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- 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 is planned with liquid cooling and an ambient temperature under
0°C: use the anti-freeze liquid suggested by the manufacturer or completely
empty the hydraulic circuit and the tank of liquid.
Always use adequate measures to protect the machine from humidity, dirt and
corrosion.
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 INTRODUCTION
Mobile resistance welding system (spot welding machine) with digital microprocessor
control. Equipped with quick couplings for the welding cables, it facilitates the immediate
interchange of equipment, allowing numerous hot and spot welding operations on
sheet metal, specifically in body shops and sectors with similar processing of sheet
metal.
The spot welding machine is available in two versions:
-
Air cooled version abbreviated to "A.F.".
-
Air and liquid cooled version (clamp) abbreviated to "AQUA"
Their main characteristics are:
-
automatic selection of welding parameters;
-
automatic recognition of the tool inserted;
-
automatic, timed switch off command of air (liquid, if present) cooling;
-
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 work on sheet metal in iron with low carbon content or
on sheet metal in zinc-plated iron.
2.2 STANDARD ACCESSORIES
-
Pneumatic clamp with air cooled cables (120mm arms and standard electrodes):
A.F. version
-
Pneumatic clamp with liquid cooled cables (120 mm arms): AQUA version;
-
Unit integrated for closed circuit liquid cooling: AQUA VERSION;
-
Pressure reducer-filter unit with gauge and solenoid valve (compressed air supply);
-
Integrated trolley;
2.3 OPTIONAL ACCESSORIES
-
Pairs of arms with electrodes in various lengths and/or shapes for the pneumatic
clamp with air/liquid cooling (see spare parts list).
-
Manual clamp with cable pair.
-
Pair of arms with electrodes in various lengths and/or shapes for the manual clamp
(see spare parts list).
-
Manual "C" clamp with cables.
-
Studder kit with separate earth cable and accessories box.
-
Double spot gun, air cooled, with cables.
-
Studder kit without trigger, with earth cable (contact welding without using button).
-
Support pole kit with weight unloader for clamp.
3. TECHNICAL DATA
3.1 DATA PLATE (Fig. A)
The main data required for spot welding machine use and performance are given in
the characteristics plate and have the following meaning.
1 - Number of phases and frequency of the power supply line.
2 - Power supply voltage.
3 - Network power at permanent regime (100%).
4 - Nominal network power with 50% intermittence ratio.
5 - Maximum no-load voltage at the electrodes.
6 - Maximum current with electrodes in short-circuit.
7 - Secondary power at permanent regime (100%).
8 - Gauge and length of the arms (standard).
9 - Minimum and maximum force adjustable from the electrodes.
10 - Nominal pressure of the compressed air source.
11 - Compressed air source pressure necessary for obtaining maximum electrode
force.
12 - Cooling liquid capacity.
13 - Cooling liquid nominal pressure drop.
14 - Equipment mass.
15 - Safety symbols, the meaning of which is given in chapter 1 "General resistance
welding safety".
Note: The meanings of the symbols and numbers on the example plate are indicative;
the exact technical values of your spot welding machine can be found directly on the
spot welding machine plate.
3.2 OTHER TECHNICAL DATA
3.2.1 Spot welding machine
General characteristics
- Voltage and power supply frequency
or
- Electrical protection class
- Insulation class
- Casing protection rating
- Cooling type
- (*) Dimensions (LxWxH)
- (**) Weight
Input
- Max. power in short-circuit (Scc)
- Max. power factor
- Delayed network fuses
- Automatic line switch
- Power supply cable (L≤4 m)
Output
- No-load secondary voltage (U
- Max. spot welding current (I
2
- Spot welding capacity
- Intermittence ratio
- Maximum force at the electrode
- Arm projection
- Spot welding current adjustment
- Spot welding time adjustment
of the sheet and the clamp used
(*) NOTE: the mass does not include the cables and the support column.
(**) NOTE: the generator weight does not include the clamp and the support column.
3.2.2 Cooling group (GRA)
General characteristics
- Maximum pressure (pmax)
- Cooling power (P @ 1l/min.)
- Tank capacity
- Cooling liquid
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 (ATLAS);
3 - Quick coupling for air hose connection;
4 - Rapid hold to attach the cooling tubes (AQUA version);
5 - 14-pin connector;
At the back:
6 - Main switch;
7 - Power cable input;
8 - Pressure regulator, gauge and air input filter unit;
9 - Cooling unit tank tap (AQUA version);
10 - GRA liquid level (AQUA version);
11 - GRA air valve (AQUA version).
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
;
- 6 -
:
400 V (±15%) ~ 2 ph-50/60 Hz
:
230 V (±15%) ~1 ph-50/60 Hz
:
:
:
: A.F. (Forced air), liquid (AQUA version)
:
710 x 450 x 910 mm
:
66 kg A.F., 81 kg AQUA
:
:
:
32 A (400 V)/64 A (230 V)
:
32 A @ 400 V ("C"- IEC60947-2)
63 A @ 230 V ("C"- IEC60947-2)
: 3 x 4 mm²(400 V) - 3 x 6 mm² (230 V)
d)
:
2
max.)
:
:
:
1.5% A.F., 3% AQUA
:
:
:
: automatic according to the thickness
:
:
:
:
(can only be activated with pneumatic
SELECTION FUNCTION :
I
H
IP 20
58 kVA
0.8
10 V
7 kA
max. 3 + 3 mm
150 daN
120-500 mm
automatic
3 bar
1 kW
8 l
coolant
can be
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