Telwin Digital Car Puller 5000 Manual De Instrucciones página 8

Connecting the earth cable:
a) Bare the sheet as close as possible to the point where you intend to work,
cleaning an area corresponding to the contact surface of the earth bar.
b1) Fasten the copper bar to the sheet surface using an ARTICULATED CLAMP
(welding model).
Alternatively to method b1 (when practical difficulties arise) proceed as follows:
b2) Spot-weld a grommet to the prepared sheet surface; pass the grommet through
the slit in the copper bar and lock it with the supplied terminal.
Spot-welding the grommet for anchoring the earth terminal
Fit the appropriate electrode to the studder chuck (POS.9, FIG. E) and insert the
grommet (POS.13, FIG. E).
Place the grommet in the chosen area. Place the earth terminal in contact in the
same area; press the torch button to weld the grommet to be used for anchorage as
described above.
Connecting the earth cable (through spot welding earth):
a) Bare the sheet as close as possible to the point where you intend to work,
cleaning an area corresponding to the contact surface of the earth hexagon.
b) Connect the earth terminal (threaded earth electrode and corresponding
threaded hexagon) to the eyelet terminal on the earth cable and lock it using the
nuts and washers supplied for this purpose.
c) Fit the electrode-holder rod and corresponding electrode into the gun chuck;
place both the earth electrode and the gun electrode in contact with the bared
sheet and carry out the spot-weld.
d) Tilt and turn the rod to detach the spot-welding electrode; use gentle force to
tighten up the earth hexagon manually so as to obtain a good contact with the
sheet.
Spot-welding screws, washers, studs, rivets
Fit the appropriate electrode to the studder, insert the item to be welded and place it
on the sheet at the desired point; press the button on the studder: release the button
only after the preset time (green LED
Spot-welding sheets from one side only
Fit the appropriate electrode to the studder chuck (POS.6, FIG. E) pressing on the
surface to be welded. Press the button on the studder and only release it after the
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preset time (LED goes off).
WARNING!
The maximum sheet thickness that can be welded from only one side is 1+1 mm. This
type of welding must not be used on bodywork supporting structures.
To obtain correct results when spot-welding sheets with the studder the following
basic precautions should be taken:
1- A perfect earth connection.
2- The two parts to be spot-welded should be bared of any paint, grease or oil.
3- The parts to be welded should be in contact with one another, without an
intervening shim; if necessary press them together with a tool and not with the
studder. Too much pressure will lead to poor results.
4- The top piece should never be thicker than 1 mm.
5- The diameter of the electrode tip should be 2.5 mm.
6- Make sure that the electrode locking nut is tightened up completely and that the
welding cable connectors are locked.
7- When spot-welding, put the electrode on the sheet, exert slight pressure (3-4 kg).
Press the button, weld for the preset time and only then take the studder away.
8- Never weld more than 30 cm from where the earth bar is fastened.
9- Connect the earth to the lower sheet.
Simultaneous spot-welding and pulling on special grommets
This is carried out by fitting and locking the chuck tightly (POS.4, FIG. E) onto the
body of the extractor (POS.1, FIG. E); lock the other terminal of the extractor tightly
onto the studder (FIG. E). Insert the special grommet (POS.14, FIG. E) into the chuck
(POS.4, FIG. E), locking it with the special screw (FIG. E) Spot-weld it in the required
place, adjusting the studder as for spot-welding grommets and start pulling.
On completion, turn the extractor through 90° to detach the grommet, which can be
re-welded in a new position.
5
Heating and upsetting sheets
Operation duration is set manually, being determined by how long the gun
pushbutton is kept pressed.
The intensity of the current for the 3kA model is regulated automatically according to
the thickness of the selected sheet, while the intensity of the 2.5kA model can be
regulated using the"+" and "-" keys on the panel (Fig. B-2).
Place the carbon electrode (POS.12, FIG. E) in the gun spindle and lock it with the
ring nut. Touch the previously bared area with the carbon tip and press the gun
pushbutton. Operate from the outside to the inside using a circular movement to
warm the sheet which, becoming work-hardened, will return to its original position.
To stop the sheet from becoming too work-hardened cover small areas at a time and
immediately wipe with a damp cloth to cool the treated zone.
5
Upsetting sheet metal
In this position, working with the appropriate electrode, it is possible to flatten sheets
that have undergone localised deformation.
6
Jogged spot-welding (Patching
This function is suitable for spot-welding small rectangles of sheet to cover holes due
to rust or other causes.
