Telwin INVERSPOTTER 14000 SMART AQUA 400V Manuel D'instructions page 8

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 water cooling pipes (*), respecting the colour code (blue pipe
connected to the blue inlet, red to the red inlet). Check that the inlet quick couplings
are fastened firmly in place.
NOTE (*): if the water pipes are not connected, the clamp will NOT be cooled
properly which will cause thermal stress and damage to the electrical 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 water pipes 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 water pipes are not connected, the clamp will NOT be cooled properly
which will cause thermal stress and damage to the electrical parts.
5.9 CONNECTING THE STUDDER GUN EARTH CABLE
WARNING! Residual risk of crushing the upper limbs!
Follow the instructions below in the exact order indicated!
- Machine disconnected from the mains.
- Connect the machine's standard pneumatic clamp and remove the fixed arm (Fig.
H1).
- Position the clamp on a level surface of compact even material with so that it cannot
fall or shift dangerously.
- Remove the mobile arm by unscrewing the piston rod using a suitable key (Fig.
H2).
- Connect the studder earth cable by screwing the terminals onto the piston rod (Fig.
H3).
- Connect the cable to the studder gun using the fitting on the fixed arm. Insert it the
same way as the spot welder arm (Fig. H4).
- Connect the water fittings between the clamp's blue and red quick couplings (Fig.
H5).
- Insert the control cable connector jack into its socket on the clamp (Fig. H6).
6. WELDING (Spot welding)
6.1 PREPARATORY OPERATIONS
6.1.1 Main switch in the "O" position and padlock closed!
Before carrying out any spot welding operations it is necessary to carry out a series
of checks and adjustments, with the main switch in the "O" position and the padlock
closed.
Pneumatic and electrical mains connections:
- Make sure the electrical connections have been made correctly according to the
above instructions.
- Check the compressed air connection: connect the delivery pipe to the pneumatic
network and adjust the pressure using the reduction gear knob until the value on
the pressure gauge reads 8 bar (116 psi).
6.1.1.1 Adjusting and fixing in place of the "C" clamp arm
This operation should only be performed in the event that, after blocking the arm in
place as indicated in paragraph 5.8, the arm still moves horizontally (Fig. Q)
To complete this operation, proceed as follows:
- free the arm by turning the release lever (Fig. R);
- loosen the grub screw (Fig. S-1) and tighten the washer (Fig. S-2) by one-eighth of
a turn (roughly 45 degrees);
- tighten the lock grub screw to block the washer in place (Fig. S-1);
- block the arm in place following the instructions provided in (Fig. T).
This operation may need to be repeated, tightening or loosening the washer (Fig. S-2),
until the arm is blocked in a horizontal position and the block lever, with a rotation force
that enables manual release, slides in until it reaches the reference plug (Fig. T-1).
N.B.: it is important that, at the end of the operation, the lever is pressed up against
the stroke end plug (Fig. T-1). This position guarantees safe mechanical block of the
"C" arm.
6.1.1.2 Adjusting clamp "X" (optional):
Ensure there is a space equal to the thickness of the sheet metal between the
electrodes; manually approach the arms to check they are parallel and the electrodes
are in line (coinciding points).
Always bear in mind that the length of travel must be 5-6 mm longer than the spot
welding position so that the required force can be applied to the piece.
Where necessary, proceed by loosening the arm lock screws which can be turned or
moved in both directions along their axis; on completing the adjustments, tighten the
lock screws or the grub screws.
6.1.2 Main switch in the "I" position.
The following checks must be performed before carrying out any spot welding
operations with the main switch in the "I" ON position.
Aligning of the clamp electrodes:
- Ensure there is a space equal to the thickness of the sheet metal between the
electrodes; use the "squeeze" function (see paragraph 6.2.1) to check that the
electrodes are perfectly aligned.
- If necessary, check that the arm is fastened in place correctly (see previous
paragraphs).
Cooling system:
- Check that the Cooling system is working properly and the water pipe quick
couplings are inserted correctly (two couplings in the generator and two on the
clamp): the GRA will start up during the first spot welding cycle and switches off
automatically after a specific set time of machine inactivity.
IMPORTANT:
If the GRA alarm is triggered (AL. 7) it may be necessary to bleed the air present in the
hydraulic circuit in order to start the water circulation.
The procedure is as follows:
- Switch off the machine;
- Open the exhaust valve (FIG. B-12).
- Restart the machine and enable the GRA:
- Close the exhaust valve as soon as the air flow stops and only water starts to be
released.
6.2 ADJUSTING THE SPOT WELDING SETTINGS
The settings that are needed to determine the diameter and the mechanical seal of
the spot are:
- Force applied by the electrodes.
