Telwin INVERSPOTTER 13500 SMART AQUA Manuel D'instructions page 7

- : enabling/disabling recording of a welding job;
5- Browser knob and START button:
- rotate the knob to scroll through the various menu items;
- press to access the selected item, rotate to change the setting, press again to
confirm the value;
- if pressed on start-up or following an alarm, it enables the machine to spot weld
(START button)
6- ESC button:
- : back to the main menu;
- : back to the previous menu.
7- USB port.
4.2.2 Pressure regulator and gauge unit (Fig. B-10)
It allows you to adjust the pressure exerted on the electrodes of the pneumatic clamp
using the adjustment knob (only for pneumatic clamps in "Manual" mode).
4.3 SAFETY FUNCTIONS AND INTERLOCK
4.3.1 Protection and alarms (TAB. 1)
a) Thermal protection:
This is triggered by overheating of the spot welding machine due to low capacity
or total lack of cooling fluid, or by a work cycle that exceeds the allowed threshold
permitted.
Intervention is described and signalled in the display.
EFFECT: all movement is blocked, the electrodes open (exhauster cylinder); power
is shut down (welding inhibited).
RESET: manual (action on "START" button after falling within the allowed
temperature limits).
b) Main switch:
- Position "O" = open and lockable (see chapter 1).
WARNING! The internal power cable connection terminals (L1+L2+L3) are live
when turned to the "O" position.
- Position "I" = closed: spot welding machine powered up but not operating (STAND
BY - requires pressing of the START button).
- Emergency function
Opening the spot welding machine when it is operating (pos. "I" => pos. "O") will
instantly stop the machine in safe shutdown mode with:
- current inhibited;
- opening of the electrodes (exhauster cylinder);
- automatic restart inhibited.
WARNING! PERIODICALLY MAKE SURE THE SAFE SHUTDOWN
FUNCTION OPERATES CORRECTLY.
c) Cooling unit safety
This is triggered in the event of no or loss of cooling liquid pressure;
Intervention is described and signalled in the display.
EFFECT: all movement is blocked, the electrodes open (exhauster cylinder); power
is shut down (welding inhibited).
RESET: top-up cooling liquid then switch off and back on the machine (also see
Par. 5.6 "preparation of the cooling unit").
d) Compressed air safety
This is triggered in the event of no or loss of pressure (p < 3bar) of the compressed
air power supply;
Intervention is described and signalled in the display.
EFFECT: all movement is blocked, the electrodes open (exhauster cylinder); power
is shut down (welding inhibited).
RESET: manual (using the "START" button) after the machine pressure falls within
the allowed threshold (indication on the gauge>3bar).
e) Short circuit safety outbound (pneumatic clamp only)
Before carrying out the welding cycle, the machine checks the poles (positive and
negative) of the secondary spot welding circuit is free of accidental contact points.
Intervention is described and signalled in the display.
EFFECT: all movement is blocked, the electrodes open (exhauster cylinder); power
is shut down (welding inhibited).
RESET: manual (pressing the "START" button having removed the cause of the
short circuit).
f) Phase failure trip switch
Intervention is described and signalled in the display.
EFFECT: all movement is blocked, the electrodes open (exhauster cylinder); power
is shut down (welding inhibited).
RESET: manual (pressing the "START" button).
g) Overvoltage and undervoltage trip switch
Intervention is described and signalled in the display.
EFFECT: all movement is blocked, the electrodes open (exhauster cylinder); power
is shut down (welding inhibited).
RESET: manual (pressing the "START" button).
h) "START" button (Fig. C-5).
This push-button must be pressed to control welding in each of the following
conditions:
- every time the main switch has tripped (pos. "O" => pos. "I");
- each time the safety/protection devices cut in;
- when the power supply is reinstated (electricity and compressed air) following a
shutdown of power supplies or a malfunction;
WARNING! PERIODICALLY MAKE SURE THE SAFE START FUNCTION
OPERATES CORRECTLY
5. INSTALLATION
WARNING! ALL INSTALLATION OPERATIONS AND ELECTRICAL AND
PNEUMATIC CONNECTIONS MUST ALWAYS BE CARRIED OUT WITH THE SPOT
WELDER SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY.
THE ELECTRIC AND PNEUMATIC CONNECTIONS MUST ONLY BE CARRIED
OUT BY EXPERT OR QUALIFIED TECHNICIANS.
