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1. GENERAL SAFETY RULES FOR RESISTANCE WELDING .............................................................5
2. INTRODUCTION AND GENERAL DESCRIPTION .............................................................................6
2.1 INTRODUCTION ...........................................................................................................................6
2.2 STANDARD ACCESSORIES ........................................................................................................6
2.3 OPTIONAL ACCESSORIES ..........................................................................................................6
3. TECHNICAL DATA...............................................................................................................................6
3.1 DATA PLATE (Fig. A) .....................................................................................................................6
3.2 OTHER TECHNICAL DATA ..........................................................................................................6
3.2.1 Spot welding machine ..........................................................................................................6
3.2.2 Cooling group (GRA) ............................................................................................................6
4. SPOT WELDING MACHINE DESCRIPTION ......................................................................................6
4.1 THE SPOT WELDING MACHINE AND ITS MAIN COMPONENTS (Fig. B) .................................6
4.2 CONTROL AND ADJUSTMENT DEVICES ...................................................................................6
4.2.1 Control panel (Fig. C) ...........................................................................................................6
4.2.2 Pressure regulator and gauge unit (fig. B-8) ........................................................................7
4.3 SAFETY FUNCTIONS AND INTERLOCK .....................................................................................7
4.3.1 Safeguards and alarms (TAB. 2) ..........................................................................................7
5. INSTALLATION ....................................................................................................................................7
5.1 PREPARATION ..............................................................................................................................7
5.2 LIFTING (Fig. E). ...........................................................................................................................7
5.3 POSITION ......................................................................................................................................7
5.4 CONNECTION TO THE POWER NETWORK ...............................................................................7
5.4.1 Warnings ..............................................................................................................................7
5.4.2 Network plug and outlet ........................................................................................................8
5.5 PNEUMATIC CONNECTION .........................................................................................................8
5.6 PREPARATION OF THE COOLING UNIT (AQUA Version) ..........................................................8
5.7 PNEUMATIC CLAMP CONNECTION (Fig. F) ...............................................................................8
5.8 MANUAL CLAMP AND STUDDER GUN CONNECTION WITH EARTH CABLE (FIG. G)............8
5.9 DOUBLE TIP CLAMP CONNECTION ...........................................................................................8
APPLIANCES FOR RESISTANCE WELDING FOR INDUSTRIAL AND
PROFESSIONAL USE
Note: In the following text the term "spot welder" will be used.
1. GENERAL SAFETY RULES FOR RESISTANCE WELDING
The operator should be properly trained to use the spot welder safely and
should be informed of the risks connected with resistance welding procedures,
of related protection measures and of emergency procedures.
(Only for pneumatic cylinder-operated versions) The spot welder is provided
with a main switch with emergency functions, fitted with a padlock for locking it
in the "O" (open) position.
The padlock key should be handed over only and exclusively to an expert
operator or to an operator who has been trained for the tasks assigned to
him and has been warned of the possible hazards arising from this welding
procedure and from neglectful use of the spot welder.
When the operator is absent the switch should be set to the "O" position, the
padlock should be closed and the key removed.
- Electrical installation should be carried out following accident-prevention
legislation and standards.
- The spot welder should be connected only and exclusively to a power supply
with the neutral conductor connected to earth.
- Make sure the power supply outlet is correctly connected to the earth
protection.
- Do not use cables with worn or damaged insulation or with loosened
connections.
- Use the spot welder in an ambient air temperature ranging from 5°C to 40°C,
with relative humidity equal to 50% up to a temperature of 40°C, and 90% for
temperatures up to 20°C.
- Do not use the spot welder in damp or wet environments or in the rain.
- The connection of the welding cables and any routine maintenance
operations on the arms and/or electrodes must be carried out with the spot
welder switched off and disconnected from the electric and pneumatic (if
present) power supply networks.
- Pneumatic cylinder-operated spot welders should be locked with the main
switch in the "O" position and the padlock closed.
The same procedure must be respected for connection to the water mains or
a cooling unit with closed circuit (liquid cooled spot welding machines) and
in any case repair work (extraordinary maintenance).
