Introduction And General Description; Technical Data - Telwin PCP 18 Mode D'emploi

"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).
The safeguards and moveable parts of the spot-welder casing should all be in
position before connection to the power supply.
WARNING: All manual operations on moveable accessible parts of the spot
welder, for example:
- Electrode replacement or maintenance
- Adjusting the position of the arms or electrodes
SHOULD BE CARRIED OUT WITH THE SPOT-WELDER SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY (MAIN SWITCH LOCKED TO "O"
USING PADLOCK WITH KEY TAKEN OUT for PNEUMATIC CYLINDER-operated
models).

2. INTRODUCTION AND GENERAL DESCRIPTION

2.1 INTRODUCTION
Column spot welders with downward curvilinear electrode for resistance welding (single
spot).
Electronic power control (thyristors) integrated with timer and start current limiter.
Thermal safeguard with indicators (overload or cooling water failure).
Operation:
- "PTE" models: mechanical, equipped with pedal with adjustable lever length;
- "PCP" models: pneumatic, equipped with double effect cylinder controlled by a
pedal valve; operation shutdown due to power failure and/or compressed air failure.
2.2 OPTIONAL ACCESSORIES
- Arm pair, length 500mm, complete with electrode holders and standard electrodes.
- Arm pair, length 700mm, complete with electrode holders and standard electrodes.
- Curved electrodes.
- Closed circuit water cooling system (suitable for PTE or PCP 18 only).

