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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.
-
IMPROPER USE
It is dangerous to use the spot-welder for any other purpose than that for
which it is designed (spot resistance welding).
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
SHOULD BE CARRIED OUT WITH THE SPOT-WELDER SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY (MAIN SWITCH LOCKED TO "O"
USING PADLOCK WITH KEY TAKEN OUT for PNEUMATIC CYLINDER-operated
models).
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 INTRODUCTION
Movable resistance welding system (spot-welder) with digital microprocessor control.
Fitted with quick connections on the welding cables to enable immediate interchange of
welding tools, allowing numerous types of hot working and spot-welding on sheet metal
and made specifically for the vehicle bodyshop and sectors with similar types of
working.
Its main features are:
- automatic choice of welding parameters,
- automatic recognition of the inserted tool,
- automatic opening of the cooling air channel when the threshold temperature is
reached in the clamp and cables,
- choice of optimal welding current for the available power supply,
- limitation of main supply overcurrent at starting (starting cosj
2.2 STANDARD ACCESSORIES:
- Pneumatically operated clamp with air-cooled cables (120 mm arms and standard
electrodes).
- Pneumatically operated clamp with water-cooled cables
(250 mm arms): R.A. VERSION (WATER-COOLED).
- Closed circuit water-cooled cooling unit R.A. VERSION.
- Pressure-reduction valve-filter unit with gauge and solenoid valve (compressed air
supply).
- Trolley.
2.3 OPTIONAL ACCESSORIES
- Electrode arm pairs of different lengths and/or shapes for air-cooled pneumatic
clamp (see spare parts list).
- Pneumatically operated clamp with water-cooled cables (250mm arms); standard
accessories on R.A. version.
- Electrode arm pairs of different lengths and/or shapes for water-cooled pneumatic
clamp (see spare parts list).
- Water-cooled arms kit 250 mm and standard electrodes.
- Closed circuit water-cooled cooling unit.
Cables and clamp can be water-cooled without consuming running water.
- Manually operated clamp with cable pair.
- Electrode arm pairs of different lengths and/or shapes for manual clamp (see spare
parts list).
- Manually operated "C" clamp with cables.
- Complete studder kit with separate earth cable and accessory box.
- Air-cooled clamp for twin-spot welding, with cables.
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 :
- Electrical protection class:
- Insulation class:
- Enclosure protection rating:
- Type of cooling
- (*)Dimensions (with trolley)(LxWxH):
- (*)Weight (with trolley):
control).
400V(380V-415V) ~ 1ph-50/60 Hz
or 230V(220V-240V) ~ 1ph-50/60 Hz
IP 22
F (forced air)
760x540x1060mm
R.A. version : 850x540x1060mm
68kg - R.A. version 83kg
Input
- Max. power when spot-welding (S max):
- Rated power at 50% (Sn) (air-cooled clamp):
- Rated power at 50% (Sn) (water-cooled clamp):
- Power factor at Smax (cosj
- Main supply delayed fuses:
- Automatic circuit-breaker:
- Power supply cable (L£
4m):
Output
- Loadless secondary voltage (U max):
- Max. spot-welding current (I max):
- Spot-welding capacity (low carbon steel):
- Duty cycle:
- Spots/hour on 1+1mm steel
- Air-cooled pneumatic clamp:
- Pneumatic clamp with water-cooled arms:
- Completely water-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.
- Minimum cooling water flow rate (30°C) Q:
(*)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. DESCRIPTION OF THE SPOT-WELDER
4.1. CONTROL PANEL (FIG.B)
1- Dual function key:
a) BASIC FUNCTION
spot-welding time with respect to the preset value.
b) SPECIAL FUNCTION
5kA) for the spot-welding current: to enter this function follow the procedure
"PROGRAMMING THE CURRENT" in section 4.2.
2- Dual function key:
a)
BASIC FUNCTION
b) SPECIAL FUNCTION
" for "PROGRAMMING THE CURRENT", see section 4.2.
3- Key for selecting functions with the studder gun:
This only has any meaning when the studder kit is used:
: Spot welding: pins, rivets, washers, special washers using suitable
electrodes.
2
: Spot-welding Ø 4mm screws using a suitable electrode.
3
: Spot-welding Ø 5-6mm screws and Ø 5mm rivets using a suitable
electrode.
4
: Spot-welding single spots using a suitable electrode.
5
: Tempering sheet metal using a carbon electrode. Upsetting sheet
metal using a suitable electrode.
6
: Jogged spot-welding for patching sheet using a suitable electrode.
The spot-welder automatically adjusts the welding time according to the chosen
sheet thickness.
4- Key for selecting the tool being used
: Pneumatically operated clamp. Opposed spot-welding on sheets that
can be reached from both sides, with maximum performance
obtainable from the spot-welder.
: Pneumatically operated clamp. With pulsed welding current; improves
spot-welding capacity on high yield point sheet or on sheet with special
protective film. This type of sheet is used in bodyshops for
contemporary automotive models.
0
: "Studder" gun used for all procedures that can be selected with key (3).
7
&
:Manually operated clamp. Opposed spot-welding on sheets that
can be reached from both sides.
(
: Pneumatically operated Air-puller gun. Used for tempering dents on
motor vehicle bodywork.
)
: Twin-spot gun. Used for spot-welding sheets that cannot be reached on
I
both sides.
H
*
5-
: Indicator LED "spot-welder at work".
+
6-
: Thermal safeguard warning LED.
6
):
32A (400V)/64A (230V)
32A (400V)/64A (230V)
3 x 4mm²(400V) - 3 x 6mm² (230V)
0
2
: upward or downward correction, within preset limits, of
: modification of the programmed value (default
: selects the thickness of the sheet to be spot-welded.
: enters the procedure
5
SEC
58kVA
14.2kVA
19kVA
0.7
8.6V
7kA
max 3 + 3mm
5.5%
200
400
1000
120kg
120-500mm
2 l/min
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