Telwin DIGITAL SPOTTER 9000 Bedienungsanleitung Seite 8

operated).
b) The welding current passes for a preset period indicated by the green LED (
going on and off.
- Release the button shortly after the LED has gone off (end of welding); this delay
(holding) improves the mechanical properties of the spot-weld.
7 &
MANUAL CLAMPS
- Place the bottom electrode on the sheets to be spot-welded.
- Pull the top lever on the clamp to the end of its stroke, so that:
a) The sheets close between the electrodes with the preset force.
b) The preset welding current passes for the preset time, indicated by the green LED
*
( ) going on and off.
- Release the clamp lever shortly after the LED has gone off (end of welding); this
delay (holding) improves the mechanical properties of the weld.
0
STUDDER GUN
WARNING!
- To fit or release the accessories on the studder chuck use the two fixed hexagon
wrenches to stop the chuck turning.
- When operating on doors and bonnets the earth bar MUST be connected to the
same part to prevent current passing through the hinges, and the bar must always
be set near the welding area (if the current has to travel over long distances this
will reduce the efficiency of the weld).
- Spot-welding time is automatic and depends on which studder procedure has
been selected.
Connecting the earth cable:
a) Bare the sheet as close as possible to the point where you intend to work,
cleaning an area corresponding to the contact surface of the earth bar.
b1) Fasten the copper bar to the sheet surface using an ARTICULATED CLAMP
(welding model).
Alternatively to method b1 (when practical difficulties arise) proceed as follows:
b2) Spot-weld a grommet to the prepared sheet surface; pass the grommet through
the slit in the copper bar and lock it with the supplied terminal.
Spot-welding the grommet for anchoring the earth terminal
Fit the appropriate electrode to the studder chuck (POS.9, FIG. H) and insert the
grommet (POS.13, FIG. H).
Place the grommet in the chosen area. Place the earth terminal in contact in the
same area; press the torch button to weld the grommet to be used for anchorage as
described above.
Spot-welding screws, washers, studs, rivets
Fit the appropriate electrode to the studder, insert the item to be welded and place it
on the sheet at the desired point; press the button on the studder: release the button
only after the preset time (green LED
Spot-welding sheets from one side only
Fit the appropriate electrode to the studder chuck (POS.6, FIG. H) pressing on the
surface to be welded. Press the button on the studder and only release it after the
*
preset time (LED goes off).
WARNING!
The maximum sheet thickness that can be welded from only one side is: 1+1 mm.
This type of welding must not be used on bodywork supporting structures.
To obtain correct results when spot-welding sheets with the studder the following
basic precautions should be taken:
1- A perfect earth connection.
2- The two parts to be spot-welded should be bared of any paint, grease or oil.
3- The parts to be welded should be in contact with one another, without an
intervening shim; if necessary press them together with a tool and not with the
studder. Too much pressure will lead to poor results.
4- The top piece should never be thicker than 1 mm.
5- The diameter of the electrode tip should be 2.5 mm.
6- Make sure that the electrode locking nut is tightened up completely and that the
welding cable connectors are locked.
7- When spot-welding, put the electrode on the sheet, exert slight pressure (3-4 kg).
Press the button, weld for the preset time and only then take the studder away.
8- Never weld more than 30 cm from where the earth bar is fastened.
Simultaneous spot-welding and pulling on special grommets
This is carried out by fitting and locking the chuck tightly (POS.4, FIG. H) onto the
body of the extractor (POS.1, FIG. H); lock the other terminal of the extractor tightly
onto the studder (FIG. H). Insert the special grommet (POS.14, FIG. H) into the
chuck (POS.4, FIG. H), locking it with the special screw (FIG. H) Spot-weld it in the
required place, adjusting the studder as for spot-welding grommets and start pulling.
On completion, turn the extractor through 90° to detach the grommet, which can be
re-welded in a new position.
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Heating and upsetting sheets
In this operating mode the TIMER is off.
The operating time is therefore determined manually by the time for which the
studder button is pressed down.
Current intensity is regulated automatically depending on the selected sheet
thickness.
Fit the carbon electrode (POS.12, FIG. H) into the studder chuck and lock it with the
ring nut. Touch the previously bared area with the carbon tip and press the studder
button. Work from the outside towards the inside with a circular movement so as to
heat the sheet, which will work harden and return to its original position.
