Telwin 954056 Manuel D'instructions page 6

Both the operating method for the spot welder and the variability in shape
and size of the piece being welded make it impossible to provide integrated
protection against the danger of the upper limbs being crushed: fingers, hands,
forearm.
The risk should be reduced by appropriate preventive measures:
- The operator should either be expert or trained in resistance welding
procedures using this type of appliance.
- A risk evaluation must be performed for each type of work to be carried out;
it is necessary to use equipment and masks that support and guide the piece
to be worked in order to distance hands from the electrode danger area.
- When using a portable spot welder: solidly grasp the clamp with both hands
placed on the relative handles; always keep hands away from the electrodes.
- Whenever the shape of the piece allows it, adjust the electrode distance so
that the stroke does not exceed 6 mm.
- Do not allow more than one person to work on the same spot welder at the
same time.
- Unauthorised persons should not be allowed in the working area.
- Do not leave the spot welder unattended: in such a case it should be
disconnected from the power supply; for pneumatic cylinder-operated spot
welders turn the main switch to "O" and lock it with the supplied padlock,
take out the key and leave it with the person in charge.
- Only use electrodes that are recommended for the machine (see spare parts
list) without altering their shape.
- RISK OF BURNS
Some parts of the spot welder (electrodes arms and nearby areas) may reach
temperatures of over 65°C: suitable protective clothing must be worn.
Allow newly-welded pieces to cool before touching them.
- RISK OF TIPPING AND FALLING
- Place the spot welder on a level horizontal surface that is able to support
its weight; confine the spot welder to the support surface (when required
in the "INSTALLATION" section of this manual). Otherwise with inclined
or uneven floors or moveable supporting surfaces there is the danger of
tipping.
- Never lift the spot welder unless explicitly required by the "INSTALLATION"
section of this handbook.
- When using machines on wheels: disconnect the spot welder from the
electric and pneumatic (if present) power supplies before moving the unit
to another work area. Pay attention to obstacles and unevenness on the
ground (for example cables and piping).
- UNINTENDED USE
It is dangerous to use the spot welder for any purpose other than that for
which it is intended (see INTENDED USE).
PROTECTIONS
The safeguards and moveable parts of the spot welder casing should all be in
position before connection to the power supply.
WARNING: All manual operations on moveable accessible parts of the spot
welder, for example:
- Electrode replacement or maintenance
- Adjusting the position of the arms or electrodes
MUST BE CARRIED OUT WITH THE SPOT WELDER SWITCHED OFF AND
DISCONNECTED FROM THE ELECTRIC AND PNEUMATIC (if present) POWER
SUPPLY.
MAIN SWITCH LOCKED AT "O" WITH LOCK CLOSED AND KEY REMOVED in the
models with PNEUMATIC CYLINDER movement).
STORAGE
- Place the machine and its accessories (with or without packaging) in closed
areas.
- The relative humidity of the air must not exceed 80%.
- The environmental temperature must be between -15°C and 45°C.
If the machine has a water cooling unit and the environmental temperature is
lower than 0°C: add the indicated antifreeze liquid or completely empty the
hydraulic circuit and the water tank.
Always use suitable measures for protecting the machine from humidity, dirt
and corrosion.
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 INTRODUCTION
Mobile resistance welding system (spot welding machine) with digital control by
microprocessor. Equipped with quick coupling for welding cables, makes changing the
tools immediate and easy, which means that lots of hot machining and spot welding
can be carried out on the sheets, specifically in body shops and sectors with similar
activities.
Their main characteristics are:
- automatic choice of the welding parameters;
- automatic recognition of the inserted tool;
- automatic control for the timed switch-off of the air cooling (water cooling if present);
- choice of the best spot welding current according to the mains power available;
- limitation of line overcurrent at insertion (insertion cosφ check);
- backlit LCD display that shows the controls and the set parameters;
The spot welding machine can operate on iron sheets with a low carbon content and
on galvanized iron sheets.
2.2 STANDARD ACCESSORIES
- Air-cooled pneumatic clamp with cables (120 mm arms and standard electrodes):
A.F. version
- Pressure reducing unit - gauge filter with solenoid valve (powered by compressed
air);
- Trolley;
2.3 OPTIONAL ACCESSORIES
- Pairs of electrode arms of different lengths and/or forms for air-cooled pneumatic
clamp (see spare parts list).
