5.2 LIFTING THE SPOT-WELDER
2. INTRODUCTION AND GENERAL DESCRIPTION
WARNING:
None of the spot-welders described in this handbook have lifting devices;
2.1 INTRODUCTION
when required attach an eyebolt to suspend the spot-welder using the hole made for this
Portable spot-welder for resistance welding.
purpose
(FIG. F (2)), take care to insert the threaded bolt to a depth of no more than
The series consists of 3 models:
8mm.
-
Modular 20 TI:
Portable spot-welder with electronic timer. Used for precision spot-welding with
5.3 POSITION
electronic control of spot-welding time, and electrode force adjustment. Spot welding
The installation area must be sufficiently large and without obstacles, suitable for
capacity on low carbon steel sheet (standard arms) up to 1+1 mm thick.
ensuring completely safe access to the control panel, to the main switch and to the
-
Digital Modular 230:
working area.
Portable spot-welder with digital microprocessor control.
When not in use position the spot-welder on a plane surface able to support the weight
The most important properties managed by the control panel are:
(see the technical data ) so as to prevent it from tipping or moving dangerously.
- Selection of the thickness of the sheet to be spot-welded.
- Correction of spot-welding time.
5.4 CONNECTION TO THE MAIN POWER SUPPLY
- Possibility of enabling pulsed welding current.
5.4.1 Warnings
- Adjustment of spot-welding force.
Before making any electrical connection, make sure the rating data of the spot-welder
- Spot welding capacity on low carbon steel sheet (standard arms) up to 2+2 mm
correspond to the mains voltage and frequency available at the place of installation.
thick.
The spot-welder should be connected only and exclusively to a power supply with the
-
Digital Modular 400:
neutral conductor connected to earth.
Portable spot-welder with digital microprocessor control.
The same features as the Digital Modular 230 model, but operating with a power
5.4.2 Plug and socket
supply voltage of 400V(380V-415V).
Connect a standard plug with adequate capacity to the power supply cable and prepare
a power outlet protected by fuses or by an automatic circuit-breaker; the appropriate
2.2 STANDARD ACCESSORIES:
earth terminal should be connected to the (yellow-green) earth conductor of the power
The standard spot-welder includes 120 mm arms and standard electrodes.
line.
The power supply connection and the number of poles on the plug, which depend
2.3 OPTIONAL ACCESSORIES
on the distribution system and the power supply voltage of your spot-welder,
- Electrode arm pairs of different lengths and/or shapes, also in kits of several pairs.
should correspond with the indications given in the tables (TAB. 2; 3; 4; 5).
- Trolley for arms: to carry the spot-welder and accessories.
The capacity of the plug and specifications of the fuses and circuit-breaker are given in
the tables
TAB. 1
and
TAB. 7
.
3. TECHNICAL DATA
Should more than one spot-welder be installed, distribute the power cyclically among
3.1 RATING PLATE (FIG. A)
the three phases in order to obtain amore balanced load; e.g.
The main data relating to use and performance of the spot-welder are summarised on
230V spot-welders:
the rating plate and have the following meanings:
Spot-welder 1: power supply L1-N.
1- Number of phases and frequency of power supply.
Spot-welder 2: power supply L2-N.
2- Power supply voltage.
Spot-welder 3: power supply L3-N.
3- Rated mains power with 50% duty cycle.
etc.
4-
400V spot-welders:
5- Maximum loadless voltage over electrodes.
Spot-welder 1: power supply L1-L2.
6- Maximum current when electrodes are shorted.
Spot-welder 2: power supply L2-L3.
7- Maximum electrode force:
Spot-welder 3: power supply L3-L1.
8-
etc.
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Note: The rating plate shown is an example to show the meaning of the symbols and
numbers; the exact values of the technical specifications for your spot-welder can be
WARNING! Failure to observe the rules given above will invalidate the (class
found on the rating plate of the spot-welder itself.
I) safety system provided by the manufacturer, causing serious risks to people
(e.g. electric shock) and objects (e.g. fire).
3.2 OTHER TECHNICAL DATA
General specifications TAB. 1.
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Weight of the spot-welder TAB. 7.
