Rocker Arm Resistance Welder 4603NA-4604NA
Contents
1. 10882 44591 PART NUMBER 220 440 V DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 28 32 LORS TECNA 10 CONTROL DOCUMENTATION TE90 ROCKER ARM WELDER 4603NA 4604NA TE 90 is a microprocessor welding control unit for single phase resistance welders The welding control unit is used to control the welder parts and in particular the thyristors adjusting the welding current The working cycle carried out by the TE 90 is described through the programming parameters The TE 90 can be used for both manual and pneumatic operated welders SQUEEZE ACCOSTAGGIO WELD TIME TEMPO DI SALDATURA CURRENT CORRENTE HOLD MANTENIMENTO OFF TIME INTERVALLO 00 COMP OFF 01 COMP ON 00 SINGLE SINGOLO 01 REPEAT AUTOMATICO WELD TIME 2 TEMPO DI SALDATURA 2 CURRENT 2 CORRENTE 2 SLOPE SLOPE COLD TEMPO FREDDO IMPULSE NUMBER NUMERO IMPULSI MAIN FEATURES Synchronous thyristor drive Phase shift control for welding current adjustment Simplified programming by means of four push buttons Twin pre setting for time and current recallable by two independent controls Slope and pulse functions Single and repeat operating mode Secondary current compensation function for welding of oxidized sheets and rods Auto retain disabling for manually operated welders First phase shift delay adjustment It enables the machine line current best balance Control of solenoid valve 24 Vdc 7 2 W Max with protected2. TE 90 is a microprocessor welding control unit for single phase resistance welders The welding control unit is used to control the welder components and in particular the thyristor adjusting the welding current The TE 90 working cycle is described through 12 programming parameters MAIN FEATURES Synchronous thyristor drive phase shift control for welding current adjustment e Simplified programming by means of four push buttons Twin pre setting for time and current recallable by two independent controls Slope and pulse functions Single and automatic repeat operating mode Secondary current compensation function for the welding of oxidized sheets and rods e First phase shift delay adjustment It enables the machine line current best balance Control of solenoid valve 24 Vdc 7 2 W Max with protected output against short circuits e Watch dog safety circuit stopping the welder in case of control unit faulty operation micro interruptions or too high voltage drop For further information concerning TE 90 go to page 29 Control unit function not used on this welder DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 7 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 3 INSTALLATION These paragraphs are addressed to the specialized personnel in charge of both welder handling and installation The welder dimensions drawing placed in last pages of this manual providing useful information for carrying out th
3. as this could produce moisture inside the machine In presence of hard water it is necessary to install a water softener at the cooling circuit inlet hose this to avoid that deposits obstruct or reduce the water channels in the welder thus causing damages If the machine is operated a re circulating water supply the water softener must be placed on the supply of the cooling water tank the insertion before the machine generates damages DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 8 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 3 4 ELECTRICAL INSTALLATION Installation must be carried out by specialized personnel only and must adhere to all local safety rules As this unit can be supplied for different power supply versions before connecting the unit to the power line check if the voltage shown on the features plate corresponds to the one of your power supply Consult the technical features paragraph to determine the cables section to be used according to their length On this paragraph you find also the values of the fuses which must be placed on the welder supply input Fuses must be delayed type only Connect machine to earth by using a cable having the same section of the mains cable In order to facilitate the maintenance operation we recommend you to supply the welder machine by means of a mains disconnecting switch The welder has been designed for work with voltages of 220 or 440 supply It is shipped with the voltage
4. be set to different values according to the type of parameter The minimum and maximum limits of each parameter are described in the following table PARAMETER TRANGE COMPUTER OFF COMPUTER ON 00 01 0 29 cycles 1 50 cycles IMPULSE NUMBER oo ooo FEBRUARY 1997 Page 29 32 LORS TECNA When the pulse function is used that is when the IMPULSE NUMBER is other than 0 the welding time should not exceed 25 periods If this condition is not observed an error is signaled In this way all the parameters are set to the desired value Please notice that it is not necessary to press any push button to confirm the set value as this is automatically stored up after the adjustment When programming step is over it is possible to use the welder without previously confirming the set or the stored data Use the WELD NO WELD function to carry out any test cycle without welding current By means of the here shown proper key it is possible to enable or disable the welding current When the light is on the control unit is set to WELD and it carries out standard welding cycles When the light is off the complete test cycles without welding current even though all the time relevant parameters are preserved 7 WELD NON SALDA During the welding cycle the control unit shall display both the current function and the relevant value DESCRIPTION OF THE WORKING CYCLE The TE 90 working cycle is described by the user thr
5. circulates in the required activated quantity and or check the correct thermostat working Either SCR or firing module Identify the faulty component and replace it malfunctioning Firing modules led shows the presence of SCR trigger signals Faulty contact in the secondary circuit Check tighten and all the secondary connections Do not forget the electrode and electrode holder connection Insufficient cooling Check that water circulates in the required quantity and at a low temperature Too high welding current or welding time Reduce them Insufficient cooling Check that water circulates in the required quantity and at a low temperature Under sized electrode in comparison with Check both size and contact diameter the work to carry out Insufficient cooling Check that water circulates in the required quantity and at a low temperature Heating caused by an inadequate Carefully tighten the clamping screws clamping of the flexible connection Too high heating caused by a too high Reduce it welding rate DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 19 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 7 3 3 REMEDIES FOR WELDS IMPERFECTIONS This chapter has been introduced in order to facilitate the troubleshooting of the most common imperfections caused by a wrong adjustment Notice that each fault can be caused by different causes as there are many parameters affecting the welding process The following
