TELWIN 955249 Spot Welder Instruction Manual

TELWIN 955249 Spot Welder

Product Information

• Product Name: Aparelho de soldar por pontos Puntlasmachine
• Product Code: 955249

Product Usage Instructions

To ensure safe and proper usage of the Aparelho de soldar por pontos Puntlasmachine, please follow these instructions:

1. Before using the product, make sure to wear protective gloves.
2. Avoid using the product in areas where there is a danger of fire. Take necessary precautions and keep flammable materials away from the product.
3. Be cautious of non-ionizing radiation emitted by the product. Take necessary measures to protect yourself from exposure.
4. The product is suitable for materials that can undergo a recovery/recycling process. Dispose of the product according to local regulations and do not dispose of it as solid, mixed urban refuse.
5. Do not use the product if you are wearing metal prosthetics or have medical electronic devices. Consult a professional before using the product in such cases.
6. Avoid using the product near metal objects, watches, or magnetic cards.
7. Do not allow unauthorized personnel to use the product.

By following these instructions, you can ensure safe and effective usage of the Apareon de solder porpitas Puntillas machine.

EXPLANATION OF DANGER, MANDATORY AND PROHIBITION SIGNS.

A RECOVERY/RECYCLING PROCESS
| 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 center’s.

GUARANTEE AND CONFORMITY

EQUIPMENT FOR RESISTANCE WELDING FOR PROFESSIONAL AND INDUSTRIAL USE.
NB: In the text that follows, the term “spot welding machine” and “gun” will be used.

GENERAL SAFETY FOR RESISTANCE WELDING

The operator must be sufficiently trained on safe use of the spot welding machine and informed on the risks relating to resistance welding procedures, the relevant safety measures and the emergency procedures.

• Use the spot welding machine at an air ambient temperature between 5°C and 40°C and a relative humidity equal to 50% up to temperatures of 40°C and 90% for temperatures up to 20°C.

• Do not use the spot welding machine in damp or wet environments or under the rain.

• Any routine maintenance and/or replacement intervention of the electrodes must be carried out with the spot welding machine off.

• It is strictly forbidden to use the equipment in environments with zones classified as at risk of explosion due to the presence of gas, dust or mist.

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• Do not weld on containers or tubing containing or having contained flammable liquid or gaseous products.

• Avoid working on materials cleaned with chlorinated solvents or near said substances.

• Do not weld on pressure containers.

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

• Allow the just welded piece to cool! Do not position the piece near flammable substances.

• Ensure adequate air exchange or devices suitable to remove the welding fumes near the electrodes; a systematic approach is necessary to assess the welding fume exposure limits based on their composition, concentration and duration of exposure.

  ---

• Always protect eyes with specific safety goggles.

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

• Noise: If due to particularly intense welding operations, a daily level of exposure for personnel (LEPd) equal or over 85db(A) is verified, use is compulsory of personal protective equipment.
  

• Passage of the spot welding current creates electromagnetic fields (EMF) localized around the spot welding circuit.

The electromagnetic fields can interfere with certain medical equipment (e.g. pace-maker, breathing apparatuses, metal prostheses etc.). Adequate safety measures must be taken for wearers of such equipment. For example, access to the spot welding machine use area should be prevented. This spot welding machine complies with the technical standards for products to be exclusively used in industrial environments for professional purposes. Compliance with the basic limits of human exposure to electromagnetic fields in domestic environments is not guaranteed. Even if the equipment was designed and manufactured to reduce electromagnetic field emissions to the minimum, the operator must use the following procedures to reduce exposure to a minimum:

• Keep head and torso as far as possible from the spot welding circuit.
• Never leave iron magnetic objects near the spot welding circuit.
• Do not spot weld with your body near the gun
  • minimum distance d= 20cm (Fig. G).

