Westermans International FAST SPOTTER 3.5 Installation guide

Resistance Welding Solutions
INSTALLATION, OPERATING AND MAINTENANCE MANUAL
RESISTANCE WELDING POWER SOURCE
FAST SPOTTER 3.5 E & 5.0
Westermans International Ltd
Unit 4 Midland Distribution Centre
Markfield Road, Groby, Leicestershire
LE6 0FS
Tel[phone]
[email protected] www.westermans.com

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INDEX
1. GENERAL INSTRUCTIONS
1.1 Manufacturer and welding machine identification data
1.2 General safety warnings
1.3 Prevention measures to be taken by the user
1.4 Technical data
1.5 Intended and non intended use
1.6 Description of the product and how it works
2. INSTALLATION INSTRUCTIONS
2.1 Environmental conditions
2.2 Energy requirement
2.3 Connection to the energy sources
2.4 Transporting, storage and assembly information
2.5 Wiring diagrams
3. INSTRUCTIONS FOR THE OPERATOR
3.1 Description of the functions
3.2 Guide to starting the welding machine for the first time
3.3 Getting ready to weld
3.4 Influence of the different welding parameters
3.5 Checking spot quality
3.6 Operating guide
3.7 Description of the welding control unit
3.8.1 Troubleshooting
3.8.2 How to eliminate welding defects
4. MAINTENANCE INSTRUCTIONS
4.1 Maintenance information
4.2 Guide to maintenance
4.3 Spare parts
4.4 Technical assistance

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1. GENERAL INSTRUCTIONS
1.1 MANUFACTURER AND WELDING MACHINE IDENTIFICATION DATA
Manufacturer data
P.E.I.-POINT SRL
Welding machine data
Resistance type welding machine; see the data plate on the machine and the certificate of conformity attached to this manual for the
model, serial number and year of construction.
Introduction
This manual contains the information needed to install, use and service your welding machine.
Follow the instructions to get the best out of your welding machine, in the most economical way and in complete safety.

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1.2 GENERAL SAFETY WARNINGS
THE FAILURE TO OBSERVE THESE WARNINGS AND/OR ANY MODIFICATION OF OR TAMPERING WITH THE WELDING
MACHINE WILL RELEASE P.E.I.-POINT SRL FROM ANY LIABILITIES IN THE CASE OF ACCIDENTS TO PEOPLE OR DAMAGE
TO THINGS AND/OR TO THE WELDING MACHINE ITSELF.
Before turning the welding machine on it is essential that the user knows how to carry out all the operations described in
this manual.
The manual is an integral of the machine and must be kept until it is disposed of.
RESIDUAL RISKS
By residual risks we mean any hazard that could not be totally eliminated with the design or protection means and any potential
hazard that is not evident.
There must not be excessive quantities of dust, acids, corrosive substances or gases etc., on the
premises except those generated by the welding machine.
We recommend keeping an extinguisher near the workstation.
It must not be excessively humid on the premises.
We recommend using an insulating platform.
All maintenance jobs must be done on the machine only after having disconnected it from the
electricity mains.
Mind your hands when working; always keep them well away from the electrodes and moving parts
when welding.
The strong magnetic field that the welding machine generates during welding can be dangerous for
people wearing pacemakers.
Watches and electronic devices in general, if placed near the welding machine, can be damaged.
Only use the spot welder on a horizontal plane.
If it slants more than 15° with respect to the floor it could tip over.
An incorrect adjustment of welding pressure, an erroneous setting of parameters or malfunctioning
of the pneumatic system can all cause squirts of melted material during welding.
The electrodes become very hot during welding. Do not touch them with your bare hands
immediately after welding.