6. marked on the back and data plate of the machine If you desire a different voltage you must follow the following instructions TRANSFORMER AND CONTROL VOLTAGE CONNECTIONS WELD TRANSFORMER WIRING The transformer your 4603NA is equipped is capable of 220 or 440 volt operation To change the transformer voltage you must insure that the wire are on the correct taps For 220 volt operation be sure that the two wires are on the lower two terminals marked 220V and OV as shown in figure one 220 VOLT OPERATION Figure 1 TRANSFORMER For 440 volt operation connect the two wires to the outer most terminals marked 440V and OV as shown in figure two 440 VOLT OPERATION Figure 2 TRANSFORMER The common wire remains the same for both voltages CONTROL TRANSFORMER CONNECTIONS 0 24 440 380 220 0 m FIGURE 3 Six terminal barrier mounted on the top of the control transformer u A To change voltage loosen screw terminals and insert wire into the re AAC ANE ANA position that matches your line voltage A B To set the voltage on the control transformer follow the directions 1 Locate the control transformer located on the back of the control panel 2 For 440 volt operation there must be a wire install in position A see FIGURE 3 If the wire is not installed in position A remove the wire from position B or C and reinstall it in position A 3 For 220 volt operation
7. not switch on Control unit led ON does not light The control unit does not switch on Control unit led ON is on During the welding the machine stops the welding current The welder does not carry out the welding Control unit START led lights by pressing foot control Control unit CURRENT led is off during the welding cycle The welder does not carry out the welding Control unit START led does not light by pressing foot control The welder does not carry out the welding Control unit START led lights by pressing foot control Control unit CURRENT led lights during the welding cycle Spots or electrodes overheating Electrodes reduced life Secondary connections reduced life Either connectors or cables disconnected Fuse FU1 blown Replace it Faulty main switch Check and eventually replace it Faulty control unit Replace it Inadequate mains voltage Faulty control unit Too high voltage drop Check that when working voltage drop is lower than 25 On the contrary check that supply cables section is adequate to their length WELD NO WELD function set to NO Set to WELD WELD Faulty control unit Replace it The foot control does not activate the Check start cycle micro switch Faulty set up of the force adjusting screw Either disconnected connectors or cables Faulty micro switch Replace it Faulty control unit Replace it Thermostat ST1 placed on SCR Check that water
8. welding rating The following paragraphs carefully explain these different phases Before starting the working process Check that all the safety instructions have been operated Make sure that the microswitch is triggered at least 1 inch before the pedal touches the ground Before starting the welding process check the welding conditions time pressure etc Use two off cuts of the sheet to weld carry out two spots at the same distance used during the production then remove the first and check the second the spot is correct when the pulling test causes the coming out of the weld nugget with the hole of a sheet and the twist test shows a pure area without porosity or causes the coming out of the nugget X SAME DISTANCE OF SPOTS IN PRODUCTION REMOVE THE FIRST SPOT FIRST SPOT Va N TWIST TEST PULLING TEST During the production it is advisable to monitor those parameters which can alter the working conditions and thus the welds quality Always monitor the electrodes which must always be clean without any deformation and must have the proper diameter according to the work to be carried out Check that there is not strong changing in the welder supply pressure as this could modify the force on the electrodes and thus the welding quality Do not use sealing products to remove water losses on the electrodes conic connection To facilitate the electrode removal and to prevent from bo
9. will block the welder functioning To restore the functioning press a push button The current limit is adjusted by means of an internal trimmer by the welder manufacturer The standard value is usually about 1500 2000 A By means of JP2 jumper located on the card is possible to disable this function COMPENSATION JUMPER JP2 OPEN OFF CLOSED DELAY FUNCTION OF FIRST PHASE SHIFT This function allows to obtain the best machine line current balance Simultaneously press push buttons 4 and m for about one second to carry out the adjustment The CURRENT function lamp flashes and the display shows the actual set value As usual the adjustment is carried out by pressing push buttons H El The value can be set from 35 up to 99 When the programming is over press 4 or WM As this adjustment is carried out by the welder manufacturer the user does not need to modify this value AUTO RETAIN FUNCTION As usual when the current flow starts the welding control unit ends the welding cycle even if the cycle start control is disabled This function is called auto retain function In TE 90 it can be disabled to use the control unit for manual operated welders In this case if the cycle start signal is disabled during the machine cycle the control unit will immediately stop the welding current flow and disconnects the solenoid valve In both cases the control unit immediately stops the cycle and opens again the electrodes whene