SPECIAL WARNINGS AND SAFETY PRECAUTIONS ON THE USE OF THE LITHIUM BATTERIES INSIDE THE EQUIPMENT
Failure to observe the following rules can cause breakage, overheating, bulging, fire outbreak or explosion of the battery

• Keep batteries out of reach of children
• Never open the battery casing under any circumstances.
• Do not modify or tamper with the battery casing.
• Do not throw the battery or cause strong impacts.
• Do not perforate the battery casing with drill bits, do not hit it with a hammer or stand on it.
• Do not charge the battery in direct sunlight, near flames or in similar conditions.
• Do not use the spot welding machine or position it in the vicinity of heaters, near flames or in other hot areas.
• Do not position the battery inside stoves, microwave ovens etc.
• Do not throw the battery into a fire or heat it up.
• Do not try to invert the positive “+” and negative “-” terminal poles when inserting the battery in the gun.
• Do not short circuit the battery terminals.
• Do not keep the batteries in bulk in a box or drawer where they could mutually short circuit or be short circuited by other metal objects.
• Use and always preserve the lithium-ion battery packs correctly. On the contrary, you could cause fires or explosions or negatively influence the performance of the spot welding machine.
• Do not remove a battery from the original packaging when not necessary for use.
• Observe the plus (+) and minus (-) signs on the cell, on the battery and on the equipment and ensure correct use.
• Load the battery using the power supply unit for recharging supplied.
• Do not use cells or batteries not designed for use with the equipment.
• Always purchase the battery recommended by the manufacturer of the device for the equipment.
• Use the cell or the battery alone in the application for which it was designed.
• If during use, charge or storage of the battery strange odours are emitted, the battery heats or deforms, it must be removed from the gun and no longer used.
• Do not wet the battery.
• Keep cells and batteries clean and dry.
• Clean the terminals of the cell or the battery with a dry, clean cloth if dirty.
• Dispose of the battery correctly (see paragraph on “disposal of the battery”)
• If the battery leaks acid or emits strange smells, immediately move it away from any heat sources or open burning flames.
• In case of contact of battery acid on the skin or clothing, rinse with plenty of water.
• In case of contact of battery acid with the eyes, rinse immediately with plenty of water and call a doctor.

Keep this manual.

• The manual should be read, paying attention to all the warnings and safety precautions to be taken when using and maintaining the device, the list of components and all technical specifications.
• Please keep this manual in a secure and dry place for future reference.

INTENDED USE
The equipment was designed for the exclusive use in bodyshops for vehicle repair: it must be used for manual traction of sheet metal and to spot weld pins and slots (varying in shape and dimensions according to the work to carry out) on the sheet metal with low carbon content.

RESIDUAL RISKS

The operating mode of the spot welding machine foresees a button command to start welding; there is a risk of start-up by involuntarily resting the electrodes of the gun on the sheet metal! This can also cause electric arcs and unwanted sparks with resulting risk of damage and personal injury.
When the work has been completed, place the spot welding machine on an insulating surface and switch off!

• RISK OF BURNS
  • Some parts of the spot welding machine (electrodes, slots, pins and adjacent areas) can reach temperatures over 65°C: adequate protective clothing should be worn. Allow the just welded piece to cool before touching it!
• RISK OF FALLING
  • Position the spot welding machine on a horizontal surface of the insulating material; on the contrary, the mobile support surfaces and the tilted and smooth surfaces increase the danger of falling.
• MISUSE
  • Use of the spot welding machine is dangerous for any work other than planned use (see PLANNED USE).
• STORAGE
  • Position the machine and its accessories (with or without packaging) in closed premises.
  • The relative humidity of the air must not be over 80%.
  • The ambient temperature must be between 0°C and 45°C.

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

INTRODUCTION AND GENERAL DESCRIPTION

INTRODUCTION

• This spot welding machine is a source of battery-powered mobile energy, created specifically to repair dents on the bodywork of a vehicle, via manual traction of the specific electrode (tip) welded on the sheet metal.
• A lithium ion battery is used; this has allowed construction of equipment for spot welding with extremely contained volume and weight, facilitating handling and transport.
• No power cable or earth cable allows work to be carried out in any position.
• The duration of the lithium battery is proportionate to the type of use and allows repairs to be completed; use with battery initially charged 100% (three leds on).
• The battery can be recharged both with the battery connected to the gun and separately.

STANDARD ACCESSORIES

• Earth electrode.
• Electrode for traction (tip).
• Removable battery.
• Recharging power supply unit.
• Case.

For further details please consult the latest catalogue.

OPTIONAL ACCESSORIES

• Electrode holder for slotted pin.
• Variable consumable electrodes.
• Spare battery.

For other accessories please consult the latest catalogue.

