Telwin ALUCAR 5100 Manuel D'utilisation page 6

- In confined spaces;
- In the presence of inflammable or explosive
material;
MUST ALWAYS be evaluated in advance by an
"Expert supervisor" and must always be carried out
in the presence of other people who have received
instruction regarding emergency procedures.
Technical protection methods MUST always be
adopted, as described in 5.10; A.7; A.9. in the "IEC
TECHNICAL SPECIFICATION or CLC/TS 62081".
- Welding should NEVER be allowed if the operator is
above floor level, unless a safety platform is used.
- VOLTAGE BETWEEN GUNS OR TORCHES: working
with more than one welding machine on one piece
or on pieces that are electrically connected may
generate a dangerous sum of open circuit voltages
between two different guns or torches, with a value
that could be as much as double the allowed limit.
It is essential for an expert coordinator to use
measuring instruments to determine whether there
is a risk, and to be able to adopt adequate safety
measures as indicated in 5.9 of the "IEC TECHNICAL
SPECIFICATION or CLC/TS 62081".
RESIDUAL RISKS
- The person entrusted to carry out the work must
receive adequate instruction on capacitor discharge
welding procedures for this specific type of machine.
- People unconnected with the job must not be allowed
in the working area.
- Do not allow two or more people to work
simultaneously at the same machine.
- IMPROPER USE: it is dangerous to use the welding
machine for any other purpose than that for which it
is intended.
2. INTRODUCTION AND GENERAL DESCRIPTION
Movable. system. for. capacitor. discharge. stud. welding.
with. ignition. tip. strike.. In. this. manual. we. will. refer. to. the.
two. plant. versions. according. to. the. nominal. capacity. of.
the. capacitors:. 66mF. and. 19.5mF. (see. data. plate).. The.
machine. was. designed. and. implemented. for. the. welding.
of.iron.and.non-iron.studs,.onto.untreated.or.non-oxidised.
surfaces. in. steel,. stainless. steel,. brass. and,. in. particular,.
aluminium;.or.in.specific.processing.for.body.shops.and.in.
sectors.using.similar.works.
MAIN CHARACTERISTICS:
-. Choice. of. capacitors. charge. voltage,. that. is. of. spot.
welding.energy;
-. LED. control. of. machine. operation. ((power. supply.
presence,.overheating.safeguard,.SCR.alarm,.capacitor.
alarm,.good.electrical.contact.in.welding.circuit).
-. Only. for. the. 66mF. model,. welding. cable. quick.
couplings.
-. Only. for. the. 66mF. model,. 115/230V. automatic. voltage.
change.
. The. machine. automatically. adapts. to. the. main. power.
supply.voltage.depending.on.whether.it.is.connected.to.a.
115V.or.230V.power.supply.
STANDARD ACCESSORIES
-. Gun. with. DINSE. connection. for. model. 66mF;. in. the.
19.5mF.model,.the.gun.is.connected.permanently.to.the.
machine..The.gun.is.used.in.all.welding.processes.
-. Basic. kit. of. consumables,. including:. M4. stud-carrier.
electrode,. electrode. adjustment. spanner,. ring. with. M4.
bush,.M4.studs.
ACCESSORIES ON REQUEST
-. Alupull.Automotive.System.
-. Aluspotter.Plus.Kit:.rivet.extractor.and.accessories.box.
-. For. other. accessories,. please. refer. to. the. updated.
catalogue.
3. TECHNICAL INFORMATION
The. principal. information. about. use. and. performance. of.
the.machine.is.summarised.on.the.rating.plate.(back.panel).
and.has.the.following.meanings:
1-. EUROPEAN. standard. of. reference. for. safety. and. for.
construction.of.arc.welding.machines.
2-. S. Symbol. :. indicates. that. welding. operations. may. be.
carried.out.in.places.where.there.is.an.increased.risk.of.
electric.shock.(e.g..very.close.to.large.metal.masses).
3-. Symbol.for.the.main.power.supply.
4-. Symbol.for.the.intended.welding.procedure.
5-. Welding.circuit.performance:
-. U .:.no-load.voltage.(open.welding.circuit).
20
-. C. :. value. of. total. capacitance. installed. in. the.
machine.
-. N°. :. maximum. possible. number. of. spot. welds. per.
minute.
6-.Specifications.for.the.main.power.supply.
-. U .:.alternating.power.supply.voltage.to.the.machine.
1
(allowed.limits.±15%):
-.I .max.:.maximum.current.absorbed.from.the.mains.
1
7-. Factory. serial.
(indispensable.for.calling.for.technical.services,.ordering.
spare.parts,.identifying.the.origin.of.the.product).
8-. Symbol. representing. the. internal. structure. of. the.
machine.
9-. Symbols.referring.to.safety.standards.
Note:.The.rating.plate.shown.is.an.example.to.explain.the.
meanings. of.the.symbols.and.figures;.the.exact.technical.
specifications. for. your. machine. should. be. taken. directly.
from.the.rating.plate.on.the.machine.itself.
OTHER TECHNICAL INFORMATION:
- WELDING MACHINE : see table 1 (TAB.1)
The weight of the welding machine is shown in table
1 (TAB. 1).
4. DESCRIPTION OF THE WELDING MACHINE (Fig. B)
CONTROL, ADJUSTMENT
DEVICES
1-. Gun. button. connector. attachment. (only. for. 66mF.
model).
2-. Potentiometer. for. adjusting. capacitor. charge. voltage,.
that.is,.spot-welding.energy.
3-. LED.indicating."good.contact"
. In. order. to. prevent. dangerous. conditions. for. the.
operator,. the. machine. checks. the. spot-welding. circuit.
to. make. sure. it. is. OK.. Only. if. the. impedance. of. this.
circuit.is.sufficiently.low.("good.contact".status),.which.
is.indicated.by.LED.3.lighting.up,.will.it.give.the.OK.to.
spot-weld.
. The. led. flashing. indicates. that. the. machine. is. not. yet.
ready.for.spot.welding.(only.for.19.5mF.model).
4-. LED. indicating. overheating,. SCR. alarm,. capacitor.
alarm:.
. If.it.stays.on.this.means.the.welding.machine.has.been.
stopped.due.to.overheating.
. The.overheating.cutout.is.reset.automatically:.when.the.
machine.has.cooled.down.the.LED.will.go.off.
.
If the yellow LED is still ON after 10 min.,
switch off the machine and contact an authorised
servicing centre! Do not try to look inside the
machine.
. If.the.LED.flashes.on.and.off.this.means.there.is.a.fault.
in.the.SCR.controlling.discharge.or.a.capacitor.failure.
(call.the.servicing.centre!).
5-. LED.indicating.main.power.supply.presence.
5. INSTALLATION
WARNING! ALL INSTALLATION OPERATIONS
6
Fig. A
number.. Machine. identification.
AND CONNECTION