TELWIN 954548 Spot Welders Instruction Manual

TELWIN 954548 Spot Welders Instruction Manual

EXPLANATION OF DANGER, MANDATORY AND PROHIBITION SIGNS.

  DANGER OF ELECTRIC SHOCK

  DANGER OF WELDING FUMES

  DANGER OF EXPLOSION

  WEARING PROTECTIVE CLOTHING IS COMPULSORY

WEARING PROTECTIVE GLOVES IS COMPULSORY

DANGER OF ULTRAVIOLET RADIATION FROM WELDING

DANGER OF FIRE

DANGER OF BURNS

 DANGER OF STRONG MAGNETIC FIELD

 DANGER OF NON-IONISING RADIATION

GENERAL HAZARD

 DO NOT USE THE HANDLE TO HANG THE WELDING MACHINE

 EYE PROTECTIONS MUST BE WORN

 NO ENTRY FOR UNAUTHORISED PERSONNEL

 WEARING A PROTECTIVE MASK IS COMPULSORY

 WEARING EAR PROTECTORS IS COMPULSORY

 DANGER OF CRUSHING UPPER LIMBS

 WARNING: MOVING PARTS

 USERS OF VITAL ELECTRICAL AND ELECTRONIC APPARATUS MUST NEVER USE THE MACHINE

 PEOPLE WITH METAL PROSTHESES ARE NOT ALLOWED TO USE THE MACHINE

  DO NOT WEAR OR CARRY METAL OBJECTS, WATCHES OR MAGNETISED CARDS

  NOT TO BE USED BY UNAUTHORISED PERSONNEL

Symbol indicating separation of electrical and electronic appliances for refuse collection. The user is not allowed to dispose of these appliances as solid, mixed urban refuse, and must do it through authorised refuse collection centres.

GUARANTEE AND CONFORMITY

APPLIANCES FOR RESISTANCE WELDING FOR INDUSTRIAL AND PROFESSIONAL USE

Note: In the following text the term “spot welder” will be used.

1. GENERAL SAFETY RULES FOR RESISTANCE WELDING

The operator should be properly trained to use the spot welder safely and should be informed of the risks connected with resistance welding procedures, of related protection measures and of emergency procedures.

(Only for pneumatic cylinder-operated versions) The spot welder is provided with a main switch with emergency functions, fitted with a padlock for locking it in the “O” (open) position.

The padlock key should be handed over only and exclusively to an expert operator or to an operator who has been trained for the tasks assigned to him and has been warned of the possible hazards arising from this welding procedure and from neglectful use of the spot welder.

When the operator is absent the switch should be set to the “O” position, the padlock should be closed and the key removed.

Electrical installation should be carried out following accident-prevention legislation and standards.

• The spot welder should be connected only and exclusively to a power supply with the neutral conductor connected to earth.

• Make sure the power supply outlet is correctly connected to the earth protection.

• Do not use cables with worn or damaged insulation or with loosened connections.

• Use the spot welder in an ambient air temperature ranging from 5°C to 40°C, with relative humidity equal to 50% up to a temperature of 40°C, and 90% for temperatures up to 20°C.

• Do not use the spot welder in damp or wet environments or in the rain.

• The connection of the welding cables and any routine maintenance operations on the arms and/or electrodes must be carried out with the spot welder switched off and disconnected from the electric and pneumatic (if present) power supply networks.

• Pneumatic cylinder-operated spot welders should be locked with the main switch in the “O” position and the padlock closed.
  The same procedure must be respected for connection to the water mains or a cooling unit with closed circuit (liquid cooled spot welding machines) and in any case repair work (extraordinary maintenance).

• It is forbidden to use the equipment in environments comprising areas classed as being at risk of explosion because of the presence of gas, dust or mist.

• Do not weld on containers, receptacles or piping that contain or have contained flammable liquid or gas products.

• Do not operate on materials cleaned with cholorinated solvents or near such substances.

• Do not weld on pressurised containers.

• Remove all flammable substances from the work area (e.g. wood, paper, rags etc.).

