Telwin DIGITAL CAR SPOTTER 5500 400V + ACC (823232) [6/116] Signals that the key must be pressed to prepare the machine for welding
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Telwin DIGITAL CAR SPOTTER 5500 400V + ACC (823232) [6/116] Signals that the key must be pressed to prepare the machine for welding

Telwin DIGITAL CAR SPOTTER 5500 400V + ACC (823232) [6/116] Signals that the key must be pressed to prepare the machine for welding
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disconnected from the power supply; for pneumatic cylinder-operated spot
weldersturnthemainswitchto“O”andlockitwiththesuppliedpadlock,
take out the key and leave it with the person in charge.
- Only use electrodes that are recommended for the machine (see spare parts
list) without altering their shape.
- RISK OF BURNS
Some parts of the spot welder (electrodes arms and nearby areas) may reach
temperaturesofover65°C:suitableprotectiveclothingmustbeworn.
Allow newly-welded pieces to cool before touching them.
- RISK OF TIPPING AND FALLING
- Place the spot welder on a level horizontal surface that is able to support
itsweight;connethespotweldertothesupportsurface(whenrequired
in the “INSTALLATION” section of this manual). Otherwise with inclined
orunevenoorsormoveablesupportingsurfacesthereisthedangerof
tipping.
- Neverliftthespotwelderunlessexplicitlyrequiredbythe“INSTALLATION”
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).
PROTECTIONS
The safeguards and moveable parts of the spot welder casing should all be in
position before connection to the power supply.
WARNING: All manual operations on moveable accessible parts of the spot
welder,forexample:
- Electrode replacement or maintenance
- Adjustingthepositionofthearmsorelectrodes
MUST BE CARRIED OUT WITH THE SPOT WELDER SWITCHED OFF AND
DISCONNECTEDFROMTHEELECTRICANDPNEUMATIC(ifpresent)POWER
SUPPLY.
MAINSWITCHLOCKEDAT“O”WITHLOCKCLOSEDANDKEYREMOVEDinthe
modelswithPNEUMATICCYLINDERmovement).
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. Equipped with quick coupling for welding cables, makes changing the
tools immediate and easy, which means that lots of hot machining and spot welding
can be carried out on the sheets, specically in body shops and sectors with similar
activities.
Their main characteristics are:
- automatic choice of the welding parameters;
- automatic recognition of the inserted tool;
- limitation of line overcurrent at insertion (insertion cos φ check);
- backlit LCD display that shows the controls and the set parameters;
The spot welding machine can operate on iron sheets with a low carbon content and
on galvanized iron sheets.
2.2 STANDARD ACCESSORIES
- Studder gun.
- Cable with earth clamp.
- Extractor with mass.
- Various electrodes.
- Consumables box.
2.3 OPTIONAL ACCESSORIES
- Manual clamp with cable pair.
- Pairs of electrode arms of different lengths and/or shapes for manual clamp (see
spare parts list).
- Manual “C” clamp with cables.
- Studder Kit without trigger, complete with earth cable (for contact welding without
using the push-button).
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 (±15%) ~ 2ph-50/60 Hz
or: 230V (±15%) ~ 1ph-50/60 Hz
- Electrical protection class: I
- Insulation class: H
- Enclosure protection rating: IP22
- Dimensions (LxWxH): 390x260x225mm
- Weight: 18.5kg
Input
- Max. power when spot-welding (S max): 16kVA
- Power factor at Smax (cosφ): 0.7
- Main supply delayed fuses: 16A (400V)/25A (230V)
- Automatic circuit-breaker: 16A (400V)/25A (230V)
- Power supply cable (L≤4m): 3 x 2.5mm
2
(400V) - 3 x 4mm
2
(230V)
Output
- Loadless secondary voltage (U
0
max): 6V
- Max. spot-welding current (I
2
max): 3kA
- 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 - Clamp cable attachment (dinse);
3 - 14-pin connector;
Attheback:
4 - Main switch;
5 - 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 “impulse” spot welding
(can only be activated with pneumatic
clamps) or selects the studder tool (g. C-8a / 8f, can only be activated with the
studder gun).
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.
Shows the sheet thickness and possible alarm codes.
7.
It can be activated by connecting the Studder gun either with or without trigger
(contact activation version).
8a.
Indicates the spot welding of plugs, rivets, washers and special washers with
suitable electrodes.
8b.
Indicates the spot welding of screws having a diameter of 4-6 and rivets having a
diameter of 5 with suitable electrode.
8c.
Indicates individual spot welding with suitable electrode.
8d.
Indicates sheet tempering with the carbon electrode.
8e.
Indicates sheet upsetting with the relative electrode.
8f.
Indicates intermittent spot welding for sheet patching with relative electrode.
9.
Indicates the level of the welding time respect at the automatically set value
.

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