CHIEF Electron MultiSpot M25 AL Instruction Manual
US INSTRUCTION MANUAL FOR CAPACITOR DISCARGE
WELDING MACHINE page 2
F MANUEL D’INSTRUCTIONS POUR POSTE A SOUDER
A DESCHARGE DE CONDENSATEURS page 9
E MANUAL DE INSTRUCCIONES PARA SOLDADORA
DE DESCARGA DE CONDENSADORES pag. 16
Spare parts and electrical schematic
Pièces détachées et schéma électrique
Partes de repuesto y esquema eléctrico
Page: 24÷ 27
05/03/2015
3.300.081
2
INSTRUCTION MANUAL FOR CAPACITOR DISCARGE WELDING MACHINE
IMPORTANT: BEFORE STARTING THE EQUIPMENT,
READ THE CONTENTS OF THIS MANUAL, WHICH MUST
BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR
THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.
THIS EQUIPMENT MUST BE USED SOLELY FOR WELDING OPERATIONS.
1 SAFETY PRECAUTIONS
WELDING AND ARC CUTTING CAN BE
HARMFUL TO YOURSELF AND OTHERS. The
user must therefore be educated against the hazards, summarized below, deriving from welding operations. For more
detailed information, order the manual code 3.300.758
NOISE
These power source alone do not produce noise
levels exceeding 80 dB. The welding procedure,
however, may produce noise levels in excess of
80 dB. in which case the machine operator must take the
necessary safety precautions as prescribed by the national safety regulation.
ELECTRIC AND MAGNETIC FIELDS INFORMATION
· Electric current following through any conductor causes localized Electric and Magnetic Fields (EMF). Welding/cutting current
creates EMF elds around cables and power sources.
· The magnetic elds created by high currents may affect
the operation of pacemakers. Pacemaker wearers are
prohibited from using the machine or approach the
cables.
· Exposure to EMF elds in welding/cutting may have
other health effects which are now not known.
· All operators should use the followingprocedures in or-
der to minimize exposure to EMF elds from the welding/
cutting circuit:
- Route the electrode and work cables together
- Secure them with tape when possible.
- Never coil the electrode/torch lead around your body.
- Do not place your body between the electrode/torch
lead and work cables. If the electrode/torch lead
cable is on your right side, the work cable should also
be on your right side.
- Connect the work cable to the workpiece as close as
possible to the area being welded/cut.
- Do not work next to welding/cutting power source.
EXPLOSIONS
· Do not weld in the vicinity of containers under pres-
sure, or in the presence of explosive dust, gases or
fumes. · All cylinders and pressure regulators used
in welding operations should be handled with care.
DISPOSAL OF ELECTRICAL AND ELECTRONIC
EQUIPMENT.
Do not dispose of electrical equipment together
with normal waste! Electrical equipment that has reached
the end of its life must be collected separately and returned to an environmentally compatible recycling facility. As the owner of the equipment, you should get information on approved collection systems from our local
representative.
Extra precautions are to be observed when working
on elevated positions.
Electromagnetic compatibility
In Canada, the EMC classication does not apply to arc
welding power source.
Safety standards
To provide minimum requirements and recommendations to protect persons who work in an
environment affected by welding, cutting, and allied processes see CAN/CSA-W117.2 standard.
IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE
FROM QUALIFIED PERSONNEL.
1.1 WARNING LABEL
The following numbered text corresponds to the label
numbered boxes.
B. Drive rolls can injure ngers.
3
C. Welding wire and drive parts are at welding volta-
ge during operation - keep hands and metal objects
away.
1 Electric shock from welding electrode or wiring can kill.
1.1 Wear dry insulating gloves. Do not touch electrode
with bare hand. Do not wear wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating
yourself from work and ground.
1.3 Disconnect input plug or power before working on
machine.
2 Breathing welding fumes can be hazardous to your
health.
2.1 Keep your head out of fumes.
2.2 Use forced ventilation or local exhaust to remove
fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion or re.
3.1 Keep ammable materials away from welding.
3.2 Welding sparks can cause res. Have a re extingui-
sher nearby and have a watchperson ready to use it.
3.3 Do not weld on drums or any closed containers.
4 Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear protection and
button shirt collar. Use welding helmet with correct
shade of lter. Wear complete body protection.
5 Become trained and read the instructions before
working on the machine or welding.