6. (SPOT) WELDING
4. DESCRIPTION OF THE SPOT-WELDER
6.1 PRELIMINARY OPERATIONS
4.1 PRINCIPAL COMPONENTS AND ADJUSTMENTS (FIG.B)
Before carrying out any spot-welding operation, it is necessary to carry out a series of
1- Electrode force adjustment screw.
checks and tests with the spot-welder disconnected from the main power supply.
2- Left/right hand positionable handgrip.
1-
Ensure that the electrical connections are correct, in accordance with the above
3- Hole for eyebolt if used.
instructions.
4- Movable welding arm.
2
- Electrode force and alignment
5- Fixed welding arm.
- lock the lower electrode securely in the most suitable position for the job to be
6- Power supply cable.
done,
7- Rating plate.
- loosen the fastening screw on the top electrode so that it is able to slide in the hole
8- Microswitch.
in the arm,
9- Spot-welding time adjustment (only on 20TI models (
FIG. B1)
) ; for DIGITAL
- between the electrodes place a shim with the same thickness as the sheets to be
models see 4.2:
CONTROL PANEL.
spot-welded,
10-Spot-welding lever.
-
FIG. D
close lever 2 until the arms are parallel and the electrode tips coincide;
insert screw 3 (d.M6) which is supplied into hole 1 and tighten it to lock the lever in
4.2 CONTROL PANEL (only for DIGITAL models) (FIG. C)
a suitable position for adjusting the electrode force,
1- Key for correcting spot-welding time.
- lock the top electrode in the correct position, tightening the screw securely,
- adjusts spot-welding time with respect to the factory default setting.
- regulate the force exerted by the electrodes during spot-welding
FIG.E
, by
2- Key for selecting sheet thickness.
adjusting the screw (
1
) fitted for this purpose using the key supplied; the value of
- selects the thickness of the sheet to be welded.
the setting, according to the position of the indicator on the graduated scale, is
3- Key for selecting spot-welding mode.
shown in
FIG. F .
TAB. 6
shows the value of the force that can be obtained with different arm
9
: the welding current is pulsed.
lengths.
Making this selection will improve spot-welding capacity on high yield
Turn it clockwise to increase the force in proportion to the increase in sheet
point sheets or on sheets with special protective film. The length of the
thickness but make the adjustment so that the clamp is able to close, and trigger
pulse is automatic and requires no regulation.
the corresponding microswitch, with very little effort.
________ : Normal spot welding.
6.2 ADJUSTING THE PARAMETERS
4- LED's for indicating triggering of thermal safeguard .
6.2.1 Digital Models
The two LED's flash alternately, the remaining LED's are off, indicating that the spot-
- select the thickness of the sheet to be spot-welded using the key
(2 - FIG. C)
on the
welder is shut down due to overheating; reset is automatic when the temperature
spot-welder control panel.
returns within the allowed limits.
- select the type of spot-welding (continuous or pulsed) using the key
(3 - FIG. C).
When necessary it is possible to correct the default spot-welding time upwards or
downwards using key
(1- FIG: C).
5. INSTALLATION
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6.2.2 Model TI
WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND
- regulate the spot-welding time using the potentiometer (
9 - FIG.B1
) on the back of the
spot-welder; using the lowest possible values compatible with correct execution of the
ELECTRICAL AND PNEUMATIC CONNECTIONS WITH THE SPOT-WELDER
spot-weld (see 6.3 PROCEDURE).
COMPLETELY SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY OUTLET.
6.3 PROCEDURE
THE ELECTRICAL AND PNEUMATIC CONNECTIONS MUST BE MADE ONLY AND
To make a spot-weld, power the spot-welder then follow the instructions below:
EXCLUSIVELY BY EXPERT OR SKILLED PERSONNEL.
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- place the bottom electrode on the sheet to be spot-welded;
- pull the clamp lever to the end of its stroke, and hence until the microswitch is pressed
5.1 PRELIMINARY OPERATIONS
(
8 - FIG.B
) so that:
Unpack the spot-welder, assemble the separate parts included in the package.
a) the sheets close between the electrodes with the preset force;
b) the welding current passes for the preset time.
Mains power with permanent running (100%).
Current to secondary when running permanently (100%).
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