Special Maintenance - Telwin inverspotter 13500 smart aqua Manuel D'instructions

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 "AUTOMATIC" mode using the "MODE" key to enter the preliminary
"ZEROING" procedure.
To zero correctly, keep the clamp pushbutton pressed for all 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
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,
3 - The points to be spot welded must be in contact with each other, without gaps; if
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
7 - When spot welding, lightly push the electrode (3-4 kg). Press the pushbutton, and
8 - Never stand more than 30 cm away from the earth fixing point.
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.
In this operation mode the TIMER is disabled by default: If the welding time is selected,
the display shows "inf " = Infinite time.
The duration of the operations is therefore manual, being determined by how long the
gun pushbutton is kept pressed.
Current intensity is adjusted automatically according to the selected panel thickness.
Fit the carbon electrode (POS. 12, Fig. I) onto the gun chuck, locking it with the ring
nut. Touch the area that was previously cleaned with the carbon tip and press the gun
pushbutton. Work from outside to inside, using a circular movement, to heat the panel
which becomes work hardened and returns to its original position.
To prevent the panel from tempering too much, treat small areas and pass a wet cloth
immediately over the worked area, which cools the treated part.
has switched off.
Panels that have deformed in areas can be flattened in this position and using the
relative electrode.
This function is suitable for spot welding small rectangles of panel for covering holes
caused by rust or other causes.
Fit the relative electrode (POS. 5, Fig. I) onto the chuck, and carefully tighten the fixing
ring. Clean the involved area and make sure that the piece of panel to be spot welded
is clean and free from grease or paint.
Position the piece and place the electrode against it, then push the gun pushbutton
and keep it pressed. Move forward rhythmically, following the work/pause intervals
given by the spot welder.
N.B.: Press lightly (3-4 kg) while working, the ideal position is a line that is 2-3 mm from
the edge of the new piece to be welded.
For good results:
1 - Never stand more than 30 cm away from the earth fixing point.
2 - Use covering sheets with a maximum thickness of 0.8 mm, better if made of
3 - Make sure your forward movements have the same rhythm as the one dictated
Using the supplied extractor (POS. 1, Fig. I)
Coupling washers and traction
This is carried out by fitting and locking the chuck (POS 3, Fig. I) to the electrode
body (POS. 1, Fig. I). Hook the washer (POS. 13, Fig. I), spot welded as described
previously, and begin traction. When finished, rotate the extractor by 90° to detach
the washer.
Plug hooking and traction
This is carried out by fitting and locking the chuck (POS 2, Fig. I) to the electrode
body (POS. 1, Fig. I). Insert the plug (POS. 15-16, Fig. I), spot welded as described
previously, into the chuck (POS. 1, Fig. I), keeping the terminal pulled 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 plug.
7. MAINTENANCE
THE MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
The switch must be locked at "O" using the supplied lock.
7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR.
- adaptation/restoration of the diameter and profile of the electrode tip;
- replacement of the electrodes and the arms;
- electrode alignment check;
- cooling check on cables and clamp;
- condensate discharge from the compressed air entry filter.
- check integrity of the spot welder and clamp power cable.
7.2 SPECIAL MAINTENANCE
SPECIAL MAINTENANCE MUST ONLY BE CARRIED OUT BY TECHNICIANS
switches off). WHO ARE EXPERT OR QUALIFIED IN AN ELECTRIC-MECHANICAL AMBIT.
- 9 -
switches off).
WARNING!
oil.
necessary press with a tool, not the gun. Pressure that is too strong causes bad
results.
connectors are locked.
only move yourself and the gun away from the workpiece when the spot welding
time has passed.
Contemporaneous spot welding and traction of special washers
Panel heating and upsetting
Panel heating
Panel upsetting
Intermittent spot welding (Patching)
stainless steel.
by the spot welder. Move forward during the pauses, stop during spot welding.
WARNING! BEFORE CARRYING OUT MAINTENANCE, MAKE SURE