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5.4.2 Network plug and outlet
Connect a normalised plug (3P + E: only 2 poles are used; INTERPHASE connection!)
of suitable capacity to the power supply plug and prepare a mains socket that is
protected by fuses or by a circuit breaker; the relative earth terminal must be connected
to the earth conductor (yellow-green) of the power line.
The capacity and intervention characteristic of the fuses and circuit breaker switch are
given in the "TECHNICAL DATA" paragraph.
Should several spot welding machines be installed, distribute the power supply
cyclically between the three phases so as to create a more balanced load, for example:
spot welding machine 1: L1-L2 power supply;
spot welding machine 2: L2-L3 power supply;
spot welding machine 3: L3-L1 power supply.
ATTENTION! Failure to comply with the above rules renders the safety
system (class I) ineffective, with resulting serious risks for people (e.g. electric
shock) and for property (e.g. fire).
5.5 PNEUMATIC CONNECTION
-
Prepare a compressed air line with a working pressure of 8 bar.
-
Assemble one of the compressed air connections onto the reducer filter unit, to
adapt to the connections available in the installation area.
5.6 PREPARATION OF THE COOLING UNIT (AQUA Version)
ATTENTION! The filling operations should always be performed with
the machine switched off and disconnected from the mains supply.
Never use polypropylene based antifreeze liquids.
Only use the coolant recommended by the manufacturer.
-
Open the discharge valve (FIG. B-11).
-
Fill the tank with coolant using the nozzle (Fig. B-9): capacity of the tank = 8 l; pay
attention to avoid excess leakage of coolant at the end of filling.
-
Close the tank cap.
-
Close the discharge valve.
5.7 PNEUMATIC CLAMP CONNECTION (Fig. F)
-
Connect the ATLAS plugs to the specific sockets.
WARNING! The cable "ATLAS" connect to the panel sockets
with clockwise rotation: check cable torsion does not tend to loosen the
connection; if so, rotate the cable "ATLAS" anti-clockwise before inserting
them and fasten them on the panel.
-
Connect the two air plugs in the specific spot welding machine sockets: small plug
(air cooling); large plug (pneumatic gun control air).
-
AQUA version only, connect the cooling tubes of the clamp to the specific quick
couplings of the machine, respecting the colours: blue tube on blue socket, red
tube on red socket.
-
Insert the control cable connector into the relative 14 pin socket.
5.8 MANUAL CLAMP AND STUDDER GUN CONNECTION WITH EARTH CABLE
(FIG. G)
-
Connect the ATLAS plugs with the relative sockets; only for the studder: connect
the gun and the earth to the relative ATLAS, as shown in the machine screen
printing.
-
Insert the control cable connector into the relative socket.
The compressed air vents do not have to be connected.
5.9 DOUBLE TIP CLAMP CONNECTION
-
Proceed in the same manner as with the pneumatic clamp, using only the cooling
air plug.
6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
Before carrying out any spot welding operation, a series of checks and adjustments
must be made with the main switch at "O" and the padlock closed.
-
Make sure the electrical connection has been carried out correctly as indicated in
the previous instructions.
-
Check the compressed air connection; connect the supply hose to the pneumatic
network, adjust the pressure using the reduction knob until a value of between 4
and 8 bar (60 - 120 psi), according to the thickness of the plate to be spot welded,
can be read on the gauge.
-
Place a shim of the same thickness between the electrodes; make sure the arms,
which have manually been brought closer, are parallel and the electrodes are
aligned (coinciding tips).
Adjust if necessary, by loosening the locking screws of the arms that can be rotated
or moved in both directions along their axis; after adjusting, carefully tighten the
locking screws.
-
The work stroke can be adjusted using the electrodes. Always remember that a
stroke that is 6-8 mm longer than the spot welding position is necessary, to exercise
the required force on the workpiece.
FIG. I shows a "standard" adjustment of the electrode position with clamp resting.
-
Using the manual clamp, consider that the power of the electrodes during the spot
welding phase can be adjusted with the knurled nut (FIG. L); turn it clockwise (to
the right) to increase the force proportional to the increase in the sheet thickness,
selecting adjustments that make it possible to close the clamp (and relative micro
switch activation) using very limited power. The correct position of the arms and
electrodes is the same as that of the pneumatic clamp.
6.2 PARAMETER ADJUSTMENT (in spot welding)
The parameters that determine the diameter (section) and mechanical seal of the
spot are:
-
Force at the electrode.
-
Spot welding current.
-
Spot welding time.
If there is no specific experience, it is a good idea to carry out some spot welding tests
using sheets of the same quality and thickness as those to be worked on.
Adjust the electrode power using the pressure adjusters ad indicated in 6.1, selecting
medium-high values.
