Technical Data - Telwin PCP 28 Manual De Instrucciones

- Only use electrodes that are recommended for the machine (see spare parts
list) without altering their shape.
- RISK OF BURNING
Some of the spot welder parts (electrodes - arms and adjacent areas) can
reach temperatures of above 65°C: suitable protective clothing must be
worn.
Allow newly-welded pieces to cool before touching them!
- RISK OF TOPPLING AND FALLS
- Place the spot welder on a horizontal surface that can suitably support the
mass; constrain the spot welder to the supporting surface (when indicated
in the "INSTALLATION" section of this manual). In contrary cases, where
the flooring is sloped or broken, or with mobile supporting surfaces, the
danger of toppling exists.
- It is forbidden to lift the spot welder, excluding where expressly indicated in
the "INSTALLATION" section of this manual.
- When using machines on wheels: disconnect the spot welder from the
electric and pneumatic (if present) power supplies before moving the unit
to another work area. Pay attention to obstacles and unevenness on the
ground (for example cables and piping).
- UNINTENDED USE
It is dangerous to use the spot welder for any purpose other than that for
which it is intended (see INTENDED USE).
SAFEGUARDS AND SHIELDS
The safeguards and mobile parts of the spot welder casing must be in position,
before connecting it to the power supply.
WARNING! Any manual intervention on the accessible mobile parts of the spot
welder, for example:
- Replacement of or maintenance on the electrodes
- Adjustment of the arm or electrode positions
MUST BE CARRIED OUT WITH THE SPOT WELDER SWITCHED OFF AND
DISCONNECTED FROM THE ELECTRIC AND PNEUMATIC (if present) POWER
SUPPLY.
MAIN SWITCH LOCKED AT "O" WITH LOCK CLOSED AND KEY REMOVED in the
models with PNEUMATIC CYLINDER movement).
STORAGE
- Place the machine and its accessories (with or without packaging) in closed
areas.
- The relative humidity of the air must not exceed 80%.
- The environmental temperature must be between -15°C and 45°C.
If the machine has a water cooling unit and the environmental temperature is
lower than 0°C: add the indicated antifreeze liquid or completely empty the
hydraulic circuit and the water tank.
Always use suitable measures for protecting the machine from humidity, dirt
and corrosion.
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 MAIN CHARACTERISTICS
Column spot welding machine with electrode and curved descent for resistance
welding system (single spot) with digital microprocessor control.
Their main characteristics are:
- limitation of line overcurrent at insertion (insertion cosφ check);
- choice of the best spot welding current according to the mains power available;
- choice of the optimal welding cycles parameters (approach time, ramp time,
welding time, pause time and pulse number);
- saving of favourite programmes;
- backlit LCD display that shows the controls and the set parameters;
- thermal protection with indicator (overload or lack of cooling water);
- indicating and blocking in the event of overload or underload of delivered voltage;
- no air indicator (only on PCP pneumatic control models);
- air flow regulation for slow arm closing (only on PCP pneumatic control models).
Operation:
- "PTE" models: mechanical, equipped with pedal with adjustable lever length;
- "PCP" models: pneumatic, equipped with double effect cylinder controlled by a
pedal valve.
2.2 OPTIONAL ACCESSORIES
- Arm pair, length 500mm, complete with electrode holders and standard electrodes.
- Arm pair, length 700mm, complete with electrode holders and standard electrodes.
- Curved electrodes.
- Closed circuit water cooling system (suitable for PTE or PCP 18 only).

