Telwin 5500 Manual De Instrucciones página 7

5. INSTALLATION
ATTENTION! CARRY OUT ALL INSTALLATION AND ELECTRICAL AND
PNEUMATIC CONNECTION OPERATIONS WITH THE SPOT WELDING MACHINE
RIGOROUSLY SWITCHED OFF AND DISCONNECTED FROM THE MAINS.
THE ELECTRICAL AND PNEUMATIC CONNECTIONS MUST ONLY BE CARRIED
OUT BY EXPERT OR QUALIFIED TECHNICIANS.
5.1 PRELIMINARY OPERATIONS
Unpack the spot-welder, assemble the separate parts included in the package.
5.2 LIFTING THE SPOT-WELDER
WARNING: None of the spot-welders described in this handbook have lifting devices.
5.3 POSITION
Reserve a space in the installation area that is large enough and without obstacles
for guaranteeing access to the control panel, the main switch and the work area in
complete safety.
Make sure there are no obstacles near the areas where the cooling air enters and exits,
ensuring that conductive power, corrosive vapour, humidity, etc. cannot be sucked in.
Place the spot welding machine on a surface of homogeneous material that is flat and
compact, and suitable for supporting the weight (see "technical data") to prevent the
danger of toppling or dangerous movements.
5.4 CONNECTION TO THE POWER NETWORK
5.4.1 Warnings
Before making any electrical connection, make sure the spot welding machine plate
data correspond with the mains voltage and frequency available in the installation
area.
The spot welding machine must only be connected to a power supply system with
neutral conductor connected to earth.
To guarantee protection against indirect contact, use residual-current devices of the
following type:
) for single-phase machines;
- Type A (
- Type B ( ) for three-phase machines.
- The spot welding machine does not meet the requirements of the IEC/EN 61000-
3-12 directive.
If it is connected to a public power grid, the installer or user must make sure that
the welding machine can be connected (if necessary consult the utility company).
5.4.2 Network plug and outlet
Connect a normalised plug (3P + E: only 2 poles are used; INTERPHASE connection!)
of suitable capacity to the power supply plug and prepare a mains socket that is
protected by fuses or by a circuit breaker; the relative earth terminal must be connected
to the earth conductor (yellow-green) of the power line.
The capacity and intervention characteristic of the fuses and circuit breaker switch are
given in the "TECHNICAL DATA" paragraph.
Should several spot welding machines be installed, distribute the power supply
cyclically between the three phases so as to create a more balanced load, for example:
spot welding machine 1: L1-L2 power supply;
spot welding machine 2: L2-L3 power supply;
spot welding machine 3: L3-L1 power supply.
ATTENTION! Failure to comply with the above rules renders the safety
system (class I) ineffective, with resulting serious risks for people (e.g. electric
shock) and for property (e.g. fire).
6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
Before commencing any spot welding operations, check the main switch is set to the
"O" position, and the electrical connection is performed correctly in accordance with
the instructions above.
6.2 PARAMETER ADJUSTMENT (in spot welding)
The parameters that determine the diameter (section) and mechanical seal of the
spot are:
- Force exercised by the electrode.
- Spot welding current.
- Spot welding time.
If there is no specific experience, it is a good idea to carry out some spot welding tests
using sheets of the same quality and thickness as those to be worked on.
The current and spot welding time parameters are adjusted automatically by selecting
the thickness of the sheet to be welded with the (+ / - icons) keys. Adjustments can
be made to the standard spot time (DEFAULT), within set limits, using the key (icon
fig. C-2).
6.3 PROCEDURE
6.3.1 STUDDER GUN
To spot weld, just place the tool against the piece to be welded, which is connected to
the earth cable: after a few moments, the machine recognises the contact and starts
the spot weld automatically.
ATTENTION!
- To fix or remove the tools from the gun spindle, use two hex keys in a manner
that stops the spindle from rotating.
- If working on doors or hoods, connect the earth bar to them to prevent
current from passing through the hinges, and near the area to be spot welded
(long current runs reduce spot efficiency).
- DO NOT PLACE THE STUDDER ON THE PIECE IF YOU DON'T INTEND TO
START WELDING!
6.3.2 Earth cable connection
a) Bare the sheet as close as possible to the working area, for a surface that
corresponds to the earth bar contact surface.
b1) Fix the copper bar to the sheet surface, using a JOINTED CLAMP (welding
model).
As an alternative to method "b1" (difficult t carry out):
b2) Spot weld a washer to the previously prepared sheet surface; pass the washer
through the slit in the copper bar and lock it in position with the supplied clamp.
