Telwin INVERSPOTTER 13500 smart aqua Manuel D'instructions page 8

also Par. 5.6 "Cooling system settings").
d) Compressed air safety
Activates if the compressed air pressure (p < 3bar) drops or is absent;
The intervention is signalled on the display by AL 6 = no air alarm.
EFFECT: movement stopped, electrodes opened (cylinder to discharge); current
stopped (welding impeded).
RESETTING: manual ("START" pushbutton pressed) after returning within the
permitted pressure limits (manometer indicates >3bar).
e) Output short circuit safety (only pneumatic clamp)
Before starting the welding cycle, the machine checks that the poles (positive and
negative) of the secondary welding circuit have no accidental contact points.
The intervention is signalled on the display as AL 9 = output short circuit alarm
EFFECT: movement stopped, electrodes opened (cylinder to discharge); current
stopped (welding impeded).
RESETTING: manual ("START" pushbutton pressed after having removed the
cause of the short circuit).
f) No phase safeguard
The intervention is signalled on the display by AL 11 = no phase alarm.
EFFECT: movement stopped, electrodes opened (cylinder to discharge); current
stopped (welding impeded).
RESETTING: manual ("START" pushbutton pressed).
g) Undervoltage and overvoltage safeguard
Intervention is signalled on the display by AL 3 = overvoltage alarm and by AL 4 =
undervoltage alarm.
EFFECT: movement stopped, electrodes opened (cylinder to discharge); current
stopped (welding impeded).
RESETTING: manual ("START" pushbutton pressed).
h) "START" pushbutton (Fig. C-8).
It must be pressed to command welding in each of these conditions:
- each time the main switch is closed (pos "O"=>pos " I ");
- after the safety/protective devices cut in;
- after the power supplies (electricity and compressed air) that were previously
interrupted because of upstream disconnection or failure have returned.
- with protected mode active (see paragraph 4.2.2).
WARNING! PERIODICALLY MAKE SURE THE SAFETY STOP IS
OPERATING CORRECTLY
5. INSTALLATION
WARNING! ALL INSTALLATION OPERATIONS AND ELECTRICAL AND
PNEUMATIC CONNECTIONS MUST ALWAYS BE CARRIED OUT WITH THE SPOT
WELDER SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY.
THE ELECTRIC AND PNEUMATIC CONNECTIONS MUST ONLY BE CARRIED
OUT BY EXPERT OR QUALIFIED TECHNICIANS.
5.1 UNPACKING
Unpack the spot welder, assemble the separate parts (to be found in the packaging)
as indicated in this chapter (Fig. D).
5.2 LIFTING MEANS (Fig. E)
The spot welder must be lifted using a double cable and hooks that are suitably sized
for the machine weight, and using the relative M8 rings.
It is forbidden to sling the spot welder using means other than those indicated.
5.3 POSITIONING
Make sure the installation area is suitably large and without obstacles to guarantee
that the control panel, the main switch and the working area can be accessed in
complete safety.
Make sure there are no obstacles near the cooling air entry or exit points, and make
sure that conductive dust, corrosive vapours, humidity, etc. cannot be sucked in.
Position the spot welder on a flat surface made of homogeneous, compact material
that is suitable for supporting the weight of the machine (see "technical data") to avoid
the danger of toppling or dangerous movements.
5.4 CONNECTION TO THE MAINS
5.4.1 Warnings
Before carrying out any electric connection, make sure the machine plate data
corresponds with the voltage and frequency of the mains available in the installation
place.
The spot welder must be connected only and exclusively to a power supply with the
neutral conductor connected to earth.
To guarantee protection against indirect contact use these types of residual current
device;
) for single-phase machines;
- A type (
- B type ( ) for three-phase machines.
- The IEC/EN 61000-3-12 Standard is not applicable to the spot welder.
If the welding machine is connected to a public electricity grid, the installer or user
must make sure that the machine can be connected (if necessary, consult the
company that manages the electricity grid).
5.4.2 Plug and mains outlet
Connect the power supply cable to a standard (3P + T) plug of appropriate capacity
and prepare a power supply outlet fitted with fuses or an automatic circuit-breaker; the
corresponding earth terminal must be connected to the (yellow-green) earth conductor
of the power supply.
The capacity and intervention characteristics of the fuses and circuit-breaker switch
are given in the "OTHER TECHNICAL DATA" paragraph.
WARNING! Not observing the regulations above renders the
manufacturer's safety system (class I) inefficient, with resulting serious risks to
people (e.g. electric shock) and goods (e.g. fire).
5.5 PNEUMATIC CONNECTION
- Prepare a compressed air line with a working pressure of 8 bar.
- Fit one of the available compressed air connections to the filter group reducer
to make the reducer suitable for the connections where the spot welder is to be
installed.
5.6 COOLING SYSTEM ASSEMBLY (GRA)
WARNING! The filling operations should always be performed with
the machine switched off and disconnected from the mains supply.