6 Do not remove or paint over (cover) label.
2 GENERAL DESCRIPTIONS
2.1 SPECIFICATIONS
The machine has been designed and built for welding
ferrous and non-ferrous stud bolts, Ø 3, 4, 5, 6 and 8 mm.
This welding system uses the extremely rapid (2-3 ms)
discharge of a battery of charged capacitors, which allows
the welding of stud bolts with contact point start-up.
2.2 EXPLANATION OF THE TECHNICAL
SPECIFICATIONS LISTED ON THE MACHINE
PLATE
N° Serial number, which must be indicated on any
request regarding the welding machine
1
~
Single-phase transformer-rectier with device
for charging and discharging the capacitors
U0 Secondary open-circuit voltage
E Welding energy
C Capacity value
Uc Voltage adjustable on the capacitors
U1 Rated supply voltage. The machine is set up for
voltages of 120V and 240V with automatic
voltage change.
1-50/60Hz 50- or 60-Hz single-phase power supply
I1 Max Max. absorbed current at the corresponding
supply voltage.
I1 Eff This is the current absorbed considering the duty
cycle at the corresponding input voltage.
IP21S Protection rating for the housing.
Note:
The machine has also been designed for use in
environments with a pollution rating of 3. (See IEC 60664).
2.3 DESCRIPTION OF PROTECTIVE DEVICES
2.3.1 Thermal protection
This machine is protected by a thermostat, which prevents
the machine from operating if the allowable temperatures
are exceeded. Under these conditions the fan keeps
running and the display will show "Warning 08".
3 INSTALLATION
WARNING
See complete listing of safety messages at the beginning
of this manual.
Only skilled personnel should install the machine. All
connections must be carried out according to current
regulations, and in full observance of safety laws.
1. Do not place the welding machine on oor with
inclination greater than 10°.
Air must circulate freely, both incoming and outgoing,
and the welding machine must be protected from entry
by liquids, dirt, metal lings, etc.
2. Make sure that the supply voltage is either 120 volts
and a minimum of 20 amp service or 240 volt and a
minimum of 20 amp service. If connected to a circuit
protected by fuses, use time dely fuse marked "D".
Use a plug Nema type 5-20P for 120 V and make sure
that the "green conductor" of the power supply cable
is connected to the ground or “earth” terminal. Make
sure that the white wire is connected to the W plug
terminal.
Use a plug Nema type 6-20P for 240 V and make sure
that the "green conductor" of the power supply cable
is connected to the ground or “earth” terminal. Make
sure that the white wire is connected to the Y plug
terminal.
The machine must be switched off when changing
the power supply.
3. Pacemaker wearers are prohibited from using the
machine or approach the cables.
4. Fully insert the earth cable plug into the socket B and
turn clockwise.
5. Fully insert the gun plug into the socket C and turn
clockwise.
6. Turn on the welding machine using the E switch.
(start-up and shutdown should not be repeated
frequently, because dissipating the energy contained
in the capacitors may cause overheating and damage).
7. To limit exposure to the magnetic eld, keep the gun
cable on the side of the hand holding it, avoiding
wrapping the cable around.
4
3.1 DESCRIPTION OF THE EQUIPMENT
A- Display for the setting and control of welding operations
B- Positive output terminal
C- Negative output terminal
D- Torch trigger connector
E- Main switch
F- Fuse Ø 6.3x32 (delayed type). The equipment is tted
with a 12A-T fuse.
G- Knob for the setting and control of welding operations.
3.2 GUN DESCRIPTION
K- Gun body
L- Grip
M- Control cable
N- Welding current cable
O- Welding command button (works only with the gun
pressed against the sheet metal)
P- Force setting indicator
Q- Force adjustment screw (increases when turned clock
wise)
R- Ring to hold spacer Z
S- Clamp locking ring-nut
T- Safety bellows
U- Holding screws for ring R
V- Screw to adjust stud bolt protrusion
W- Holding nut.
X- Stud bolt gripping clamp
Y- Screw
Z- Spacer
X
M N L
S Z T
R U
O P QK
Fig. 2
X W V
1÷1,5 mm
Y
3.2.1 Preparing the gun
Always use high-quality studs with contact point startup for capacitor discharge welding, which comply with
standards and are made of a metal compatible with the
welding to be done.
