Telwin INVERSPOTTER 13000 Manuel D'instructions page 5

ENGLISH
1. GENERAL SAFETY RULES FOR RESISTANCE
WELDING .................................................................. 5
2. INTRODUCTION AND GENERAL DESCRIPTION ... 6
2.1 INTRODUCTION....................................................................................
2.2 STANDARD ACCESSORIES .................................................................
2.3 OPTIONAL ACCESSORIES ..................................................................
3. TECHNICAL DATA .................................................... 6
3.1 RATING PLATE ......................................................................................
3.2 OTHER TECHNICAL DATA ....................................................................
3.2.1 Spot-welding machine...................................................................
3.2.2 Studder Generator .......................................................................
4. DESCRIPTION OF THE SPOT-WELDER .................. 6
4.1 CONTROL AND ADJUSTMENT DEVICES ...........................................
4.1.1 Control panel .................................................................................
4.1.2 Pressure regulation unit and pressure gauge ...............................
4.2 SAFETY FUNCTIONS AND INTERLOCK .............................................
4.2.1 Safeguards and alarms .................................................................
5. INSTALLATION.......................................................... 7
5.1 PRELIMINARY OPERATIONS ...............................................................
5.2 HOW TO LIFT THE SPOT-WELDER......................................................
5.3 POSITION ..............................................................................................
APPLIANCES FOR RESISTANCE WELDING FOR INDUSTRIAL AND
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.
INDEX
page
5.4 CONNECTION TO THE MAIN POWER SUPPLY ..................................
5.4.1 Warnings .......................................................................................
5.4.2 Plug and socket.............................................................................
5.5 PNEUMATIC CONNECTION .................................................................
5.6 PNEUMATIC CLAMP CONNECTION ....................................................
5.7 STUDDER GENERATOR CONNECTION .............................................
6
5.8 STUDDER GUN CONNECTION TO THE EARTH CABLE ....................
6
6
6. (SPOT) WELDING...................................................... 8
6.1 PRELIMINARY OPERATIONS ..............................................................
6.2 ADJUSTING THE (spot-welding) PARAMETERS .................................
6
6.2.1 Adjusting the force and squeeze function
6
(pneumatic clamp only) .................................................................
6
6.2.2 Adjusting the spot-welding current and times ...............................
6
6.2.3 Storage of the customized spot welding programmes ..................
6.2.4 Recall of spot welding programmes ..............................................
6.3 SETTINGS FOR THE MATERIAL ..........................................................
6
6.4 SPOT-WELDING PROCEDURE ............................................................
6
6.4.1 PNEUMATIC CLAMP ....................................................................
7
6.4.2 STUDDER GUN ............................................................................
7
7
7. MAINTENANCE......................................................... 9
7.1 ROUTINE MAINTENANCE ....................................................................
7.2 EXTRAORDINARY MAINTENANCE .....................................................
7
7
8
,
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- 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 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. H);
- d= 3cm, f= 50cm (Fig. I);
- d= 30cm (Fig. L);
- d= 20cm (Fig. M) 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:
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