TECHNICAL SPECIFICATIONS

DATA PLATE (Fig. A)

The main data on use and performance of the spot welding machine is summarised on the rating plate and has the following meaning.

1. Rated voltage no load.
2. Maximum short circuit current.
3. Permanent fully operational rated current (100%).
4. Symbols referring to safety whose meaning is outlined in chapter 1 “General safety for resistance welding”.

NB: The rating plate shown is an example to explain the meanings of the symbols and figures; the exact technical specifications for the spot welding machine should be taken directly from the rating plate on the spot welding machine.

OTHER TECHNICAL DATA General characteristics

• Protection rating of casing: IP 20
• Weight: 2.3kg
• Dimensions (LxWxH): 480x85x220 mm

Battery

• Type: Lithium polymer rechargeable battery
• Rated voltage: 7.4V
• Rated capacity: 8Ah
• Storage temperature: 0°C÷45°C max
• Recharge time: 4h max

Recharging power supply unit

• Power supply voltage and frequency: 100V-240V ~ 2ph 50/60 Hz
• Output rated current:  2A
• Protection rating of casing: IP 20

DESCRIPTION OF THE SPOT WELDING MACHINE

GUN AND MAIN COMPONENTS GROUP (Fig. B)

At the top

1. Control panel, formed by:

2. Spot duration level led;

3. Button with multiple functions: keep pressed for 3 seconds to switch on the gun, for 5 seconds to switch off;

4. Battery charge level;

5. Alarm led.
   At the bottom

6. Recharge inlet.

7. Red led, battery charging.

8. Green led, power supply unit connected.
   On the side

9. Spot control button.

10. Earth electrode.

11. Tip electrode (point).

12. Battery lock and unlock.

CONTROL, ADJUSTMENT AND SIGNALLING DEVICES

Control panel (Fig. B-1)

• The button (Fig. B-3) allows the spot welding machine to be switched on and off to switch off, the button must be pressed until all the leds flash (Fig. B-2), then release the button.
• With the machine on, the button (Fig. B-3) allows the duration to be set of the spot, choosing from 5 available levels: the leds (Fig. B-2) indicate the level set (increasing upwards).
• The three segments (Fig. B-4) allow monitoring of the battery charge: when they are on, the battery is completely charged, when the first section flashes and the yellow led (Fig. B- 5) stays on, it means the battery must be recharged before using the gun.
• The led in Figure B-8 indicates the power supply unit is connected correctly for recharge.
• The led in Figure B-7 indicates the battery is charging. If off, recharging has terminated.

SAFETY FUNCTIONS

Protection and alarms

1. Thermal protection
   • This is triggered by overheating of the spot welding machine due to a work cycle that exceeds the permitted threshold.
   • Intervention is signalled by the slow flashing (every second) of the YELLOW LED (Fig. B-5). In this condition, spot welding is not permitted;
   • Reset: Automatic. Wait for the spot welding machine to cool.
2. Poor contact alarm
   • This is triggered if you want to spot weld without good electrical contact between the gun electrodes (e.g. insulated sheet metal, gun raised from piece, etc.).
   • Intervention is signalled by intermittent, rapid switch on of the YELLOW LED (Fig. B-5) when the spot welding trigger is pressed (Fig. B-9).
   • Reset: Clean the sheet metal to weld, the electrodes of the gun and make precise contact.
3. Charge anomaly alarm
   • This is triggered when an anomaly is found in the power supply voltage or in the battery voltage (led in Fig. B-7 flashing).
   • Reset: Resetting operation takes place once the source of error has been eliminated (e.g. replace the power supply unit, replace the battery).

ASSEMBLY AND PREPARATION FOR USE

SET-UP

• Unpacking the spot welding machine, assemble the detached parts contained in the packaging, as outlined in Fig. C.
• Install the charged battery, sliding it in the grip of the gun to end of stroke (Fig. C-1).
• Fasten the locking screw supplied with the specific key (Fig. C-2).
• To disconnect the battery from the gun, work in reverse order.

RECHARGE (Fig. B)

• The battery can be recharged if installed on the gun (Fig. B), or separately.
• Connect the power supply unit to recharge to the power supply unit 100V÷240V 50/60Hz; connect the power supply unit cable to the specific recharge socket (Fig. B-6).
• During the charging phase, the led in Figure B-7 switches on together with the led in Figure B-8. When charging is complete, the led in Figure B-7 switches off.