3. TECHNICAL DATA

3.1 RATING PLATE (FIG.A)
The main data relating to use and performance of the spot-welder are summarised on
the rating plate and have the following meanings:
1- Number of phases and frequency of power supply.
2- Power supply voltage.
3- Mains power with permanent running (100%).
Rated mains power with 50% duty cyde.
4-
5- Maximum loadless voltage over electrodes.
6- Maximum current when electrodes are shorted.
7- Current to secondary when running permanently (100%).
8- Gauge and length of arms (standard).
9- Minimum and maximum adjustable electrode force.
10- Rated pressure of compressed air supply.
11- Pressure of compressed air supply needed to obtain maximum electrode force.
12- Cooling water flow rate.
13- Rated pressure drop for coolant liquid.
14- Weight of welding device.
15- Safety symbols, the meanings of which are given in chapter 1 "General safety rules
for resistance welding".
Note: The rating plate shown is an example to show the meaning of the symbols and
numbers; the exact technical specifications of your spot-welder can be found on the
rating plate of the spot-welder itself.
3.2 OTHER TECHNICAL DATA (FIG.B)
4. DESCRIPTION OF THE SPOT-WELDER
4.1 SPOT-WELDER ASSEMBLY AND DIMENSIONS (FIG. C)
4.2 CONTROL AND ADJUSTMENT DEVICES
4.2.1 Control panel (FIG. D1)
1- General switch (in PCP models with emergency stop functions and possibility of
padlock in "O" position: padlock and keys supplied).
*
2- Indicator LED's:
a) (green) machine powered, control board "ON",
%
b) (green) welding "ON" (control and thyristor model activated),
&
c) (yellow) thermal safeguard triggered: welding disabled (in PCP models
arm operation is also disabled).
3- "POWER" : welding current adjustment potentiometer;
4- "TIMER" : welding time adjustment potentiometer;
(
5- start-up/reset push-button (PCP models);
/ $
#
6- pressure only (machine does not weld) / welding device selector (PCP
models only).
4.2.2 Compression nut (FIG. D2)
This can be reached by opening the gate on the rear of the spot-welder; it is used to
regulate the force exerted by the electrodes by adjusting the pre-load of the spring.
4.3 INTERLOCK AND SAFETY FUNCTIONS
4.3.1 PTE Models
Thermal safeguard.
Triggers if the spot-welder overheats due to insufficient flow or lack of cooling water or to
an excessively heavy duty cycle.
Triggering is indicated by the yellow LED
EFFECT: current shutdown (welding disabled).
RESET : automatic when temperature returns within allowed limits (yellow LED goes
off).
4.3.2 PCP Models
General switch
- Position " O " = open, can be padlocked (see chapter 1).
WARNING! In position "O" = internal power supply cable terminals (L1 + L2) are
live.
- Position "I" = closed: the spot welder is in STAND BY
Emergency function: while the spot-welder is running (opening the switch from "I" =>
to "O" position), the spot-welder will shut down, in safety mode.
- current off;
- electrodes opening up (cylinder discharging);
- automatic re-start disabled.
(
Start-up push-button
You must push this button in order to control the welding operations (from the pneumatic
pedal) in each one of the following conditions:
- whenever the general switch has shut off (position "O" => position "I");
- whenever the safety/protection devices have triggered;
- whenever the (electric and compressed air) power supply returns after being cut off
due to a fault or disconnection.
# $
Cycle selector
/
#
- Cycle : it allows the control of the spot-welder (from the pneumatic pedal)
without welding. It is used to move the arms and to close the electrodes without
power supply.
FURTHER RISKS! Be aware that even in this machine mode the risk of crushing
the upper limbs exists. (see chapter on safety).
$
- Cycle (normal welding cycle) enables the spot-welder to make the weld.
Thermal safeguard
Triggers if the spot-welder overheats due to insufficient cooling water flow rate or to an
excessively heavy duty cycle.
This intervention is signalled by the yellow LED
EFFECT: current off (welding disabled).
RESET: manual (push the button
limits (yellow LED switches off).
Compressed air safety switch
Triggers if there is a compressed air pressure drop or failure (p<2.5 ÷ 3 bar). This
intervention is signalled by the gauge (0 ÷ 3 bar) located on the compressed air input
system.
EFFECT: movements blocked: electrodes opening up: cylinder released.
Current off: welding disabled.
(
RESET: manual (push button
the gauge: >>3 bar).
5. INSTALLATION
______________________________________________________________________________________________________________________
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
ELECTRICAL AND PNEUMATIC CONNECTIONS WITH THE SPOT-WELDER
COMPLETELY SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY OUTLET. THE ELECTRICAL AND PNEUMATIC CONNECTIONS MUST BE
MADE ONLY AND EXCLUSIVELY BY AUTHORISED, SKILLED PERSONNEL.
______________________________________________________________________________________________________________________
5.1 PRELIMINARY OPERATIONS
Unpack the spot-welder, assemble the separate parts as indicated below.
5.2 LIFTING THE SPOT-WELDER (FIG. E)
The spot-welder should be lifted with a double cable and hooks, using the eyebolts
fitted for this purpose.
It is absolutely prohibited to sling the spot-welder in a different way from the one we
prescribed (e.g. on arms or electrodes).
5.3 POSITION
The installation area must be sufficiently large and without obstacles, suitable for
ensuring safe access to the control panel and to the work area (electrodes).
Ensure that there are no obstacles near the cooling air inlets and outlets and that no
conductive dusts, corrosive vapour, humidity, etc. can be sucked in.
Position the spot-welder on a plane surface made of homogeneous and compact
material (floor made of concrete or similar physical characteristics).
Fasten the spot-welder to the floor by means of four M10 bolts, using the special holes
on the base; each individual element anchoring the spot-welder to the floor must
guarantee a tensile strength of at least 60 Kg. (60daN).
Maximum load
The maximum load that can be applied to the lower arm (concentrated on the electrode
axis) is 35 Kg. (35daN).
5.4 CONNECTION TO THE MAIN POWER SUPPLY
5.4.1 Warnings
Before making any electrical connection, make sure the rating data of the spot-
- 6 -
&
lighting up on the control panel.
mode
(green LED on
&
l
ocated on the control panel.
(
) after the temperature returns within the allowed
) after the pressure reaches the allowed limit. (On
*
).