10. 6 58 78 DISTANGE BETWEEN SPOTS FA qe OVERLAPPING P DOCUMENT NUMBER 1053 EDITION FEBRUARY 1997 Page 21 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA Crossed Rods Welding of Cold Drawn Low Carbon Steel Rod diameter Set down 15 Electrodes force Welding current inches Lbs kA 1 16 3 16 N B In the welding of reinforced concrete rods there are cases which the same parameters be used to weld different much higher diameters td A B BEFORE WELDING AFTER WELDING 8 2 PRODUCTION FORM FACSIMILE FIRM DATA WELDER DATA Welder Model Number Welding transformer connecting positions PIECE TO BE WELDED Description Code WELDING PARAMETER ADJUSTMENT Reached welding current kA Working stroke adjustment mm Arms length adjustment mm WELDING CONTROL UNIT NOTES CONCERNING EITHER ELECTRODES OR WELDING TOOLS TE90 PARAMETERS Electrode type and diameter maintenance and electrode replacement terms etc SQUEEZE er i a ae es WELDTIME EE Ho NN Frere Se anm yes MT eR KEE Ms i DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 22 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 9 TECHNICAL DOCUMENTATION The following technical documentation is addressed to the factory responsible in charge and to the person
11. LING CIRCUIT CONNECTION DATA bar Minimum water pressure a 58 Hoses inside diameter input output 8 mm 3 8 inch Minimum consumption for nominal power 180 I h 48 gal h 2 5 ADDITIONAL FEATURES ae Standard gray RAL7032 Machine painting color Aerial noise produced Continuous equivalent acoustic Pk level a weighed value Measurement position h 1 60m 1 0 5 Measurement conditions working stroke mm 20 welding time cycles 17 welding current 11 working rating welds min 10 DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 6 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 2 6 WELDER MAIN FEATURES Rocker arm foot operated spotwelder with microprocessor welding control unit Adjustable arms enabling to adjust the welder according to the work exigencies Chrome copper electrode holders for heavy duty and long life designed for both straight and angled assembling Adjustable electrodes stroke enabling to reach the max working rate Water cooled transformer with epoxy resin coated windings Water cooled arms electrode holders and electrodes Synchronous SCR contactor insulated from cooling water circuit with protection thermostat Adjustable electrodes force microswitch starts the welding cycle when the desired pre set value is reached by operating the foot control e Foot control adjustable in length 2 7 WELDING CONTROL UNIT TE 90 DESCRIPTION
12. LORS TECNA 1090 LOUSONS ROAD UNION NEW JERSEY 07083 USA Tel 908 964 9100 Fax 908 964 4492 email sales lors com ROCKER ARM RESISTANCE WELDER MODELS 4603NA 4604NA USER MANUAL DOCUMENT NUMBER MAN 1053 EDITION FEBRUARY 1997 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 2 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA INDEX 3 3 UNPACKING AND TRANSPORT 3 COOLING WATER INSTALLATION 3 4 PRODUCTION FORM e TecHNCaLDOCUMENTATON MACHINE OVERALL DIMENSIONS w f a coounGemcurommNG T gt 10 CONTROL DOCUMENTATION TE90 N 1 2 3 1 2 3 5 6 7 1 PLACE OF INSTALLATION 2 3 1 2 3 1 2 3 1 2 DID P DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 3 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 1 INTRODUCTION 1 1 PRELIMINARY REMARKS CAREFULLY READ THIS MANUAL BEFORE INSTALLING AND OPERATING THE WELDER This manual is addressed to the factory responsible in charge who must release it to the personnel in charge of both welder installation use and maintenance He she must check that the information stated on this manual and on the enclosed documents have been read and understood The manual must be stored in a well known place in an easily accessible area and must be looked up each time
13. NA ROCKER ARM WELDER 4603NA 4604NA 4 4 CALCULATION OF THE MAXIMUM WELDING RATING Before starting the production it is necessary to check that the welding rating does not exceed the maximum welding rating allowed by the welder in comparison with the set welding conditions time and current otherwise causing a too high over heating To carry out this test it is necessary to know the used welding current which must be measured with an adequate welding ammeter The welder maximum welding rating is the function of the thermal load applied to the welder itself depending from both the used time and welding current and from the numbers of welds for unit of time With these different parameters it is possible to define the li value that is the equivalent thermal current at the duty cycle of 100 Its value is calculated as follows welding cycles per minute X welding current in kA 3600 The resulting value must be lower than the welder maximum one this value is stated on the Technical Features paragraph On the contrary it is necessary to reduce the welding rate When two different welding programs are employed the value of the two welds must be calculate separately then added in order to obtain the equivalent total value Example 1 Single welding program Welding current 8000 A welding time 18 periods 5 welds per minute 18 x 5 x 8000 SEN 3600 Example 2 Two different welding programs 2 welds pe
14. e can be adjusted by carrying out the following operations 1 Remove the safety protection 39360 2 Slacken lock nut 10262 by means of the box wrench supplied with the standard accessories 3 Adjust the working stroke by turning the cylinder stem by means of an Allen key 8 mm The adjustment is carried out considering that when clamping the pieces to weld the arms must be in a parallel position 4 Carefully tighten nut 10262 5 Assemble again safety protection 39360 The stroke limiting device 70146 placed on the welder front side enables adjustment of the foot control and thus to reduce the working stroke Set it up to get the foot control desired height DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 12 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 4 2 ELECTRODE FORCE ADJUSTMENT The welding force must be selected taking into consideration both tables and personal experience and in relation to the sheets thickness the desired spot quality etc An excessive electrodes force can cause Leave weld marks Shorten electrode life Weak welding or false welding due to a reduction of the contact resistance which allows the current to pass through without bringing the piece to the melting temperature An insufficient force on electrodes can cause Spatters of melted material Stuck weld of the pieces on the electrode bad outside surfaces The electrode force is adjust
