-
IMPROPER USE
3.2 OTHER TECHNICAL DATA
It is dangerous to use the spot-welder for any other purpose than that for
General specifications
which it is designed (spot resistance welding).
- (*)Power supply voltage and frequency :
400V ~ 1ph-50/60 Hz
or 230V ~ 1ph-50/60 Hz
- Enclosure protection rating:
IP 22
PROTECTIONS
(*) The spot welder can be supplied with a 400V or 230V power supply; check the correct
value on the technical information plate
The safeguards and moveable parts of the spot-welder casing should all be in
position before connection to the power supply.
3kA model
WARNING: All manual operations on moveable accessible parts of the spot
Input
welder, for example:
- Max. spot welding power (S max):
16.2 kVA
- Electrode replacement or maintenance
- Nominal power at 50%
(Sn):
4 kVA
- Adjusting the position of the arms or electrodes
- Delayed main power line fuses:
16 A (400V ) / 25A (230V)
SHOULD BE CARRIED OUT WITH THE SPOT-WELDER SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY.
Output
- Secondary no-load voltage (U max):
5.4 V
0
- Max. spotting current
(I max):
3 kA
2
2. INTRODUCTION AND GENERAL DESCRIPTION
Mobile system for resistance welding ("spot welder") with microprocessor digital
2.5kA model
control.
Input
This manual refers to two system versions in relation to their maximum output current:
- Max. spotting power
(S max):
15.6 kVA
3kA or 2.5kA (see technical information plate).
- Nominal power at 50%
(Sn):
2.5 kVA
The machine can be used to carry out numerous specific operations in the car
- Delayed main power line fuses:
10 A (400V) / 16 A (230V)
bodywork sector, or other similar sectors (hot sheet working, spot working, etc.)
Output
2.1 MAIN CHARACTERISTICS
- Secondary no-load voltage (U max):
6 V
0
Model 3kA:
- Max. spot welding current (I max):
2.5 kA
2
- Automatic welding parameters selection;
- Quick couplings for the welding cables;
WEIGHT OF THE SPOT-WELDER TAB.1.
- Automatic detection of the inserted tool:
4. DESCRIPTION OF THE SPOT-WELDER
0
: The "Studder" gun is used in all procedures that can be selected
4.1. CONTROL PANEL (FIG.B1)
using the key (3).
1- Spot-welding time key
:
for upward or downward correction, within preset
7
&
: Manual clamp. Opposed spot welding of sheets that can be
accessed from both sides.
limits, of spot-welding time with respect to the preset (factory default) value.
(
: Pneumatic air puller gun. Used to draw dents on vehicle
2- “Thickness” key
:
used to select the thickness of the sheet to be spot-
bodywork.
welded.
- Line overcurrent limitation at input (cos input check).
3- Key for selecting functions with the studder gun:
Model 2.5kA:
This
only
has any meaning when the studder kit is used:
- "Studder" gun connected permanently to the machine;
:
Spot welding: pins, rivets, washers, special washers using suitable
- Choice of five different spot welding systems;
electrodes.
- Multilevel adjustment of the spot welding energy;
- Line overcurrent limitation at input (cos input check).
2
:
Spot-welding Ø 4mm screws using a suitable electrode.
2.2 STANDARD ACCESSORIES
- Model 3kA:
- Studder gun
3
:
Spot-welding Ø 5-6mm screws and Ø 5mm rivets using a suitable
- Cable with earth clamp.
electrode.
- Extractor
- Various electrodes.
4
:
Spot-welding single spots using a suitable electrode.
- Consumables box.
- Model 2.5kA:
5
:
Tempering sheet metal using a carbon electrode. Upsetting sheet
- Studder gun.
metal using a suitable electrode.
- Cable with earth clamp.
- Extractor.
6
:
Jogged spot-welding for patching sheet using a suitable electrode.
- Electrode for star washer.
- Star washer.
The spot-welder automatically adjusts the welding time according to the chosen
sheet thickness.
For more detailed information please refer to the updated catalogue.
4- LED's for selection of tool being used
2.3 ACCESSORIES
-Model 3kA:
0
: ”Studder” gun used for all procedures that can be selected with key (3).
- Manual clamp with cable pair.
- Straight arm pairs with electrodes of different lengths and/or shapes for manual
clamp (see spare parts list).
7
&
:Manually operated clamp. Opposed spot-welding on sheets that
- Manual "C" clamp with cables.
can be reached from both sides.
- Trolley.
(
: Pneumatically operated Air-puller gun. Used for tempering dents on
motor vehicle bodywork.
- Model 2.5kA:
- Consumables box.
- Trolley.
5-
*
: Indicator LED “spot-welder at work”.
For other accessories please refer to the updated catalogue.
6-
+
: Thermal safeguard warning LED.
3. TECHNICAL DATA
Indicates that the spot-welder has been shut down due to overheating on
the output bars, the welding cables or the tool being used. Reset is
automatic when the temperature returns within the allowed limits.
3.1 RATING PLATE (FIG. A)
The main data relating to use and performance of the spot-welder are summarised on
the rating plate and have the following meanings:
7-
,
:
Power supply indicator LED's :
1- Number of phases and frequency of power supply.
2- Power supply voltage.
-
: Low power supply voltage (spot-welder under-powered).
3- Rated mains power with 50% duty cycle.
4- Mains power with permanent running (100%)
5- Maximum loadless voltage over electrodes.
.
: Normal power supply voltage (spot-welder powered correctly).
6- Maximum current when electrodes are shorted.
7- Safety symbols, the meaning of which is given in chapter 1 “General safety rules for
resistance welding”.
/
: High power supply voltage (spot-welder over-powered).
8- Current to secondary when running permanently (100%).
_____________________________________________________________________________________________________________________
Note: The rating plate shown is an example to show the meaning of the symbols and
numbers; the exact values of the technical properties of your spot-welder can be found
WARNING:
When the power supply is abnormal, with the over- or under-voltage
on the rating plate of the spot-welder itself.
LED's lit up and an intermittent beep, we advise switching off the spot-welder to prevent
φ
φ
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Summary of Contents for Digital Car Puller 5000
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