Having selected the stud bolt to be welded for type,
diameter, length and material, use and adjust the gripping
clamp according to the corresponding diameter.
A
B C
G
D
E
F
Fig. 1
5
Insert the stud bolt in the clamp X so that it is rmly held
in place by the four springs.
Adjust the protrusion of the stud bolt from the front of the
clamp to 1 ÷ 1.5 mm using the screw V, then tighten with
the nut W ( gure 2).
Insert the clamp X into the chuck of the gun ( g. 2), press
until you feel it rest all the way down, and tighten the nut
S using the 17-mm hexagon wrench provided.
3.3 DESCRIPTION OF FUNCTIONS SHOWN ON THE
DISPLAY A.
When the machine is switched
on, for a few seconds the
display A will show the
machine item number, version
and development date of the
software.
A few seconds later, the following screen will appear on
the display A:
a
b
f
c
d
e
g h
a Stud bolt
b Base material
c Rivet material and dimensions
NOTE: the maximum rivet length that can be used is
30mm (1-1/4”)
d Type of base material
e Indication as to weld quality.
This symbol with the letter Q indicates that the stud
material and the base material that have been selected
are weldable, poorly weldable or non-weldable (See
table 1).
good weldability
poor weldability
non-weldable
f Indications/warnings during the welding phase.
During welding phases these symbols provide
process-related indications:
f
f steadily lit: indicates that the generator is ready
to carry out a welding operation.
f
f steadily lit: indicates that the stud bolt is in
contact with the base material and
the generator is ready to carry out the
welding operation.
f
f ashing: indicates that, after the welding was
completed, the gripping clamp X of
the gun was not removed from the
stud bolt.
f
f ashinge: indicates that, after the welding
was completed, the start button
and microswitch inside the gun
were pressed during charging of the
capacitors.
g Value suggested by the force of the spring inside the
gun (if the force setting is changed, it is recommended
also to change the value indicated on the display so
that in the future this change will remain memorized.
The change from the suggested value will be indicated
by an arrow pointing upward if it is increased or
downward if it is decreased).
h Charge voltage of the capacitors (if the voltage
setting is changed from the suggested value, it will
be indicated by an arrow pointing upward if it is
increased or downward if it is decreased).
During the adjustment, the voltage value will ash to
indicate that the generator is working to reach the
requested value.
Whilst the voltage value is ashing, it is not possible
to perform any welding operation.
3.3.1 SETTINGS
Press the knob G for at least 2 seconds to open the
“Process Params” (Process Parameters) menu.
The following parameters are selectable from this menu:
- Stud Material
- Base material
- Spring Force
- Language
- Measure system
- LCD contrast
- Factory Setup
To access each parameter, select it by turning the knob G
and then press it for less than 2 seconds.
Once you have accessed the parameter, turn the knob G
to make the desired choice and then press it again for less
than 2 seconds to con rm the choice made and go back
to the menu with the list of parameters. To go back to the
initial screen, press the knob G for more than 2 seconds.
6
• “Stud Material” parameter.
• “Base Material” parameter.
• “Spring Force” parameter.
The value can be changed by
means of the knob Q.
Note: if the force on the gun
is changed from the proposed value, we recommend
adjusting this value. The
newly changed value will appear on the display and next to
it an arrow pointing downward if the value was decreased
or upward the value was increased.
Based on the choices made, the force and voltage to be
used will be indicated on the display.
It is possible to change the voltage by means of the knob
G, whereas the force displayed on the scale P can be
changed by means of the knob Q.
• “Language” parameter.
• “Measure system” parameter.
• “LCD contrast” parameter.
The value can be changed
from 0 to 100% by means of
the knob G.
This function enables you
to increase or reduce the
brightness of the display A.
• “Factory setup” parameter.
“ON” can be selected by
turning the knob G and
pressing it brie y; the
message “Factory Done”
will appear to con rm that
the reset was successful.
4 OPERATING PRINCIPLE OF WELDING THREADED
STUD BOLTS WITH CONTACT POINT START-UP
(Fig. 3)
The stud bolt is inserted in the clamp X (phase 1), then
positioned and pressed with its start-up contact directly
against the surface of the sheet metal to be welded (phase
2). The spring of the gun presses the stud bolt against
the metal, the start command begins sending current
which melts the start-up contact, and the electrical arc
is propagated along the entire surface of the stud bolt
(phase 4) pushed against the metal surface. The molten
metal solidi es, thereby welding the stud bolt (phase 5).
