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pulse range from 0 to 100 cycles.
Spot-welding time: time for which the spot-welding current is held practically
constant. For pulsed operation with the pneumatic clamp this time is refers to
the duration of the single pulse range from 0,5 to 100 cycles (*).
Cool time: (only for pulsed spot-welding) time elapsing between one current
pulse and the next range from 0.5 to 20 cycles.
Number of pulses: (only for pulsed spot-welding) number of spot-welding
current pulses, each lasting for the set spot-welding time range from 1 to 10
(**).
Hold time: time for which the electrodes of the pneumatic clamp continue to
squeeze the sheets that have just been spot-welded, without delivering
current. During this interval the welded spot will be cooled and the welded core
will crystallise; during this stage the pressure will refine the metal grain,
increasing the mechanical strength range from 2 to 50 cycles.
(*)NOTE: the sum of ramp cycles and spot-welding cycles may not exceed 100 (2
seconds).
(**)NOTE: the maximum possible setting for the number of pulses depends on the
length of a single pulse: the total effective spot-welding time may not exceed 100 cycles.
1- Dual function key "A"
:
a) BASIC FUNCTION
: sequential display of spot-welding parameters:
supplyable power,
squeeze time,
cool time (only in pulsed mode),
hold time.
b) SPECIAL FUNCTION
: changing the spot-welding parameters on display: to
enter this function it is necessary to follow the procedure described in section 6.2.2.
2 Key "B" for selecting the function used and displaying the tool used:
: Pneumatic clamp function with direct spot-welding current: the spot-
welding cycle starts with a squeeze time, continues with a ramp time, a spot-welding
time and ends with a hold time. This function can be selected with the "B" key.
: Pneumatic clamp function with "pulsed" spot-welding current: the
spot-welding cycle starts with a squeeze time, continues with ramp time, spot-welding
time, cool time, a set number of pulses and ends with hold time.
This function improves spot-welding capacity on high stress sheet or on sheet that has
been galvanised or has a special protective film.
This function can be selected with the "B" key.
: Manually operated clamp. Opposed spot-welding on sheet
that can be reached from both sides. This tool is recognised automatically.
: Pneumatically-operated Air-puller gun. Used for tempering dents on motor
vehicle bodywork. This tool is recognised automatically.
: Twin-spot gun. Used for spot-welding sheet that cannot be reached on both
sides. This tool is recognised automatically.
3 Yellow LED - tool thermostat triggered
relay triggers; the machine blocks the tool being used. The machine is ready to resume
operation when "START" appears on the display (press the "START" button): this will
occur when the tool has been changed or when it has cooled down.
4- Key for selecting functions with the studder gun
This only has any meaning when the studder kit is used:
: Spot welding: pins, rivets, washers, special washers using suitable
electrodes.
2
: Spot-welding Ø 4mm screws using a suitable electrode.
3
: Spot-welding Ø 5-6mm screws and Ø 5mm rivets using a suitable
electrode.
4
: Spot-welding single spots using a suitable electrode.
5
: Tempering sheet metal using a carbon electrode. Upsetting sheet
metal using a suitable electrode.
6
: Jogged spot-welding for patching sheet using a suitable electrode.
ramp time,
spot-welding time,
number of pulses (only in pulsed mode),
(
)
: this lights up when the tool thermal
0
:
5 Yellow LED STUDDER thermostat triggered
studder thermal relay triggers; the machine blocks its use. The machine is ready to
resume operation when "START" appears on the display (press the "START" button):
this will occur when the tool has been changed or when it has cooled down.
6 - "D" key for selecting thickness
This is used to position the spot-welding programme according to the thickness of the
piece to be welded.
If the LED flashes this means welding is critical for the selected thickness with the
currently used tool; if the LED does not light up this means that the currently connected
tool is unable to weld at this thickness.
7- Dual function key "E"
(
a) BASIC FUNCTION
electrode force (pneumatic clamp only), setting for arm length (pneumatic clamp
only).
b) SPECIAL FUNCTION
(pneumatic clamp only): to enter this function it is necessary to follow the procedure
"SETTING THE MATERIAL AND ARM LENGTH" in section 6.3.
8 - LOAD and STORE keys:
These are active only in programming mode (see section 6.2.2). The "STORE" key is
used to save the welding cycle setting for a given tool, thickness and material.
The "LOAD" key is used to load the DEFAULT welding cycle setting for a given tool,
thickness and material.
___________________________________________________________________
WARNING! if the "load" and "store" keys are pressed simultaneously when the
machine starts up, all the factory settings for each tool, thickness and material
will be loaded; any customised programme will therefore be lost!
___________________________________________________________________
9 - Encoder:
Only active during programming. Used to change the value of the spot-welding
parameters, material, and arm length.
10 - Display:
Is able to show:
- Alarm signals (see section 4.3.1)
- Warning signals (LO FO = low pressure in electrodes, HI FO = electrode pressure too
high, OP ELE = insulation between electrodes, NO CON = no tool connected). (See
Tab. 2 for the complete list of warnings). The red LED on the clamp lights up when
there is a warning signal.
- "START" whenever the machine is started up or to reset the machine after an alarm
signal.
- The percentage power setting [%].
- Spot-welding parameter time expressed in cycles at 50Hz (1 cycle = 20ms).
- Current used in the spot-welding cycle [A].
- The force exerted on the electrode tips [daN] (for pneumatic clamp only).
- The material settings for the sheet being welded.
- Arm length [mm] (for pneumatic clamp only).
11 - LED's for general alarm, spot welding, programming:
Yellow LED general alarm: this lights up when the thermal relays trigger, when
alarms trigger for overvoltage, undervoltage, overcurrent, phase failure, air
failure or for an alarm in the GRA.
Red LED spot-welding: this lights up for the entire duration of the spot-welding
cycle.
Red programming LED: the machine is in programming mode and cannot
carry out any spot-welding cycle.
4.2.2 Pressure regulation unit and pressure gauge.(FIG. B-2)
Used to adjust the pressure exerted on the electrodes of the pneumatic clamp by turning
the adjustment knob (only for the pneumatic clamp).
NOTE: the pressure regulator only makes the correct adjustment when the pressure is
increased. For example: to take the pressure correctly from 8 bar to 6 bar we
recommend decreasing the pressure gauge reading to below 6 bar and then increasing
the pressure until the required value is reached.
4.3 SAFETY FUNCTIONS AND INTERLOCK
4.3.1 Safeguards and alarms
a) Thermal relay:
Triggers if the spot-welder overheats due to insufficient or lack of cooling water or to
an excessively heavy duty cycle.
Triggering is indicated by the yellow LED
If the relay has triggered due to overheating of the tool the corresponding yellow
(
)
LED
also lights up (fig. C -3 ; C-5).
The alarm is shown on the display as:
AL 1 = primary overheating alarm
AL 2 = secondary overheating alarm
AL 8 = clamp overheating alarm
EFFECT: movement blocked: electrodes open (cylinders discharged); current
- 7 -
(
)
: this lights up when the
:
:
)
: sequential display of material setting,
: for changing the material and setting the arm length
( )
lighting up on the control panel.
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