Telwin ALUSPOTTER 6100 Инструкция по эксплуатации онлайн [6/96] 283779

connectors will overheat, wear rapidly and become inefficient. point where the stud bolt is welded to the base metal. For steel, you

- Do not use metal structures that are not part of the workpiece to should be beware of fragility due to hardening. The material and

substitute for the welding current return cable; this could endanger strength of the stud bolt are subject to limited tolerance. The carbon

safety and produce an unsatisfactory weld. content of steel stud bolts should be ≤ 0.2% (cast analysis). The

weldability of various materials and the possible combinations of stud

6. WELDING: DESCRIPTION OF PROCEDURE bolt and base metal are shown in Tab. 2.

Preparatory operations N.B. The base metal surface must be clean. Layers of paint, rust, slag,

Before carrying out any spot-welding operation it is necessary to carry grease and coatings in non-weldable metals should be removed from

out a series of checks and adjustments, with the main switch in the “O” the welding area. Do this adopting the method suited to the job. Base

3- Preparing the gun. pins).

Fig. D Note: for ferrous materials, reduce the energy values in the table by 20-

- Choose the type, diameter and length of stud bolt (1) to be welded 30%.

then use and adjust the stud bolt holder (2) to the corresponding

diameter. For correct insertion see fig. D (stud bolt holder 2). IMPERFECTIONS AND REMEDIES DURING CAPACITOR

- Insert the stud bolt to be welded (it should be held tightly); adjust its DISCHARGE STUD BOLT WELDING (FIG. H).

protrusion to 0.8 – 1.2 mm using the screw (3) and lock the nut (4). To help assessment of weld quality, the illustration shows possible

- Insert the stud bolt holder (2) into the gun’s chuck, push it in until you imperfections that may occur during the welding process, with the

feel it resting on the base and then lock the nut. corresponding remedies.

PRINCIPLES OF STUD WELDING OPERATIONS WITH IGNITION

to Ø 8 mm.

hex key.

With this technology it is possible to weld stud bolts onto clean, non-

- When working on doors, bonnets or boots, you must make the earth

oxidised mild steel, galvanised steel, stainless steel, aluminium and

connection on these parts so as to prevent current from passing

brass surfaces.

through the hinges, and in any case the connection must be near the

The process is so quick that it does not alter the surface on the other

area being spot-welded (if the current has to travel long distances

the pre-charge spring by means of the screw on the back of the gun

- Bare the sheet as close as possible to the point where you intend to

(see stage 1), and is positioned with its ignition strike directly on the

work, then connect the earth clamp.

surface of the sheet being welded (see stage 2). Warning: the gun

should be kept perpendicular to the sheet being welded.

Spot welding threaded stud bolts ( Pos.6, Fig.G ), smooth pins

The gun is pressed against the metal until the four fins of the support on

(POS.5, Fig.G ), rivets (POS.4, Fig.G ), faston holders (POS.7,

the head of the gun are in perfect contact with the material; the start

and gun pressure appropriately and press the button on the gun.

Warning: DO NOT apply excessive pressure to the stud.

The melted metal will solidify to weld the stud bolt (stage 4). The pistol

Using the (optional) extractor (POS.1, Fig. G)

should be extracted in perfect alignment with the stud to prevent

Coupling washers and traction

deformation of the clamp and ensure it a long working life (stage 5 + Fig.

This is carried out by fitting and locking the chuck (POS 3, Fig. G) to the

F).

extractor and then working on the washer (POS.8 Fig. G) that has

order to regulate the power source correctly and find the correct

pressure to be applied to the gun. Proceed as follows:

This is carried out by fitting and locking the chuck (POS 2, Fig. G) to the

- Insert the chosen stud bolt into the stud bolt holder (2) (which has

body of the extractor (POS.1, Fig. G). Make the rivet enter the extractor

already been adjusted as described in Fig. D).

(POS. 4, Fig. G) by pulling the chuck towards the hammer. After

- start the power source by turning on light switch I.

completing insertion release the chuck and start traction. Finally, pull

- prepare the base sheet in conditions that are identical to working

- the earth clamp should be placed as close as possible to the welding

spot.

WARNING! BEFORE CARRYING OUT MAINTENANCE

- make a number of test welds, adjusting the voltage and pressure

until you obtain a perfect weld.

WORK, MAKE SURE THAT THE WELDING MACHINE IS

Note: larger sized stud bolts (M5, M6), require higher pressure to

SWITCHED OFF AND DISCONNECTED FROM THE POWER

produce a correct weld, therefore the sheet to be welded should have

SUPPLY.

ROUTINE MAINTENANCE WORK CAN BE DONE BY THE

The gun should be extracted, keeping it perfectly aligned with the stud

OPERATOR.

to prevent deformation of the clamp.

Check the main power cable and the welding cables. They should be

properly insulated and in perfect condition; check twists and bends

WELDABILITY OF TYPICAL COMBINATIONS OF STUD BOLT AND

carefully: near the connection terminals and the earth clamp, and

BASE METAL IN CAPACITOR DISCHARGE WELDING.

where they enter the gun.