Spot) Welding - Telwin Inverspotter 12000 Manual De Instrucciones

shutdown (welding disabled).
RESET: manual (by pressing the "START" button after the temperature has
returned within the allowed limits the yellow LED [-] goes off).
b) Main switch:
- Position " O " = open (OFF), can be padlocked (see chapter 1).
WARNING! In position "O" the terminals inside the machine
(L1+L2+L3) for connecting the power supply cable are live.
- Position " I " = closed (ON): the spot-welder is powered but is not in operation
(STANDBY - it is necessary to press the "START" button).
- Emergency function
When the spot-welder is in operation, opening (pos. " I "=>pos " O ", switching off)
will stop the machine in safety mode:
- current disabled;
- electrodes open (cylinder discharged);
- automatic restart disabled.
c) Compressed air safeguard
Triggers if there is a pressure failure or pressure drop (p < 3bar) in the compressed
air supply;
The display indicates triggering of this safeguard with the message "AL 6"
EFFECT: movement blocked: electrodes open (cylinder discharged);
current shut-down (welding disabled).
RESET: manual (by pressing the "START" button after the pressure has returned
within the allowed limits (pressure gauge shows >3bar).
d) Cooling system safeguard
Triggers if there is a pressure failure or pressure drop in the coolant water:
The display indicates triggering of this safeguard with the message "AL 7"
EFFECT: movement blocked: electrodes open (cylinder discharged); current shut-
down (welding disabled)
RESET: switch the machine off and on again!!
e) Phase failure safeguard
The display indicates triggering of this safeguard with the message "AL 11"
EFFECT: movement blocked: electrodes open (cylinder discharged); current shut-
down (welding disabled).
RESET: manual (press "START" button)
f) Over/undervoltage safeguard
The display indicates triggering of this safeguard with the message "AL3" for
OVERVOLTAGE and "AL4" for UNDERVOLTAGE.
EFFECT: movement blocked: electrodes open (cylinder discharged); current shut-
down (welding disabled)
RESET: manual (press "START" button)
g) "START" button
This button must be pressed to control the welding operation in each of the following
cases:
- whenever the main switch is closed (pos " O "=>pos " | ", switching on):
- whenever the safeguards/thermal relays have triggered:
- whenever the (electrical or compressed air) power supply is restored following an
interruption due to disconnection upstream or a fault.
5. INSTALLATION
_____________________________________________________________________________________________________________________
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, as
described in this chapter.(FIG. C)
5.2 HOW TO LIFT THE SPOT-WELDER (FIG. D)
The spot-welder should be lifted with a double cable and hooks, using the M12 ISO3266
rings provided for this purpose.
Slinging the spot-welder in any other way than as indicated (e.g. through the arms or the
electrodes) is absolutely forbidden.
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.
In order to guarantee protection against indirect contact use RCD's of the following
types:
- Type A ( ) for single phase machines;
- Type B ( ) for 3-phase machines.
In order to satisfy the requirements of the EN 61000-3-11 (Flicker) standard we
recommend connecting the spot welder to interface points of the main power supply that
have an impedance of less than Zmax = 0,034 ohm.
The spot welder does not fall within the requisites of IEC/EN 61000-3-12 standard.
Should it be connected to a public mains system, it is the installer's responsibility to
verify that the spot welding machine itself is suitable for connecting to it (if necessary,
consult the distribution network company).
5.4.2 Plug and socket
Connect the power supply cable to a standardised plug (3P + G) 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 "OTHER TECHNICAL DATA".
_____________________________________________________________________________________________________________________
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 PREPARATION OF THE WATER COOLING SYSTEM (GRA)
_____________________________________________________________________________________________________________________
WARNING! Operations to fill the system should be carried out with the
apparatus switched off and disconnected from the power supply.
Do not use electrically conductive anti-freeze liquids.
Use only demineralised water.
_____________________________________________________________________________________________________________________
- Fill the tank with demineralised water through the filler cap (fig. B-8): tank capacity =
10 l; make sure that, as you complete filling, the water does not overflow.
- Close the cap on the tank.
5.7 CONNECTING THE PNEUMATIC CLAMP
The pneumatic clamp is permanently connected by cables to the power source.
Insert the 14-pin connector of the clamp into the socket on the machine (FIG. E) so that
the tool is recognised.
5.8 CONNECTING THE MANUAL CLAMP AND STUDDER GUN WITH THE EARTH
CABLE (FIG. F)
- Disconnect the connector for recognising the pneumatic clamp (the display will show
"NO CON").
- Connect the DINSE plug of the tool that is to be used into the appropriate socket.
- Connect the connector for recognising the tool to the spot-welder and press the
"START" button (FIG. B-3).
5.9 CONNECTING THE AIR PULLER WITH EARTH CABLE (FIG. F)
- Disconnect the connector for recognising the pneumatic clamp (the display will show
"NO CON").
- Connect the DINSE plugs to their corresponding sockets.
- Connect the air puller to the pneumatic power supply (6-8 bar).
- Connect the connector for recognising the air puller to the spot-welder and press the
"START" button (FIG. B-3).
5.10 CONNECTING THE TWIN-SPOT CLAMP
- Proceed as for the "air puller" tool.

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.
- 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 (see TAB.1).
- 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. H); 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.
Checks and adjustments to be carried out with the main switch in the "I" position
(ON)
Aligning the arms/electrodes of the pneumatic clamp:
- Between the electrodes, slide a shim equivalent to the thickness of the sheets to be
welded; bring the arms together using the squeeze function (see section 6.2.1) and
ensure that they are parallel and that the electrodes are centred (the tips meet).
- Align the arms, if necessary, by releasing the jaws of the arm-holder with the centring
dowel and inserting them completely into the arm-holder; then centre the locating
hole with the dowel inserted into the arm-holder itself and proceed to relock the jaws.
- Carry out the squeeze function on the electrodes once more before proceeding with
the spot-welding cycle.
Cooling system:
- Make sure the cooling system works properly and there are no leaks in the hydraulic
circuit: the GRA will start operation at the first spot-welding cycle of the pneumatic
clamp and will switch off if the clamp remains inactive for a preset length of time.
IMPORTANT:
If the yellow light comes on (fig. B-11) it may be necessary to remove the air
present in the circuit in order to start water circulation.
Proceed as follows:
A) Switch off the machine.
B) Position the clamp and cables at the same level as the surface on which the
spot-welder rests.
C) Restart the unit and immediately open the discharge valve (fig. B-0) by turning
it manually until water comes out.
D) Close the valve immediately to prevent more water from leaking out.
- 8 -