15. ed by operating on screw 10371 which alters the load on a spring The electrode force cannot be measured unless one has a dynamometer If this is not the case the adjustment has to be made by trail and error effecting test welds on material similar to that one to be welded 4 3 WORKING PROGRAM ADJUSTMENT This operation enables to choose the welding parameters and to enter them directly on the welding control Select parameters from tables or personal experience taking into consideration the plate thickness the welding desired quality etc It is recommended to cut coupons of your material and make sample welds to help determine your parameter values We suggest to use short welding times to reduce the electrodes heating thus increasing their life at the same time avoiding oxidation on the contact surfaces The best quality welds are obtained by using times as short as possible with high current and high electrode force Notice that when operating pieces with different thickness the welding parameters to be used are those which refer to the lower thickness We recommend to set SQUEEZE parameter to 1 5 cycles Parameters HOLD and OFF not used on this welder can be set to 0 When the current has stopped the electrodes must be kept closed for a few moments this to avoid the spot being stressed before sufficiently cooled This precaution enables to improve the weld quality DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 13 32 LORS TEC
16. elding time x impulse number is higher than the limit of 150 cycles Do not exceed this value so as not to overheat the machine The compensation function is enabled and the control unit has extended the welding time up to the maximum limit of 99 periods The set welding time has not been carried out with a welding current higher than the limit EDITION FEBRUARY 1997 It signals that control unit is generating the control impulses for SCR NX It signals that the solenoid valve is on Press a push button to cancel the error Check all the values set in the parameters and correct them if necessary Apply to the after sale service if the trouble occurs frequently Press a push button to cancel the error Set the welding time to a value lower or equal to 25 cycles Press a push button to cancel the error Decrease the welding time or the impulse number so that their product is lower than 150 cycles Press a push button to cancel the error Before restart the welding process check the welding conditions If the pieces are too oxidized they must be cleaned Page 32 32
17. ese operations 3 1 PLACE OF INSTALLATION The welder must be installed in a position to allow the following features e Ina controlled enclosed environment The welder has not been designed for being used outdoors Room temperature included between 0 and 40 C If water is removed storage is allowed down to 20 C below 0 1000 m maximum altitudes Ina well ventilated area free from dust steam and acid exhalations The working place must be free from inflammable materials because the working process can produce spatters of melted metal e Around the welder there must be enough room to carry out both working and maintenance in a comfortable manner and without any risk e Ina place with a suitable lighting system in comparison with the work to be carried out The place of installation must necessarily be flat and the ground must be without unevenness which can be dangerous during the working If the welder is used to carry out welding processes which can cause smoke exhalations there must be installed a proper aspirator The welder must be carefully fixed to the floor through the proper holes placed on the welder basement Do not install nearby the welder neither supporting tables nor equipment limiting the approaching to the devices and or making inaccessible or ineffectual the safety devices 3 2 UNPACKING AND TRANSPORT On receipt of the welder verify the perfect integrity of the outer package report to a res
18. even little doubts should arise This welder has been designed for resistance welding of ferrous materials The welder must not be used for other applications i e pieces heating mechanical working carried out by using the electrodes force The welder has been designed for being used by an operator by means of the foreseen control devices All modifications even slight ones are forbidden TEGNA S p A is not responsible for any damage to both people animals things and to the welder itself caused by either a improper use or the lack or the superficial observance of the safety warnings stated on this manual nor is it responsible for damages coming from even slight tampering or from the use of not suitable spare parts or of spare parts other than the original ones 1 2 SYMBOLS ON BOTH WELDER AND MANUAL WARNING Important safety information enclosed in this paragraph 1 3 STANDARD ACCESSORIES The welder is supplied equipped with the following accessories N 1 Allen wrench set 4 5 6 8 mm N 1 Socket wrench 30 32 mm N 1 TE90 control unit instruction manual N 1 Welder use and maintenance manual Check that the welder is equipped with all the standard accessories immediately inform the manufacturer in case some components are missing or damaged DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 4 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 2 TECHNICAL FEATURES 2 1 IDENTIFICATION DATA pm Mai
19. from possible damages caused by frozen water ELECTRIC CIRCUIT Electric circuit maintenance must be carried out only by specialized personnel trained to accomplish it under safety conditions Disconnect electric mains before carrying out the following instructions Periodically check the ground efficiency Check the power supply cable status Often check the proper functioning of the machine the microswitch has to be triggered at least 1 inch before the pedal touches the ground DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 17 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 7 2 EMERGENCY CONDITIONS WARNINGS In case of emergency turn off the main switch immediately stopping the welder working In case of any water leakage which could enter the welder immediately disconnect the electric supply In case of fire do not use water but proper fire extinguishers The placing in service of the welder after an emergency condition must be carried out only by qualified personnel trained to accomplish all the machine necessary tests If the machine stopped during the welding process it is necessary to execute the following procedure before restart the production in order to restore the normal transformer magnetization condition carry out some welds with an insulator placed between the electrodes with different current adjustments first low ones then progressively higher remove the insulator between electrodes and execute s
