Telwin ALUCAR 5100 Manuel D'utilisation page 7

AND ELECTRICAL CONNECTIONS MUST ALWAYS
BE CARRIED OUT WITH THE WELDING MACHINE
SWITCHED OFF AND DISCONNECTED FROM THE
POWER SUPPLY.
ELECTRICAL CONNECTIONS SHOULD BE MADE
ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED
PERSONNEL.
POSITIONING THE WELDING MACHINE
Choose. the. place. where. the. welding. machine. is. to. be.
installed. so. that. there. are. no. obstructions. to. the. cooling.
air. inlets. and. outlets;. at. the. same. time. make. sure. that.
conductive. dust,. corrosive. vapours,. humidity. etc.. cannot.
be.drawn.into.the.machine.
Leave. at. least. 250mm. free. space. all. around. the. welding.
machine.
WARNING! Position the welding machine on a
level surface with sufficient load-bearing capacity, so
that it cannot be tipped over or shift dangerously.
CONNECTION TO THE MAIN POWER SUPPLY
Warnings
-.. Before.making.any.electrical.connection,.check.the.rating.
plate. data. on. the. welding. machine. to. make. sure. they.
correspond.to.the.voltage.and.frequency.of.the.available.
power.supply.where.the.machine.is.to.be.installed.
-.. The. welding. machine. must. be. connected. only. and.
exclusively.to.a.power.supply.with.the.neutral.conductor.
connected.to.earth.
-. the.welding.machine.falls.within.the.requisites.of.IEC/EN.
61000-3-2.standard.
Plug and socket
The.welding.machine.is.supplied.from.the.factory.with.a.power.
supply.cable.fitted.with.a.standard.plug.(2P.+.T).16A/250V.
It. can. therefore. be. connected. to. a. mains. socket. fitted.
with.fuses.or.automatic.circuit.breaker;.the.corresponding.
earth.terminal.should.be.connected.to.the.earth.conductor.
(yellow-green). of. the. power. supply. line.. Table. 1. (TAB.. 1).
shows.the.recommended.delayed.fuse.sizes,.in.amps,.for.
the.main.supply,.which.have.been.chosen.according.to.the.
maximum.rated.current.output.from.the.welding.machine,.
and.to.the.nominal.power.supply.voltage.
Voltage change (only for 66mF model)
This.is.done.automatically,.only.from.115V.to.230V.and.vice.
versa,.depending.on.the.actual.power.supply.
WARNING! Failure to observe the above rules
will render the manufacturer's (class I) safety system
ineffective and constitute a serious risk to people (e.g.
electric shock) and property (e.g. fire).
WELDING CIRCUIT CONNECTIONS
WARNING! BEFORE CARRYING OUT THE
FOLLOWING CONNECTIONS MAKE SURE THAT
THE WELDING MACHINE IS SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY.
Table 1 (TAB. 1) shows the recommended sizes of the
welding cables (in mm
current output from the welding machine.
Connecting the welding gun and control cable (only for
66mF model - Fig. C)
-.Connect.the.DINSE.connector.to.its.socket.
-.Insert.the.control.cable.connector.into.its.socket.
Connecting the welding current return cable
Connect.the.welding.current.return.cable.to.the.piece.to.be.
welded,.as.close.as.possible.to.the.join.being.made.
), according to the maximum
2
Warnings:
-. Screw. the. welding. cable. connectors. right. down. into.
the. quick. couplings. (if. any),. so. as. to. ensure. a. perfect.
electrical.contact;.otherwise,.the.connectors.will.overheat,.
wear.rapidly.and.become.inefficient.
-.. Do. not. use. metal. structures. that. are. not. part. of. the.
workpiece. to. substitute. for. the. welding. current. return.
cable;. this. could. endanger. safety. and. produce. an.
unsatisfactory.weld.
