Telwin Inverspotter 13000 400V [5/144] General safety rules for resistance

Telwin Inverspotter 13000 400V [5/144] General safety rules for resistance
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- Always protect the eyes with suitable eye protectors.
- Wear protective gloves and clothing suitable for resistance welding work.
APPLIANCES FOR RESISTANCE WELDING FOR INDUSTRIAL AND
- Noise levels: If the personal daily exposure level (LEPd) is found to be greater
PROFESSIONAL USE
than 85db(A) due to particularly intensive welding operations, wearing personal
Note: In the following text the term “spot-welder” will be used.
protection devices is compulsory.
1. GENERAL SAFETY RULES FOR RESISTANCE
WELDING
The operator should be properly trained to use the spot-welder safely and should
be informed of the risks connected with resistance welding procedures, of related
protection measures and of emergency procedures.
- The flowing of spot welding currents generates electromagnetic fields (EMF)
(Only for pneumatic cylinder-operated versions) The spot-welder is provided with
around the spot welding circuit.
a main switch with emergency functions, fitted with a padlock for locking it in the
Electromagnetic fields can interfere with certain medical equipment (e.g. Pace-
“O” (open) position.
makers, respiratory equipment, metallic prostheses etc.).
The padlock key should be handed over only and exclusively to an expert operator
Adequate protective measures must be adopted for persons with these types of
or to an operator who has been trained for the tasks assigned to him and has been
medical apparatus. For example, they must be forbidden access to the area in
warned of the possible hazards arising from this welding procedure and from
which spot welding machines are in operation.
neglectful use of the spot-welder.
This spot welder conforms to technical product standards for exclusive use in an
When the operator is absent the switch should be set to the “O” position, the
industrial environment for professional purposes. It does not assure compliance
padlock should be closed and the key removed.
with the basic limits relative to human exposure to electromagnetic fields in the
domestic environment.
The operator must adopt the following procedures in order to reduce exposure to
electromagnetic fields:
- Electrical installation should be carried out following accident-prevention
- Fasten the two spot welding cables (if present) as close together as possible.
legislation and standards.
- Keep head and trunk as far away as possible from the spot welding circuit.
- The spot-welder should be connected only and exclusively to a power supply
- Never wind spot welding cables around the body.
with the neutral conductor connected to earth.
- Avoid spot welding with the body within the spot welding circuit. Keep both
- Make sure the power supply outlet is correctly connected to the earth
cables on the same side of the body.
protection.
- Connect the spot welding current return cable to the piece being spot welded, as
- Do not use cables with worn or damaged insulation or with loosened
close as possible to the welding joint.
connections.
- Do not spot weld while close to, sitting on or leaning against the spot welder
- Do not use the spot-welder in damp or wet environments or in the rain.
(keep at least 50 cm away from it).
- When connecting the welding cables or carrying out any routine maintenance
- Do not leave objects in ferromagnetic material in proximity of the spot welding
operation on the arms and/or electrodes the spot-welder should be switched off
circuit.
and disconnected from the power supply. Pneumatic cylinder-operated spot-
- Minimum distance:
welders should be locked with the main switch in the “O” position and the
- d= 3cm, f= 50cm (Fig. H);
padlock closed.
- d= 3cm, f= 50cm (Fig. I);
The same procedure should be followed when making connections to the water
- d= 30cm (Fig. L);
supply or to a closed circuit cooling unit (water-cooled spot-welders) and
- d= 20cm (Fig. M) Studder.
whenever repairs are made (extraordinary maintenance).
- Class A equipment:
- Do not weld on containers, receptacles or piping that contain or have contained
This spot welder conforms to technical product standards for exclusive use in an
flammable liquid or gas products.
industrial environment and for professional purposes. It does not assure
- Do not operate on materials cleaned with cholorinated solvents or near such
compliance with electromagnetic compatibility in domestic dwellings and in
substances.
premises directly connected to a low-voltage power supply system feeding
- Do not weld on pressurised containers.
buildings for domestic use.
- Remove all flammable substances from the work area (e.g. wood, paper, rags
etc.).
- Make sure there is sufficient ventilation or provide means for removing welding
RESIDUAL RISKS
fumes near the electrodes; a systematic approach is necessary to evaluate
limits of exposure to the welding fumes depending on their composition and
- RISK OF UPPER LIMBS BEING CRUSHED
concentration and on the length of exposure.
Both the operating method for the spot-welder and the variability in shape and
size of the piece being welded make it impossible to provide integrated
protection against the danger of the upper limbs being crushed: fingers, hands,
forearm.
The risk should be reduced by appropriate preventive measures:
5.4 CONNECTION TO THE MAIN POWER SUPPLY .................................. 8
1. GENERAL SAFETY RULES FOR RESISTANCE
5.4.1 Warnings ....................................................................................... 8
WELDING .................................................................. 5
5.4.2 Plug and socket............................................................................. 8
5.5 PNEUMATIC CONNECTION ................................................................. 8
5.6 PNEUMATIC CLAMP CONNECTION.................................................... 8
2. INTRODUCTION AND GENERAL DESCRIPTION... 6
5.7 STUDDER GENERATOR CONNECTION ............................................. 8
2.1 INTRODUCTION.................................................................................... 6
5.8 STUDDER GUN CONNECTION TO THE EARTH CABLE .................... 8
2.2 STANDARD ACCESSORIES ................................................................. 6
2.3 OPTIONAL ACCESSORIES .................................................................. 6
6. (SPOT) WELDING...................................................... 8
6.1 PRELIMINARY OPERATIONS.............................................................. 8
3. TECHNICAL DATA .................................................... 6
6.2 ADJUSTING THE (spot-welding) PARAMETERS ................................. 8
3.1 RATING PLATE ...................................................................................... 6
6.2.1 Adjusting the force and squeeze function
3.2 OTHER TECHNICAL DATA .................................................................... 6
(pneumatic clamp only) ................................................................. 8
3.2.1 Spot-welding machine................................................................... 6
6.2.2 Adjusting the spot-welding current and times ............................... 8
3.2.2 Studder Generator ....................................................................... 6
6.2.3 Storage of the customized spot welding programmes .................. 8
6.2.4 Recall of spot welding programmes .............................................. 8
4. DESCRIPTION OF THE SPOT-WELDER.................. 6
6.3 SETTINGS FOR THE MATERIAL .......................................................... 8
4.1 CONTROL AND ADJUSTMENT DEVICES ........................................... 6
6.4 SPOT-WELDING PROCEDURE ............................................................ 8
4.1.1 Control panel................................................................................. 6
6.4.1 PNEUMATIC CLAMP .................................................................... 8
4.1.2 Pressure regulation unit and pressure gauge ............................... 7
6.4.2 STUDDER GUN............................................................................ 9
4.2 SAFETY FUNCTIONS AND INTERLOCK ............................................. 7
4.2.1 Safeguards and alarms ................................................................. 7
7. MAINTENANCE......................................................... 9
7.1 ROUTINE MAINTENANCE.................................................................... 9
5. INSTALLATION.......................................................... 7
7.2 EXTRAORDINARY MAINTENANCE ..................................................... 9
5.1 PRELIMINARY OPERATIONS............................................................... 7
5.2 HOW TO LIFT THE SPOT-WELDER...................................................... 7
5.3 POSITION .............................................................................................. 8
INDEX
ENGLISH
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