• Allow newly-welded pieces to cool! Do not leave the piece near flammable substances.

• Make sure there is sufficient ventilation or provide means for removing welding fumes near the electrodes; a systematic approach is necessary to evaluate limits of exposure to the welding fumes depending on their composition and concentration and on the length of exposure.

• Always protect the eyes with suitable eye protectors.

• Wear protective gloves and clothing suitable for resistance welding work.

• Noise levels: If the personal daily exposure level (LEPd) is found to be greater than 85db(A) due to particularly intensive welding operations, wearing personal protection devices is compulsory.

• The flowing of spot welding currents generates electromagnetic fields (EMF) around the spot welding circuit.

Electromagnetic fields can interfere with certain medical equipment (e.g. Pacemakers, respiratory equipment, metallic prostheses etc.).
Adequate protective measures must be adopted for persons with these types of medical apparatus. For example, they must be forbidden access to the area in which spot welding machines are in operation.

This spot welder conforms to technical product standards for exclusive use in an industrial environment for professional purposes. It does not assure compliance with the basic limits relative to human exposure to electromagnetic fields in the domestic environment.

The operator must adopt the following procedures in order to reduce exposure to electromagnetic fields:

• Fasten the two spot welding cables (if present) as close together as possible.
• Keep head and trunk as far away as possible from the spot welding circuit.
• Never wind spot welding cables around the body.
• Avoid spot welding with the body within the spot welding circuit. Keep both cables on the same side of the body.
• Connect the spot welding current return cable to the piece being spot welded, as close as possible to the welding joint.
• Do not spot weld while close to, sitting on or leaning against the spot welder (keep at least 50 cm away from it).
• Do not leave objects in ferromagnetic material in proximity of the spot welding circuit.
• Minimum distance:
  – d= 3cm, f= 50cm (Fig. O);
  – d= 3cm, f= 50cm (Fig. P);
  – d= 30cm (Fig. Q);
  – d= 20cm (Fig. R) Studder.

Class A equipment:
This spot welder conforms to technical product standards for exclusive use in an industrial environment and for professional purposes. It does not assure compliance with electromagnetic compatibility in domestic dwellings and in premises directly connected to a low-voltage power supply system feeding buildings for domestic use.

INTENDED USE
The system was designed to be used only and exclusively in body shops to repair vehicles: it must be used for spot welding one or more steel plates with a low carbon content, having a shape and size that vary according to the work to be carried out.

RISK OF UPPER LIMBS BEING CRUSHED
DO NOT PLACE HANDS NEAR MOVING PARTS!
Both the operating method for the spot welder and the variability in shape and size of the piece being welded make it impossible to provide integrated protection against the danger of the upper limbs being crushed: fingers, hands, forearm.

The risk should be reduced by appropriate preventive measures:

• The operator should either be expert or trained in resistance welding procedures using this type of appliance.

• A risk evaluation must be performed for each type of work to be carried out; it is necessary to use equipment and masks that support and guide the piece to be worked in order to distance hands from the electrode danger area.

• When using a portable spot welder: solidly grasp the clamp with both hands placed on the relative handles; always keep hands away from the electrodes.

• 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.

• Only use electrodes that are recommended for the machine (see spare parts list) without altering their shape.

• 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. Allow newly-welded pieces to cool before touching them.

• 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.

• When using machines on wheels: disconnect the spot welder from the electric and pneumatic (if present) power supplies before moving the unit to another work area. Pay attention to obstacles and unevenness on the ground (for example cables and piping).

• UNINTENDED USE
  It is dangerous to use the spot welder for any purpose other than that for which it is intended (see INTENDED USE).

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

MUST BE CARRIED OUT WITH THE SPOT WELDER SWITCHED OFF AND DISCONNECTED FROM THE ELECTRIC AND PNEUMATIC (if present) POWER SUPPLY.

MAIN SWITCH LOCKED AT “O” WITH LOCK CLOSED AND KEY REMOVED in the models with PNEUMATIC CYLINDER movement).