20. he best performances can be reached by using sand paper folded upon a support having the same thickness of the sheets to weld In case of steel welding the electrodes diameter should correspond to the values shown on the following table Sheet thickness 0 5 0 8 1 1 5 2 2 5 3 3 5 inches 021 031 040 062 078 094 109 125 Reauired diameter mm 4 4 5 5 6 7 7 5 85 9 5 q inches 0 16 0 18 0 20 0 23 0 27 0 29 0 33 0 36 Suggested electrode tip angle is 120 degrees If the thickness of the two plates is different the electrode must have the diameter corresponding to the one required by the plate to which it gets in touch A too small diameter in comparison with the thickness to be welded produces spatters of melted material sheets over mark low spot quality If the electrode diameter is too large longer welding times are necessary causing a higher heating of the welder and a shorter life of the electrodes For aluminum spot welding we suggest to use spherical electrodes radius value varies according to the thickness to be welded and to the kind of quality required 100 120 0 8 mm 031 DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 11 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA Working Stroke Adjustment Adjust working stroke as short as possible to get Higher productivity Higher working precision Reduced chance of accident The working strok
21. high welding current Reduce it Inadequate electrodes diameter Restore it to the correct dimensions Inadequate welding force Increase the welding pressure DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 20 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 8 ENCLOSURES 8 1 WELDING TABLES In order to facilitate the search for the best welding conditions we have inserted the following tables stating the approximate adjusting values Notice that the same weld can be carried out under different working conditions so much so that the following data are not binding ones Low Carbon Steel Spotwelding Welding class A Thickness Spots min Minimum Electrodes Electrodes Welding Welding Obtained distance overlapping force current time nugget a D min d max d1 inches inches inches inches inches pounds cycles inches 3 8 200 021 3 8 300 031 400 040 3 4 5 8 500 Welding class B Thickness Spots min Minimum Electrodes Electrodes Welding Welding Obtained distance overlapping force current time nugget a inches inches inches pounds cycles ET OE EJ oan as me w ane 20 s w 16 5 40 8 24 23 062 1 58 ss 14 so gt Welding class C Thickness Spots min Minimum Electrodes Electrodes Welding Welding Obtained distance overlapping force current i nugget inches pounds 58 58 58 58 51
22. ient regulation of this time causes the formation of flashes between the electrodes and the sheet at the beginning of the welding process this inconvenient could lead to an unsteady quality level Should the cycle start signal be disabled during the squeeze time then the sequence is interrupted WELD TIME The WELD TIME parameter indicates the current flow duration It will be carried out with the power value indicated in parameter CURRENT When the pulse operation is on this parameter signals the duration of each pulse CURRENT The value expressed in CURRENT indicates the welding operating power HOLD The HOLD parameter describes the time elapsing between the end of the welding process and the opening of the electrodes It enables a shorter cooling of the welding spot and avoids its stress before a proper cooling OFF TIME The OFF TIME parameter describes the machine waiting time elapsing between one machine cycle and the other when the welder is used in repeat mode SINGLE REPEAT set to 01 HO COMP OFF COMP ON By setting this parameter to 01 the secondary current compensation function is enabled By setting the parameter to 00 the function is disabled When working the relevant led shows that this function is activated 30 32 LORS TECNA SINGLE REPEAT By setting this parameter to 00 the machine will operate in SINGLE mode the control unit carries out only one welding cyc
23. le whenever a cycle start signal has been received By setting this parameter to 01 the machine will operate in REPEAT mode the welder will go on carries out welding cycles until the cycle start signal is released Welding cycles are repeated with a time interval as defined in parameter OFF TIME When working the relevant led shows that REPEAT mode is activated WELD TIME 2 Should the cycle be enabled with the cycle start signal START 2 by means of either a second foot control or a proper selector the control unit carries it out considering this welding time adjustment instead of the one set in the WELD TIME parameter If this time is set to zero then the control unit will carry out the welding cycle following the main parameters CURRENT 2 The CURRENT 2 parameter indicates the welding power adjustment whenever the cycle has been carried out starting from the second start of cycle signal START 2 If this parameter is set to zero the control unit will perform the welding cycle following the main parameters SLOPE The SLOPE parameter describes the time used to reach the programmed welding current The initial value of this slope always corresponds to the minimum current value while the final value corresponds to the current value programmed in parameter CURRENT or CURRENT 2 The slope of this parameter is automatically calculated by the microprocessor according to the programmed values COLD The COLD paramete
24. nd frequency of the welder they must be assembled on Available accessories 70379 Additional electric foot for carrying out welding processes with direct recall of welding program no 2 equipped with stirrup for the connection to the main foot Cable L 1 4 m 4566 Brass arm with reduced overall dimensions 65 D 40 L 300 mm L 380 700 mm 4569 Brass arm with reduced overall dimensions with frontal electrode 50 D 40 L 300 mm L 380 700 mm Item 4566 Item 4569 l Check LORS Machinery catalog for additional accessories and expendable materials DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 16 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 7 MAINTENANCE 7 1 ORDINARY MAINTENANCE This chapter states the necessary maintenance operations to be carried out for 1 Keeping the welding unit safe operating and preserving its efficiency 2 Avoiding the most common causes of improper operation causing poor weld quality GENERAL WARNINGS Always disconnect both electrical supply before carrying out the following maintenance operations Always keep the screws of both arm electrode holders and rigid flexible connections well tightened Remove possible oxidation from secondary circuit with fine sandpaper e Periodically lubricate with grease and some drops of oil the joints 30107 30107 30521 30382 Keep welder clean from dirt and metal scraps attracted by magnetic field generated by the welder d