3. TECHNICAL DATA

3.1 RATING PLATE (FIG. A)
The main data relating to use and performance of the spot-welder are summarised on
the rating plate and have the following meanings:
1- Number of phases and frequency of power supply.
2- Power supply voltage.
3- Mains power with permanent running (100%).
4- Rated mains power with 50% duty cyde.
5- Maximum loadless voltage over electrodes.
6- Maximum current when electrodes are shorted.
7- Current to secondary when running permanently (100%).
8- Gauge and length of arms (standard).
9- Minimum and maximum adjustable electrode force.
10- Rated pressure of compressed air supply.
11- Pressure of compressed air supply needed to obtain maximum electrode force.
12- Cooling water flow rate.
13- Rated pressure drop for coolant liquid.
14- Weight of welding device.
15- Safety symbols, the meanings of which are given in chapter 1 "General safety
rules for resistance welding".
Note: The rating plate shown is an example to show the meaning of the symbols and
numbers; the exact technical specifications of your spot-welder can be found on the
rating plate of the spot-welder itself.
3.2 OTHER TECHNICAL DATA (FIG. B)
4. DESCRIPTION OF THE SPOT-WELDER
4.1 SPOT-WELDER ASSEMBLY AND DIMENSIONS (FIG. C)
4.2 CONTROL AND ADJUSTMENT DEVICES
4.2.1 Control panel (FIG. D1).
1- main switch (in PCP models with emergency stop function and lock function in
position "O": lock and key supplied).
2- increase (+) decrease (-) buttons.
3- "MODE" settings selector button.
4- rear-lit LCD display;
5- run / START button (mod. PCP);
/ pressure only switch (no welding) / welding.
6-
4.2.2 Description of the icons (FIG. D2).
Spot welding parameters (1-7):
1- power (%): spot welding current as a percentage of the maximum value;
2- approach (cycles): stand-by times in cycles before delivering current from the
contact of the electrodes with the piece being processed;
3- ramp (cycles): time in cycles that the spot welding current takes to reach the
value set for "power";
4- spot welding time (cycles): time in cycles that the current remains at the set
value;
5- pause time (cycles): time in cycles during which the current is zero between
one pulse and another (only in pulse mode);
6- pulse number (n°): if 1 then the spot welding stops after spot welding time (4);
if greater than 1, it indicates the number of current pulses delivered by the
machine (pulse mode);
7- circular synoptic indicator, with numerical value in the centre, of the set
cycles;
8- thermal alarm icon;
9- multifunction numerical display;
10- spot welding enabled icon (delivery of current);
11- approach enabled icon, with selector switch in FIG. D1-6 in the NO
WELDING position;
12- START indicator: press the button in FIG. D1-5 to start the machine;
13- customised PROGRAMME icon;
14- save / do not save customised programme icon;
15- circular synoptic indicator, with numerical value in the centre, of the set
power.
4.2.3 Setting of the spot welding parameters
Each time the machine is switched on, and before pressing the "START" button, it is
possible to change the function mode used to set the welding parameters:
- "REDUCED" = EASY mode: allows quick and user-friendly selecting of the two
main spot welding parameters "POWER" (1) and "welding time" (4). This function
mode does not foresee the saving of customised programmes.
- "EXTENDED" = EXPERT mode: allows the selecting of all the welding parameters
described in the paragraph above. This function mode allows the saving of
customised programmes.
4.2.4 Compression and flow regulator nut (FIG. D3)
1- The nut can be accessed via the hatch door on the rear of the spot welding
machine.
The nut is used to regulate the force exerted by the electrodes intervening on the
spring preload: the greater the spring load, the greater the force of the spot welding
machine electrodes.
2- The flow regulator (PCP mod. only) is used to decrease the arm closure speed to
prevent the electrodes from rebounding on the piece.
Rotate the adjuster screw counter clockwise (+) to increase air flow and descent
speed of the electrodes; rotate the screw clockwise (-) to decrease air flow and the
descent speed of the electrodes.
4.2.5 Pressure and pressure gauge regulation (FIG. D4 - PCP mod. only)
1- Pressure regulator knob;
2- Pressure gauge.
4.2.6 Air and water couplings (FIG. G and H)
G (1) - Compressed air pipe coupling (PCP mod. only);
G (2) - Condensate filter and bleeder (PCP mod. only);
H (1) - INLET water couplings.
H (2) - OUTLET water couplings.
4.3 SAFETY FUNCTIONS AND INTERLOCK
4.3.1 Main switch
- Position "O" = open and lockable (see chapter 1).
ATTENTION! The internal power cable connection terminals
(L1+L2) are live when turned to the "O" position.
- Position "I" = closed: spot welding machine powered up but not operating (STAND
BY) display ON.
Emergency function
Opening the spot welding machine when it is operating (position "I" => position "O") will
instantly stop the machine in safe shutdown mode with:
- current inhibited;
- all movement is blocked: exhauster cylinder (if installed);
- automatic restart inhibited.
ATTENTION! PERIODICALLY MAKE SURE THE SAFE SHUTDOWN
FUNCTION OPERATES CORRECTLY.
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