Telwin INVERSPOTTER 13000 Manuel D'instructions page 9

see TAB.1).
- At the end of the job replace the clamp in its support on the trolley.
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WARNING: presence of dangerous voltage! Always check the integrity of
the supply cable of the clamp, the protective pipe must not be cut, broken or
squeezed! Before and during the use of the clamp check that the cable is far from
parts in movement, heat sources, cutting surfaces, liquids, etc..
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WARNING: the clamp contains the transformer, isolation and rectifying
set which is necessary for the spot welding, in case of doubts on the integrity of the
clamp (due to accidental falls, violent collisions, etc...) disconnect the spot welder
and call an authorized service center.
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6.4.2 STUDDER GUN
WARNING!
- To fit or release the accessories on the studder chuck use the two fixed hexagon
wrenches to stop the chuck turning.
- When operating on doors and bonnets the earth bar MUST be connected to the same
part to prevent current passing through the hinges, and the bar must always be set
near the welding area (if the current has to travel over long distances this will reduce the
efficiency of the weld).
Connecting the earth cable:
a) Bare the sheet as close as possible to the point where you intend to work, cleaning
an area corresponding to the contact surface of the earth bar.
b1) Fasten the copper bar to the sheet surface using an ARTICULATED CLAMP (welding
model).
Alternatively to method b1 (when practical difficulties arise) proceed as follows:
b2) Spot-weld a grommet to the prepared sheet surface; pass the grommet through the
slit in the copper bar and lock it with the supplied terminal.
Spot-welding the grommet for anchoring the earth terminal
Fit the appropriate electrode to the studder chuck (POS.9, Fig. G) and insert the grommet
(POS.13, Fig. G).
Place the grommet in the chosen area. Place the earth terminal in contact in the same
area; press the torch button to weld the grommet to be used for anchorage as described
above.
Spot-welding screws, washers, studs, rivets
Fit the appropriate electrode to the studder, insert the item to be welded and place it on
the sheet at the desired point; press the button on the studder: release the button only
*
after the preset time (LED goes off).
Spot-welding sheets from one side only
Fit the appropriate electrode to the studder chuck (POS.6, Fig. G) pressing on the surface
to be welded. Press the button on the studder and only release it after the preset time
*
(LED goes off).
WARNING!
The maximum sheet thickness that can be welded from only one side is: 1+1 mm. This
type of welding must not be used on bodywork supporting structures.
To obtain correct results when spot-welding sheets with the studder the following basic
precautions should be taken:
1 - A perfect earth connection.
2 - The two parts to be spot-welded should be bared of any paint, grease or oil.
3 - The parts to be welded should be in contact with one another, without an intervening
shim; if necessary press them together with a tool and not with the studder. Too much
pressure will lead to poor results.
4 - The top piece should never be thicker than 1 mm.
5 - The diameter of the electrode tip should be 2.5 mm.
6 - Make sure that the electrode locking nut is tightened up completely and that the
welding cable connectors are locked.
7 - When spot-welding, put the electrode on the sheet, exert slight pressure (3-4 kg).
Press the button, weld for the preset time and only then take the studder away.
8 - Never weld more than 30 cm from where the earth bar is fastened.
Simultaneous spot-welding and pulling on special grommets
This is carried out by fitting and locking the chuck tightly (POS.4, Fig. G) onto the body of
the extractor (POS.1, Fig. G); lock the other terminal of the extractor tightly onto the
studder (Fig. G). Insert the special grommet (POS.14, Fig. G) into the chuck (POS.4, Fig.
G), locking it with the special screw (Fig. G) Spot-weld it in the required place, adjusting
the studder as for spot-welding grommets and start pulling.
On completion, turn the extractor through 90° to detach the grommet, which can be re-
welded in a new position.
5
Heating and upsetting sheets
In this operating mode the TIMER is off: by selecting welding time
"InF" (infinite time).
The operating time is therefore determined manually by the time for which the studder
button is pressed down.
Current intensity is regulated automatically depending on the selected sheet thickness.
Heating sheets metal
Fit the carbon electrode (POS.12, Fig. G) into the studder chuck and lock it with the ring
nut. Touch the previously bared area with the carbon tip and press the studder button.
Work from the outside towards the inside with a circular movement so as to heat the
sheet, which will work harden and return to its original position.