STORAGE

• Place the machine and its accessories (with or without packaging) in closed areas.
• The relative humidity of the air must not exceed 80%.
• The environmental temperature must be between -15°C and 45°C.

If the machine is planned with liquid cooling and an ambient temperature under 0°C: use the anti-freeze liquid suggested by the manufacturer or completely empty the hydraulic circuit and the tank of liquid.

Always use adequate measures to protect the machine from humidity, dirt and corrosion.

2. INTRODUCTION AND GENERAL DESCRIPTION

2.1 INTRODUCTION
Mobile resistance welding system (spot welding machine) with digital microprocessor control. Equipped with quick couplings for the welding cables, it facilitates the immediate interchange of equipment, allowing numerous hot and spot welding operations on sheet metal, specifically in body shops and sectors with similar processing of sheet metal.

The spot welding machine is available in two versions:

• Air cooled version abbreviated to “A.F.”.
• Air and liquid cooled version (clamp) abbreviated to “AQUA”

Their main characteristics are:

• automatic selection of welding parameters;
• automatic recognition of the tool inserted;
• automatic, timed switch off command of air (liquid, if present) cooling;
• choice of the best spot welding current according to the mains power available;
• limitation of line overcurrent at insertion (insertion cosφ check);
• Backlit LCD display that shows the controls and the set parameters;

The spot welding machine can work on sheet metal in iron with low carbon content or on sheet metal in zinc-plated iron.

2.2 STANDARD ACCESSORIES

• Pneumatic clamp with air cooled cables (120mm arms and standard electrodes): A.F. version
• Pneumatic clamp with liquid cooled cables (120 mm arms): AQUA version;
• Unit integrated for closed circuit liquid cooling: AQUA VERSION;
• Pressure reducer-filter unit with gauge and solenoid valve (compressed air supply);
• Integrated trolley;

2.3 OPTIONAL ACCESSORIES

• Pairs of arms with electrodes in various lengths and/or shapes for the pneumatic clamp with air/liquid cooling (see spare parts list).
• Manual clamp with cable pair.
• Pair of arms with electrodes in various lengths and/or shapes for the manual clamp (see spare parts list).
• Manual “C” clamp with cables.
• Studder kit with separate earth cable and accessories box.
• Double spot gun, air cooled, with cables.
• Studder kit without trigger, with earth cable (contact welding without using button).
• Support pole kit with weight unloader for clamp.

3. TECHNICAL DATA

3.1 DATA PLATE (Fig. A)
The main data required for spot welding machine use and performance are given in the characteristics plate and have the following meaning.

1. Number of phases and frequency of the power supply line.
2.  Power supply voltage.
3. Network power at permanent regime (100%).
4. Nominal network power with 50% intermittence ratio.
5. Maximum no-load voltage at the electrodes.
6. Maximum current with electrodes in short-circuit.
7. Secondary power at permanent regime (100%).
8. Gauge and length of the arms (standard).
9. Minimum and maximum force adjustable from the electrodes.
10. Nominal pressure of the compressed air source.
11. Compressed air source pressure necessary for obtaining maximum electrode force.
12. Cooling liquid capacity.
13. Cooling liquid nominal pressure drop.
14. Equipment mass.
15. Safety symbols, the meaning of which is given in chapter 1 “General resistance welding safety”.

Note: The meanings of the symbols and numbers on the example plate are indicative; the exact technical values of your spot welding machine can be found directly on the spot welding machine plate.

3.2 OTHER TECHNICAL DATA
3.2.1 Spot welding machine

3.2.2 Cooling group (GRA)

General characteristics

• Maximum pressure (pmax) : 3 bar
• Cooling power (P @ 1l/min.) : 1 kW
• Tank capacity : 8 l
• Cooling liquid : coolant

4. SPOT WELDING MACHINE DESCRIPTION

4.1 THE SPOT WELDING MACHINE AND ITS MAIN COMPONENTS (Fig. B)

At the front:

1. Control panel;
2. Clamp cable attachment (ATLAS);
3. Quick coupling for air hose connection;
4. Rapid hold to attach the cooling tubes (AQUA version);
5. 14-pin connector;

At the back:
6 – Main switch;
7 – Power cable input;
8 – Pressure regulator, gauge and air input filter unit;
9 – Cooling unit tank tap (AQUA version);
10 – GRA liquid level (AQUA version);
11 – GRA air valve (AQUA version).

