Special Maintenance - Telwin DIGITAL CAR SPOTTER 5500 Manuel D'instructions

To obtain correct results when sport welding sheets, some fundamental precautions
must be taken:
1 - An impeccable earth connection.
2 - Any paint, grease, oil must be cleaned from the two parts to be spot welded.
3 - The parts to be spot welded must be in contact with each other, without gaps;
if necessary press with a tool, not with the gun. Excessive pressure brings bad
results.
4 - The upper piece must not be thicker than 1 mm.
5 - The electrode tip must have a diameter of 2.5 mm.
6 - Tighten the nut that locks the electrode well, make sure the welding cable
connectors are locked.
7 - When spot welding, position the electrode and push it slightly (3÷4 kg). Press the
push-button and allow the spot welding time to elapse, and only then remove the
gun.
8 - Never distance yourself further than 30 cm from the earth fixing point.
Contemporaneous spot welding and drawing of special washers
This function can be carried out by assembling and fully tightening the spindle (POS.
4, Fig. F) on the body of the extractor (POS. 1, Fig. F): hook and fully fasten the other
end of the extractor on the gun. Insert the special washer (POS. 14, Fig. F) into the
spindle (POS. 4, Fig. F), and lock it with the relative screw (Fig. F). Spot weld in the
relative area, adjusting the spot welding machine as if spot welding washers, and start
drawing.
At the end, rotate the extractor by 90° to release the washer, which can be spot welded
in a new position.
Sheet heating and upsetting
In this mode the TIMER is disabled.
Operation duration is therefore manual, being determined by the time in which the gun
push-button is kept pressed.
Current intensity is adjusted automatically according to the thickness of the selected
sheet.
Fit the carbon electrode (POS. 12, FIG, F) into the gun spindle, locking it with the ring
nut. Touch the area, that was previously bared, with the carbon tip and press the gun
push-button. Work from the outside to the inside, using a circular movement to heat
the sheet which undergoes work hardening and returns to its original position.
To prevent the sheet from drawing too much, treat small areas and immediately after
wipe using a damp cloth to cool the treated part.
Sheet upsetting
From this position operate on the relative electrode to flatten sheets that have localized
deformations.
Intermittent spot welding
This function is suitable for spot welding small rectangles of sheet in order to cover
holes caused by rust or other reasons.
Place the relative electrode (POS. 5, Fig. F) on the spindle, accurately tighten the ring
nut. Bare the involved area and make sure the piece of sheet to be spot welded is
clean and free from grease or paint.
Position the workpiece and place the electrode against it, then press the gun push-
button. Keeping it constantly pressed move forward rhythmically, following the work/
pause intervals given by the spot welding machine.
N.B.: Press lightly while working (3÷4 kg), following a line that is ideally 2-3 mm from
the edge of the new piece to be welded.
To obtain good results:
1 - Remain within 30 cm from the earth fixing point.
2 - Use cover sheets that are no more than 0.8 mm thick, better if of stainless steel.
3 - Move forward in time with the spot welding machine rhythm. Move forward during
the pause moments, and stop while spot welding.
Using the supplied extractor (POS. 1, Fig. F)
Washer hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 3, Fig. F)
onto the body of the electrode (POS. 1, Fig. F). Hook the washer (POS. 13, Fig. F),
spot welded as described previously, and begin drawing. When finished, rotate the
extractor by 90° to detach the washer.
Plug hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 2, Fig. F)
onto the body of the electrode (POS. 1, Fig. F). Make the plug enter (POS. 15-16, Fig.
F), after spot welding it as described previously, the spindle (POS. 1, Fig. F) keeping
the terminal tightened towards the extractor (POS. 2, Fig. F). When completely
introduced, release the spindle and start drawing. When finished, pull the spindle
towards the hammer to remove the plug.
STUDDER TOUCH
The studder can be supplied in the version without push-button.
To spot weld, just place the tool against the piece to be welded, which is connected to
the earth cable: after a few moments, the machine recognises the contact and starts
the stop automatically.
ATTENTION: DO NOT PLACE THE STUDDER ON THE PIECE WITHOUT
WELDING!
7. MAINTENANCE
WARNING! BEFORE CARRYING OUT MAINTENANCE, MAKE SURE
THE MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR.
- adaptation/restoration of the diameter and profile of the electrode tip;
- replacement of the electrodes and the arms;
- electrode alignment check;
- cooling check on cables and clamp;
- check the integrity of the spot welding machine power cable and the clamp.
7.2 SPECIAL MAINTENANCE
SPECIAL MAINTENANCE MUST ONLY BE CARRIED OUT BY TECHNICIANS WHO
ARE EXPERT OR QUALIFIED IN AN ELECTRIC-MECHANICAL AMBIT.
WARNING! BEFORE REMOVING THE SPOT WELDER OR CLAMP
PANELS AND LOOKING INSIDE, MAKE SURE THE SPOT WELDER IS OFF AND
DISCONNECTED FROM THE ELECTRIC AND PNEUMATIC (if present) POWER
SUPPLIES.
Carrying out checks while the inside of the spot welder is live can cause serious
electric shock due to direct contact with live parts and/or injury due to direct contact
with moving parts.
Periodically and as frequently as required by the use and environmental conditions,
inspect inside the spot welder and clamp and remove the dust and metal particles that
have deposited on the transformer, diode module, power terminal board, etc. using a
blast of dry compressed air (max. 5 bar).
Do not direct the jet of compressed air onto the electronic circuit board; if necessary
clean with a very soft brush or suitable solvents.
At the same time:
- Make sure the wiring does not show signs of insulation damage or loose-oxidised
connections.
- Make sure the screws that connect the transformer secondary with the output bars
/ wires are tight and that there are no signs of oxidation or overheating.
8. TROUBLESHOOTING
SHOULD MACHINE OPERATION NOT BE SATISFACTORY, AND BEFORE
CARRYING OUT MORE SYSTEMATIC CHECKS OR CONTACTING YOUR
TECHNICAL ASSISTANCE CENTRE, MAKE SURE THAT:
- With the main switch of the spot welder closed (pos. " I ") the display is lit; if not
the problem is in the power line (cables, plug and socket, fuses, excessive voltage
drop, etc.).
- The display does not show the alarm signals (see TAB. 1): when the alarm stops
press "START" to reactivate the spot welder.
- The elements that are part of the secondary circuit (fuses – arm-holders – arms –
electrode holders – cables) are not inefficient because of loose screws or oxidation.
- The welding parameters are suitable for the work to be carried out
- After having carried out maintenance or repairs, restore the connections and wiring
as they were before, making sure they do not come into contact with moving parts
or parts that can reach high temperatures. Band all the wires as they were before,
being careful to keep the primary high voltage connections separate from the
secondary low voltage ones.
Use all the original washers and screws when re-closing the structural work.
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