- Manual clamp with cable pair.
- Pairs of electrode arms of different lengths and/or shapes for manual clamp (see
spare parts list).
- Manual "C" clamp with cables.
- Studder Kit complete with separate earth cable and accessory box.
- Studder Kit without trigger, complete with earth cable (for contact welding without
using the push-button).
3. TECHNICAL DATA
3.1 RATING PLATE (FIG. A)
The main data relating to use and performance of the spot-welder are summarised on
the rating plate and have the following meanings:
1- Number of phases and frequency of power supply.
2- Power supply voltage.
3- Rated mains power with 50% duty cycle.
4- Mains power with permanent running (100%).
5- Maximum loadless voltage over electrodes.
6- Maximum current when electrodes are shorted.
7- Safety symbols, the meaning of which is given in chapter 1 "General safety rules
for resistance welding".
8- Current to secondary when running permanently (100%).
Note: The rating plate shown is an example to show the meaning of the symbols and
numbers; the exact values of the technical properties of your spot-welder can be found
on the rating plate of the spot-welder itself.
3.2 OTHER TECHNICAL DATA
General specifications
- (*)Power supply voltage and frequency:
or:
- Electrical protection class:
- Insulation class:
- Enclosure protection rating:
- Type of cooling:
- (*)Dimensions (with trolley)(LxWxH):
- (*)Weight (with trolley):
Input
- Max. power when spot-welding (S max):
- Rated power at 50% (Sn):
- Power factor at Smax (cosφ):
- Main supply delayed fuses:
- Automatic circuit-breaker:
- Power supply cable (L≤4m):
Output
- Loadless secondary voltage (U
- Max. spot-welding current (I
- Spot-welding capacity (low carbon steel):
- Duty cycle:
- Spots/hour on 1+1mm steel
- Air-cooled pneumatic clamp:
- Maximum electrode force:
- Arm projection:
- Automatic spot-welding current adjustment,
- Automatic spot-welding time adjustment according to sheet thickness and the clamp
used.
(*)NOTES:
- The spot-welder can be supplied for a 400V or 230V power supply; make sure the
value on the data plate is correct.
- Spot-welding clamp excluded.
4. SPOT WELDING MACHINE DESCRIPTION
4.1 THE SPOT WELDING MACHINE AND ITS MAIN COMPONENTS (Fig. B)
At the front:
1 - Control panel;
2 - Clamp cable attachment (dinse);
3 - Quick coupling for air hose connection;
4 - 14-pin connector;
At the back:
5 - Main switch;
6 - Power cable input;
7 - Pressure regulator, gauge and air input filter unit;
4.2 CONTROL AND ADJUSTMENT DEVICES
4.2.1 Control panel (Fig. C)
1.
Multifunction button
a) "START" FUNCTION:
starts the machine at first starting or after an alarm state.
NOTE: Whenever necessary, the display indicates to the operator that he
must press the "START" button to use the machine.
b) "MODE" FUNCTION:
selects "impulse" spot welding
clamps) or selects the studder tool (fig. C-8a / 8f, can only be activated with the
studder gun).
c) CHOOSING THE UNIT of MEASUREMENT:
keeping this key pressed for 3 seconds, the operator can set the units for
measuring the thickness of the sheets in "millimetres" [mm], "gauge" [ga] or
inches [in].
- / +
2-3.
Double function buttons
a) SHEET THICKNESS FUNCTION:
keeping the [+] key pressed increases the sheet thickness, while pressing the
[-] key decreases it.
b) TIME or POWER
by keeping the [-] key pressed for 3 seconds, the welding time
increased or decreased as to the value set automatically by the machine
;
4. LCD display
5.
Signals that the key must be pressed to prepare the machine for welding.
6.
Shows the sheet thickness and possible alarm codes.
- 6 -
400V (±15%) ~ 2ph-50/60 Hz
230V (±15%) ~ 1ph-50/60 Hz
25A (400V)/50A (230V)
25A (400V)/50A (230V)
3 x 2.5mm
2 (400V) - 3 x 4mm
max):
0
max):
2
(can only be activated with pneumatic
SELECTION FUNCTION :
I
H
IP22
A.F. (forced air)
520x380x885mm
39kg
39kVA
9.5kVA
0.7
2 (230V)
8.6V
4.5kA
max 1.5 + 1.5mm
3%
200
120kg
120-500mm
can be