ATTENTION!

• If the battery is connected to the spot welding machine and is recharging, spot welding cannot take place. Disconnect the power supply unit for recharging before using the gun to spot weld.
• Charge the battery before first use or if not used for more than one week. Always recharge the battery before it is completely flat.
• Unused batteries must be recharged at least once a year.

USE AREA

• Reserve a sufficiently ample zone for the use area to guarantee accessibility to the control panel and the spot welding command in complete safety.
• Move all flammable substances away from the work area (e.g. wood, paper, rags, etc.).

WELDING (Spot welding)

PRELIMINARY OPERATIONS
Before carrying out any spot welding operation, correct fastening must be checked of the battery, the electrodes or the pin/slot holder (Fig. C) and check all the electrodes and the metal piece are very clean.

ATTENTION!

• DO NOT SPOT WELD ON SHEET METAL IN DIRECT CONTACT WITH FLAMMABLE MATERIALS!
• AVOID RESTING THE TOOL NOT IN USE ON THE PIECE TO WORK!
• ALWAYS BRING THE TOOL NOT IN USE ON A STABLE AND NON-CONDUCTIVE SURFACE!

PARAMETERS ADJUSTMENT (in spot welding)
The parameters used to determine penetration and mechanical sealing of the pin/slot are:

• Force exerted by the electrode.
• Spot welding current.
• Spot welding time.

The particular work of spot welding which is carried out with this gun only requires adjustment of the spot welding time and pressure exertion necessary on the gun so that good contact is made between the electrodes and the piece, however without exaggerating; the electrodes have well-determined stroke and there is no need to press too much on the gun to avoid going to stop; in this way, the pressure exerted will be optimal. If lacking specific experience, some spot welding tests should be carried out using sheet metal thicknesses of the same quality and thickness of the work to carry out.

PROCEDURE (Fig. D)

Switch on and off

• Switch the spot welding machine on by keeping the button pressed (Fig. B-3) for 3 seconds then release.
• To switch on the spot welding machine, wait for timeout (preset inactivity time) or keep the button pressed (Fig. B-3) for 5 seconds, then release.

Spot welding and simultaneous traction of the sheet metal
This particular work uses the sharpened electrode (tip) to adhere to the sheet metal to repair; after spotting, traction takes place by taking advantage of the earth of the gun as blowback.

1. Screw in the specifically sharpened tip in the planned compartment.

2. Position the gun so that the electrodes are perpendicular to the sheet metal (Fig. D-1).

3. Exert force in the direction of the electrodes to obtain good contact without going to stop (Fig. D-2).

4. Press and release the spot welding button (Fig. B-9) to weld the tip of the electrode to the sheet metal (Fig. D-3).

5. Lightly press the gun towards the sheet metal to send the electrodes to stop and thereby have the maximum stroke available when lifting the gun (Fig. D-4).

6. Hold the gun using the specific grips (Fig. D-5).
   

7. Quickly lift the gun perpendicular to the sheet metal in such a way to exert traction on the sheet metal, without torsion (Fig. D-6).
   

8. Repeat the operation from point e) until the desired traction of the sheet metal is obtained. To detach the welded electrode, simply turn the gun slightly to obtain torsion of the weld and then detach the electrode.

ATTENTION!

• This particular work requires certain practice and a bit of attention: do not press the gun too hard on the sheet metal to avoid damaging it!
• If the electrode should detach too early, increase the spot welding time and/or revive the tip of the electrode and/or execute traction perpendicular to the sheet metal.

Spot welding of the pins/slots (optional)

1. Insert the pin/slot in the appropriate electrode holder (Fig. E).
   

2. Position the gun so that the electrodes are perpendicular to the sheet metal (Fig. F-1).

3. Exert force in the direction of the electrodes to obtain good contact without going to stop (Fig. F-2).

4. Press and release the spot welding button (Fig. B-9) to weld the tip of the pin/slot to the sheet metal (Fig. F-3).

5. Lift the gun perpendicular to the sheet metal to remove without torsion, the pin/slot from the electrode holder (Fig. F-4).

6. Repeat the operation from point a).
   

ATTENTION!
When the work has been completed, place the tools on an insulating surface and switch off the machine!

