Telwin INVERSPOTTER 13000 Manuel D'instructions page 8

5.3 POSITION
The installation area must be sufficiently large and without obstacles, suitable for
ensuring completely safe access to the control panel, to the main switch and to the
working area.
Ensure that there are no obstacles near the cooling air inlets and outlets and that no
conductive dusts, corrosive vapour, moisture etc. can be sucked in.
Position the spot-welder on a plane surface made of uniform, compact material able to
support the weight (see the "technical data") so as to prevent it from tipping or moving
dangerously.
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-welder
correspond to the mains voltage and frequency available at the place of installation.
The spot-welder should be connected only and exclusively to a power supply with the
neutral conductor connected to earth.
In order to guarantee protection against indirect contact use RCD's of the following types:
- Type A ( ) for single phase machines;
- Type B ( ) for 3-phase machines.
The spot welder does not fall within the requisites of IEC/EN 61000-3-12 standard.
Should it be connected to a public mains system, it is the installer's responsibility to verify
that the spot welding machine itself is suitable for connecting to it (if necessary, consult
the distribution network company).
5.4.2 Plug and socket
Connect the power supply cable to a standardised plug (3P + G) of adequate capacity
and prepare a power outlet protected by fuses or by an automatic circuit-breaker; the
appropriate earth terminal should be connected to the (yellow-green) earth conductor of
the power line.
The capacity and specifications of the fuses and circuit-breaker are given in the
paragraph on "OTHER TECHNICAL DATA".
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WARNING! Failure to observe the rules given above will invalidate the (class I)
safety system provided by the manufacturer causing serious risks to people (e.g.
electric shock) and objects (e.g. fire).
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5.5 PNEUMATIC CONNECTION
- Set up a compressed air line with working pressure between 6 and 8 bar.
- Fit one of the compressed air connectors to the filter-reducing valve unit to make it
compatible with the connectors available where the spot-welder is installed.
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The clamp performances depend on the quality of the compressed air source
to which the machine is connected; the quality of the point is granted by a pressure
operation not less than 6 bar.
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5.6 PNEUMATIC CLAMP CONNECTION (Fig. D1)
Insert the pole-plug of the clamp into the proper socket of the spot welder, then lift the two
levels until you reach the complete fixing of the plug.
If the Studder kit is not used (Optional), connect the relative 14 pin plug (Fig. D2).
NOTE: if the clamp plug is not connected, it is free to rotate twisting the corrugated hose;
pls avoid any excessive plug rotations in order not to compromise the internal cables
connections.
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ATTENTION ! Dangerous voltage! Pls absolutely avoid to connect different
plugs than recommended by the manufacturer to the spot-welder sockets. Pls
don't try to insert any object into the sockets!
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5.7 STUDDER GENERATOR CONNECTION
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This studder gun supply unit must be used only with its power sources
adequate for the use.
Installation must be performed only by personnel authorized to working on
electrical equipments.
- It must not be connected to the mains.
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- Connect the two pole plugs of the studder generator to the proper socket of the spot
welder and fix them as explained in Fig. E .
5.8 STUDDER GUN CONNECTION TO THE EARTH CABLE (Fig. F)
- Connect the DINSE plugs to the propter sockets.
- Insert the connector of the control cable into the propter socket.
- The connection of the compressed air is not necessary.
6. (Spot) WELDING
6.1 PRELIMINARY OPERATIONS
Main switch in the "O" position with the padlock closed!
Before carrying out any spot-welding operation it is necessary to make a series of checks
and adjustments, which should be carried out with the main switch in the "O" position and
with the padlock closed.
Connections to the electricity and pneumatic supplies:
- Ensure that the electrical connections are correct, in accordance with the instructions
above.
- Check the compressed air hookup; connect the compressed air feed pipe to the
pneumatic plant, use the reduction valve knob to adjust the pressure until the gauge
gives a reading close to 8 bar (116 psi).
Adjusting the clamp:
Between the electrodes, slide a shim equivalent to the thickness of the sheets; ensure
that the arms, brought together manually, are parallel and that the electrodes are centred
(tips meet).
Always bear in mind that the stroke should be 5-6 mm greater than the spot-welding
position so as to exert the required force on the piece.
If necessary loosen the arm locking screws to adjust the arms by turning them or moving
them in either direction along their axis; on completion secure the locking screws or nuts
tightly.
6.2 ADJUSTING THE (spot-welding) PARAMETERS
Main switch in the "I" position.
The parameters that affect the diameter (section) and mechanical strength of the spot
weld are:
- Force exerted by the electrodes.