4.2 CONTROL AND ADJUSTMENT DEVICES
4.2.1 Control panel (Fig. C)

4.2.2 Pressure regulator and gauge unit (fig. B-8)
Adjusts the pressure applied to the pneumatic clamp electrodes using the adjustment knob and modifies the clamp cooling air flow where programmed. We recommend setting the maximum pressure below 8 bar.

4.3 SAFETY FUNCTIONS AND INTERLOCK
4.3.1 Safeguards and alarms (TAB. 2)
a) Thermostatic safeguard:
Intervenes if the spot welding machine overheats because the cooling liquid is missing or is insufficient, or due to a work cycle that exceeds the permitted limit.
The icon on the display (fig. C-17) switches on to signal intervention and with:
AL1 = machine thermal alarm.
AL2 = clamp, studder thermal alarm.
EFFECT: movement blocked, electrodes opened (cylinder at discharge); current blocked (welding inhibited).
RESET: manual (use the “START” push-button when the permitted temperature limits are reached – the [symbol] icon switches off).
b) Main switch:
– Position “O” = open and lockable (see chapter 1).

ATTENTION! When at position “O” the internal clamps L1+L2(N) that connect the power cable are being powered.
– Position “I” = closed: stapler being powered but not operating (STAND BY – the “START” push-button must be pressed).
– Emergency function
With the spot welding operating, the opening (pos. “I”=>pos “O”) determines a stop in safety conditions:
– current inhibited;
– electrodes open (cylinder at discharge);
– automatic restarting inhibited.

ATTENTION! PERIODICALLY MAKE SURE THE SAFETY STOP OPERATES CORRECTLY.
c) Cooling unit safety (AQUA version)
This is triggered in the event of no or loss of cooling liquid pressure;
The operation is signalled on the display with AL 9 = no liquid alarm.
EFFECT: movement blocked, electrodes opened (cylinder at discharge); current blocked (welding inhibited).
RESET: top-up the cooling liquid then switch the machine off and on again (see also Par. 5.6 “cooling unit configuration”).
d) Over and under voltage protection
The intervention is signalled on the display by AL 3 = overvoltage alarm and by AL
4 = undervoltage alarm.
EFFECT: movement blocked, electrodes opened (cylinder at discharge); current blocked (welding inhibited).
RESET: manual (use the “START” push-button).
e) “START” push-button (Fig. C-5).
This push-button must be pressed to control welding in each of the following conditions:
– when the master switch is switched off (pos “O” => pos “I”);
– each time the safety/protection devices cut in;
– after the power supply (electricity and compressed air) has been returned after being disconnected upstream or after a failure;

ATTENTION! PERIODICALLY MAKE SURE SAFE STARTING OPERATES CORRECTLY.

5. INSTALLATION
ATTENTION! CARRY OUT ALL INSTALLATION AND ELECTRICAL AND PNEUMATIC CONNECTION OPERATIONS WITH THE SPOT WELDING MACHINE RIGOROUSLY SWITCHED OFF AND DISCONNECTED FROM THE MAINS.
THE ELECTRICAL AND PNEUMATIC CONNECTIONS MUST ONLY BE CARRIED OUT BY EXPERT OR QUALIFIED TECHNICIANS.
5.1 PREPARATION
Unpack the spot welding machine, and assemble the detached parts that are in the packaging as indicated in this chapter (Fig. D).
5.2 LIFTING (Fig. E).
The spot welding machine must be lifted with a double cable and hooks that are of a suitable size for the machine weight, using the relative M8 rings.
Slinging the spot welding machine using means other than those indicated is FORBIDDEN.

