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- on first start-up of the machine;
- each time the safety/protection devices cut in;
- when the power supply is reinstated (electricity) following a shutdown of power
supplies or a malfunction;
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 PRELIMINARY OPERATIONS
Unpack the spot-welder, assemble the separate parts included in the package.
5.2 LIFTING THE SPOT-WELDER
WARNING: None of the spot-welders described in this handbook have lifting devices.
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:
-
Type A (
) for single-phase machines;
-
Type B (
) for three-phase machines.
-
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 Plug and mains socket
- Version 230V:
The power supply cable is supplied with a Schuko (2 poles + earth) plug already
assembled.
- Version 400V:
Connect a standard plug (3P + E: only 2 poles are used: INTERPHASE connection!)
to the power supply cable of adequate capacity.
- Mains socket
Prepare a mains socket protected with fuses or an automatic circuit breaker switch;
the specific earth lug must be connected to the earth conductor (yellow-green) of the
power supply line.
The capacity and characteristics of fuse and circuit breaker switch intervention are
outlined in the "TECHNICAL DATA" paragraph.
If multiple spot welding machines are used, distribute the power supply cyclically
between the three phases to create a more balanced load; for example:
spot welding machine 1: power supply L1-L2;
spot welding machine 2: power supply L2-L3;
spot welding machine 3: power supply L3-L1.
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).
6. WELDING (Spot welding)
6.1 PRELIMINARY OPERATIONS
Before commencing any spot welding operations, check, with the power cable
disconnected from the mains, that the electrical connection is performed correctly in
accordance with the instructions above.
6.1.1 CONNECTION OF TOOLS (Fig. B)
For correct functioning of the machine, connect the tools to the relevant sockets as
described below:
-
Connect the studder gun with trigger to the socket in Fig. B-2 (for "DUO" version
only).
-
Connect the 14 PIN connector of the studder gun with trigger to the socket in Fig.
B-3 (for "DUO" version only).
-
To the socket in Fig. B-4 connect the studder gun without trigger or the quick
connection cable (see catalogue).
ATTENTION!
- Once spot welding has begun, using the button or contact with the piece, the
machine energises both the tools connected to it (for "DUO" version only).
- 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!
6.2 PARAMETER ADJUSTMENT (in spot welding)
The parameters that determine the diameter (section) and mechanical seal of the
spot are:
-
Force exercised by 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.
The current and spot welding time parameters are adjusted automatically by selecting
the thickness of the sheet to be welded with the (+ / - icons) keys. Adjustments can
be made to the standard spot time (DEFAULT), within set limits, using the key (icon
fig. C-2).
6.3 PROCEDURE
6.3.1 SELECTION OF THE STUDDER GUN WITH OR WITHOUT TRIGGER (for
"DUO" version only)
If the gun activates, it is the one WITH THE TRIGGER (see fig. C-7) the first contact
with the sheet metal of the gun WITHOUT TRIGGER activates recognition of the tool.
If the active gun is the one WITHOUT the trigger (see fig. C-7) simply press the trigger
once on the other gun to select it.
6.3.1.1 SPOT WELDING WITH GUN WITH TRIGGER
After recognition, spot welding begins simply by resting the tool on the piece to weld
and pressing the trigger.
6.3.1.2 SPOT WELDING WITH GUN WITHOUT TRIGGER
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 spot weld automatically.
ATTENTION!
- To fix or remove the tools from the gun spindle, use two hex keys in a manner
that stops the spindle from rotating.
- If working on doors or hoods, connect the earth bar to them to prevent
current from passing through the hinges, and near the area to be spot welded
(long current runs reduce spot efficiency).
- DO NOT PLACE THE STUDDER ON THE PIECE IF YOU DON'T INTEND TO
START WELDING!
6.3.2 FASTENING THE EARTH CABLE TO THE SHEET METAL
a) Switch on the machine and press the "Start" button (fig. C-1). The display shows
the spot welding programme for the earth"
b) Bare the sheet metal as near as possible to the point where you intend to work, for
a surface corresponding to the contact surface of the earth nut (fig. D-26).
c) Connect the head of the earth electrode to the eyelet of the earth cable (fig. I).
d) Rest the tip of the earth electrode (fig. D-25) on the bare sheet metal previously
prepared and close the circuit resting the tip of the studder gun without trigger on
the bare sheet metal.
e) Check the welding seal of the earth electrode by exerting light traction of the
electrode in an orthogonal direction compared to the surface on which it is welded
and then fasten the earth nut against the sheet metal (fig. L).
Note: if the earth electrode should easily detach during traction, try to increase the
welding time using the "+" and "-" buttons (fig. C-2, C-3).
Washer welding for mass terminal fixing
Select the programme in fig. C-8a using the "MODE" key.
Mount the relative electrode (POS. 9, Fig. D) in the gun spindle, and insert the washer
(POS. 13, Fig. D).
Place the washer in the selected area. Place the earth terminal in contact in the
same area; press the gun push-button to weld the washer, which should be fixed as
indicated previously.
Slotted washers spot welding
Select the icon of the slotted washer using the potentiometer.
This function is executed by assembling and tightening the electrode holder (POS. 28,
Fig. D) of the gun. Insert the slotted washer (POS. 27, Fig. D) in the electrode holder
and spot weld as previously described.
Screw, washer, nail, rivet spot welding
Select the programme in fig. C-8b using the "MODE" key.
Fit the most suitable electrode on the gun, insert the element to be spot welded and
place it on the sheet in the necessary spot; press the gun push-button: release the
push-button only after the set time has elapsed.
Contemporaneous spot welding and drawing of special washers
Select the programme in fig. C-8a using the "MODE" key
This function can be carried out by assembling and fully tightening the spindle (POS.
4, Fig. D) on the body of the extractor (POS. 1, Fig. D): hook and fully fasten the other
end of the extractor on the gun. Insert the special washer (POS. 14, Fig. D) into the
spindle (POS. 4, Fig. D), and lock it with the relative screw (Fig. D). Spot weld in the
relative area, adjusting the spot welding machine as if spot welding washers, and start
drawing.
At the end, rotate the extractor by 90° to release the washer, which can be spot welded
in a new position.
Sheet metal heating
Select the programme in fig. C-8d using the "MODE" key.
In this mode the TIMER is disabled.
Operation duration is therefore manual, being determined by the time for which the
gun electrode is kept pressed on the piece connected to the earth.
Current intensity is adjusted automatically according to the thickness of the selected
sheet.
Assemble the carbon electrode (POS. 12, FIG. D) on the gun chuck and block in place
with the ring nut. Touch the area, that was previously bared, with the carbon tip. Work
from the outside to the inside, using a circular movement to heat the sheet which
undergoes work hardening and returns to its original position.
To prevent the sheet from drawing too much, treat small areas and immediately after
wipe using a damp cloth to cool the treated part.
Sheet metal recalculation
Select the programme in fig. C-8e using the "MODE" key.
In this position, working with the specific electrode, you can flatten the sheet metal that
underwent localised deformation.
NOTE: ALL THE PROGRAMMES DESCRIBED ABOVE CAN ALSO BE
IMPLEMENTED WITH THE TOOL WITHOUT THE TRIGGER BY PLACING THE
PIECE TO SPOT WELD IN CONTACT WITH THE SHEET METAL!
Using the supplied extractor (POS. 1, Fig. D)
Washer hooking and drawing
This function is carried out by assembling and tightening the spindle (POS. 3, Fig. D)
onto the body of the electrode (POS. 1, Fig. D). Hook the washer (POS. 13, Fig. D),
- 7 -
".
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