6. WELDING: DESCRIPTION OF PROCEDURE
Preparatory operations
Before. carrying. out. any. spot-welding. operation. it. is.
necessary.to.carry.out.a.series.of.checks.and.adjustments,.
with.the.main.switch.in.the."O".position:
1-. Make.sure.the.electrical.connections.have.been.made.
correctly.. according.to.the.above.instructions.
2-. The.welding.machine.should.not.be.switched.on.and.off.
repeatedly. because. dissipation. of. the. energy. held. by.
the.capacitors.could.cause.heating.and.damage.
3-. Preparing.the.gun.
-.. Choose.the.type,.diameter.and.length.of.stud.bolt.(1).to.
be.welded.then.use.and.adjust.the.stud.bolt.holder.(2).to.
the.corresponding.diameter..For.correct.insertion.see.fig..
D.(stud.bolt.holder.2).
-.. Insert.the.stud.bolt.to.be.welded.(it.should.be.held.tightly);.
adjust.its.protrusion.to.0.8.-.1.2.mm.using.the.screw.(3).
and.lock.the.nut.(4).
-.. Insert.the.stud.bolt.holder.(2).into.the.gun's.chuck,.push.
it.in.until.you.feel.it.resting.on.the.base.and.then.lock.the.
nut..
PRINCIPLES OF STUD WELDING OPERATIONS WITH
IGNITION SPOT STRIKE (Fig. E):
These.welding.systems.work.by.extremely.rapid.discharge.
(2.3. ms). of. a. battery. of. capacitors,. enabling. welding. of.
studs. ranging. from. Ø. 3. mm. to. Ø. 8. mm. according. to. the.
model.used.
With. this. technology. it. is. possible. to. weld. stud. bolts. onto.
clean,. non-oxidised. mild. steel,. galvanised. steel,. stainless.
steel,.aluminium.and.brass.surfaces.
The. process. is. so. quick. that. it. does. not. alter. the. surface.
on.the.other.side.of.the.weld.i.e..painted.sheet,.pre-paint.
treatments,. plasticised. and. galvanised. surfaces.. . It. is. not.
possible. to. weld. on. hardened. steel,. or. on. oxidised. or.
painted.metal.
The. stud. bolt. is. inserted. into. the. stud. holder. clamp,. after.
adjustment.of.the.pre-charge.spring.by.means.of.the.screw.
on.the.back.of.the.gun.(see.stage.1),.and.is.positioned.with.
its.ignition.strike.directly.on.the.surface.of.the.sheet.being.
welded. (see. stage. 2).. Warning:. the. gun. should. be. kept.
perpendicular.to.the.sheet.being.welded.
The.gun.is.pressed.against.the.metal.until.the.four.fins.of.
the.support.on.the.head.of.the.gun.are.in.perfect.contact.
with. the. material;. the. start. control. will. cause. the. start. of.
current.passage,.which.will.vaporise.the.ignition.strike.and.
the.electric.arc.will.spread.over.the.whole.surface.of.the.stud.
bolt.(stage.3),.which.is.pressed.onto.the.metal.surface.
Warning:.DO.NOT.apply.excessive.pressure.to.the.stud.
The.melted.metal.will.solidify.to.weld.the.stud.bolt.(stage.
4)..The.pistol.should.be.extracted.in.perfect.alignment.with.
the.stud.to.prevent.deformation.of.the.clamp.and.ensure.it.
a.long.working.life.(stage.5.+.Fig..F).
STUD BOLT WELDING TESTS
Before. starting. production. it. is. essential. to. make. several.
test.welds.in.order.to.regulate.the.power.source.correctly.
and. find. the. correct. pressure. to. be. applied. to. the. gun..
Proceed.as.follows:
-.. Insert. the. chosen. stud. bolt. into. the. stud. bolt. holder. (2).
(which. has. already. been. adjusted. as. described. in. Fig..
D).
-.. start.the.power.source.by.turning.on.light.switch.I.
-.. prepare. the. base. sheet. in. conditions. that. are. identical.
7
Fig. D
Fig. F