5.3 POSITION
Reserve a space in the installation area that is large enough and without obstacles for guaranteeing access to the control panel, the main switch and the work area in complete safety.
Make sure there are no obstacles near the areas where the cooling air enters and exits, ensuring that conductive power, corrosive vapour, humidity, etc. cannot be sucked in.

Place the spot welding machine on a surface of homogeneous material that is flat and compact, and suitable for supporting the weight (see “technical data”) to prevent the danger of toppling or dangerous movements.

5.4 CONNECTION TO THE POWER NETWORK
5.4.1 Warnings
Before making any electrical connection, make sure the spot welding machine plate data correspond with the mains voltage and frequency available in the installation area.
The spot welding machine must only be connected to a power supply system with neutral conductor connected to earth.
To guarantee protection against indirect contact, use residual-current devices of the following type:

– The spot welding machine does not meet the requirements of the IEC/EN 61000- 3-12 directive.
If it is connected to a public power grid, the installer or user must make sure that the welding machine can be connected (if necessary consult the utility company).

5.4.2 Network plug and outlet
Connect a normalised plug (3P + E: only 2 poles are used; INTERPHASE connection!) of suitable capacity to the power supply plug and prepare a mains socket that is protected by fuses or by a circuit breaker; the relative earth terminal must be connected to the earth conductor (yellow-green) of the power line.

The capacity and intervention characteristic of the fuses and circuit breaker switch are given in the “TECHNICAL DATA” paragraph.

Should several spot welding machines be installed, distribute the power supply cyclically between the three phases so as to create a more balanced load, for example:
spot welding machine 1: L1-L2 power supply;
spot welding machine 2: L2-L3 power supply;
spot welding machine 3: L3-L1 power supply.

ATTENTION! Failure to comply with the above rules renders the safety system (class I) ineffective, with resulting serious risks for people (e.g. electric shock) and for property (e.g. fire).
5.5 PNEUMATIC CONNECTION
– Prepare a compressed air line with a working pressure of 8 bar.
– Assemble one of the compressed air connections onto the reducer filter unit, to adapt to the connections available in the installation area.
5.6 PREPARATION OF THE COOLING UNIT (AQUA Version)

ATTENTION! The filling operations should always be performed with the machine switched off and disconnected from the mains supply.
Never use polypropylene based antifreeze liquids.
Only use the coolant recommended by the manufacturer.

• Open the discharge valve (FIG. B-11).
• Fill the tank with coolant using the nozzle (Fig. B-9): capacity of the tank = 8 l; pay attention to avoid excess leakage of coolant at the end of filling.
• Close the tank cap.
• Close the discharge valve.

5.7 PNEUMATIC CLAMP CONNECTION (Fig. F)
– Connect the ATLAS plugs to the specific sockets.

WARNING! The cable “ATLAS” connect to the panel sockets with clockwise rotation: check cable torsion does not tend to loosen the connection; if so, rotate the cable “ATLAS” anti-clockwise before inserting them and fasten them on the panel.

• Connect the two air plugs in the specific spot welding machine sockets: small plug (air cooling); large plug (pneumatic gun control air).
• AQUA version only, connect the cooling tubes of the clamp to the specific quick couplings of the machine, respecting the colours: blue tube on blue socket, red tube on red socket.
• Insert the control cable connector into the relative 14 pin socket.

5.8 MANUAL CLAMP AND STUDDER GUN CONNECTION WITH EARTH CABLE (FIG. G)
– Connect the ATLAS plugs with the relative sockets; only for the studder: connect the gun and the earth to the relative ATLAS, as shown in the machine screen printing.
– Insert the control cable connector into the relative socket.
The compressed air vents do not have to be connected.

5.9 DOUBLE TIP CLAMP CONNECTION
– Proceed in the same manner as with the pneumatic clamp, using only the cooling air plug.

6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
Before carrying out any spot welding operation, a series of checks and adjustments must be made with the main switch at “O” and the padlock closed.

