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Indicates that the spot-welder has been shut down due to overheating on
the output bars, the welding cables or the tool being used. Reset is
automatic when the temperature returns within the allowed limits.
,
Power supply indicator LED's :
7-
-
: Low power supply voltage (spot-welder under-powered).
.
: Normal power supply voltage (spot-welder powered correctly).
/
: High power supply voltage (spot-welder over-powered).
WARNING: When the power supply is abnormal, with the over- or under-voltage
LED's lit up and an intermittent beep, we advise switching off the spot-welder to
prevent it being damaged.
4.2 PROGRAMMING THE (SPOT-WELDING) CURRENT
It is possible to modify the factory-programmed default value (5kA) of the current, which
is suitable for an installed power of 10 kW .
WARNING; IMPORTANT: TABLE 1 shows the correspondence between the
selected current and the minimum main supply power, which must be available at
the place of installation (installed power), in order to prevent inappropriate
triggering of the main supply safeguard.
We advise adjusting the programmed values if the default value is insufficient for perfect
execution of the spot-weld at the selected thickness (the corresponding LED flashes)
or, provided the installed power is compatible, to select the value of 7kA to
guarantee greater safety while operating in all applications.
Choosing lower programmed current values will result in limiting the maximum
thickness it is possible to weld.
4.2.1 Procedure
- Press key "2" for more than 5 seconds~ : the numerical scale to the far right of the
control panel ("power") will take a value in " kA" ( from 3 kA to 7kA).
- Press key "1" repeatedly to select the current to be programmed (corresponding LED
lights up).
- Press key "2" for more than 5 seconds~ : the selected current will be stored; key "1"
and the corresponding scale will return to the basic function (spot-welding time
correction).
The "stored" current value can be changed by following the above procedure each time.
5. INSTALLATION
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WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
ELECTRICAL AND PNEUMATIC CONNECTIONS WITH THE SPOT-WELDER
COMPLETELY SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY OUTLET.
THE ELECTRICAL AND PNEUMATIC CONNECTIONS MUST BE MADE ONLY AND
EXCLUSIVELY BY EXPERT OR SKILLED PERSONNEL.
----------------------------------------------------------------------------------------------------------------
5.1 PRELIMINARY OPERATIONS
Unpack the spot-welder, assemble the separate parts included in the package.
5.2 LIFTING THE SPOT-WELDER
WARNING: None of the spot-welders described in this handbook have lifting devices.
5.3 POSITION
The installation area must be sufficiently large and without obstacles, suitable for
ensuring completely safe access to the control panel, to the main switch and to the
working area.
Ensure that there are no obstacles near the cooling air inlets and outlets and that no
conductive dusts, corrosive vapour, moisture etc. can be sucked in.
Position the spot-welder on a plane surface made of uniform, compact material able to
support the weight (see the "technical data") so as to prevent it from tipping or moving
dangerously.
5.4 CONNECTION TO THE MAIN POWER SUPPLY
5.4.1 Warnings
Before making any electrical connection, make sure the rating data of the spot-welder
correspond to the mains voltage and frequency available at the place of installation.
The spot-welder should be connected only and exclusively to a power supply with the
neutral conductor connected to earth.
5.4.2 Plug and socket
Connect the power supply cable to a standardised plug (3P + G only two pins are
used: INTERPHASE CONNECTION!) of adequate capacity and prepare a power
outlet protected by fuses or by an automatic circuit-breaker; the appropriate earth
terminal should be connected to the (yellow-green) earth conductor of the power line.
The capacity and specifications of the fuses and circuit-breaker are given in the
paragraph on "TECHNICAL DATA".
Should more than one spot-welder be installed, distribute the power cyclically among
the three phases in order to obtain amore balanced load; e.g.
spot-welder 1: power supply L1-L2;
spot-welder 2: power supply L2-L3;
spot-welder 3: power supply L3-L1.
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WARNING! Failure to observe the rules given above will invalidate the (class
I) safety system provided by the manufacturer causing serious risks to people
(e.g. electric shock) and objects (e.g. fire).
----------------------------------------------------------------------------------------------------------------
5.5 PNEUMATIC CONNECTION
- Set up a compressed air line with working pressure between 6 and 8 bar.
- Fit one of the compressed air connectors to the filter-reducing valve unit to make it
compatible with the connectors available where the spot-welder is installed.
5.6 CONNECTING THE COOLING CIRCUIT (FIG. C)
For the R.A. version (with cooling unit supplied) connect the pneumatic clamp water
pipes.
In other cases it is possible to set up an open cooling circuit (discarding the return
water); set up a water delivery pipe for maximum temperature 30°C, with the minimum
flow rate (Q) at least the one specified in the technical data.