The gun must be extracted in perfect alignment with the
bolt to avoid deforming the clamp, and thus ensuring its
long life-span (phase 6).
7
Stud material
Base metal
Copper plated steel
up to 0.2 C%
Stainless steel
304/316
Al Mg 3 AI Si 12 Al 99,5
Steel up to 0.30 C % A A - - Galvanized steel B B - - Stainless steel 304/316 A A - - Al 99,5 - - A B B
Al Mg 3 - - B A B
Al Si 12 - - B A B
High weldability: A Low weldability: B Not weldable: -
Tab. 1
Fig. 3
1 2 3 4 5
5 WELDABILITY OF TYPICAL STUD BOLT/BASE
METAL COM BINATIONS FOR CAPACITOR
DISCHARGE WELDING. (Table 1)
It is important to pay careful attention to the resistance and
deformity at the welding point between the stud bolt and base
metal. In the case of steel, you must pay particular attention
to brittleness. The material and resistance of the stud bolt
have limited tolerance; the carbon content in steel threaded
stud bolts must be < 0.20%.
The surface of the base metal must be clean. Layers
of paint, rust, waste, grease and non-weldable metal
coatings must be removed from the welding area. This
must be done using appropriate means. Base metals with
layers of waste and rust must be cleaned thoroughly.
6 WELDING
This technology makes it possible to weld stud bolts on
clean, but not oxidized, surfaces of mild steel, galvanized
steel, stainless steel, aluminum and brass.
The rapidity of the process does not alter the surfaces on the
side opposite from the welding. Welding is not possible on
case-hardened steel, oxidized or painted metal.
Before beginning production it is essential to carry out a
few test welds to determine the proper setting of the power
source and gun (spring force), proceeding as follows:
• Insert the chosen stud bolt in the clamp X (previously
adjusted as described in Fig. 2).
• Arrange the base sheet metal in conditions identical to
those that will be used for the job in terms of thickness,
earth connection area, size of the workpiece, material
quality.
• The terminals of the earth cable should be placed
symmetrically, and as close as possible to the welding
point.
• Activate the power source by means of the lighted
switch E.
• Hold the gun and place the stud on the welding spot,
avoiding to give blows, consequently damaging the
striking tip of the stud. Press the trigger O and, holding it
pressed, push the gun evenly and not quickly. Once the
right pressure is reached, the weld will be automatically
activated. If the surface of the material on which the stud
bolt is to be welded is at, we recommend mounting the
three spacers Z after rst unscrewing the screws Y
• In this case it is recommended to push the gun until the
three spacers are in touch with the piece and then press
the trigger to activate the welding.
These procedures are required to obtain the same
pressure of the stud on the base material and
consequently a higher quality of the weld.
• The voltage and force values recommended on the display
are intended as a starting point for calculating the correct
power source setting and for calibrating gun force.
These values have been tested on samples of “base
materials” 0.079" (2 mm) thick for steel and stainless steel
and 0.047" (1.2 mm) thick for aluminium.
8
• Carry out a few welds, adjusting the voltage using the knob
G, and the force of the gun using the setting knob Q, until
the welding is perfect.
• The gun should be removed keeping it perfectly aligned
with the bolt, to avoid deforming the clamp (Fig4).
• Do not make welds to welded stud bolts.
OK
NO
Fig. 4
7 MAINTENANCE
7.1 ROUTINE
Keep all instructions and gures on the welding machine
clear and legible.
The mains cable and welding cables must be insulated
and in perfect condition; be careful with the tips, which ex:
near the connection terminals, earth clamps and gun input.
Keep the welding current connectors to sockets B and C
clean and rmly tightened (see Fig. 1)
The terminals for connecting to the base metal must
make good contact to avoid overheating, sparks, uneven
current circulation, damage to the components where the
pins are welded, and welding of uneven quality.
Prevent dirt, dust and lings from getting into the welding
machine.
Always make sure the cooling air circulates freely.
Make sure that the fan functions properly.
Make sure that the clamps hold the stud bolts rmly, with
all contact springs.
The clamp must slide freely throughout its length, without
changes due to friction or foreign matter.
7.2 SPECIAL
Only quali ed personnel should perform maintenance.
Some functional errors are highlighted by the appearance
of an error code on the display A.
