Telwin Inverspotter 12000 Manual De Instrucciones página 10

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.
Simultaneous spot-welding and pulling on special grommets
This is carried out by fitting and locking the chuck tightly (POS.4, FIG. I) onto the body of
the extractor (POS.1, FIG. I); lock the other terminal of the extractor tightly onto the
studder (FIG. I). Insert the special grommet (POS.14, FIG. I) into the chuck (POS.4, FIG.
I), locking it with the special screw (FIG. I) 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
In this operating mode the TIMER is off: by selecting welding time the display shows
"InF" (infinite time).
The operating time is therefore determined manually by the time for which the studder
button is pressed down.
Current intensity is regulated automatically depending on the selected sheet thickness.
Fit the carbon electrode (POS.12, FIG. I) into the studder chuck and lock it with the ring
nut. Touch the previously bared area with the carbon tip and press the studder button.
Work from the outside towards the inside with a circular movement so as to heat the
sheet, which will work harden and return to its original position.
To prevent the sheet from over-hardening treat small areas and immediately afterwards
wipe them with a damp cloth to cool the treated part.
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. I) 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.
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. I)
Locking on and pulling grommets
This is carried out by fitting and locking the chuck tightly (POS.3, FIG. I) on the body of
the electrode (POS.1, FIG. I) Lock onto the grommet (POS.13, FIG. I), 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. I) on the body of
the electrode (POS.1, FIG. I) Insert the pin (POS.15-16, FIG. I), which was spot-welded
as described previously, into the chuck (POS.1, FIG. I) keeping the end pulled towards
the extractor (POS.2, FIG. I) After insertion release the chuck and start pulling. On
completion pull the chuck towards the hammer to extract the pin.
7. MAINTENANCE
_____________________________________________________________________________________________________________________ WARINING! BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
MAKE SURE THE SPOT-WELDER HAS BEEN SWITCHED OFF AND
DISCONNECTED FROM THE MAIN POWER SUPPLY.
The main switch must be locked in the "O" position using the supplied padlock.
_____________________________________________________________________________________________________________________
7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR
- adjustment/reset of electrode tip diameter and profile;
- replacing the electrodes and arms (see NOTES 1 and 2 in section 6.4.1).
- electrode alignment checks;
- cable and clamp cooling checks;
- discharge of condensation from the compressed air inlet filter.
- check the water level in the tank regularly, with a frequency proportional to the
amount of use.
- make regular checks to make sure the liquid is not leaking.
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.
Depending on how often the spot-welder is run and on the environmental conditions,
make regular checks inside the machine and remove the dust and the metallic particles
deposited on the transformer, the thyristor module, the terminal box, etc., using dry
compressed air (max. 5 bar).
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.
- Ensure that the transformer secondary screws connecting the output bars are tightly
secured and that there are no signs of oxidation or overheating.
- 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.
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; ensure correct cooling water flow and, 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.
7.2.1 Working on the GRA
In the case of:
- the need to top up the water level in the tank becoming excessively frequent;
- alarm 7 triggering too often;
- water leaks;
we recommend checking for problems that may be present inside the cooling unit area.
Always refer to section 7.2 for general instructions and warnings and always disconnect
the spot-welder from the power supply, then proceed to remove the side panel (FIG.L).
Check for leaks in the connections and in the piping. If you find a leak, replace the
damaged part. Remove any water that may have leaked during maintenance and close
the side panel.
Then proceed with resetting the spot-welder, following the appropriate instructions in
section 6 (Spot welding).
7.2.2 Replacing the GRA
To replace the cooling unit completely and/or to enable operations that cannot be
carried out as described in section 7.2.1, proceed as follows:
1 refer to section 7.2 for general instructions and warnings and always disconnect the
spot-welder from the power supply;
2 loosen the screws and take the lifting arm support out of its housing (FIG.M);
3 remove the side panels (FIG.N);
4 undo the screws fastening the cooling unit to the trolley structure (FIG.O);
5 Disconnect the flexible water hoses, labelled "OUTLET" and "INLET", by unscrewing
the hose clips fastening them to the pipe fittings (FIG. P).
Watch out for water that may leak out of the circuit.
6 disconnect the control wiring for the clamp button (FIG.O);
7 take out the cooling unit from the back of the spot-welder (FIG.R);
To insert the new cooling unit or to reinsert the extracted and repaired unit, proceed in
the reverse order, taking care to connect the clamp button cable correctly and also the
piping. Remove any water that may have leaked during maintenance.
Then proceed with resetting the spot-welder, following the appropriate instructions in
section 6 (Spot welding).
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