Technical Data; Welding Process - DECAWELD SPOT Manuel D'instruction

3) (SYNERGIC): inactive push-button
(MANUAL): Power increasing / decreasing values
4) (SYNERGIC): Program selection
(MANUAL): Timer increasing / decreasing values
3,1) (SYNERGIC): Program selected
(MANUAL): Power display
4,1) (SYNERGIC): Program selected
(MANUAL): Timer display
5) Heat cut-out signal (resets automatically)

Technical data

A data plate is affixed to the welding machine. Fig. 2 shows an example of this plate.
A) Constructor name and address
E) European reference standard for the construction and safety of welding equipment
B) Symbol of delivered current: alternate / frequency
U20 Minimum and maximum open circuit voltage (open welding circuit).
I2cc (min imp) Current delivered by the welding machine. (minimum impedance)
I2cc (max imp) Current delivered by the welding machine. (maximum impedance)
I2p
Current delivered by the welding machine. (duty cycle 100%)
Duty cycle at maximum power is approx 1%
C) Input power required: 1˜ alternate single phase voltage, frequency
U1N Input voltage.
Sp Installation power (duty cycle 100%).
S50 Installation power (duty cycle 50%).
e Distance between the arms
L Arms length
Fmax Maximum force to the electrodes: (short arms / long arms)
Fmin Miniumum force to the electrodes.
P1 Compressed air: maximum pressure
P2 Compressed air: force: maximum force to the electrodes
Mass Weight
D) Serial number
L) Safety symbols: Refer to Safety Warnings
„ Connections to the mains must be made by expert or qualified personnel.
„ Make sure that the welding machine is switched off and the plug is not in the power
socket before carrying out this procedure.
„ Make sure that the power socket that the welding machine is plugged into is protected
by safety devices (fuses or automatic switch) and grounded.
„ The device must be connected only to a supply system, with an earthed 'neutral' lead.
Assembly and electrical connections
¾ Assembly the detached parts found in the packaging Fig.8.
¾ Check that the electrical supply delivers the voltage and frequency corresponding to
the welding machine and that it is fitted with a delayed fuse suited to the maximum
delivered rated current
TN systems
Fig.3
¾ P r o t e c t b y m e a n s o f a u t o m a t i c c i r c u i t b r e a k e r ( D c u r v e )
r a t e d : 5 0 A f o r 1 P h 2 2 0 / 2 3 0
The disconnection time in case of fault must not be higher than 0.4sec (for supply network
having a nominal voltage to earth of 230V) and should be evaluated at the installation:
if, due to installation conditions, the fault current becomes too low to properly operate
the circuit breaker, the use of an additional RCD (residual current device) may become
necessary (not on TN-C systems).
TT systems
Fig.3
¾ According to IEC 60364-4-41 the installation must be protected by an RCD which
sensitivity depends upon the earth connection resistance of each installation, IEC
60364-4-41 also requires that the RCD tripping time is lower than 1sec.
¾ The earth connection resistance of the installation must be considered for the
selection of the RCD sensitivity; the maximum resistance of the protective bonding
circuit of the welding equipment is 0.14 Ohm
L
The requirements set out in the IEC/EN61000-3-12 standard do not apply to this
equipment. If this equipment is connected to low voltage power supply network, either
the installer or the user is responsible for checking that this can be done (consult the
distribution system operator if required).
L
In order to comply with the requirements set out in EN61000-3-11 (Flicker), it is
advisable to connect the welder to the supply mains interface points with a service
current capacity of >/= 100A per phase.
L
Either the installer or the user is responsible for checking that the welder can be properly
connected; (consult the electrical grid operator if required).
¾ Plug. If the welding machine is not fitted with a plug, fit a normalised plug (2P+T for
1Ph) of suitable capacity to the power cable Fig.3.

Welding process

Once you have put the welding machine into operation, switch it on and carry out the
adjustments following the order shown in the description of the controls FIG.1
Studder: tecnique for use
¾ Firmly connect the copper bar to a part of the element being repaired, screwing or
clamping it on or welding a washer to the piece and using the terminal clamp as in
the fig. 4.
L
For repairing doors or cases, it is necessary to connect the copper bar to the part, to
prevent current from passing through the hinges.
950628-04 13/11/15
Starting up
o r 3 2 A f o r 1 P h 3 8 0 / 4 0 0 .
¾ Position (1) on STUDDER
¾ Position (2) on SYNERGIC
¾ Select the program of the preferred tool for studder (4) and fix it on the gun.
Spot welding and washer, nail, rivet traction Prg 32 > Prg 36
Spot welding Prg 37
L
Do not use this system on carrying structures of the body.
Sheet heating and overturning Prg 38
Patching Prg 39
L
In this function the pause time is fixed (approx. 0.5 sec.)
L
Please keep non-operating studder away from the working area to avoid any accidental
contact.
Spot welder
For successful work results the following regulations must be observed: Fig.6.1, 6.2,
6,3
„ Accurately clean the parts to be welded, eliminating paint, rust, etc.
„ Prepare the tips correctly
„ Check tip alignment
„ Select the arm and the electrode best suited to the part to be welded
„ Check that the inside surfaces of the parts match as closely as possible
Spot-welder
¾ Connect compressed air hose and adjust the pressure to 5-7 BARS (for the pneumatic
spot welder) Fig.5
Continuous single point spot-welding "Prg 2 > 15"
¾ Position (1) on SPOT WELDER
¾ Position (2) on SYNERGIC
¾ Select programs Continuous single point spot-welding./ thickness to spot-weld (4)
Pulsating single point spot-welding "Prg 16 > 31" (for sheet metal with a high yield
point or galvanized steel)
¾ Position (1) on SPOT WELDER
¾ Position (2) on SYNERGIC
¾ Select the program pulsating single point spot-welding / thickness to spot-weld (4)
L
AUTOMATIC COMPENSATION If the earth contact is not sufficient, the timer will not
weld the point, hence the sheet the piece is to be welded on must be bared.
Test for adjusting spot-welder arms
¾ Position (1) on SPOT WELDER
¾ Position (2) on SYNERGIC
¾ Select the program "PRG 1" (4)
Revision of preset programs
To revise preset TIME and POWER values, you should:
¾ Position (2) on SYNERGIC
¾ Select the program to be revised (4).
¾ Position (2) on MANUAL
¾ Revise preferred time or power values by reading the value on display and pushing
buttons (3, 4). Once revision is over, the equipment with the new setting can operate
immediately.
L
Attention: Should you need to revise the values, please take care to start always
revising POWER first and then eventually TIME.
Thermal cutout signal (5)
The warning light switched on means that the thermal protections of the welder or of the
studder torch are running.
Switch off the welder and remove the plug from the power socket before carrying out any
maintenance operations.
STUDDER
Torch = check that there are no cuts or abrasions in the cable that bare the internal
conductors.
Earth = check the efficiency of connections and terminal.
SPOT WELDERS
Cables = check that there are no cuts or abrasions in the cable that bare the internal
conductors.
Hoses = check that there are no compressed air leaks so that there is no loss of pressure
during spot-welding.
Electrodes = adjustment/reset of electrode tip diameter and profile. Electrode alignment
checks
Extraordinary maintenance to be carried out by expert staff or qualified electrical
mechanics periodically depending on use.
• Inspect the inside of the welder and remove any dust deposited on the electrical parts
(using compressed air) and the electronic cards (using a very soft brush and appropriate
cleaning products). • Check that the electrical connections are tight and that the insulation
on the wiring is not damaged.
8
Maintenance