Never use polypropylene based antifreeze liquids.
Only use the coolant recommended by the manufacturer of the cooling unit.
- Open the discharge valve (FIG. B-13).
- Fill the tank with coolant using the nozzle (Fig. B-11): capacity of the tank = 8 l; pay
attention to avoid excess leakage of liquid at the end of filling.
- Close the tank cap.
- Close the discharge valve.
5.7 PNEUMATIC CLAMP CONNECTION (Fig. F)
WARNING! Dangerous high voltage! Never under any circumstances
connect plugs other than those approved by the manufacturer to the spot
welder. Do not attempt to insert any other object in the socket!
- Machine disconnected from the mains.
- Insert the clamp polarised plug into the machine socket, then raise the two levers
until the plug is fastened firmly in place.
- (if present) insert the cooling tubes(*), respecting the colours (blue tube on blue
socket, red tube on red socket). Check rapid coupling of the tubes is correctly
carried out.
NOTE(*): if the cooling tubes are not inserted, the clamp is NOT cooled
correctly resulting in thermal stress which damages the electric parts.
5.8 CLAMP "C": CONNECTION TO THE ARM
WARNING! Residual risk of crushing the upper limbs!
Follow the instructions below in the exact order indicated!
- Disconnect the machine from the mains.
- Turn the block as seen in Fig. G1.
- Now assemble the clamp support (Fig. G2) if used.
- Angle the arm as necessary and slide it into its seat (Fig. G3).
- Align the arm with the piston electrode and tighten the block in place (Fig. G4-A).
- Connect the cooling tubes to the relative quick couplings (Fig. G4-B).
- Check that the pipe quick coupling is fastened firmly in place.
- Now assemble the clamp support sleeve from the correct side (Fig. G5) if used.
NOTE: if the cooling tubes are not connected, the clamp will NOT be cooled
properly which will cause thermal stress and damage to the electrical parts.
6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
6.1.1 Main switch at "O" and lock closed!
A series of checks and adjustments must be carried out before starting to spot weld,
with the main switch in the "O" position and the lock closed.
Connecting to the electric and pneumatic supply sources:
- Make sure the electric connection has been carried out correctly in compliance with
the instructions given previously.
- Check compressed air connection: connect the supply hose to the pneumatic
supply point and adjust the pressure using the reducer knob until the manometer
shows a value close to 8 bar (116 psi).
6.1.1.1 Adjusting and fixing the "C" clamp arm
This operation must only be carried out if the arm moves horizontally even after having
been locked as explained in paragraph 5.8 (Fig. Q)
For this operation proceed as follows:
- Release the arm by rotating the release lever (Fig. R);
- Loosen the dowel (Fig. S-1) and tighten the ring nut (Fig. S-2) by one-eighth of a
turn (approx. 45 degrees);
- Lock the ring nut, tightening the locking dowel (Fig. S-1);
- Lock the arm, following the operation shown in Fig. T.
This operation may need to be carried out several times, either tightening or loosening
the ring nut (Fig. S-2), until the arm is locked horizontally and the locking lever, using
rotational power that is suitable for manual release, simultaneously closes at the stop
created by the reference plug (Fig. T-1).
NOTE: when the operation ends, the lever must be against the end stop plug (Fig.
T-1). This position guarantees that the "C" arm is locked mechanically and therefore
safe.
6.1.2 Main switch at the " I " position.
The following checks must be carried out before doing any spot welding, and with the
main switch at "I" (ON).
Clamp electrode alignment:
- Place a shim having the same thickness as the panels to be spot welded between
the electrodes; make sure the electrodes, which are now "squeezing" the panels
(see paragraph 6.2.2), are aligned.
- If necessary, make sure that the arm is correctly fixed (see previous paragraphs).
6.2 ADJUSTING THE SPOT WELDING PARAMETERS
The parameters that determine the diameter (section) and mechanical seal of the
spot are:
- Power applied by the electrodes.
- Spot welding current.
- Spot welding time.
If the operator does not have specific experience, it is best to try some spot welding
on pieces of panel with the same thickness and of the same quality as the ones to be
spot welded.
6.2.1 Setting the arm and the electrode
Press the "MODE" key several times until you access "MAINTENANCE", then set the
current arm with the electrode used, which can be type "a" (flat), type "b" (point) or
type "c" (spherical). Refer to the "Spot Welding Accessories" section in the catalogue.
For example, set CA1/b for the standard arm with "b" type electrode, set CA1/a if the
arm is the same but the electrode is type "a".
Prefer type "b" electrodes for welding that requires lots of spots, and the "a" electrodes
for work that requires few spots or in arms with wide throats (e.g. 300 mm and 550
mm).
IMPORTANT: always set the electrode being used correctly because the spot
welding parameters that the machine uses in the semi-automatic and automatic
modes can vary.
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