Residual Risks - Telwin DIGITAL SPOTTER 9000 Manuel D'instructions

ENGLISH
1. GENERAL SAFETY RULES FOR
RESISTANCE WELDING ...........................................
2. INTRODUCTION AND GENERAL DESCRIPTION .....
2.1 INTRODUCTION......................................................................................
2.2 STANDARD ACCESSORIES ...................................................................
2.3 OPTIONAL ACCESSORIES .....................................................................
3. TECHNICAL DATA ......................................................
3.1 RATING PLATE ........................................................................................
3.2 OTHER TECHNICAL DATA .......................................................................
4. DESCRIPTION OF THE SPOT-WELDER ....................
4.1 CONTROL PANEL ..................................................................................
4.2 PROGRAMMING THE (SPOT-WELDING) CURRENT .............................
4.2.1 Procedure .......................................................................................
5. INSTALLATION .........................................................
5.1 PRELIMINARY OPERATIONS.................................................................
5.2 LIFTING THE SPOT-WELDER .................................................................
5.3 POSITION ................................................................................................
APPLIANCES FOR RESISTANCE WELDING FOR INDUSTRIAL AND
PROFESSIONAL USE
Note: In the following text the term "spot-welder" will be used.
1. GENERAL SAFETY RULES FOR RESISTANCE
WELDING
The operator should be properly trained to use the spot-welder safely and should
be informed of the risks connected with resistance welding procedures, of
related protection measures and of emergency procedures.
(Only for pneumatic cylinder-operated versions) The spot-welder is provided
with a main switch with emergency functions, fitted with a padlock for locking it in
the "O" (open) position.
The padlock key should be handed over only and exclusively to an expert
operator or to an operator who has been trained for the tasks assigned to him and
has been warned of the possible hazards arising from this welding procedure and
from neglectful use of the spot-welder.
When the operator is absent the switch should be set to the "O" position, the
padlock should be closed and the key removed.
- Electrical installation should be carried out following accident-prevention
legislation and standards.
- The spot-welder should be connected only and exclusively to a power supply
with the neutral conductor connected to earth.
- Make sure the power supply outlet is correctly connected to the earth
protection.
- Do not use cables with worn or damaged insulation or with loosened
connections.
- Do not use the spot-welder in damp or wet environments or in the rain.
- When connecting the welding cables or carrying out any routine maintenance
operation on the arms and/or electrodes the spot-welder should be switched
off and disconnected from the power supply. Pneumatic cylinder-operated
spot-welders should be locked with the main switch in the "O" position and
the padlock closed.
The same procedure should be followed when making connections to the
water supply or to a closed circuit cooling unit (water-cooled spot-welders)
and whenever repairs are made (extraordinary maintenance).
- Do not weld on containers, receptacles or piping that contain or have
contained flammable liquid or gas products.
- Do not operate on materials cleaned with cholorinated solvents or near such
substances.
- Do not weld on pressurised containers.
- Remove all flammable substances from the work area (e.g. wood, paper, rags
etc.).
- Make sure there is sufficient ventilation or provide means for removing
welding fumes near the electrodes; a systematic approach is necessary to
evaluate limits of exposure to the welding fumes depending on their
composition and concentration and on the length of exposure.
INDEX
page
5.4 CONNECTION TO THE MAIN POWER SUPPLY......................................
5.4.1 Warnings...........................................................................................
5
5.4.2 Plug and socket ................................................................................
5.5 PNEUMATIC CONNECTION.....................................................................
5.6 CONNECTING THE COOLING CIRCUIT ...............................................
6
5.7 CONNECTING THE PNEUMATIC CLAMP ...............................................
6
5.8 CONNECTING THE MANUAL CLAMP AND STUDDER GUN
6
WITH EARTH CABLE ...............................................................................
6
5.9 CONNECTING THE AIR PULLER WITH EARTH CABLE........................
5.10 CONNECTING THE TWIN-SPOT CLAMP ..............................................
6
6. (SPOT) WELDING ......................................................
6
6
6.1 PRELIMINARY OPERATIONS ..................................................................
6.2 ADJUSTING THE (spot-welding) PARAMETERS ....................................
6.3 PROCEDURE............................................................................................
6
6
7. MAINTENANCE.........................................................
7
7
7.1 ROUTINE MAINTENANCE ......................................................................
7.2 EXTRAORDINARY MAINTENANCE.........................................................
7
7
7
7
, *
- Always protect the eyes with suitable eye protectors.
- Wear protective gloves and clothing suitable for resistance welding work.
- Noise levels: If the personal daily exposure level (LEPd) is found to be greater
than 85db(A) due to particularly intensive welding operations, wearing
personal protection devices is compulsory.
(
- The strong magnetic fields generated by resistance welding processes (very
high currents) may damage or interfere with:
- CARDIAC STIMULATORS (PACE MAKERS)
- ELECTRONICALLY CONTROLLED IMPLANTED DEVICES
- METAL PROSTHESES
- Data transmission or local telephone networks
- Instrumentation
- Clocks and watches
- Magnetised cards
WEARERS OF VITAL ELECTRICAL OR ELECTRONIC DEVICES AND PEOPLE
WITH METAL PROSTHESES SHOULD NOT BE ALLOWED TO USE THE SPOT-
WELDER.
SUCH PERSONS SHOULD TAKE MEDICAL ADVICE BEFORE STOPPING IN
THE VICINITY OF SPOT-WELDERS AND/OR WELDING CABLES.
- This spot-welder complies with all requirements of the technical standard for
the product, which to be used only and exclusively in industrial environments
and for professional purposes.
Electromagnetic compatibility with a domestic environment cannot be
guaranteed.

RESIDUAL RISKS

- RISK OF UPPER LIMBS BEING CRUSHED
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.
- There should be risk evaluation for every type of job to be done; equipment
and masking should be provided to support and guide the work-piece
(unless a portable spot-welder is used).
- 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.
- 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.
- RISK OF TIPPING AND FALLING
- Place the spot-welder on a level horizontal surface that is able to support its
5
)
# $ %
&
page
7
7
7
7
7
7
7
7
7
7
7
7
7
8
8
8