The current and spot welding time parameters are adjusted automatically by selecting
the thickness of the sheet to be welded with the (+ / - icons) keys. Adjustments can
be made to the standard spot time (DEFAULT), within set limits, using the key (icon
fig. C-2).
Insert the
pulse, having to spot weld sheets of thickness 0.8-1.2 mm at a high
yield point.
The pulse period is automatic, and as such does not need to be adjusted.
IMPORTANT: If the selected thickness "flashes", this means that the default
initially programmed spot welding current is insufficient for spot welding in a satisfactory
manner; compatibly with the power available in the installation area, reprogram the
spot welding machine at maximum current (see paragraph 4.2.1): high spot welding
currents combined with reduced times give better spot characteristics.
The spot is considered as correct when the nugget of the weld point can be extracted
from one of the two sheets when tension is tested.
6.3 PROCEDURE
6.3.1 PNEUMATIC CLAMP
-
The squeeze time is automatic; the value varies according to the selected sheet
thickness.
-
Place an electrode on the surface of one of the two sheets to be spot welded.
-
Press the push-button on the clamp handle to:
a) Close the sheets between the electrodes with the pre-adjusted force (cylinder
movement).
b) Pass the set welding current for the set time, signalled by the
switches on and off.
-
Release the push-button a few moments after the icon has switched off (end of
welding); this delay (maintenance) gives the weld better mechanical characteristics.
6.3.2 MANUAL CLAMPS
-
Place the lower electrode on the sheets to be spot welded.
-
Move the upper lever of the clamp to the end stop to:
a) Close the sheets between the electrodes with the pre-adjusted force.
b) Pass the set welding current for the set time, signalled by the
switches on and off.
-
Release the clamp lever a few moments after the icon has switched off (end of
welding); this delay (maintenance) gives the weld better mechanical characteristics.
6.3.3 STUDDER GUN
ATTENTION!
- To fix or remove the tools from the gun spindle, use two hex keys in a manner
that stops the spindle from rotating.
- If working on doors or hoods, connect the earth bar to them to prevent
current from passing through the hinges, and near the area to be spot welded
(long current runs reduce spot efficiency).
6.3.4 Earth cable connection
a) Bare the sheet as close as possible to the working area, for a surface that
corresponds to the earth bar contact surface.
b1) Fix the copper bar to the sheet surface, using a JOINTED CLAMP (welding
model).
As an alternative to method "b1" (difficult t carry out):
b2) Spot weld a washer to the previously prepared sheet surface; pass the washer
through the slit in the copper bar and lock it in position with the supplied clamp.
Washer welding for mass terminal fixing
Mount the relative electrode (POS. 9, Fig. M) in the gun spindle, and insert the washer
(POS. 13, Fig. M).
Place the washer in the selected area. Place the earth terminal in contact in the
same area; press the gun push-button to weld the washer, which should be fixed as
indicated previously.
Screw, washer, nail, rivet spot welding
Fit the most suitable electrode on the gun, insert the element to be spot welded and
place it on the sheet in the necessary spot; press the gun push-button: release the
push-button only after the set time has elapsed.
Spot welding sheets on one side only
Fit the most suitable electrode on the spindle (POS. 6, Fig. M), pressing on the surface
to be spot welded. Activate the gun push-button, release the push-button only after the
set time has elapsed.
ATTENTION!
Maximum thickness of the plate that can be spot welded, on only one side: 1+1
mm. This type of spot welding cannot be used on the supporting frames of the
chassis.
To obtain correct results when sport welding sheets, some fundamental precautions
must be taken:
1 - An impeccable earth connection.
2 - Any paint, grease, oil must be cleaned from the two parts to be spot welded.
3 - The parts to be spot welded must be in contact with each other, without gaps;
if necessary press with a tool, not with the gun. Excessive pressure brings bad
results.
4 - The upper piece must not be thicker than 1 mm.
5 - The electrode tip must have a diameter of 2.5 mm.
6 - Tighten the nut that locks the electrode well, make sure the welding cable
connectors are locked.
7 - When spot welding, position the electrode and push it slightly (3-4 kg). Press the
push-button and allow the spot welding time to elapse, and only then remove the
gun.
8 - Never distance yourself further than 30 cm from the earth fixing point.
Contemporaneous spot welding and drawing of special washers
This function can be carried out by assembling and fully tightening the spindle (POS.
4, Fig. M) on the body of the extractor (POS. 1, Fig. M): hook and fully fasten the other
end of the extractor on the gun. Insert the special washer (POS. 14, Fig. M) into the
spindle (POS. 4, Fig. M), and lock it with the relative screw (Fig. M). Spot weld in the
relative area, adjusting the spot welding machine as if spot welding washers, and start
drawing.
At the end, rotate the extractor by 90° to release the washer, which can be spot welded
in a new position.
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