To prevent the sheet from over-hardening treat small areas and immediately
afterwards wipe them with a damp cloth to cool the treated part.
5
Upsetting sheet metal
In this position, working with the appropriate electrode, it is possible to flatten sheets
that have undergone localised deformation.
!
*
goes off).
4
“
Jogged spot-welding (Patching)
*
) This function is suitable for spot-welding small rectangles of sheet to cover holes due
to rust or other causes.
Fit the appropriate electrode (POS.5, FIG. H) into the chuck, and tighten the ringnut
to fasten it securely. Bare the area to be worked on and make sure the patch sheet to
be welded is clean and free of grease and paint.
Position the patch and put the electrode on it then press the studder button and keep
it pressed, advancing in rhythm with the work/rest intervals determined by the spot-
welder.
N.B.: The spot-welder regulates work and pause time automatically according to the
selected sheet thickness. When working exert slight pressure (3-4 kg) and follow an
ideal line 2-3 mm from the edge of the new piece being welded.
To achieve good results:
1- Never weld more than 30 cm from where the earth is attached.
2- Use patch sheet no more than 0.8 mm thick, preferably stainless steel.
3- Move forwards in rhythm with the spot-welder. Advance during the pause and
stop during welding.
Using the supplied extractor (POS.1, FIG. H)
Locking on and pulling grommets
This is carried out by fitting and locking the chuck tightly (POS.3, FIG. H) on the body
of the electrode (POS.1, FIG. H) Lock onto the grommet (POS.13, FIG. H), which was
been spot-welded as described previously, and start pulling On completion turn the
extractor through 90° to detach the grommet.
Locking on and pulling pins
This is carried out by fitting and locking the chuck tightly (POS.2, FIG. H) on the body
of the electrode (POS.1, FIG. H) Insert the pin (POS.15-16, FIG. H), which was spot-
welded as described previously, into the chuck (POS.1, FIG. H) keeping the end
pulled towards the extractor (POS.2, FIG. H) After insertion release the chuck and
start pulling. On completion pull the chuck towards the hammer to extract the pin.
7. MAINTENANCE
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WARINING! BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
MAKE SURE THE SPOT-WELDER HAS BEEN SWITCHED OFF AND
DISCONNECTED FROM THE MAIN POWER SUPPLY.
The main switch must be locked in the "O" position using the supplied padlock.
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7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR
- adjustment/reset of electrode tip diameter and profile;
- electrode alignment checks;
- cable and clamp cooling checks;
- discharge of condensation from the compressed air inlet filter.
7.2 EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT
ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED ELECTRICAL-MECHANICAL
PERSONNEL.
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WARNING! BEFORE REMOVING THE SPOT-WELDER PANELS AND
WORKING INSIDE IT MAKE SURE IT IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OUTLET.
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If checks are made inside the spot-welder while it is live, this may cause serious
electric shock due to direct contact with live parts and/or injury due to direct
contact with moving parts.
Depending on how often the spot-welder is run and on the environmental conditions,
make regular checks inside the machine and remove the dust and the metallic particles
deposited on the transformer, the thyristor module, the terminal box, etc., using dry
compressed air (max. 5 bar).
Do not direct the compressed air jet on the electronic boards; clean them using a
very soft brush or with the appropriate solvents.
Take the opportunity to:
- Ensure that the wiring insulation is not damaged and the connections are tight and
free of oxidation.
- Ensure that the transformer secondary screws connecting the output bars are tightly
secured and that there are no signs of oxidation or overheating.
IF SPOT-WELDER OPERATION IS UNSATISFACTORY, BEFORE PERFORMING
MORE SYSTEMATIC CHECKS OR CONTACTING YOUR SERVICE CENTRE CHECK
WHETHER:
- With the spot-welder main switch closed (pos. " | ") the green LED is on; if not the fault
is in the power line (cables, outlet and plug, fuses, excessive voltage drop etc.).
- The yellow LED is on (thermal safeguard triggered); wait until the LED goes off before
re-starting the spot-welder; ensure correct cooling water flow and, if necessary,
reduce the duty cycle.
- The parts making up the secondary circuit (arm-holder castings arms electrode
holders cables ) are inefficient due to loose screws or oxidation.
- The welding parameters are actually appropriate for the job to be done.
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