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Both the operating method for the spot welder and the variability in shape
and size of the piece being welded make it impossible to provide integrated
protection against the danger of the upper limbs being crushed: fingers, hands,
forearm.
The risk should be reduced by appropriate preventive measures:
- The operator should either be expert or trained in resistance welding
procedures using this type of appliance.
- A risk evaluation must be performed for each type of work to be carried out;
it is necessary to use equipment and masks that support and guide the piece
to be worked in order to distance hands from the electrode danger area.
- When using a portable spot welder: solidly grasp the clamp with both hands
placed on the relative handles; always keep hands away from the electrodes.
- Whenever the shape of the piece allows it, adjust the electrode distance so
that the stroke does not exceed 6 mm.
- Do not allow more than one person to work on the same spot welder at the
same time.
- Unauthorised persons should not be allowed in the working area.
- Do not leave the spot welder unattended: in such a case it should be
disconnected from the power supply; for pneumatic cylinder-operated spot
welders turn the main switch to "O" and lock it with the supplied padlock,
take out the key and leave it with the person in charge.
- Only use electrodes that are recommended for the machine (see spare parts
list) without altering their shape.
-
RISK OF BURNS
Some parts of the spot welder (electrodes arms and nearby areas) may reach
temperatures of over 65°C: suitable protective clothing must be worn.
Allow newly-welded pieces to cool before touching them.
-
RISK OF TIPPING AND FALLING
- Place the spot welder on a level horizontal surface that is able to support
its weight; confine the spot welder to the support surface (when required
in the "INSTALLATION" section of this manual). Otherwise with inclined
or uneven floors or moveable supporting surfaces there is the danger of
tipping.
- Never lift the spot welder unless explicitly required by the "INSTALLATION"
section of this handbook.
- 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).
PROTECTIONS
The safeguards and moveable parts of the spot welder casing should all be in
position before connection to the power supply.
WARNING: All manual operations on moveable accessible parts of the spot
welder, for example:
-
Electrode replacement or maintenance
- Adjusting the position of the arms or electrodes
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 INTRODUCTION
Mobile resistance welding system (spot welding machine) with digital control by
microprocessor. Equipped with quick coupling for welding cables, makes changing the
tools immediate and easy, which means that lots of hot machining and spot welding
can be carried out on the sheets, specifically in body shops and sectors with similar
activities.
Two versions of the spot welding machine are available:
-
Air-cooled version, abbreviated to "A.F."
-
Air and water-cooled version (clamp), abbreviated to "AQUA"
Their main characteristics are:
-
automatic choice of the welding parameters;
-
automatic recognition of the inserted tool;
-
automatic control for the timed switch-off of the air cooling (water cooling if present);
-
choice of the best spot welding current according to the mains power available;
- limitation of line overcurrent at insertion (insertion cosφ check);
-
backlit LCD display that shows the controls and the set parameters;
The spot welding machine can operate on iron sheets with a low carbon content and
on galvanized iron sheets.
2.2 STANDARD ACCESSORIES
-
Air-cooled pneumatic clamp with cables (120 mm arms and standard electrodes):
A.F. version
-
Water-cooled pneumatic clamp with cables (120 mm arms): AQUA version;
-
Build-in unit for closed circuit water cooling: AQUA VERSION;
- Pressure reducing unit - gauge filter with solenoid valve (powered by compressed
air);
-
Built-in trolley;
2.3 OPTIONAL ACCESSORIES
-
Pairs of electrode arms of different lengths and/or forms for air/water-cooled
pneumatic clamp (see spare parts list).
-
Manual clamp with cable pair.
-
Pairs of electrode arms of different lengths and/or shapes for manual clamp (see
spare parts list).
-
Manual "C" clamp with cables.
-
Studder Kit complete with separate earth cable and accessory box.
-
Air-cooled clamp for double spot with cables.
-
Studder Kit without trigger, complete with earth cable (for contact welding without
using the push-button).
-
Supporting pole and weight discharge kit for the clamp.
3. TECHNICAL DATA
3.1 DATA PLATE (Fig. A)
The main data required for spot welding machine use and performance are given in
the characteristics plate and have the following meaning.
1 - Number of phases and frequency of the power supply line.
2 - Power supply voltage.
3 - Network power at permanent regime (100%).
