Telwin INVERSPOTTER 13000 Manuel D'instructions page 7

: Pneumatic clamp function with direct spot-welding current
The spot-welding cycle starts with a squeeze time, continues with a ramp time, a spot-
welding time and ends with a hold time. This function can be selected with the "B" key.
: Pneumatic clamp function with "pulsed" spot-welding current
The spot-welding cycle starts with a squeeze time, continues with ramp time, spot-
welding time, cool time, a series of impulses (see 4.1.1 Number of impulses) and ends
with hold time.
This function improves spot-welding capacity on high stress sheet or on sheet that has
been galvanised or has a special protective film.
This function can be selected with the "B" key.
: Studder function (with studder kit only)
The choice of this function disables the pneumatic clamp and enables the choice of
the functions of the "C" key.
: "ACCo" function: pneumatic clamp electrode squeeze.
This function can be selected by pressing key "B" for about 3 seconds (only with
pneumatic clamp). The display shows "ACCo" and the LED in the clamp flashes. In this
function there is no current output! Press key "B" again for about 3 seconds to exit the
function.
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WARNING!
RESIDUAL RISK! Also in this operating mode there is a risk of crushing the upper
limbs: take all necessary precautions (see the chapter on safety).
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3- Key for selecting functions with the studder gun
This only has any meaning when the studder kit is used:
: Spot welding: pins, rivets, washers, special washers using suitable
electrodes.
2
: Spot-welding Ø 4mm screws using a suitable electrode.
3
: Spot-welding Ø 5-6mm screws and Ø 5mm rivets using a suitable
electrode.
4
: Spot-welding single spots using a suitable electrode.
: Tempering sheet metal using a carbon electrode.
6
: Jogged spot-welding for patching sheet using a suitable electrode.
: Upsetting sheet metal using a suitable electrode.
4 - "D" key for selecting thickness
This is used to position the spot-welding programme according to the thickness of the
piece to be welded.
If the LED flashes this means welding is critical for the selected thickness with the
currently used tool; if the LED does not light up this means that the currently connected
tool is unable to weld at this thickness.
5 - "MATERIAL" key:
This is used to select the programmes corresponding to the type of material being welded
(see section 6.3)
6- RECALL and SAVE keys:
These are active only in programming mode (see section 6.2.2). The "SAVE" key is used
to save the welding cycle setting for a given tool, thickness and material.
The "RECALL" key is used to RECALL the DEFAULT welding cycle setting for a given
tool, thickness and material.
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WARNING! if the "RECALL" and "SAVE" keys are pressed simultaneously when
the machine starts up, all the factory settings for each tool, thickness and material
will be loaded; any customised programme will therefore be lost!
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7 - Encoder:
Only active during programming. Used to change the value of the spot-welding
parameters, material and to select the programmes.
8 - Display:
Is able to show:
- Alarm signals (see section 4.2.1).
- Warning signals (e.g. "OP EL" = insulation between electrodes, "NO CO" = no tool
connected. See Tab.1 for the complete list of warnings).
The red LED on the clamp lights up when there is a warning signal.
- "STRT" whenever the machine is started up or to reset the machine after an alarm
signal.
- The percentage power setting [%].
- Spot-welding parameter time expressed in cycles at 50Hz (1 cycle = 20ms).
- Current used in the spot-welding cycle [A].
- The material settings for the sheet being welded.
- The letter "d" indicates that the shown parameter is the default one.
9 - LED's for general alarm, spot welding, programming:
Yellow LED general alarm: this lights up when the thermal relays trigger, when
alarms trigger for overvoltage, undervoltage, overcurrent, phase failure, air
failure.
0
:
- 7 -
Red LED spot-welding: this lights up for the entire duration of the spot-welding
cycle.
Red programming LED: the machine is in programming mode and cannot carry
out any spot-welding cycle.
10 "START" key:
Press the button only when "Strt" appears on the display:
allows the machine to operate at the first start or after an alarm event.
