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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
SHOULD BE CARRIED OUT WITH THE SPOT-WELDER SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY (MAIN SWITCH LOCKED TO "O"
USING PADLOCK WITH KEY TAKEN OUT for PNEUMATIC CYLINDER-operated
models).
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 INTRODUCTION
Mobile unit for resistance welding (spot welder) controlled by a microprocessor, medium
frequency technological inverter, three-phase power and direct current output.
The spot welder is fitted with a water cooled pneumatic clamp. The pneumatic clamp
houses the transformation and realignment unit which, compared to traditional spot
welders, allows for high spot welding currents with lower network absorption, allows
the use of longer and lighter cables that ensure better handling and a wide range of
action and minimum magnetic fields around the cable.
The spot welder can operate on low carbon sheet iron, galvanised sheet iron, high
resistance sheet metal and boron sheet metal.
It is also fitted with quick couplings for the ancillary equipment (Studder, Clamp X),
which are used to perform various hot processing operations on sheet metal and all
specific processing used in the automobile body shop sector.
The main features of the plant are as follows:
-
back-lit LCD display to view the commands and parameter settings;
-
control panel spot welding mode buttons (continuous or pulse welding mode);
-
automatic selection of spot welder parameters according to the sheet metal used;
-
customising of spot welder parameters;
-
automatic detection of the inserted tool;
-
automatic control of the spot welder current
-
manual and automatic control of the electrode force;
-
"USB" port.
2.2 STANDARD ACCESSORIES
-
arm supports;
-
clamp cable support;
-
Reduction unit filter (compressed air pressure supply);
-
Clamp "C" with standard arms and cable with plug to disconnect it from the
generator;
-
Cooling system (integrated GRA).
2.3 OPTIONAL ACCESSORIES
-
Arms and electrodes in different lengths and/or shapes other than clamp "C" (see
spare part list);
-
Support post and clamp weight unloader;
-
Clamp "X";
-
Studder kit;
-
Clamp "C" ring kit
3. TECHNICAL INFORMATION
3.1 RATING PLATE (Fig. A)
The main information about use and performance of the spot welder is summarised on
the rating plate and has the following meanings:
1 - Number of phases and frequency of the power line
2 - Power supply voltage
3 - Network output at permanent capacity (100%).
4 - Nominal network output with duty cycle of 50%.
5 - Maximum no-load voltage to electrodes.
6 - Maximum current with electrodes in short-circuit.
7 - Secondary output at permanent capacity (100%).
8 - Arm gauge and length (standard).
9 - Minimum and maximum adjustable force to electrodes.
10 - Nominal pressure of the compressed air source.
11 - Compressed air pressure required to obtain maximum force to the electrodes.
12 - Cooling water capacity.
13 - Drop in nominal pressure of the cooling liquid.
14 - Spot welder device earthing
15 - Safety symbols whose meanings are illustrated in Chapter 1 "General safety for
resistance welding".
N.B.: The rating plate shown is an example to explain the meanings of the symbols
and figures; the exact technical specifications for your machine should be taken
directly from the rating plate on the machine itself.
3.2 OTHER TECHNICAL INFORMATION
3.2.1 Spot welder
General features
- Power supply voltage and frequency
- Electrical protection rating
- Insulation class
- Housing protection rating
- Cooling type
- (*) Overall dimensions (LxWxH)
- (**) Weight
Input
- Max output in short-circuit (Scc )
- Scc power factor (cosj)
- Delayed network fuses
- Automatic network switch
- Power supply cable (L≤4m )
Output
- Secondary no-load voltage (U
d)
2
- Max spot welder current (1
max)
2
- Spot welding capacity
- Duty cycle
- Maximum force to electrodes.
- Arm "C" throat
- Spot welding current regulation
- Spot welding time regulation
- Spot welding squeeze time
- Ramp time regulation
- Maintenance time regulation
- Cold time regulation
- Pulse number regulator
- Electrode force regulator
(*) NOTE: the overall dimensions do not contemplate the cables and support post.
(**) NOTE: the weight of the generator does not contemplate the clamp and support
post.
