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Idiomas disponibles
- The operator should either be expert or trained in resistance welding
procedures using this type of appliance.
- There should be risk evaluation for every type of job to be done; equipment
and masking should be provided to support and guide the work-piece (unless
a portable spot-welder is used).
- 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.
-
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.
-
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.
-
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 system for microprocessor-controlled resistance welding (spot-welder),
medium frequency inverter technology, 3-phase power supply and direct current output.
The spot welding machine is equipped with a pneumatic, air cooled clamp.
Inside the clamp there is the transformer and rectifying group that, in comparison with
traditional spot welders, permits to have higher spot currents, reduced mains absorptions
(the machine operates with 16 A fuses), longer and lighter cables for a better handiness
and a wider operation range as well as minium magnetic fields around the cables.
According to the material used, to its thickness and to the tool used, the machine
suggests pre-set operating programmes and enables the user to store up to three
customized programmes.
The spot welding machine can operate on low carbon metal sheets, on steel and
stainless steels, galvanized and HSS metal sheets. The presence of the compact
accessory generator allows the use of the Studder clamp and the carry out of many hot
working jobs which are specific to the vehicles body-shops.
The main features of the plant are:
- automatic recognition of the tool used;
- choice from panel of the tool to use;
- automatic choice of welding parameters according to the chosen material;
- customization of welding parameters;
- visualization of welding parameters;
- visualization of spot welding current;
- control of spot welding current;
- pneumatic internal cooling by forced air with controlled insertion/start.
2.2 STANDARD ACCESSORIES:
- Clamp supports.
- Filter and reduction unit (compressed air supply).
- Pneumatic clamp complete with cable and plug removable from generator;
- Trolley.
- 14 pin connector.
2.3 OPTIONAL ACCESSORIES
- Arms and electrodes set having length and/or shape for the air cooled pneumatic
clamp (see spare parts list).
- Compact generator to use with studder kit.
- Studder kit complete with separated earth cable and accessories case.
3. TECHNICAL DATA
3.1 RATING PLATE (Fig.A)
The main data regarding 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 - Mains power with permanent running (100%).
4 - Rated mains power with 50% duty cycle.
5 - Maximum loadless voltage over electrodes.
6 - Maximum current when electrodes are shorted.
7 - Current to secondary when running permanently (100%).
8 - Safety symbols, the meaning of which is given in chapter 1 "General safety rules
for resistance welding".
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
3.2.1 Spot-welding machine
General specifications
- Power supply voltage and frequency
:
400V(380V-415V) ~ 3ph-50/60 Hz
- Electrical protection class
- Insulation class
- Enclosure protection rating
- Type of cooling
- Overall Dimensions (LxWxH)
- Weight
Input
- Max. power in short circuit (Scc)
- Power factor at Scc (cosj
)
- Main supply delayed fuses
- Automatic circuit-breaker
- Power supply cable (L£
4m)
Output
- Loadless secondary voltage (U d)
- Max. spot-welding current (I max)
- Welding capacity
- Duty cycle
- Spots/hour on 3+3mm steel
- Maximum electrode force
- Arm projectio
- Spot-welding current adjustment
- Spot-welding time adjustment
- Squeeze time adjustment
- Ramp time adjustment
- Holding time adjustment
- Cooling time
- Pulse number adjustment
3.2.2 Studder Generator
General specifications
- Power supply voltage and frequency
- Electrical protection class
- Insulation class
- Enclosure protection rating
- Type of cooling
- Overall Dimensions (LxWxH)
- Weight
Input (*)
Output
- Loadless secondary voltage
- Max. spot-welding current (I max)
(*) NOTE: the generator is feeded exclusively by the proper connections to the main
unit of the spot welder.
See the characteristics of the spot welder.
4. DESCRIPTION OF THE SPOT-WELDER
4.1 CONTROL AND ADJUSTMENT DEVICES
4.1.1 Control panel (Fig.B)
Description of spot-welding parameters:
Power: percentage of supplyable power during spot-welding range from 5 to
100%.
Squeeze time: time for which the electrodes of the pneumatic clamp squeeze
the sheet to be spot-welded without delivering current; used to ensure that the
electrodes reach the maximum pressure setting before delivering current
range from 10 to 50 cycles (1 cycle = 20ms).
Ramp time: time taken for the current to reach the maximum set value. For
pulsed operation with the pneumatic clamp this time is only applied to the first
pulse range from 0 to 100 cycles.
Spot-welding time: time for which the spot-welding current is held practically
constant. For pulsed operation with the pneumatic clamp this time is refers to
the duration of the single pulse range from 0,5 to 100 cycles (*).
Cool time: (only for pulsed spot-welding) time elapsing between one current
pulse and the next range from 0.5 to 20 cycles.
Number of pulses: (only for pulsed spot-welding) number of spot-welding
current pulses, each lasting for the set spot-welding time range from 1 to 10 (**).
Hold time: time for which the electrodes of the pneumatic clamp continue to
squeeze the sheets that have just been spot-welded, without delivering current.
During this interval the welded spot will be cooled and the welded core will
crystallise; during this stage the pressure will refine the metal grain, increasing
the mechanical strength range from 2 to 50 cycles.
(*)NOTE: the sum of ramp cycles and spot-welding cycles may not exceed 100 (2
seconds).
(**)NOTE: the maximum possible setting for the number of pulses depends on the length
of a single pulse: the total effective spot-welding time may not exceed 100 cycles.
1- Dual function key "A"
a) BASIC FUNCTION
: sequential display of spot-welding parameters:
supplyable power/current,
cool time (only in pulsed mode),
hold time.
b) SPECIAL FUNCTION
enter this function it is necessary to follow the procedure described in section 6.2.2 .
2 Key "B" for selecting the function used and displaying the tool used:
- 6 -
:
:
:
:
:
:
:
:
:
:
16A ("C"- IEC60947-2)
:
:
2
:
2
:
:
:
:
:
:
automatic and programmable.
:
automatic and programmable.
:
automatic and programmable.
:
automatic and programmable.
:
automatic and programmable.
:
automatic and programmable.
:
automatic and programmable.
:
:
:
:
:
:
:
:
:
2
squeeze time,
ramp time,
number of pulses (only in pulsed mode),
: changing the spot-welding parameters on display: to
I
H
IP 20
F A (forced air)
650 x 500 x 900mm
40kg
38.5kVA
0.8
16A
4 x 2.5mm²
7V
8kA
max 3 + 3mm
1.8%
95
200daN
120mm standard
565V ~ 1ph-80 Hz
I
H
IP 20
N A (natural air)
320 x 240 x 180mm
15.5kg
9.5V
3kA
spot-welding time,
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