25. nearby the electrodes In case of water entering the welder immediately stop the electrical supply Notice that these types of machines generate strong magnetic fields attracting metals and damaging watches magnetic cards and magnetic data storage media Since these magnetic fields can affect pace makers the wearers must consult their doctor before approaching to the welding area The personnel must wear both safety glasses and gloves Avoid wearing rings metal watches and clothes with either metal accessories or components When operating heavy working high thickness and pieces with a difficult coupling wear safety shoes and aprons and use protection screens to protect the operator from possible spatters of melted materials The safety shoes must be worn each time the pieces because of their shape or weight bear risks requiring them Keep the welder nearby working area free from flammable materials In case the material to be welded produces either smoke or exhalations install a proper aspirator in a well ventilated area In addition to the information stated on this chapter always operate in accordance with all the relevant laws in force DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 15 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 6 ACCESSORIES AND SPARE PARTS REQUEST When ordering accessories spare parts or expendable material please always state type of machine year of manufacture serial number the voltage a
26. nel in charge of both welder installation and maintenance It contains useful information for carrying out these operations CABLE INPUT AIR INPUT OUTPUT WATER ALL DIMENSIONS IN mm 1 INCH 25 4 mm l Machine Overall Dimensions DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 23 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA Electrical Drawing DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 24 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA WATER INPUT lt gt WATER OUTPUT Cooling Circuit Drawing DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 25 32 ROCKER ARM WELDER 4603NA 4604NA LORS TECNA 9900 28185 oe 26101 28202 89002 1200 25201 6SOOL 0200 0 L2v0T 6 5 20001 09 6 8920 290 AKA AG EDITION FEBRUARY 1997 Page 26 32 DOCUMENT NUMBER MAN1053 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 10242 10024 30792 TRANSFORMER A PART NUMBER POWER SUPPLY 4603NA 4604NA PART NUMBER REFERENCE Right bracket Upper arm holder Upper electrode holde Screw Screw gt 3 DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 27 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 30035 D Nye EA gt lt Be eo 274 10356 10483 a Be gt i
27. ns voltage 220 440 V 2 2 ELECTRICAL DATA Jama am mnsvoiee vm em 1 o em 1 Nominal power BE EEN yee m 1 Maximum welding power w o o Shortcut secondarycumem a s mm 1 Maximumweldng curentonstesl a e we 4 Secondary thermal curent at so mo Secondary atemate volage v e ag 1 o Mains cables section for L 10 m Mains cables section for L 30 m Supply transformer minimum power Section for every cable calculated for PVC insulated single conductor cables considering the welder working at the maximum welding power as well as a 4 voltage drop on cables Approximate value calculated for a three phase transformer with a 4 short circuit voltage with 6 voltage drop on transformer and a 4 voltage drop on cables with the welder adjusted for the maximum welding power 2 3 MECHANICAL DATA mm am in coroados O force ate var wonsa ax workngstoke _ E elecrodes vost Eecrode fore av bar O Max working stroke 85 mm 3 1 4 inch je Fe Electrode holder diameter 25 4 mm 1 inch Standard 2MT SRW Electrodes cone Special i FEER Net weight of the machine 124 124kg 275 lbs 275 124kg 275 lbs DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 5 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 2 4 COO
28. ome welds with a low current adjustment at this point the procedure ends and the normal functioning conditions are restored 7 3 EXTRAORDINARY MAINTENANCE This chapter states the maintenance operations to be carried out in case of 1 lowering of the welder performances 2 welder not operating correctly 3 welding faults 7 3 1 LOWERING OF THE WELDING UNIT PERFORMANCES Extraordinary maintenance must be carried out by specialized personnel only equipped with the proper instruments and trained to accomplish it under safety conditions When possible the welder must be disconnected from the electric supply If the performances are lower than expected check That when welding line voltage drop is lower than 15 That the supply cables section is adequate That the electrodes diameter is appropriate for the work to be carried out That cooling water circulates in the required quantity 7 3 2 TROUBLESHOOTING Troubleshooting must be carried out by specialized personnel only equipped with the proper instruments and trained to accomplish it under safety conditions When possible disconnect the electric supply In case of a malfunctioning welder follow the instruction stated on table 1 to find out both fault cause and remedy DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 18 32 LORS TECNA Table 1 Troubleshooting ROCKER ARM WELDER 4603NA 4604NA FAULT CAUSE REMEDY The control unit does
29. ough the regulation of all programming parameters These parameters indicate the operating times and the current adjustments characterizing the working cycles whenever performed consecutively The following chart shows the order the programmed functions are carried out 5 LI a 5 The symbols refer to the programming parameters described in the following paragraph Due to safety reasons the microprocessor does not start the welding cycle when the cycle start signal is enabled during the welder connection in this case disable the control and then enable it again Any micro interrupts or excessive voltage drops block the control rather than altering the operation to reset the operation turn the machine off and then turn it on again DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 ROCKER ARM WELDER 4603NA 4604NA DESCRIPTION OF THE PARAMETERS All the following parameters indicating a period of time are expressed in mains cycles also called periods The mains frequency defines the length of a cycle Mains frequency of 50 Hz 1 period 20 ms Mains frequency of 60 Hz 1 period 16 6 ms SQUEEZE The SQUEEZE time is the time interval elapsing between the beginning of the electrode movement and the beginning of the welding cycle The set value should be long enough to allow the electrodes to reach the correct tightening force before the beginning of the welding process An insuffic