WARNING! Welding operations performed without water or with insufficient
water flow could cause the spot-welder to break down due to overheating.
5.7 CONNECTING THE PNEUMATIC CLAMP (FIG. D)
- Insert the cable connector into the spot-welder power connector, turning it until it
locks. Tighten the bottom bolt with a No. 19 wrench.
- Connect the two air plugs into their appropriate sockets on the spot-welder: small
plug: cooling air; large plug: air for operating pneumatic cylinder on clamp.
- Insert the control cable connector into its socket.
5.8 CONNECTING THE MANUAL CLAMP AND STUDDER GUN WITH EARTH
CABLE (FIG. E)
- Insert DINSE adapters into the spot-welder power connector.
- Connect the DINSE plugs to their corresponding sockets.
- Insert the control cable connector into its socket.
It is not necessary to connect the compressed air intakes.
5.9 CONNECTING THE AIR PULLER WITH EARTH CABLE (FIG. F)
- Insert DINSE adapters into the spot-welder power connector.
- Connect the DINSE plugs to their corresponding sockets.
- Connect the air plug with the corresponding intake on the spot-welder (large plug).
- Insert the control cable connector into its socket.
5.10 CONNECTING THE TWIN-SPOT CLAMP
- Proceed as for the pneumatic clamp using only the cooling air plug.
6. (SPOT) WELDING
6.1 PRELIMINARY OPERATIONS
Before carrying out any spot-welding operation it is necessary to make a series of
checks and adjustments, which should be carried out with the general switch in the "O"
position and with the padlock closed.
- Ensure that the electrical connections are correct, in accordance with the above
instructions.
- For the R.A. versions using cooled arms start cooling water circulation.
- Check the compressed air hookup; connect the compressed air feed pipe to the
pneumatic network, use the reduction valve knob to adjust the pressure until the
gauge gives a reading between 4 and 8 bar (60 - 120 psi) depending on the thickness
of the sheet to be welded.
- Between the electrodes, slide a shim equivalent to the thickness of the sheets;
ensure that the arms, brought together manually, are parallel and that the electrode
holders are centred (tips coincide).
If necessary loosen the arm locking screws to adjust the arms by turning them or
moving them in either direction along their axis; on completion secure the locking
screws tightly.
- The working stroke is regulated by adjusting the electrodes. Always bear in mind that
the stroke should be 6-8 mm greater than the spot-welding position so as to exert the
required force on the piece.
- When using the manual clamp, bear in mind that the force exerted by the electrodes
during the welding phase is achieved by adjusting the knurled nut (FIG. G); turn it
clockwise to increase the force in proportion to the increase in sheet thickness but
make the adjustment so that the clamp is able to close (triggering the corresponding
microswitch) with very little effort. Position the arms and electrodes correctly as for
the pneumatic clamp.
6.2 ADJUSTING THE (spot-welding) PARAMETERS
The parameters that affect the diameter (section) and mechanical strength of the spot
weld are:
- Force exerted by the electrodes.
- Spot-welding current.
- Spot-welding time.
When specific experience is lacking we recommend carrying out a number of test welds
using sheet of the same thickness and quality as that of the workpiece.
Regulate electrode force by adjusting the pressure regulator as instructed in section
6.1, choosing medium-high values.
Spot-welding current and time are regulated automatically when the thickness of the
sheet to be welded is selected with key (2). If the spot-welding time is to be adjusted with
respect to the standard (DEFAULT) value, this can be done within preset limits using key
(1). For example, with a low power supply voltage ( LED (
to increase the spot-welding time slightly and vice versa if LED (
the operator can always take advantage of this opportunity to satisfy specific
requirements.
Enable pulsed mode (
9
) when 0.8-1.2mm thick high yield point sheet is used.
The length of the pulse is automatic and requires no regulation.
IMPORTANT:
If the LED corresponding to the selected thickness "flashes" this means that the
default welding current, or the initially programmed current, is insufficient to
achieve a satisfactory weld; reprogram the spot-welder to the maximum current
compatible with the power available at the place of installation (see section 4.2).
High welding currents combined with reduced welding time improve the properties of
the weld.
The spot-welding operation is deemed correct when a tensile test causes the spot-
welding core to come out of one of the two sheets.
6.3 PROCEDURE
PNEUMATIC CLAMP
- SQUEEZE TIME is automatic. The value depends on the selected sheet thickness.
- Place an electrode on the surface of one of the two sheets to be spot-welded.
- Press the button on the handgrip of the clamp so that:
a) The sheets close between the electrodes with the preset force (cylinder-
7
-
) on) it may be necessary
/
) is on. In any case
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