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1.3 PREVENTION MEASURES TO BE TAKEN BY THE USER
▪We recommend wearing safety glasses.
▪The user must observe the safety instructions given on the welding machine.
▪Personal protection gear must comply with and be certified by current standards.
▪Signs must be placed in the vicinity of the machine relative to the risks that call for personal protection gear.
▪It is compulsory that the user observe the accident prevention laws in force in his country.
▪Just one operator who has been specifically trained to use welding machines and welding equipment can use the welding
machine.
▪Install a suction unit if the material to be welded produces fumes.
▪The operator must wear glasses to protect his eyes against squirts of melted material, a protective apron and leather gloves.
▪The operator must avoid wearing metal objects (bracelets, watches etc.)
▪Routine and extraordinary maintenance jobs must only be done on the machine after having disconnected the power sources
(electricity, pneumatic power).
▪Make sure the machine is earthed effectively and protected by a suitable RCD/CB.
1.4 TECHNICAL DATA
FAST SPOTTER 3,5 E
400V 230V
FAST SPOTTER 5.0
400V 230V
Rated Power output at 50% duty cycle
kVA
2,8
5
Sec. short circuit current
kA
3,0
4.0
Secondary voltage
V
6,6
6.3
Single-phase supply voltage
V
400 230
400 230
Nominal frequency
Hz
50 *
50*
Delayed fuses
A
10 16
10 16
Dimensions WxDxH
mm
320*345*280
320*345*280
Weight
Kg
20
32
Spotter Gun
Welding capacity
mm
0,8+0,8
1 + 1
Section cables
mm²
95
95
Gun cable length
mm
1800
1900
Earth cable length
mm
1800
1500
* other frequency on request
1.5 INTENDED AND NON INTENDED USE
The failure to observe the prescribed instructions constitutes a condition of improper use from a technical point of view
and as regards the safety of people.
Intended use conditions
P.E.I.-POINT SRL welding machines must only be used for welding metals keeping within the power limits given on the data plate.
Only one trained operator is allowed to use the machine, who has experience in handling welding equipment.
Non intended use conditions
P.E.I.-POINT SRL welding machines cannot be used to exert pressure or deform materials.
It is forbidden to weld materials that can generate toxic vapours or cause explosions due to heating.

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1.6 DESCRIPTION OF THE PRODUCT AND HOW IT WORKS
P.E.I.-POINT SRL spot welders belong to the family of resistance type welding machines.
By this we mean autogenous welding obtained by pressure, without using weld material, using the thermal effect of electricity flowing
through the components to be welded (Joule effect) for heating.
The components to be welded are gripped between two electrodes with a dual purpose: to let electricity pass through and to exert
enough force for welding.
The intensity of the current, the force on the electrodes and weld time are the most important parameters for welding. Force must be
applied during the electrodes’ squeeze time phases, weld time and holding time.
The welding cycle phases are managed by the welding control unit; the times set are given in mains periods (1/50th of a second if
mains frequency is 50 Hz).
The main switch turns the welding machine on (item 6) which also has the function of an emergency stop switch.
Welding is started the lever switch (trigger) on the studder gun (2).
The welding machine is equipped with safety thermostats to stop operation if it overheats.