• Make sure the electrical connection has been carried out correctly as indicated in the previous instructions.

• Check the compressed air connection; connect the supply hose to the pneumatic network, adjust the pressure using the reduction knob until a value of between 4 and 8 bar (60 – 120 psi), according to the thickness of the plate to be spot welded, can be read on the gauge.

• Place a shim of the same thickness between the electrodes; make sure the arms, which have manually been brought closer, are parallel and the electrodes are aligned (coinciding tips).
  Adjust if necessary, by loosening the locking screws of the arms that can be rotated or moved in both directions along their axis; after adjusting, carefully tighten the locking screws.

• The work stroke can be adjusted using the electrodes. Always remember that a stroke that is 6-8 mm longer than the spot welding position is necessary, to exercise the required force on the workpiece.
  FIG. I shows a “standard” adjustment of the electrode position with clamp resting.

• Using the manual clamp, consider that the power of the electrodes during the spot welding phase can be adjusted with the knurled nut (FIG. L); turn it clockwise (to the right) to increase the force proportional to the increase in the sheet thickness, selecting adjustments that make it possible to close the clamp (and relative micro switch activation) using very limited power. The correct position of the arms and electrodes is the same as that of the pneumatic clamp.

6.2 PARAMETER ADJUSTMENT (in spot welding)
The parameters that determine the diameter (section) and mechanical seal of the spot are:
– Force at the electrode.
– Spot welding current.
– Spot welding time.
If there is no specific experience, it is a good idea to carry out some spot welding tests using sheets of the same quality and thickness as those to be worked on.
Adjust the electrode power using the pressure adjusters ad indicated in 6.1, selecting medium-high values.

The pulse period is automatic, and as such does not need to be adjusted.

IMPORTANT: If the selected thickness “flashes”, this means that the default AUTO or initially programmed spot welding current is insufficient for spot welding in a satisfactory manner; compatibly with the power available in the installation area, reprogram the spot welding machine at maximum current (see paragraph 4.2.1): high spot welding currents combined with reduced times give better spot characteristics.

The spot is considered as correct when the nugget of the weld point can be extracted from one of the two sheets when tension is tested.

Using the supplied extractor (POS. 1, Fig. M)
Washer hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 3, Fig. M) onto the body of the electrode (POS. 1, Fig. M). Hook the washer (POS. 13, Fig. M), spot welded as described previously, and begin drawing. When finished, rotate the extractor by 90° to detach the washer.

Plug hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 2, Fig. M) onto the body of the electrode (POS. 1, Fig. M). Make the plug enter (POS. 15- 16, Fig. M), after spot welding it as described previously, the spindle (POS. 1, Fig. M) keeping the terminal tightened towards the extractor (POS. 2, Fig. M). When completely introduced, release the spindle and start drawing. When finished, pull the spindle towards the hammer to remove the plug.

STUDDER TOUCH
The studder can be supplied in the version without push-button.
To spot weld, just place the tool against the piece to be welded, which is connected to the earth cable: after a few moments, the machine recognises the contact and starts the stop automatically.

ATTENTION: DO NOT PLACE THE STUDDER ON THE PIECE WITHOUT WELDING!

7. MAINTENANCE

WARNING! BEFORE CARRYING OUT MAINTENANCE, MAKE SURE
THE MACHINE IS OFF AND DISCONNECTED FROM THE MAINS.
The switch must be locked at “O” using the supplied lock.

7.1 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE WORK CAN BE PERFORMED BY THE OPERATOR.

• adapt/restore the diameter and profile of the tip of the electrode;
• replace the electrodes and arms;
• control alignment of the electrodes;
• control cooling of the cables and clamp;
• exhaust condensation from the compressed air intake filter.
• control the power supply cable is intact on the spot welding machine and the clamp AQUA version ONLY:
• periodic control of the level of the cooling liquid tank.
• periodic control of the total absence of liquid leaks.
• change the coolant every 6 months.