5.1 UNPACKING
Unpack the spot welder, assemble the separate parts (to be found in the packaging)
as indicated in this chapter (Fig. D).
5.2 LIFTING MEANS (Fig. E)
The spot welder must be lifted using a double cable and hooks that are suitably sized
for the machine weight, and using the relative M12 rings.
It is forbidden to sling the spot welder using means other than those indicated.
5.3 POSITIONING
Make sure the installation area is suitably large and without obstacles to guarantee
that the control panel, the main switch and the working area can be accessed in
complete safety.
Make sure there are no obstacles near the cooling air entry or exit points, and make
sure that conductive dust, corrosive vapours, humidity, etc. cannot be sucked in.
Position the spot welder on a flat surface made of homogeneous, compact material
that is suitable for supporting the weight of the machine (see "technical data") to avoid
the danger of toppling or dangerous movements.
5.4 CONNECTION TO THE MAINS
5.4.1 Warnings
Before carrying out any electric connection, make sure the machine plate data
corresponds with the voltage and frequency of the mains available in the installation
place.
The spot welder must be connected only and exclusively to a power supply with the
neutral conductor connected to earth.
To guarantee protection against indirect contact use these types of residual current
device;
- A type ( ) for single-phase machines;
- B type ( ) for three-phase machines.
- The IEC/EN 61000-3-12 Standard is not applicable to the spot welder.
If the welding machine is connected to a public electricity grid, the installer or user
must make sure that the machine can be connected (if necessary, consult the
company that manages the electricity grid).
5.4.2 Plug and mains outlet
Connect the power supply cable to a standard (3P + T) plug of appropriate capacity
and prepare a power supply outlet fitted with fuses or an automatic circuit-breaker; the
corresponding earth terminal must be connected to the (yellow-green) earth conductor
of the power supply.
The capacity and intervention characteristics of the fuses and circuit-breaker switch
are given in the "OTHER TECHNICAL DATA" paragraph.
WARNING! Not observing the regulations above renders the
manufacturer's safety system (class I) inefficient, with resulting serious risks to
people (e.g. electric shock) and goods (e.g. fire).
5.5 PNEUMATIC CONNECTION
- Prepare a compressed air line with a working pressure of 8 bar.
- Fit one of the available compressed air connections to the filter group reducer
to make the reducer suitable for the connections where the spot welder is to be
installed.
5.6 PREPARATION OF THE COOLING UNIT (GRA)
WARNING! The filling operations should always be performed with
the machine switched off and disconnected from the mains supply.
Never use polypropylene based antifreeze liquids.
Only use the coolant recommended by the manufacturer of the cooling unit.
- Open the discharge valve (FIG. B-13).
- Fill the tank with coolant using the nozzle (Fig. B-11): capacity of the tank = 8 l; pay
attention to avoid excess leakage of liquid at the end of filling.
- Close the tank cap.
- Close the discharge valve.
5.7 PNEUMATIC CLAMP CONNECTION (Fig. F)
WARNING! Presence of dangerous voltage! Never connect the spot
welder sockets to plugs other than those planned by the manufacturer. Do not
attempt to insert any other type of object in the sockets!
- Machine disconnected from the power supply mains.
- Insert the polarised plug (Fig. F-1) in the clamp in the specific socket of the
machine, then lift the two levers until complete fastening of the plug is obtained.
- Insert the 8 pin polarised plug in Figure F-2 to use the automatic spot welding
mode.
- Insert the cooling tubes(*), respecting the colours (blue tube on blue socket, red
tube on red socket). Check rapid coupling of the tubes is correctly carried out (Fig.
F-3).
NOTE(*): if the cooling tubes are not inserted, the clamp is NOT cooled
correctly resulting in thermal stress which damages the electric 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 cooling tubes 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 cooling tubes are not connected, the clamp will NOT be cooled
properly which will cause thermal stress and damage to the electrical parts.
6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
6.1.1 Main switch at "O" and lock closed!
A series of checks and adjustments must be carried out before starting to spot weld,
with the main switch in the "O" position and the lock closed.
Connecting to the electric and pneumatic supply sources:
- Make sure the electric connection has been carried out correctly in compliance with
the instructions given previously.
- Check compressed air connection: connect the supply hose to the pneumatic
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