: 400V(380V-415V) ~ 3ph-50/60 Hz
:
:
:
IP 21
:
Water
:
820 x 610 x 1150mm
:
77kg
:
75kVA
:
0.8
:
32A
:
25A ("C"- IEC60947-2)
:
4 x 6 mm²
:
13V
:
12kA
:
max 3 + 3 + 3 mm
:
3%
:
550 daN
:
95 mm standard
:
automatic and programmable
:
automatic and programmable
:
automatic and programmable
:
automatic and programmable
:
automatic and programmable
:
automatic and programmable
:
automatic and programmable
:
automatic or manual
3.2.2 Cooling system (GRA).
General features
- Maximum pressure (pmax)
- Cooling capacity (P @ 1l/min)
- Tank capacity
- Cooling liquid
4. DESCRIPTION OF THE SPOT WELDER
4.1 SPOT WELDER UNIT AND MAIN COMPONENTS (Fig. B)
On the front:
1 - Control panel
2 - USB port.
3 - Clamp connector socket;
4 - Quick couplings for water pipes;
5 - Clamp cable support
On the back:
6 - Main switch;
7 - Supply cable input;
8 - Arm supports;
9 - Pressure regulator, pressure gauge and air intake filter;
10 - Cooling system tank cap (GRA);
11 - GRA water level;
12 - GRA air exhauster.
4.2 CONTROL AND ADJUSTMENT DEVICES
4.2.1 Control Panel (Fig. C)
Spot welding parameter descriptions;
Power: spot welder output delivery percentage – range from 5 to 100%;
Force to the electrodes (automatic mode): force with which the pneumatic
clamp electrodes squeeze the sheet metal to be spot-welded; the machine
automatically adjusts the force setting entered before welding commenced.
Squeeze time (manual mode): time in which the pneumatic clamp electrodes
squeeze the sheet metal to be spot-welded without current delivery; this
enables the electrodes to reach maximum pressure, set via the pressure
regulator, before current delivery - range from 200 ms to 1 second.
Ramp time: time required by the current to reach the maximum set value.
When running in pulse pneumatic clamp mode, the time applied to the first
pulse only - range from 0 to 1 second.
Spot welding time: time in which the spot–welding current remains more or
less consistent. When running in pulse pneumatic clamp mode, the time
applies to the length of each pulse - range from 0 to 1 second (*).
Cold or Pause time: (for pulse spot welding mode only) the time that elapses
between one current pulse and another - range from 10 ms to 400 ms (*).
Number of pulses: (for pulse spot welding mode only) the number of spot
welding current pulses, each of which is equal to the set spot welding time -
range from 1 to 10 (*).
Maintenance time: time for which the pneumatic clamp electrodes maintain
the squeezing action on the sheet metal which has just been spot-welded,
without current delivery. During this phase, the welding spot is cooled and the
welded kernel crystallised; the pressure during this phase refines the metal
grain and increases mechanical resistance - range from40 ms to 1 second.
(*) NOTE: the total of the ramp cycles and the spot welding cycles cannot exceed 1
second.
(**) NOTE: the maximum number of pulses set depends on the duration of each
individual pulse: the total actual spot welding time cannot exceed 1 second.
1 - Dual-function button
a) BASIC FUNCTION: sequential viewing of spot welding parameters:
output/current delivery; squeeze force/time, ramp time,
Spot welding time, cold time (in pulse mode only), number of pulses (in pulse mode
only), maintenance time.
b) SPECIAL FUNCTION: changes to displayed spot welding parameters and
programme customisation.
To access this function, please follow the procedure illustrated in paragraph 6.2.3.
2 - Function and tool selection button
Pneumatic clamp function with direct spot welding current:
The spot welding cycle starts with a squeeze time, followed by a ramp time, a spot
welding time and terminates with a maintenance time.
I
H
Pneumatic clamp function with "pulse" spot welding current:
The spot welding cycle starts with a squeeze time, followed by a ramp time, a spot
welding time, a cold time, a series of pulses (see Number of pulses" in this paragraph)
and terminates with a maintenance time.
This function improves the spot welding capacity on galvanised sheet metal or sheet
metal with particular protective film.
Studder function (with studder gun only).
This function can only be selected by connecting the studder gun to the relative socket
on the standard clamp (see paragraph 5.9 studder connections).
The processing phases which can be performed using this function can be viewed on
the control panel (Fig. C) with the following meaning:
Spot welding with relative electrodes of: plugs, rivets, washers, special
washers, corrugated wire.
Spot welding with relative electrode of Ø 4mm screws:
Spot welding with relative electrode of: Ø 5÷6mm screws and Ø 5mm
rivets.
Spot welding with relative electrode on one side of the sheet metal
only.
Carbon electrode sheet tempering.
Sheet upsetting with relative electrode.
Intermittent spot welding with relative electrode for patching of sheet
- 6 -
:
3 bar
:
1 kW
:
:
demineralised water
8 l
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