4 - Nominal network power with 50% intermittence ratio.
5 - Maximum no-load voltage at the electrodes.
6 - Maximum current with electrodes in short-circuit.
7 - Secondary power at permanent regime (100%).
8 - Gauge and length of the arms (standard).
9 - Minimum and maximum force adjustable from the electrodes.
10 - Nominal pressure of the compressed air source.
11 - Compressed air source pressure necessary for obtaining maximum electrode
force.
12 - Cooling water flow rate.
13 - Cooling liquid nominal pressure drop.
14 - Equipment mass.
15 - Safety symbols, the meaning of which is given in chapter 1 "General resistance
welding safety".
Note: The meanings of the symbols and numbers on the example plate are indicative;
the exact technical values of your spot welding machine can be found directly on the
spot welding machine plate.
3.2 OTHER TECHNICAL DATA
3.2.1 Spot welding machine
General characteristics
- Voltage and power supply frequency
or
- Electrical protection class
- Insulation class
- Casing protection rating
- Cooling type
- (*) Dimensions (LxWxH)
- (**) Weight
Input
- Max. power in short-circuit (Scc)
- Max. power factor
- Delayed network fuses
- Automatic line switch
- Power supply cable (L≤4 m)
Output
- No-load secondary voltage (U
- Max. spot welding current (I
- Spot welding capacity
- Intermittence ratio
- Maximum force at the electrode
- Arm projection
- Spot welding current adjustment
- Spot welding time adjustment
of the sheet and the clamp used
(*) NOTE: the mass does not include the cables and the support column.
(**) NOTE: the generator weight does not include the clamp and the support column.
3.2.2 Cooling group (GRA)
General characteristics
- Maximum pressure (pmax)
- Cooling power (P @ 1l/min.)
- Tank capacity
- Cooling liquid
4. SPOT WELDING MACHINE DESCRIPTION
4.1 THE SPOT WELDING MACHINE AND ITS MAIN COMPONENTS (Fig. B)
At the front:
1 - Control panel;
2 - Clamp cable attachment (dinse);
3 - Quick coupling for air hose connection;
4 - Quick coupling for water hose connection (AQUA version);
5 - 14-pin connector;
At the back:
6 - Main switch;
7 - Power cable input;
8 - Pressure regulator, gauge and air input filter unit;
9 - Cooling unit tank tap (AQUA version);
10 - GRA water level (AQUA version);
11 - GRA air valve (AQUA version).
4.2 CONTROL AND ADJUSTMENT DEVICES
4.2.1 Control panel (Fig. C)
1.
Multifunction button
a) "START" FUNCTION:
starts the machine at first starting or after an alarm state.
NOTE: Whenever necessary, the display indicates to the operator that he
must press the "START" button to use the machine.
b) "MODE" FUNCTION:
selects "impulse" spot welding
clamps) or selects the studder tool (fig. C-8a / 8f, can only be activated with the
studder gun).
c) CHOOSING THE UNIT of MEASUREMENT:
keeping this key pressed for 3 seconds, the operator can set the units for
measuring the thickness of the sheets in "millimetres" [mm], "gauge" [ga] or
inches [in].
- / +
2-3.
Double function buttons
a) SHEET THICKNESS FUNCTION:
keeping the [+] key pressed increases the sheet thickness, while pressing the
[-] key decreases it.
- 6 -
:
400 V (±15%) ~ 2 ph-50/60 Hz
:
230 V (±15%) ~1 ph-50/60 Hz
:
:
:
: A.F. (Forced air), Water (AQUA version)
:
:
66 kg A.F., 81 kg AQUA
:
:
:
32 A (400 V)/64 A (230 V)
:
32 A @ 400 V ("C"- IEC60947-2)
63 A @ 230 V ("C"- IEC60947-2)
: 3 x 4 mm²(400 V) - 3 x 6 mm² (230 V)
d)
:
2
max.)
:
2
:
:
:
:
:
: automatic according to the thickness
:
:
:
:
(can only be activated with pneumatic
I
H
IP 20
710 x 450 x 910 mm
58 kVA
0.8
10 V
7 kA
max. 3 + 3 mm
1.5% A.F., 3% AQUA
150 daN
120-500 mm
automatic
3 bar
1 kW
8 l
purified water
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