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2. INSTALLATION INSTRUCTIONS
2.1 ENVIRONMENTAL CONDITIONS
Operating clearances
The machine must be positioned to ensure working and maintenance clearances and for any emergency situations that may arise.
For this reason we recommend leaving a clearance of about 1 metre all around the machine.
Environmental characteristics
The place where the machine is going to be used must be suitably illuminated for both production and maintenance, free from dust,
acids, corrosive substances or gases, with temperatures ranging between +5°C and +40°C.
Altitude must be less than 1000 metres.
Relative air humidity: 50% up to 40°C
90% up to 20°C
Floor
The machine must be put on a flat surface that must also be able to withstand its weight.
2.2 ENERGY REQUIREMENT
Electricity
Model
Mains power
(single-phase power) kVA
FAST SPOTTER 3,5 E
5
FAST SPOTTER 5.0
6
2.3 CONNECTION TO THE ENERGY SOURCES
Qualified personnel who can also certify their work must install the machine.
THE INSTALLER IS RESPONSIBLE FOR A CORRECT INSTALLATION AND, IN PARTICULAR, FOR THE CHOICE OF DEVICES
TO PROTECT AGAINST SHORT CIRCUITING, OVERLOADS, LEAKAGE CURRENTS IN THE CASE OF A FAILURE AND OF THE
WIRES USED TO CONNECT TO THE MAINS WHICH MUST COMPLY WITH CURRENT LAWS AND STANDARDS.
THE INSTALLER MUST ALSO CHECK THAT THE EARTHING SYSTEM, TO WHICH THE WELDING MACHINE IS CONNECTED,
IS EFFECTIVE. THE MACHINE MUST BE CONNECTED WITH A PLUG TO THE POWER SOURCE IN ORDER TO BE UNDER
THE OPERATOR SURVEILLANCE.
Electrical connection
Dimensioning of line fuses and the cross section of the supply cables.
With a mains voltage of V1=400V and a mains frequency of f=50Hz.
Model
Normal current
delayed fuses (A)
Supply cable cross section up to
20 metres (mm²)
FAST SPOTTER 3,5 E
10
4
FAST SPOTTER 5
16
6
-Check machine plate data before connecting it (voltage rating, nominal frequency and number of phases).
-Connect the welding machine to an RCD with a minimum current dispersion of 30 mA.
-The welding machine must be protected with either delayed line fuses or a circuit breaker with the values given in the above
table.

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2.4 DATA ON TRANSPORTING, STORAGE AND ASSEMBLY
Shipping
Make sure that the means used to transport the welding machine is strong enough to withstand its weight.
Pay attention to the air connections and projecting parts to avoid any damage being done.
The weights of the different models are given in the technical data.
Unpacking - Assembly
Remove the packaging from the welding machine with care, checking that all the accessories are inside and that nothing has be en
damaged during shipping.
THE PEOPLE IN CHARGE OF LIFTING AND POSITIONING THE MACHINE MUST BE SUITABLY QUALIFIED.

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2.5 WIRING DIAGRAMS

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3. INSTRUCTIONS FOR THE OPERATOR
3.1 DESCRIPTION OF THE FUNCTIONS
To weld, the operator can either press the green button on the gun or use the lever switch on the studder gun. Squeeze time tests
can be run without welding by pressing the black push button.
When the welding control unit receives consent to start the cycle it performs the welding sequence according to the parameters set
on it.
The sequence can be interrupted at any time by releasing the cycle start push button.
If the start push button is released during weld time, the spot might not be strong enough.
3.2 GUIDE TO STARTING THE WELDING MACHINE FOR THE FIRST TIME
a) power on via the main switch
b) set welding parameters on the control unit (see next paragraph)
3.3 GETTING READY TO WELD
WELDING CYCLE
The welding cycle consists of three basic times:
Squeeze time: it is the interval of time between the start of the cycle and the moment the electrodes, under the
force exerted on them, come into contact with the piece to be welded.
Weld time: this is the time during which the welding current passes through the electrode contact area.
Holding time: this is the time during which the force of the electrodes is maintained after weld time has finished
3.4 INFLUENCE OF THE VARIOUS PARAMETERS ON THE WELDING RESULT
Force on the electrodes
The greater the force is on the electrodes, the weaker contact resistance will be between the electrodes and the sheets and the less
risk there will be of melted material being squirted.
However, the force on the electrodes is limited by the welding machine’s capacity. The greater the force is on the electrodes, the
greater the current value will be to achieve welding.
Weld time
Welding can be achieved with different weld times:
Short weld time: it effects a small area of material being heated but the welding machine’s performance is
( less than 10 periods) superior.
Long weld time: it leaves a heavy electrode mark on the sheets and utilises the machine to the utmost.
( 20-60 periods )
Medium weld time: a good compromise between the two extremes
( 10÷20 periods )