To prevent the sheet from over-hardening treat small areas and immediately afterwards
wipe them with a damp cloth to cool the treated part.
Upsetting sheet metal
In this position, working with the appropriate electrode, it is possible to flatten sheets that
have undergone localised deformation.
6
Jogged spot-welding (Patching)
This function is suitable for spot-welding small rectangles of sheet to cover holes due to
"
4
the display shows
rust or other causes.
Fit the appropriate electrode (POS.5, Fig. G) into the chuck, and tighten the ringnut to
fasten it securely. Bare the area to be worked on and make sure the patch sheet to be
welded is clean and free of grease and paint.
Position the patch and put the electrode on it then press the studder button and keep it
pressed, advancing in rhythm with the work/rest intervals determined by the spot-welder.
When working exert slight pressure (3-4 kg) and follow an ideal line 2-3 mm from the edge
of the new piece being welded.
To achieve good results:
1 - Never weld more than 30 cm from where the earth is attached.
2 - Use patch sheet no more than 0.8 mm thick, preferably stainless steel.
3 - Move forwards in rhythm with the spot-welder. Advance during the pause and stop
during welding.
Using the supplied extractor (POS.1, Fig. G)
Locking on and pulling grommets
This is carried out by fitting and locking the chuck tightly (POS.3, Fig. G) on the body of the
electrode (POS.1, Fig. G) Lock onto the grommet (POS.13, Fig. G), which was been spot-
welded as described previously, and start pulling On completion turn the extractor
through 90° to detach the grommet.
Locking on and pulling pins
This is carried out by fitting and locking the chuck tightly (POS.2, Fig. G) on the body of the
electrode (POS.1, Fig. G) Insert the pin (POS.15-16, Fig. G), which was spot-welded as
described previously, into the chuck (POS.1, Fig. G) keeping the end pulled towards the
extractor (POS.2, Fig. G) After insertion release the chuck and start pulling. On
completion pull the chuck towards the hammer to extract the pin.
7. MAINTENANCE
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WARINING! BEFORE CARRYING OUT ANY MAINTENANCE OPERATION MAKE
SURE THE SPOT-WELDER HAS BEEN SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY.
The main switch must be locked in the "O" position using the supplied padlock.
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7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR
- adjustment/reset of electrode tip diameter and profile;
- electrode alignment checks;
- cable and clamp cooling checks;
- discharge of condensation from the compressed air inlet filter.
- check the integrity of the supply cable of both spot welder and clamp.
7.2 EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT
ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED ELECTRICAL-MECHANICAL
PERSONNEL.
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WARNING! BEFORE REMOVING THE SPOT-WELDER OR CLAMP PANELS AND
WORKING INSIDE IT MAKE SURE IT IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
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If checks are made inside the spot-welder while it is live, this may cause serious
electric shock due to direct contact with live parts and/or injury due to direct
contact with moving parts.
Depending on how often the spot-welder is run and on the environmental conditions,
make regular checks inside the machine or clamp and remove the dust and the metallic
particles deposited on the transformer, the thyristor module, the terminal box, etc., using
dry compressed air (max. 5 bar).
Do not direct the compressed air jet on the electronic boards; clean them using a
very soft brush or with the appropriate solvents.
Take the opportunity to:
- Ensure that the wiring insulation is not damaged and the connections are tight and free
of oxidation.
- Check that the connecting screws of the secondary transformer to the output bars/
plaits are wlell tightned and no signs of oxidation or overheating are present.
IF SPOT-WELDER OPERATION IS UNSATISFACTORY, BEFORE PERFORMING
MORE SYSTEMATIC CHECKS OR CONTACTING YOUR SERVICE CENTRE
CHECK WHETHER:
- With the spot-welder main switch closed (pos. " | ") the display is lit up; if not the fault is in
the power line (cables, outlet and plug, fuses, excessive voltage drop etc.).
- The display does not show any alarm signals (see TAB. I): when the alarm has stopped
press "START" to restart the spot-welder; make sure the cooling air is circulating
properly and if necessary reduce the duty cycle.
- The parts making up the secondary circuit (arm-holder castings arms electrode
holders cables ) are inefficient due to loose screws or oxidation;
- The welding parameters are suitable for the job to be done.
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