Washer welding for mass terminal fixing
Mount the relative electrode (POS. 9, Fig. D) in the gun spindle, and insert the washer
(POS. 13, Fig. D).
Place the washer in the selected area. Place the earth terminal in contact in the
same area; press the gun push-button to weld the washer, which should be fixed as
indicated previously.
Screw, washer, nail, rivet spot welding
Fit the most suitable electrode on the gun, insert the element to be spot welded and
place it on the sheet in the necessary spot; press the gun push-button: release the
push-button only after the set time has elapsed.
Contemporaneous spot welding and drawing of special washers
This function can be carried out by assembling and fully tightening the spindle (POS.
4, Fig. D) on the body of the extractor (POS. 1, Fig. D): hook and fully fasten the other
end of the extractor on the gun. Insert the special washer (POS. 14, Fig. D) into the
spindle (POS. 4, Fig. D), and lock it with the relative screw (Fig. D). Spot weld in the
relative area, adjusting the spot welding machine as if spot welding washers, and start
drawing.
At the end, rotate the extractor by 90° to release the washer, which can be spot welded
in a new position.
Sheet heating and upsetting
In this mode the TIMER is disabled.
Operation duration is therefore manual, being determined by the time for which the
gun electrode is kept pressed on the piece connected to the earth.
Current intensity is adjusted automatically according to the thickness of the selected
sheet.
Assemble the carbon electrode (POS. 12, FIG. D) on the gun chuck and block in place
with the ring nut. Touch the area, that was previously bared, with the carbon tip. Work
from the outside to the inside, using a circular movement to heat the sheet which
undergoes work hardening and returns to its original position.
To prevent the sheet from drawing too much, treat small areas and immediately after
wipe using a damp cloth to cool the treated part.
Sheet upsetting
From this position operate on the relative electrode to flatten sheets that have localized
deformations.
Using the supplied extractor (POS. 1, Fig. D)
Washer hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 3, Fig. D)
onto the body of the electrode (POS. 1, Fig. D). Hook the washer (POS. 13, Fig. D),
spot welded as described previously, and begin drawing. When finished, rotate the
extractor by 90° to detach the washer.
Plug hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 2, Fig. D)
onto the body of the electrode (POS. 1, Fig. D). Make the plug enter (POS. 15-16, Fig.
D), after spot welding it as described previously, the spindle (POS. 1, Fig. D) keeping
the terminal tightened towards the extractor (POS. 2, Fig. D). When completely
introduced, release the spindle and start drawing. When finished, pull the spindle
towards the hammer to remove the plug.
WARNING:
when the work has been completed, place the gun on an insulating surface and
switch off the machine!
7. MAINTENANCE
WARNING! BEFORE CARRYING OUT MAINTENANCE, MAKE SURE
THE MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR.
- adaptation/restoration of the diameter and profile of the electrode tip;
- replacement of the electrodes;
- check the integrity of the power cable;
- check the integrity of the gun and output cables.
7.2 SPECIAL MAINTENANCE
SPECIAL MAINTENANCE MUST ONLY BE CARRIED OUT BY TECHNICIANS WHO
ARE EXPERT OR QUALIFIED IN AN ELECTRIC-MECHANICAL AMBIT.
WARNING! BEFORE REMOVING THE SPOT WELDING MACHINE OR
GUN PANELS AND ACCESSING THE UNIT, MAKE SURE THE SPOT WELDING
MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER
AND PNEUMATIC SUPPLIES (if present).
Carrying out checks while the inside of the spot welder is live can cause serious
electric shock due to direct contact with live parts and/or injury due to direct contact
with moving parts.
Periodically and as frequently as required by the use and environmental conditions,
inspect inside the spot welder and clamp and remove the dust and metal particles that
have deposited on the transformer, diode module, power terminal board, etc. using a
blast of dry compressed air (max. 5 bar).
Do not direct the jet of compressed air onto the electronic circuit board; if necessary
clean with a very soft brush or suitable solvents.
At the same time:
- Make sure the wiring does not show signs of insulation damage or loose-oxidised
connections.
- Make sure the screws that connect the transformer secondary with the output bars
/ wires are tight and that there are no signs of oxidation or overheating.
8. TROUBLESHOOTING
SHOULD MACHINE OPERATION NOT BE SATISFACTORY, AND BEFORE
CARRYING OUT MORE SYSTEMATIC CHECKS OR CONTACTING YOUR
TECHNICAL ASSISTANCE CENTRE, MAKE SURE THAT:
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