- Spot-welding current.
- Spot-welding time.
When specific experience is lacking we recommend carrying out a number of test welds
using sheet of the same thickness and quality as that of the workpiece.
6.2.1 Adjusting the force and squeeze function (pneumatic clamp only)
The force is regulated by adjusting the air group pressure regulator (see section 4.1.2).
The squeeze function can be selected in two ways:
a) At the panel:
keep key "B" as in Fig.B pressed for about 3 seconds. 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.
b) Using the clamp:
press and release the button on the clamp and then immediately hold the button
pressed down. The clamp will squeeze and keep the electrodes closed until the next
time the button is released. The display shows "ACCo" and the LED in the clamp
flashes. In this function there is no current output!
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WARNING: when using safety gloves it may be difficult to select the squeeze
function using the clamp. We therefore recommend selecting the squeeze function
on the panel.
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WARNING!
RESIDUAL RISKS! 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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6.2.2. Adjusting the spot-welding current and times (Fig. B)
The spot-welding parameters are described in section 4.1.1
Spot-welding current and time are set automatically by selecting the thickness of the
sheet to be welded with key D as in Fig. B and selecting the material.
IMPORTANT:
If the LED corresponding to the selected thickness "flashes" this means that the
default welding current, or the initially programmed current, is insufficient to
achieve a satisfactory weld;
The spot-welding operation is deemed correct when a tensile test causes the spot-
welding core to come out of one of the two sheets.
6.2.3 Storage of the customized spot welding programmes (Fig. B)
It is possible to store three customized spot welding programmes, indicated on the
display by "Su_1" "Su_2" "Su_3" accordingly, for each material, thickness and tool, by
the procedure "SAVE":
a) Choose the tool you intend to use.
b) Keep key A as in Fig. B pressed for approx. 3 seconds; the display will flash and the
"PRG" LED will light up.
c) Use key A to select the parameter to be modified and select the desired value by
turning the encoder knob.
d) Repeat the operation for all the parameters that are to be modified as in Fig. B1.
e) Press the "SAVE" button and select personal programme "St_1,2,3".
f) Keep the "SAVE" key pressed down for about 3 seconds in order to SAVE the
parameter values in the chosen personal programme (make sure the display shows
"Yes" before you release the key).
g) The machine is now ready to spot-weld.
NOTA: during programming the spot-welder is unable to supply current output.
6.2.4 Recall of spot welding programmes (Fig. B)
It is possible to recall the factory programme ("rE_d") or the customized programmes
("rE_1", "rE_2", "rE_3") relative to a certain tool, thickness and material by the
procedure "RECALL":
h) Enter the programming system as specified at issue b) of this paragraph.
i) Press and release the "RECALL" button.
l) Turn the encoder and select "rE_d" (default program) or "rE_1", "rE_2", "rE_3"
(personal program).
m)Keep the "RECALL" button pressed for about 3 seconds to recall the selected program
(you will have to read "Yes" on the display before releasing the button).
n) The machine is now ready to spot-weld.
NOTE: to exit programming mode without storing the parameter settings press the "A" key
for about 3 seconds.
6.3 SETTINGS FOR THE MATERIAL (Fig. B)
- Press the "MATERIAL" button to display the available materials.
The available materials are:
FE = low content iron sheet;
StSt = "stainless" steel sheet;
FE Zn = low carbon content iron sheet treated with surface galvanisation.
HSS = high yield point iron sheet.
- Use the encoder to select the material to be spot-welded from the materials available in
the list.
- Press the "MATERIAL" key for about 3 seconds: "RECALL" and "YES" will appear; the
material has been selected.
6.4 SPOT-WELDING PROCEDURE
Operations that are valid for all tools:
- Selecting the material to be welded (see 6.3).
- Selecting the material thickness (key D as in Fig.B).
- Displaying the preset spot-welding parameters (key A in Fig.B).
- If desired, customising the spot-welding programme (see section 6.2.2).
6.4.1 PNEUMATIC CLAMP
- Select the continuous or pulsed spot-welding function (see section 4.1.1 for a
description of key "B").
- Place the fixed arm electrode on the surface of one of the two sheets to be spot-welded.
- Press the button on the handgrip of the clamp so that:
a) The sheets close between the electrodes.
b) The spot-welding cycle starts with current passage indicated by the LED
on the control panel.
- Release the button a few moments after the LED
- At the end of the spot-weld the average welding current will be displayed (excluding the
initial and final ramps). The current value may alternate with "warning" messages as (
- 8 -
(
( )
has gone off.
)