- It is forbidden to use the equipment in environments comprising areas
classed as being at risk of explosion because of the presence of gas, dust or
mist.
- Do not weld on containers, receptacles or piping that contain or have
contained flammable liquid or gas products.
- Do not operate on materials cleaned with cholorinated solvents or near such
substances.
- Do not weld on pressurised containers.
- Remove all flammable substances from the work area (e.g. wood, paper, rags
etc.).
- Allow newly-welded pieces to cool! Do not leave the piece near flammable
substances.
- Make sure there is sufficient ventilation or provide means for removing
welding fumes near the electrodes; a systematic approach is necessary
to evaluate limits of exposure to the welding fumes depending on their
composition and concentration and on the length of exposure.
- Always protect the eyes with suitable eye protectors.
INDEX
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6. WELDING (Spot welding) ...................................................................................................................8
6.1 PRELIMINARY OPERATIONS ......................................................................................................8
6.2 PARAMETER ADJUSTMENT (in spot welding) ............................................................................8
6.3 PROCEDURE ................................................................................................................................8
6.3.1 PNEUMATIC CLAMP ...........................................................................................................8
6.3.2 MANUAL CLAMPS ...............................................................................................................8
6.3.3 STUDDER GUN ...................................................................................................................8
6.3.4 Earth cable connection .........................................................................................................8
7. MAINTENANCE ...................................................................................................................................9
7.1 ROUTINE MAINTENANCE ............................................................................................................9
7.2 SPECIAL MAINTENANCE .............................................................................................................9
7.2.1 Interventions on the liquid cooling unit (AQUA version only) ................................................9
8. TROUBLESHOOTING .........................................................................................................................9
- Wear protective gloves and clothing suitable for resistance welding work.
- Noise levels: If the personal daily exposure level (LEPd) is found to be greater
than 85db(A) due to particularly intensive welding operations, wearing
personal protection devices is compulsory.
- The flowing of spot welding currents generates electromagnetic fields (EMF)
around the spot welding circuit.
Electromagnetic fields can interfere with certain medical equipment (e.g. Pace-
makers, respiratory equipment, metallic prostheses etc.).
Adequate protective measures must be adopted for persons with these types of
medical apparatus. For example, they must be forbidden access to the area in
which spot welding machines are in operation.
This spot welder conforms to technical product standards for exclusive use
in an industrial environment for professional purposes. It does not assure
compliance with the basic limits relative to human exposure to electromagnetic
fields in the domestic environment.
The operator must adopt the following procedures in order to reduce exposure
to electromagnetic fields:
- Fasten the two spot welding cables (if present) as close together as possible.
- Keep head and trunk as far away as possible from the spot welding circuit.
- Never wind spot welding cables around the body.
- Avoid spot welding with the body within the spot welding circuit. Keep both
cables on the same side of the body.
- Connect the spot welding current return cable to the piece being spot welded,
as close as possible to the welding joint.
- Do not spot weld while close to, sitting on or leaning against the spot welder
(keep at least 50 cm away from it).
- Do not leave objects in ferromagnetic material in proximity of the spot
welding circuit.
- Minimum distance:
- d= 3cm, f= 50cm (Fig. O);
- d= 3cm, f= 50cm (Fig. P);
- d= 30cm (Fig. Q);
- d= 20cm (Fig. R) Studder.
- Class A equipment:
This spot welder conforms to technical product standards for exclusive use
in an industrial environment and for professional purposes. It does not assure
compliance with electromagnetic compatibility in domestic dwellings and in
premises directly connected to a low-voltage power supply system feeding
buildings for domestic use.
INTENDED USE
The system was designed to be used only and exclusively in body shops to
repair vehicles: it must be used for spot welding one or more steel plates with
a low carbon content, having a shape and size that vary according to the work
to be carried out.
RESIDUAL RISKS
RISK OF UPPER LIMBS BEING CRUSHED
DO NOT PLACE HANDS NEAR MOVING PARTS!
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:
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