2, Fig. I). After completing insertion release the chuck and start
traction. Finally, pull the chuck towards the hammer to slide out the rivet.
7. MAINTENANCE
WARNING! BEFORE
MAKE SURE THAT THE SPOT WELDER IS SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY.
The main switch must be blocked in the "O" position using the supplied
padlock!

7.1 ROUTINE MAINTENANCE

ROUTINE MAINTENANCE WORK CAN BE PERFORMED BY THE OPERATOR.
- adjustment/resetting of the diameter and profile of the electrode tip;
- replacing the electrodes and arms;
- checking electrode alignment:
- checking cable and clamp cooling;
- exhausting of condensation from the compressed air intake filter;
- periodic check of the level of cooling water in the tank.
- periodic check to ensure there are no water leaks.
- checks to ensure the spot welder and clamp power supply cables are in perfect
condition.
7.2 EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED
OUT ONLY AND EXCLUSIVELY BY SKILLED OR AUTHORISED ELECTRICAL-
MECHANICAL TECHNICIANS.
WARNING! BEFORE REMOVING THE SPOT WELDER PANELS OR THE
CLAMP AND ACCESSING THE UNIT, MAKE SURE THE SPOT WELDER
IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY
OUTLET.
If checks are carried out while the inside of the spot welder is live, this could cause a
serious electric shock due to direct contact with live parts and/or injury due to direct
contact with moving parts.
Inspect the inside of the spot welder and clamp regularly, with a frequency depending on
use and environmental conditions, and remove the dust and metal particles deposited on
the transformer, diode module, power terminal board etc. using a jet of dry compressed
air (max. 5 bar).
Do not direct the jet of compressed air on the electronic boards; these can be cleaned
with a very soft brush or suitable solvents.
During this phase, take this opportunity to:
- Check that the insulation of the cables shows no forms of damage, and they have
not worked loose or have oxidised.
- Check that the screws connecting the transformer secondary unit to the output bars/
plaits are all firmly tightened and there are no signs of oxidising or overheating.
IF THE SPOT WELDER IS NOT WORKING PROPERLY, BEFORE MAKING MORE
SYSTEMATIC CHECKS OR CALLING YOUR SERVICING CENTRE MAKE THE
FOLLOWING CHECKS:
- Check that with the spot welder main switch closed (pos. "I") the display is ON; if
this is not the case, the problem is in the power line (cables, plug and socket, fuses,
excessive voltage drop etc.).
- Check that the display does not indicate any alarm signals (see TAB. 2): when the
alarm has stopped, press "START" to restart the spot welder; check that the cooling
water is circulating correctly and decrease the intermittence ratio of the work cycle
where necessary.
- Check that the elements of the secondary circuit parts (arm-holder – arms –
electrode holder – cable connections) are working efficiency and have not loosened
or rusted.
- Check that the spot welding parameters are suitable for the work being
performed.
7.2.1 Interventions on the GRA
In the case of:
- excessive need to top-up the water level in the tank;
- excessive tripping of alarm 7;
- water leaks;
it is recommended to check for any problems inside the Cooling system zone.
Refer to the instructions in section 7.2 regarding general checks and, after disconnecting
the spot welder from the mains, remove the side panel (FIG .L).
Make sure there are no leaks in the couplings or pipes. If there are water leaks, replace
all damaged parts. Eliminate any water which has leaked during the maintenance
work, and replace the side panel.
Then reset the spot welder following the instructions provided in paragraph 6 (Spot
welding).
7.2.2 Replacing the internal battery
If the memory does not maintain the correct date and time, replace the battery (CR2032
- 3V) found in the compartment at the back of the control panel.
When the spot welder is disconnected from the mains, remove the control panel
screws, remove the connectors and replace the battery.
WARNING! Make sure that all the connectors are connected properly before re-
assembling the control panel on the machine.
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CARRYING OUT MAINTENANCE WORK,