Important - Telwin inverspotter 13500 smart aqua Manuel D'instructions

as indicated in this chapter (Fig. D).
5.2 LIFTING MEANS (Fig. E)
The spot welder must be lifted using a double cable and hooks that are suitably sized
for the machine weight, and using the relative M8 rings.
It is forbidden to sling the spot welder using means other than those indicated.
5.3 POSITIONING
Make sure the installation area is suitably large and without obstacles to guarantee
that the control panel, the main switch and the working area can be accessed in
complete safety.
Make sure there are no obstacles near the cooling air entry or exit points, and make
sure that conductive dust, corrosive vapours, humidity, etc. cannot be sucked in.
Position the spot welder on a flat surface made of homogeneous, compact material
that is suitable for supporting the weight of the machine (see "technical data") to avoid
the danger of toppling or dangerous movements.
5.4 CONNECTION TO THE MAINS
5.4.1 Warnings
Before carrying out any electric connection, make sure the machine plate data
corresponds with the voltage and frequency of the mains available in the installation
place.
The spot welder must be connected only and exclusively to a power supply with the
neutral conductor connected to earth.
To guarantee protection against indirect contact use these types of residual current
device;
- A type ( ) for single-phase machines;
- B type ( ) for three-phase machines.
- The IEC/EN 61000-3-12 Standard is not applicable to the spot welder.
If the welding machine is connected to a public electricity grid, the installer or user
must make sure that the machine can be connected (if necessary, consult the
company that manages the electricity grid).
5.4.2 Plug and mains outlet
Connect the power supply cable to a standard (3P + T) plug of appropriate capacity
and prepare a power supply outlet fitted with fuses or an automatic circuit-breaker; the
corresponding earth terminal must be connected to the (yellow-green) earth conductor
of the power supply.
The capacity and intervention characteristics of the fuses and circuit-breaker switch
are given in the "OTHER TECHNICAL DATA" paragraph.
WARNING! Not observing the regulations above renders the
manufacturer's safety system (class I) inefficient, with resulting serious risks to
people (e.g. electric shock) and goods (e.g. fire).
5.5 PNEUMATIC CONNECTION
- Prepare a compressed air line with a working pressure of 8 bar.
- Fit one of the available compressed air connections to the filter group reducer
to make the reducer suitable for the connections where the spot welder is to be
installed.
5.6 PNEUMATIC CLAMP CONNECTION (Fig. F)
WARNING! Dangerous electric current present! Do not for any reason
connect plugs other than those indicated by the manufacturer to the spot welder
outlets. Do not insert any kind of object into the outlets!
- Machine disconnected from the mains.
- Insert the polarised clamp plug (fig. F-1) into the relative machine outlet, then lift the
two levers until the plug is completely fixed.
- Insert the 8-pin polarised plug shown in figure F-2 to use the automatic spot welding
mode.
5.7 "C" CLAMP: CONNECTING THE ARM
WARNING! Risk of crushing the upper limbs!
Scrupulously follow the instructions in the sequence given below!
- Machine disconnected from the mains.
- Rotate the stop as shown in fig. G1.
- If used, assemble the clamp support (Fig. G2).
- Insert the arm into its seat, angling it as required (Fig. G3).
- Align the arm with the piston electrode and tighten the stop (Fig. G4).
- If used, assemble the clamp support handle from the relative side (Fig. G5).
6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
6.1.1 Main switch at "O" and lock closed!
A series of checks and adjustments must be carried out before starting to spot weld,
with the main switch in the "O" position and the lock closed.
Connecting to the electric and pneumatic supply sources:
- Make sure the electric connection has been carried out correctly in compliance with
the instructions given previously.
- Check compressed air connection: connect the supply hose to the pneumatic
supply point and adjust the pressure using the reducer knob until the manometer
shows a value close to 8 bar (116 psi).
6.1.1.1 Adjusting and fixing the "C" clamp arm
This operation must only be carried out if the arm moves horizontally even after having
been locked as explained in paragraph 5.7 (Fig. Q)
For this operation proceed as follows:
- Release the arm by rotating the release lever (Fig. R);
- Loosen the dowel (Fig. S-1) and tighten the ring nut (Fig. S-2) by one-eighth of a
turn (approx. 45 degrees);
- Lock the ring nut, tightening the locking dowel (Fig. S-1);
- Lock the arm, following the operation shown in Fig. T.
This operation may need to be carried out several times, either tightening or loosening
the ring nut (Fig. S-2), until the arm is locked horizontally and the locking lever, using
rotational power that is suitable for manual release, simultaneously closes at the stop
created by the reference plug (Fig. T-1).
NOTE: when the operation ends, the lever must be against the end stop plug (Fig.
T-1). This position guarantees that the "C" arm is locked mechanically and therefore
safe.
6.1.2 Main switch at the " I " position.
The following checks must be carried out before doing any spot welding, and with the
main switch at "I" (ON).
Clamp electrode alignment:
- Place a shim having the same thickness as the panels to be spot welded between
the electrodes; make sure the electrodes, which are now "squeezing" the panels
(see paragraph 6.2.2), are aligned.
- If necessary, make sure that the arm is correctly fixed (see previous paragraphs).
6.2 ADJUSTING THE SPOT WELDING PARAMETERS
The parameters that determine the diameter (section) and mechanical seal of the
spot are:
- Power applied by the electrodes.
- Spot welding current.
- Spot welding time.
If the operator does not have specific experience, it is best to try some spot welding
on pieces of panel with the same thickness and of the same quality as the ones to be
spot welded.
6.2.1 Setting the arm and the electrode
Press the "MODE" key several times until you access "MAINTENANCE", then set the
current arm (see the "Spot Welding Accessories" section in the catalogue) with the
electrode used, which can be type A (flat) or type E (point) according to the ISO 5821
standard.
For example, set CA1/E for the standard "C" arm with the type E electrode, set CA1/A
if the arm is the same but the electrode is type A.
Prefer type E electrodes for welding that requires lots of spots, and type A electrodes
for work that requires few spots or with C arms with a wide mouth (for example 300mm
and 550mm).
IMPORTANT: always set the electrode being used correctly because the spot
welding parameters that the machine uses in the semi-automatic and automatic
modes can vary.
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-9): 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: AUTOMATIC
mode. Both C clamp plugs 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.
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