Telwin Digital Puller 5500 Duo 230V [6/112] Signals that the key must be pressed to prepare the machine for welding
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Telwin Digital Puller 5500 Duo 230V [6/112] Signals that the key must be pressed to prepare the machine for welding

Telwin Digital Puller 5500 Duo 230V [6/112] Signals that the key must be pressed to prepare the machine for welding
- 6 -
section of this handbook.
- 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).
STORAGE
- Place the machine and its accessories (with or without packaging) in closed
areas.
- The relative humidity of the air must not exceed 80%.
- Theenvironmentaltemperaturemustbebetween-15°Cand45°C.
If the machine has a water cooling unit and the environmental temperature is
lower than 0°C: add the indicated antifreeze liquid or completely empty the
hydraulic circuit and the water tank.
Always use suitable measures for protecting the machine from humidity, dirt
and corrosion.
2. INTRODUCTION AND GENERAL DESCRIPTION
2.1 INTRODUCTION
Mobile resistance welding system (spot welding machine) with digital control by
microprocessor. The system can perform numerous hot and spot welding operations
on the sheet metal that are specic to the automobile body shop sector and those with
similar processing of sheet metal.
Their main characteristics are:
- automatic choice of the welding parameters;
- possibility of varying the welding time compared to the value selected automatically;
- limitation of line overcurrent at insertion (insertion cos φ check);
- backlit LCD display that shows the controls and the set parameters;
- specic programme for welding of the earth to the sheet metal to repair.
The spot welding machine also enables connection of two studder guns and rapid use
of one or the other gun with independent programmes.
The spot welding machine can work on sheet metal in iron with low carbon content or
on sheet metal in zinc-plated iron.
2.2 STANDARD ACCESSORIES
- Studder gun with trigger.
- Studder gun without trigger.
- Earth cable with earth to spot weld.
- Extractor with blowback.
- Electrode for star washers.
- Star washers for traction.
For further details please consult the latest catalogue.
2.3 OPTIONAL ACCESSORIES
- Consumables box.
- Trolley.
- Ringvolver.
- Quick connection cable.
- Various tools for traction.
For other accessories please consult the latest catalogue
3. TECHNICAL DATA
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:
1- Number of phases and frequency of power supply.
2- Power supply voltage.
3- Rated mains power with 50% duty cycle.
4- Mains power with permanent running (100%).
5- Maximum loadless voltage over electrodes.
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”.
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
on the rating plate of the spot-welder itself.
3.2 OTHER TECHNICAL DATA
Generalspecications
- (*)Power supply voltage and frequency: 400V ~ 2ph-50/60 Hz
or: 230V ~ 1ph-50/60 Hz
- Electrical protection class: I
- Insulation class: H
- Enclosure protection rating: IP 22
- Weight: 18kg
Input
- Max. power when spot-welding (S max): 13kVA
- Power factor at Smax (cosφ): 0.8
- Main supply delayed fuses: 10A (400V)/16A (230V)
- Automatic circuit-breaker: 10A (400V)/16A (230V)
- Power supply cable (L≤4m): 3G x 2.5mm
2
Output
- Loadless secondary voltage (U
0
max): 5.6V
- Max. spot-welding current (I
2
max): 2.5kA
- Spot-welding capacity (low carbon steel): max 1.5 + 1.5mm
(*)NOTES:
- The spot-welder can be supplied for a 400V or 230V power supply; make sure the
value on the data plate is correct.
4.SPOTWELDINGMACHINEDESCRIPTION
4.1THESPOTWELDINGMACHINEANDITSMAINCOMPONENTS(Fig.B)
Atthefront:
1 - Control panel;
2 - Studder gun cable attachment with trigger;
3 - Studder gun 14 pin connector attachment with trigger;
4 - Studder gun cable attachment without trigger or rapid connection cable (see
catalogue);
5 - Earth cable.
Attheback:
6 - Main switch;
7 - Power cable input.
4.2CONTROLANDADJUSTMENTDEVICES
4.2.1Controlpanel(Fig.C)
1.
Multifunction button
a) “START”FUNCTION:
startsthemachineatrststartingorafteranalarmstate.
NOTE:Whenevernecessary,thedisplayindicatestotheoperatorthathe
mustpressthe“START”buttontousethemachine.
b)“MODE” FUNCTION:
selects the programme of the tool in use (g. C-8a / 8e).
c) CHOOSING THE UNIT of MEASUREMENT:
keeping this key pressed for 3 seconds, the operator can set the units for
measuring the thickness of the sheets in “millimetres” [mm], “gauge” [ga] or
inches [in].
2-3.
- / + Double function buttons
a) SHEET THICKNESS FUNCTION:
keeping the [+] key pressed increases the sheet thickness, while pressing the
[-] key decreases it.
b) TIME
SELECTION FUNCTION :
by keeping the [-] key pressed for 3 seconds, the welding time
can be
increased or decreased as to the value set automatically by the machine
;
4. LCDdisplay
5.
Signals that the key must be pressed to prepare the machine for welding.
6.
Displays the programme " " for welding the earth clamp; also displays the
thickness of the sheet metal and any alarm codes.
7.
Indicates the Studder gun without trigger (contact version).
8a.
Indicates spot welding of plugs, rivets, washers, slotted washers, bits for special
traction with specic hammers (see catalogue).
8b.
Indicates the spot welding of screws having a diameter of 4-6 and rivets having a
diameter of 5 with suitable electrode.
8d.
Indicates sheet tempering with the carbon electrode.
8e.
Indicates sheet upsetting with the relative electrode.
9.
Indicates the level of the welding time respect at the automatically set value
.
12.
Indicates that the clamp being used is energised.
13.
activated using the Studder gun.
16.
Is the thickness of the sheet to be welded.
17.
Indicates that the machine is being thermostatically protected.
19.
Indicates the measurement unit of the metal sheet thickness .
4.3SAFETYFUNCTIONSANDINTERLOCK
4.3.1Safeguardsandalarms(TAB.1)
a) Thermostatic safeguard:
Intervenes if the spot welding machine overheats because the cooling liquid is
missing or is insufcient, or due to a work cycle that exceeds the permitted limit.
The icon on the display (g. C-17) switches on to signal intervention and with:
AL1 = machine thermal alarm.
AL2 = clamp, studder thermal alarm.
EFFECT: current blocked (welding inhibited).
RESET: manual (use the “START” push-button when the permitted temperature
limits are reached - the [symbol] icon switches off).
b) Over and under voltage protection
The intervention is signalled on the display by AL 3 = overvoltage alarm and by AL
4 = undervoltage alarm.

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