7.2 SPECIAL MAINTENANCE
SPECIAL MAINTENANCE MUST ONLY BE CARRIED OUT BY TECHNICIANS WHO ARE EXPERT OR QUALIFIED IN AN ELECTRIC-MECHANICAL AMBIT.

WARNING! BEFORE REMOVING THE SPOT WELDER OR CLAMP PANELS AND LOOKING INSIDE, MAKE SURE THE SPOT WELDER IS OFF AND DISCONNECTED FROM THE ELECTRIC AND PNEUMATIC (if present) POWER SUPPLIES.
Carrying out checks while the inside of the spot welder is live can cause serious electric shock due to direct contact with live parts and/or injury due to direct contact with moving parts.

Periodically and as frequently as required by the use and environmental conditions, inspect inside the spot welder and clamp and remove the dust and metal particles that have deposited on the transformer, diode module, power terminal board, etc. using a blast of dry compressed air (max. 5 bar).
Do not direct the jet of compressed air onto the electronic circuit board; if necessary clean with a very soft brush or suitable solvents.

At the same time:

• Make sure the wiring does not show signs of insulation damage or loose-oxidised connections.
• Make sure the screws that connect the transformer secondary with the output bars / wires are tight and that there are no signs of oxidation or overheating.

7.2.1 Interventions on the liquid cooling unit (AQUA version only)
In case of:
– excess need to restore the liquid level in the tank;
– excess frequency of alarm 9 activation;
– liquid leaks;

you should proceed to check for any problems inside the cooling unit.
Always refer to section 7.2 for overall warnings and however having disconnected the spot welding machine from the power supply mains, proceed with removing the side panel (FIG. N).

Check there are no leaks both on connections and tubing. If liquid is leaking, replace the damaged part. Eliminate the liquid residue possibly leaked during maintenance and close the side panel again.

Then proceed to reset the spot welding machine using the appropriate information indicated in paragraph 6 (Spot welding).

8. TROUBLESHOOTING

IN THE EVENT OF UNSATISFACTORY OPERATION, AND BEFORE CARRYING OUT THE MOST SYSTEMATIC CHECKS OR CONTACTING YOUR SUPPORT CENTRE, CHECK:

• With the spot welding machine main switch closed (pos. “I”) the display is ON; if this is not the case, the problem is in the power line (cables, plug and socket, fuses, excessive voltage drop etc.).
• The display does not have any alarm signals (see TAB. 2): once the alarm stops, press “START” to re-activate the spot welding machine; check correct circulation of the cooling liquid and, if necessary, reduce the intermittence ratio of the work cycle.
• The elements of the secondary circuit parts (arm-holder – arms – electrode holder moulds -cables) are not working efficiently due to loosened or rusted screws.
• The welding parameters are adequate for the work being done.
• Having carried out maintenance and repairs, restore the connections and wiring as they were originally, taking care they do not obstruct any moving parts or parts which can reach high temperatures. Wrap all the conductors as they were originally, taking care to keep the high voltage primary connections clearly separated from the secondary low voltage connections.
  Use all the washers and original screws to close the framework up again.

GUARANTEE
The manufacturer guarantees proper operation of the machines and undertakes to replace free of charge any parts should they be damaged due to poor quality of materials or manufacturing defects within 12 months of the date of commissioning of the machine, when proven by certification. Returned machines, also under guarantee, should be dispatched CARRIAGE PAID and will be returned CARRIAGE FORWARD. This with the exception of, as decreed, machines considered as consumer goods according to European directive 1999/44/EC, only when sold in member states of the EU. The guarantee certificate is only valid when accompanied by an official receipt or delivery note. Problems arising from improper use, tampering or negligence are excluded from the guarantee. Furthermore, the manufacturer declines any liability for all direct or indirect damages.

CERTIFICATE OF GUARANTEE

Date of buying

Sales company (Name and Signature)

The product is in compliance with:

DIRECTIVES

LVD 2014/35/EU + Amdt.

EMC 2014/30/EU + Amdt.

RoHS 2011/65/EU + Amdt.

MD 2006/42/EC + Amdt.

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