4.1.2 Pressure regulation unit and pressure gauge.
Used to adjust the pressure exerted on the electrodes of the pneumatic clamp by turning
the adjustment knob (only for the pneumatic clamp).
NOTE: in order to allow the machine to perform at its best we always recommend
working at the maximum allowed pressure (8 bar).
4.2 SAFETY FUNCTIONS AND INTERLOCK
4.2.1 Safeguards and alarms
a) Thermal relay:
Triggers if the spot-welder overheats due to insufficient or lack of cooling air or to an
excessively heavy duty cycle.
Triggering is indicated by the yellow LED
The alarm is shown on the display as:
AL 1= safety thermal alarm (*).
AL 2 = secondary overheating alarm.
AL 8 = studder overheating alarm.
AL 12 = clamp overheating alarm.
EFFECT: movement blocked: electrodes open (cylinders discharged); current
shutdown (welding disabled).
RESET: manual (by pressing the "STRT" button after the temperature has returned
within the allowed limits the yellow LED
(*) NOTE: AL 1 will appear even if the 14 pin "Studder" socket (located on the back of
the generator) is disconnected.
If the Studder kit is not available, connect the relative 14 pin plug.
b) Main switch:
- Position " O " = open (OFF), can be padlocked (see chapter 1).
WARNING! In position "O" the terminals inside the machine (L1+L2+L3)
for connecting the power supply cable are live.
- Position " I " = closed (ON): the spot-welder is powered but is not in operation
(STANDBY - it is necessary to press the "STRT" button).
- Emergency function
When the spot-welder is in operation, opening (pos. " I "=>pos " O ", switching off)
will stop the machine in safety mode:
- current disabled;
- electrodes open (cylinder discharged);
- automatic restart disabled.
c) Compressed air safeguard
Triggers if there is a pressure failure or pressure drop (p < 3bar) in the compressed air
supply;
The display indicates triggering of this safeguard with the message "AL 6"
EFFECT: movement blocked: electrodes open (cylinder discharged);
current shut-down (welding disabled).
RESET: manual (by pressing the "START" button after the pressure has returned
within the allowed limits (pressure gauge shows >3bar).
d) Safeguard for short circuit at output (only pneumatic clamp)
Before starting the welding cycle the machine checks to make sure the (positive and
negative) poles of the secondary spot-welding circuit are free of accidental contact
points.
The display indicates triggering of this safeguard with the message "AL 7"
EFFECT: movement blocked: electrodes open (cylinders discharged); current
blocked (welding disabled).
RESET: manual (press the "STRT" button after eliminating the cause of short
circuit).
e) Phase failure safeguard
The display indicates triggering of this safeguard with the message "AL 11"
EFFECT: movement blocked: electrodes open (cylinder discharged); current shut-
down (welding disabled).
RESET: manual (press "STRT" button)
f) Over/undervoltage safeguard
The display indicates triggering of this safeguard with the message "AL3" for
OVERVOLTAGE and "AL4" for UNDERVOLTAGE.
EFFECT: movement blocked: electrodes open (cylinder discharged); current shut-
down (welding disabled)
RESET: manual (press "STRT" button)
g) "STRT" button
This button must be pressed to control the welding operation in each of the following
cases:
- whenever the main switch is closed (pos " O "=>pos " | ", switching on):
- whenever the safeguards/thermal relays have triggered:
- whenever the (electrical or compressed air) power supply is restored following an
interruption due to disconnection upstream or a fault.
5. INSTALLATION
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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 EXPERT OR SKILLED PERSONNEL.
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5.1 PRELIMINARY OPERATIONS
Unpack the spot-welder, assemble the separate parts included in the package, as
described in this chapter (Fig. C).
5.2 HOW TO LIFT THE SPOT-WELDER
The spot-welding machine described in this handbook is not equipped with lifting
devices.
( )
lighting up on the control panel.
( )
goes off).