- Spot welding current
- Spot welding time
If there has been no specific experience in this sense, it is recommended to perform
some trial spot welding runs using sheet metal of the same thickness and quality as
that to be used for processing operations.
6.2.1 Adjusting the force and squeeze function (pneumatic clamp only)
Force is adjusted in automatic or manual mode (using the air unit pressure
regulator).
To select automatic mode (default settings) or manual mode, press the "MODE" button
(Fig. C-5) until the "MAINTENANCE" option appears on the display; then use the
cursors to reach the "AUTO" option and use the encoder to select "AUTO" or "MAN".
Press the encoder to confirm the setting.
Automatic adjustment:
By selecting "AUTO" it is possible to set the required force value; on pressing the clamp
button the electrodes will squeeze using the force settings, without current delivery.
In "AUTO" mode, during the spot welding cycle, the force of the electrodes is adjusted
automatically according to the settings entered for the spot welding program.
Manual adjustment:
By selecting "MAN" it is possible to set the force value by manually adjusting the
pressure regulator (Fig. B-9): adjust it to 3 bar and squeeze the electrodes using
the clamp button, then read the squeeze force indicated on the display; increase the
pressure and repeat the squeeze operation until the desired force value is reached.
In "MAN" mode, during the spot welding cycle, the force of the electrodes is adjusted
manually following the procedure illustrated above.
Tab. 1 lists the recommended pressure values according to the material being
welded.
Squeeze function:
This allows squeezing of the electrodes using the set force value without current
delivery.
It is possible to squeeze the electrodes in any spot welding programme by following
the procedure below (double click):
Press and release the clamp button and then immediately press and hold the button.
The clamp will squeeze and the electrodes will remain closed until the button is
released. The "SQUEEZING" option will be visible on the display and the clamp LED
will blink.
WARNING: the use of protective gloves can make the double click
squeezing operation slightly difficult. It is therefore recommended to
select the squeeze function in the "MAINTENANCE" program.
WARNING!
RESIDUAL RISK! This operating mode also causes residual risk of
crushing of the upper limbs: operators must take all necessary precautions (see
safety chapter).
6.2.2 Automatic setting of spot welding parameters (Current, Time)
(Paragraph 4.2.1 and Fig. C)
The spot welding parameters are set automatically when the thickness and material (*)
of the sheet metal to be welded is selected, as follows:
- EASY (two identical sheets).
- PRO (two identical or different sheets).
- MULTI (three identical or different sheets).
The spot is deemed to have been performed correctly when a piece undergoes a
tensile strength test and causes the extraction of the welding point kernel from one
of the two sheets.
(*) NOTE: the standard materials available are as follows:
- "Ferro" (abbreviated in "Fe"): low carbon content steel sheets;
- "Fe Zn" (abb. "Fz"): low carbon content galvanised steel sheets;
- "Hss" (abb. "Hs"): high rupture point steel sheets (700 MPat max);
- "Boro" (abb. "Br"): boron sheet metal.
6.2.3 Manual setting of spot welding parameters and creation of a customised
programme.
It is possible to manually set the spot welding parameters to perform a trial welding run
or to create a customised programme.
Starting from the "Easy, Pro, Multi" mode, press button 1 seen in Fig. C for about three
seconds to enter "MANUAL/PROGR" mode, then use the same button to select the
parameter to be changed: press and turn the encoder to change the value, press the
encoder once again to confirm. When operating with this mode, it is possible to use
the selected parameters during spot welding operation, but they will not be saved to
the machine's memory.
To return to the initial mode, press button 1 seen in Fig. C for 3 seconds; the words
"program store?" will appear; select "NO" to NOT save the setting, press "YES" to
save with name.
All customised programmes can be reused when required by selecting the "CUST"
mode option.
6.3 SPOT WELDING PROCEDURE
Operations applicable to all tools, starting from the "Easy, Pro, Multi" modes:
- Select the sheet metal to be welded (materials and thicknesses) using the
encoder.
- View the pre-set spot welding parameters (Fig.C-1).
- Customise the spot welding programme where used (see previous paragraph).
6.3.1 PNEUMATIC CLAMP
- Select the continuous or pulse spot welding mode Fig. C-2).
- Place the fixed arm electrode on the surface of one of the two sheets to be
welded.
- Press the button on the clamp handgrip to trigger the:
a) Closing of the sheet metal between the electrodes.
b) Start of the spot welding cycle with current flow indicated by LED
control panel.
- Release the button a few seconds after LED
- When the welding has been completed, the average welding current is displayed
(except for the initial and final ramps) along with the electrode force.
A "warning" may also be displayed along with the values, indicated by a blinking red
clamp LED (see TAB. 2), according to the results achieved by the welding.
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on the
has switched off.