Fit the appropriate electrode (POS.5, FIG. E) into the chuck, and tighten the ringnut
to fasten it securely. Bare the area to be worked on and make sure the patch sheet to
be welded is clean and free of grease and paint.
Position the patch and put the electrode on it then press the studder button and keep
it pressed, advancing in rhythm with the work/rest intervals determined by the spot-
welder.
N.B.: The spot-welder regulates work and pause time automatically according to the
!
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goes off).
4
(only for model 3kA)
“
only for model 3kA)
selected sheet thickness. When working exert slight pressure (3-4 kg) and follow an
ideal line 2-3 mm from the edge of the new piece being welded.
To achieve good results:
1- Never weld more than 30 cm from where the earth is attached.
2- Use patch sheet no more than 0.8 mm thick, preferably stainless steel.
3- Move forwards in rhythm with the spot-welder. Advance during the pause and
stop during welding.
Using the supplied extractor (POS.1, FIG. E)
Locking on and pulling grommets
This is carried out by fitting and locking the chuck tightly (POS.3, FIG. H) on the body
of the electrode (POS.1, FIG. H) Lock onto the grommet (POS.13, FIG. H), which was
been spot-welded as described previously, and start pulling On completion turn the
extractor through 90° to detach the grommet.
Locking on and pulling pins
This is carried out by fitting and locking the chuck tightly (POS.2, FIG. E) on the body
of the electrode (POS.1, FIG. E) Insert the pin (POS.15-16, FIG. E), which was spot-
welded as described previously, into the chuck (POS.1, FIG. E) keeping the end
pulled towards the extractor (POS.2, FIG. E) After insertion release the chuck and
start pulling. On completion pull the chuck towards the hammer to extract the pin.
Spot welding and drawing on sheets
Put the tie rod complete with hammer and electrode in the gun, then place it against
the sheet at the required point. Press the gun pushbutton: release the pushbutton
after the set time (GREEN LED
When finished, tilt and rotate the rod to remove the welding electrode, which can be
used again.
7. MAINTENANCE
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WARINING! BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
MAKE SURE THE SPOT-WELDER HAS BEEN SWITCHED OFF AND
DISCONNECTED FROM THE MAIN POWER SUPPLY.
_____________________________________________________________________________________________________________________
7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR
- adjustment/reset of electrode tip diameter and profile;
- electrode alignment checks;
- efficiency checks on cables and gun.
7.2 EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT
ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED ELECTRICAL-MECHANICAL
PERSONNEL.
_____________________________________________________________________________________________________________________
WARNING! BEFORE REMOVING THE SPOT-WELDER PANELS AND
WORKING INSIDE IT MAKE SURE IT IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
_____________________________________________________________________________________________________________________
If checks are made inside the spot-welder while it is live, this may cause serious
electric shock due to direct contact with live parts and/or injury due to direct
contact with moving parts.
Inspect the inside of the spot welder periodically, and in any case as frequently as
required by use and the surrounding conditions. Remove the dust and metal parts that
have deposited on the transformer, thyristors module, supply terminal board, etc. using
a jet of dry compressed air (max 5bar).
Do not direct the compressed air jet on the electronic boards; clean them using a
very soft brush or with the appropriate solvents.
Take the opportunity to:
- Ensure that the wiring insulation is not damaged and the connections are tight and
free of oxidation.
- Make sure that the connecting screws of the transformer secondary (if present) are
securely tightened and that there are no signs of oxidation or overheating.
IF SPOT-WELDER OPERATION IS UNSATISFACTORY, BEFORE PERFORMING
MORE SYSTEMATIC CHECKS OR CONTACTING YOUR SERVICE CENTRE CHECK
WHETHER:
- With the spot-welder main switch closed (pos. " | ") the green LED is on; if not the fault
is in the power line (cables, outlet and plug, fuses, excessive voltage drop etc.).
- The yellow LED is on (thermal safeguard triggered); wait until the LED goes off before
re-starting the spot-welder; if necessary, reduce the duty cycle.
- The parts making up the secondary circuit (arm-holder castings arms electrode
holders cables ) are inefficient due to loose screws or oxidation.
- The welding parameters are actually appropriate for the job to be done.
- After having carried out maintenance or repairs, restore the connections and wiring
as they were before, making sure they do not come into contact with moving parts or
parts that can reach high temperatures. Tie all the wires as they were before, being
careful to keep the high voltage connections of the primary transformer separate from
the low voltage ones of the secondary transformer.
Use all the original washers and screws when closing the casing.
- 8 -
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switches off) and start drawing.