MAINTENANCE

ATTENTION! BEFORE CARRYING OUT THE MAINTENANCE OPERATIONS, ENSURE THE SPOT WELDING MACHINE IS OFF.

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

• Adapt/restore the tip profile of the electrode.
• Replace the electrodes / electrode holder.
• Check the electrodes / electrode holder are intact.
• Check the gun and the battery are intact.
• Check fastenings.
• Check the battery and its correct installation.

EXTRAORDINARY MAINTENANCE
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT ONLY AND EXCLUSIVELY BY SKILLED OR AUTHORISED ELECTRICAL-MECHANICAL TECHNICIANS.

WARNING! BEFORE REMOVING THE SHELLS OF THE GUN AND ACCESSING INSIDE, ENSURE IT IS OFF AND THAT THE BATTERY IS DISCONNECTED AND EVERYTHING IS REMOVED.

Periodically, and however frequently, based on the use and environmental conditions, inspect inside the spot welding machine to remove the dust and metallic particles deposited on the components, using a dry compressed air jet (max 5 bar). Avoid directing the compressed air jet on the electronic cards; clean them with a very soft brush or appropriate solvents.
Take the opportunity to

• Check the cabling has no damage on insulation or loose-oxidized connections.
• Check the electrical connection screws.
• Check intactness of the fuse and its power connections.
• Check correct connection to the power cable of the temperature sensor.

BATTERY DISMANTLING
The exhausted battery of the spot welding machine should be recycled. In some cases, this is compulsory. Contact the local special refuse authority for information on recycling.

WARNING!

• Do not burn the battery to dispose of it. This could cause an explosion.
• Before disposing of the battery, apply insulating tape to the bare terminals to prevent shorting.
• Do not expose the battery to intense heat or fire as this could cause an explosion.

TROUBLESHOOTING

IN THE EVENT OF UNSATISFACTORY OPERATION AND BEFORE CARRYING OUT MORE SYSTEMATIC CHECKS OR CONTACTING YOUR SUPPORT CENTRE, CHECK THE MOST COMMON PROBLEMS, LISTED HERE, AND THE RELEVANT SOLUTIONS

• The spot welding machine does not switch on.
  Possible solution

• Check battery connection is correct.

• Check the start button.

  • The spot welding machine switches off by itself.
    Possible solution

  • The machine “timeout” has triggered which switched off the power supply after a certain period of inactivity. Press the start button.

• The spot welding machine is not spot welding properly.
  Possible solution

  • Recharge the battery.
  • Clean the electrodes and the contact zones with the sheet metal
  • Maintain the correct position, orthogonal to the sheet metal, during spot welding.
  • Do not exert excessive pressure on the piece to weld.

• The spot welding machine is not spot welding.
  Possible solution (see protection and alarms paragraph)

  • Check proper contact of the electrodes on the sheet metal: yellow alarm led off.
  • The battery is damaged; replace the battery.
  • The internal fuse is broken; contact an authorised support centre.

• The spot welding machine is blocked with the yellow alarm led flashes slowly.
  Possible solution (see protection and alarms paragraph)

  • The thermal alarm has triggered: leave the spot welding machine to cool, then switch the gun off and back on again.

• The spot welding machine does not repeat the spot and the yellow alarm led flashes quickly.
  Possible solution (see protection and alarms paragraph)

  • The spot welding machine does not allow a second spot on the one already welded: raise the gun off the piece and reposition the electrodes on the sheet metal.

• The battery is not charging.
  Possible solution (see protection and alarms paragraph)

  • The power supply unit is not connected to the power mains or is not working.
  • The power supply unit is not corrected to the battery.
  • The battery is damaged: replace the battery.

• The spot welding machine is blocked with the yellow alarm led flashing and the first green led in Figure B-4 flashing.

  •  The battery is damaged (e.g. shorted cell): replace the battery.

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.
• To protect the battery and lengthen its working life, charge it before using it for the first time, then after every time it is used and, in any case, at least every 3 months.
• If these recommendations are not followed, the battery may undergo an irreversible chemical deterioration process.
• As the battery is a component subject to wear and tear and its level of performance and preservation over time depend on how well it is used and looked after, this element is not covered by any form of warranty.

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.

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