30. output against short circuits TECHNICAL DATA f 24 Vdc 10 20 Electronic circuit supply 50 60 Hz Consumption TANTEI pugi 21 VA when welding Operative temperature 5 40 C PROGRAMMING THE WELDING CONTROL UNIT Straight after the control unit is switched on the display shows the program version after a few seconds the TE 90 equipment is set in a waiting condition enabling the operator either to carry out the programming or any welding process The control unit is programmed through the regulation of all parameters describing the welding cycle select the DOCUMENT NUMBER MAN1053 EDITION ON ACCESO START INIZIO CICLO START 2 INZIO CICLO 2 AUX AUSILIARIO CURRENT CORRENTE SOLENDOID VALVE ELETTROVALVOLA TE 90 concn VALUE VALORE WELD SALDA NO WELD NON SALDA parameters and set the desired values one by one See the relevant paragraph to better understand the meaning of each parameter The parameters are marked with international symbols which are listed on the left side of the control unit Each parameter is combined with a pilot light Select the parameters by means of push buttons and M the pilot light cor responding to the selected parameter lights on and its value is shown on the display Change the welding parameters value by means of push buttons and 5 thus increasing or decreasing the value shown on the display The parameters can
31. ponsible person in charge any possible anomalies which should be noticed Possible damages on the outer package should arise some doubts on the integrity of its content Remove the package and visually verify the welder integrity Check that the welder is equipped with all the standard components immediately inform the manufacturer in case some components are missing All the material forming the package must be removed according to the present environmental protection regulations The welder barycentre is high from ground For this reason the welder must be moved only by means of the proper attachment placed on the top of the welder Consider the welder weight stated on the TECHNICAL FEATURE paragraph 3 3 COOLING WATER INSTALLATION For a correct cooling of the welder it is necessary clean water at a maximum temperature of 30 C at the quantity stated on the paragraph Technical features When connecting the unit to the water line check for dirt or packing scraps in the hoses and connect the supply to the inlet and the drain to the outlet this to allow that the still cool water immediately reaches the parts of the welder most subject to heating Different cooling circuit systems are available with city supply water with re circulating water with heat exchanger air water and with refrigerator If the circuit is with city supply or refrigerator and you are working in presence of high humidity we suggest to avoid the use of low temperature water
32. r is used in the pulse operating mode and indicates the time elapsing between one welding pulse and the next one IMPULSE NUMBER The IMPULSE NUMBER parameter indicates the number of impulses used to carry out the welding process When this parameter is set to 0 the pulse operation is disabled The length of each impulse corresponds to the time set in the WELD TIME or WELD TIME 2 parameter When working the relevant led shows that this function is activated DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 ROCKER ARM WELDER 4603NA 4604NA COMPENSATION FUNCTION OF SECONDARY CURRENT The compensation function of secondary current is used to facilitate the welding process of oxidized sheets and rods The pieces oxidation blocks the current flow during the first welding phase thus limiting in a different way depending from the welding process the real time of current flow The compensation function controls the welding current by means of a coil located inside the secondary circuit Until the welding current does not exceed a pre set limit the welding time is automatically extended up to a limit of 99 cycles In this way it is possible to carry out welding processes with an always constant real time of current flow If after having reached the 99 welding periods limit the current limit is not exceeded the control unit will indicate that the welding process has not been correctly carried out by displaying the E4 error and
33. r minute with welding current 9000 A welding time 13 periods 6 welds per minute with welding current 5000 A welding time 8 periods 13 x 2 x 9000 ee 3600 8 x 6 5000 re eee DT 3600 In Tiny Im 765 578 1343A DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 14 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 5 SAFETY RULES For a safe welder operation the installation must be carried out by specialized personnel following all the instructions stated on the INSTALLATION chapter The welder maintenance must be carefully carried out by following all the safety instructions stated on the MAINTENANCE chapter The welder should be operated by trained personnel only in any case users operating the welder must be aware of the possible risks and must have both read and understood this manual Only authorized personnel can carry out the welder adjustment The welder adjustments affect the operative safety so much so that they must be carried out by qualified personnel only Carefully follow the instructions stated on the WORKING PROCESS chapter It is forbidden to have multiple people working on the welder at the same time Only the operator should be in the work area during machine operation It is necessary to pay attention to the movement of the movable components It is suggested to adjust the working stroke to the minimum allowed value and avoid working with the hands
