- 5 -
EQUIPMENT 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 must receive full instructions regarding safe use of the spot welder
and must be informed of the risks related to resistance welding procedures, as
well as the related safety measures and emergency procedures.
- Electrical installation must comply with health and safety legislations and
standards.
- The spot welder must be connected only and exclusively to a power supply
with the neutral conductor connected to earth.
- The power supply outlet must be correctly connected to the earth conductor.
- Do not use cables with worn insulation or loose 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 conditions or under 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.
The same procedure must be respected when connecting to the hydraulic
network or a closed circuit cooling unit (water cooled spot welders) and
whenever repairs (extraordinary maintenance) are carried out.
- 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 containers, receptacles or piping that contain or have contained
flammable liquids or gases.
- Do not work on materials cleaned with chlorinated solvents or in the vicinity
of such substances.
- Do not weld containers under pressure.
- Remove all flammable substances (e.g. wood, paper, rags etc.) from the
working area.
- Allow newly-welded pieces to cool! Do not leave the piece near flammable
substances.
- Make sure there is an adequate air exchange or means suitable for removing
the welding smoke near the electrodes; a systematic approach for evaluating
the welding smoke exposure limits according to composition, concentration
and exposure duration is necessary.
- Always wear suitable protection glasses.
- Wear protection gloves and clothing that is suitable for working with
resistance welding machines.
- Noise level: If particularly intensive welding operations lead to a daily
personal noise exposure (LEP,d) of 85dB(A) or more, the use of suitable
personal protection equipment is obligatory.
- The passage of the spot welding current generates electromagnetic fields
(EMF) around the spot welding circuit.
The electromagnetic fields can interfere with some medical equipment (e.g.
Pace-makers, respirators, metal prostheses, etc.).
Suitable measures must be taken to protect those who use this equipment. As
an example, prohibit access to the spot welder use area.
This spot welder complies with the requirements of the technical standard for
products to be used only and exclusively in industrial environments and for
professional purposes. Correspondence with the basic limits regarding human
exposure to electromagnetic fields in a domestic environment is not guaranteed.
The operator must follow the procedures given below in order to reduce
exposure to electromagnetic fields:
- Fix the two spotting cables (if present) as near to each other as possible.
- Operators must keep their heads and trunks as far away as possible from the
spotting circuit.
- Operators must never wind the spotting cables (if present) around their body.
- Operators must not spot weld with their body in the middle of the spotting
circuit. Operators must keep both cables on the same side of their body.
- Connect the spot welding current return cable (if present) to the piece to be
welded, as close as possible to the join being made.
- Never spot weld near, sitting on, or leaning against the spot welder (minimum
distance: 50cm).
- Do not leave ferromagnetic objects near the spot welding circuit.
- Minimum distance:
- d= 3cm, f= 50cm (Fig. G);
- d= 3cm, f= 50cm (Fig. H);
- d= 30cm (Fig. I);
- d= 20cm (Fig. L) Studder.
- Class A equipment:
This spot welder complies with the requirements of the technical standard for
products to be used only and exclusively in industrial environments and for
professional purposes.
Correspondence with the electromagnetic compatibility in domestic buildings
and in those directly connected to a low voltage power supply network that
supplies buildings for domestic use is not guaranteed.
INTENDED USE
The system must be used for spot welding one or more steel plates with a low
carbon content, having a shape and size that varies according to the work to
be carried out.
RESIDUAL RISKS
RISK OF CRUSHING THE UPPER LIMBS
DO NOT PLACE HANDS NEAR MOVING PARTS!
The spot welder operation mode and the variability of shape and size of the
piece to be worked do not allow the realization of an integrated protection
against the danger of crushing of the upper limbs (fingers, hands, forearms).
The risk must be reduced using suitable preventive measures:
- The operator must be an expert on or trained in resistance welding
procedures using this type of equipment.
- 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 two or more people to work simultaneously with the same spot
welder.
- People unconnected with the job must not be allowed in the working area.
- Do not leave the spot welder unattended: in this case it must be disconnected
from the mains; with spot welders with pneumatic cylinder operation move
the main switch to “O” and lock it with the supplied lock; the key must be
removed and kept by the person in charge.
- Only use electrodes that are recommended for the machine (see spare parts
list) without altering their shape.
- RISK OF BURNING
Some of the spot welder parts (electrodes - arms and adjacent areas) can
reach temperatures of above 65°C: suitable protective clothing must be
worn.
Allow newly-welded pieces to cool before touching them!
- RISK OF TOPPLING AND FALLS
- Place the spot welder on a horizontal surface that can suitably support the
mass; constrain the spot welder to the supporting surface (when indicated
in the “INSTALLATION” section of this manual). In contrary cases, where
the flooring is sloped or broken, or with mobile supporting surfaces, the
danger of toppling exists.
- It is forbidden to lift the spot welder, excluding where expressly indicated in
the “INSTALLATION” section of this manual.
- 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).
ENGLISH
INDEX
1. GENERAL SAFETY RULES FOR RESISTANCE WELDING.
..............................5
2. INTRODUCTION AND GENERAL DESCRIPTION
...............................................
6
2.1 INTRODUCTION ..............................................................................................6
2.2 STANDARD ACCESSORIES: .........................................................................6
2.3 OPTIONAL ACCESSORIES ............................................................................6
3. TECHNICAL DATA
................................................................................................
6
3.1 RATING PLATE (FIG. A) ..................................................................................6
3.2 OTHER TECHNICAL DATA ..............................................................................6
4. DESCRIPTION OF THE SPOT-WELDER
............................................................
6
4.1 PRINCIPAL COMPONENTS AND ADJUSTMENTS (FIG.B) ..........................6
4.2 CONTROL PANEL (only for 6.9kA models) (FIG. C) ........................................6
5. INSTALLATION ......................................................................................................
6
5.1 PRELIMINARY OPERATIONS .........................................................................6
5.2 LIFTING THE SPOT-WELDER ........................................................................6
5.3 POSITION ........................................................................................................6
5.4 CONNECTION TO THE MAIN POWER SUPPLY ............................................6
5.4.1 Warnings .................................................................................................6
5.4.2 Plug and socket .......................................................................................6
6. (SPOT) WELDING
................................................................................................
6
6.1 PRELIMINARY OPERATIONS .........................................................................6
6.2 ADJUSTING THE PARAMETERS ....................................................................7
6.2.1 6.9kA Models ...........................................................................................7
6.2.2 Model 5.8kA.............................................................................................7
6.3 PROCEDURE ..................................................................................................7
7. MAINTENANCE .....................................................................................................7
7.1 ROUTINE MAINTENANCE ..............................................................................7
7.2 SPECIAL MAINTENANCE ...............................................................................7
7.3 TROUBLESHOOTING .....................................................................................7
page
page