34. table specifically refers to low carbon steel spot welding but with the due considerations it can be usefully used also for other applications FAULT POSSIBLE CAUSE POSSIBLE REMEDY Weak welding Low welding current Increase it Low welding time Increase it Too high electrodes force Reduce pressure Lacking electrodes maintenance or too Clean and line up the electrodes restore high electrodes diameter their dimensions Faulty pieces contact Increase the electrodes force Spatters of melted material Paint or dirt among pieces Clean the pieces Inadequate electrodes cooling Check the cooling circuit Faulty pieces contact or pieces and Increase the electrodes force by increasing electrodes faulty contact pressure Too high welding current Reduce it Too high welding time Reduce it Too small electrodes diameter Adjust diameter to the value shown on the table Inadequate welding force Increase pressure Electrodes faulty clamping of the Check stroke pieces Burned welds or welds showing either Too high welding current Reduce it craters or fissures Inadequate welding force Increase welding pressure Oxidized pieces to weld Clean them by means of emery paper Faulty pieces contact or pieces and Increase electrodes force electrodes faulty contact Faulty pieces lining up Correct it Electrodes tips deformations Restore them to the correct size Pieces stuck weld on the electrode Too
35. th cone seizure and water losses use high conductivity grease similar to the standard one The cooling water must circulate inside the welder for a few minutes after having completed the production in order to allow the welder cooling To prevent from both losses and moisture deposits do not leave the cooling circuit open when the unit is not used Electrodes must not be used to force the clamping of the pieces to weld We recommend you to notice the adjustments carried out for each type of piece In order to make it easier a specific table has been added at the end of this manual DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 10 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 4 1 MECHANICAL SET UP Arms and electrodes adjustment The arms length can be adjusted in comparison with the different working exigencies The lengthening of the arms causes a decreasing of the performances so that it is advisable always to work with the shortest available length Under working conditions both arms and electrodes holder must be adjusted in order to have the electrodes tip coincide Carry out some tests with the control uniton NO WELD mode using the same electrodes force employed to carry out the work place among the electrodes a thickness equal to that which must be weld If it is necessary pull out both arms and electrodes holder and carry out the adjustment operations It is advisable to adjust electrodes with a fine file or with sandpaper T
36. the wire must be installed in position B see FIGURE 3 The wire must be installed in position A or position B not in both The position of the labeled wire are not to be changed The only wire you can change is on the opposite side of the labeled wires on the Terminal Barrier DOCUMENT NUMBER MAN1053 EDITION FEBRUARY 1997 Page 9 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA 4 WORKING PROCESS The welder has been designed for being used by an operator placed in front of the unit and operating on the welder same working plane When arranging the working place always follow the herewith stated instructions Use a well ventilated area free from dust steam and acid exhalations The working place must be free from flammable materials because the working can produce spatters of melted metal Around the welder there must be enough room to carry out both working and maintenance in a comfortable manner and without any risk If the welder is used to carry out welding processes which can cause smoke exhalations there must be installed a proper aspirator Do not install on the welder neither supporting tables nor equipment which either limit the approaching to the devices or make inaccessible or ineffectual the safety devices Before starting the working process carry out the following adjustments 1 Mechanical set up 2 Electrode force adjustment 3 Welding parameters adjustment 4 Calculation of the maximum
37. uring the operation e Never wash the welding unit with jets of water which could enter it or use strong solvents thinner or benzine that could damage either painting or the machine plastic components ELECTRODES MAINTENANCE Electrodes maintenance must be carried out with the welder switched off When operating the electrodes must be kept clean and their diameter must kept suitable for the work to be carried out Worn electrodes must be dressed or replaced When replacing electrodes check that the tube bringing water to the electrode inside stops at a few mm s from the bottom of the electrode hole Do not use sealing products to remove water leakage on the electrode taper To facilitate the electrode removal and to prevent from both taper seizure and leakage use high conductivity grease COOLING CIRCUIT MAINTENANCE Cooling circuit maintenance must be carried out by specialized personnel only trained to accomplish it under safety conditions When possible maintenance must be carried out with the welder disconnected from both electric and pneumatic supply Check that cooling water circulates freely and in the required quantity and that the input temperature 15 included within 10 and 30 Check the status of both water hoses and corresponding connections If during the winter terms the welder must be stored up cool rooms it is necessary to carefully drain the cooling circuit to prevent
38. ver the cycle start signal is disabled during the squeeze phase The auto retain function selection is carried out through jumper JP1 located on the card AUTORETAIN JUMPER JP1 CLOSED OFF OPEN While using electric operated welders this function should always be enabled in order to prevent any welding cycle from having a welding time other than the set one Page 31 32 LORS TECNA ROCKER ARM WELDER 4603NA 4604NA CONTROL PANEL PILOT LIGHTS It signals that the mains voltage is on START INIZIO CICLO START 2 INZIO CICLO 2 AUX AUSILIARIO CURRENT CORRENTE SOLENDOID VALVE ELETTROVALVOLA ERROR LIST DOCUMENT NUMBER MAN1053 lt It signals that the main cycle start control is on D It signals that the additional cycle start control is on It signals that the block control with pressure only is on This input is activated by the first stage of a foot control or by other devices that should hinder the welding process such as for example flow switches pressure switches or the interlocking system of another welder The value of one of the stored parameters exceeds the preset limits This could be caused by a loss of data due to any interference or wrong functioning The welding time is set to a value higher than 25 and pulses operating mode is activated This parameter cannot be higher than 25 in the pulse mode operation Pulses operating mode is activated and the total welding time w
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