Wait at least 5 minutes after shutting off the switch E
before opening the welding machine, and unplug the plug
from the power socket.
Use a volt meter to make sure that the capacitors are
discharged.
Carefully remove any dust, metal fragments and lings
from the machine using compressed air to avoid damaging
or projecting metal fragments onto the electronic or
electrical parts.
Make sure that all connectors are fully inserted.
Make sure that all welding circuit terminals are rmly
tightened.
After making a repair, make sure to rearrange the wiring
so that there is secure insulation between the primary and
secondary sides of the machine. Do not allow wires to
come into contact with moving parts or those that heat
up during operation. Reassemble all of the clamps as they
were on the original machine, to prevent an accidental
connection between the primary and secondary circuits if
a conductor should break or disconnect.
Also remount the screws with geared washers as on the
original equipment.
Error code Problem Solution
WARNING 1 It means that the gun start button and microswitch
are pressed at the moment the generator is turned
on.
Release the start button.
ERROR 2 It means that the relay RL1 is faulty. Power circuit fault.
Contact the technical support service.
ERROR 3 It means that the relay RL1 is faulty. Power circuit fault.
Contact the technical support service.
ERROR 4 It means that the SCR has short circuited Contact the technical support service.
ERROR 5 It means that there is a fault in the capacitor
charging circuit
Contact the technical support service.
ERROR 7 It means that there is a fault in the capacitor
charging circuit
Contact the technical support service.
WARNING TH
It means that the thermal protector has tripped.
Wait a few minutes without turning off the welding
machine.
ERROR 9
It means that there is a fault in the circuit that
measures the voltage across the capacitors.
Power circuit fault.
Contact the technical support service.
ERROR 10
It means that there is a short circuit in the
capacitor discharging circuit.
Power circuit fault.
Contact the technical support service.
9
MANUEL D’INSTRUCTIONS POUR POSTE A SOUDER A FIL
IMPORTANT: AVANT LA MISE EN MARCHE DE LA MA-
CHINE, LIRE CE MANUEL ET LE GARDER, PENDANT
TOUTE LA VIE OPÉRATIONNELLE, DANS UN ENDROIT
CONNU PAR LES DIFFÉRENTES PERSONNES INTÉRESSÉES. CETTE MACHINE NE DOIT ÊTRE UTILISÉE
QUE POUR DES OPÉRATIONS DE SOUDURE.
1 PRÉCAUTIONS DE SÉCURITÉ
LA SOUDURE ET LE DÉCOUPAGE À L’ARC
PEUVENT ÊTRE NUISIBLES À VOUS ET AUX
AUTRES. L’utilisateur doit pourtant connaître les risques,
résumés ci-dessous, liés aux opérations de soudure. Pour
des informations plus détaillées, demander le manuel
code.3.300758
BRUIT
Cette machine ne produit pas elle-même des bruits
supérieurs à 80 dB. Le procédé de découpage au
plasma/soudure peut produire des niveaux de bruit
supérieurs à cette limite; les utilisateurs devront donc mette
en oeuvre les précautions prévues par la loi.
CHAMPS ELECTROMAGNETIQUES- Peuvent être dangereux.
· Le courant électrique traversant n’importe
quel conducteur produit des champs électromagnétiques (EMF). Le courant de soudure ou de découpe produisent des champs
électromagnétiques autour des câbles ou
des générateurs.
• Les champs magnétiques provoqués par des courants
élevés peuvent interférer avec le fonctionnement des stimulateurs cardiaques. Aux porteurs de stimulateurs
cardiaques il est défendu d'utiliser la machine ou de
s'approcher des câbles.
• L’ exposition aux champs électromagnétiques de soudure ou de découpe peut produire des effets inconnus
sur la santé.
Pour reduire les risques provoqués par l’exposition aux
champs électromagnétiques chaque opérateur doit
suivre les procédures suivantes:
- Vérier que le câble de masse et de la pince porte
électrode ou de la torche restent disposés côte à côte.
Si possible, il faut les xer ensemble avec du ruban.
- Ne pas enrouler les câbles de masse et de la pince
porte-électrode ou de la torche autour du corps.
- Ne jamais rester entre le câble de masse et le câble
de la pince porte-électrode ou de la torche. Si le câble
de masse se trouve à droite de l’opérateur, le câble de
la pince porte-électrode ou de la torche doit être égale
ment à droite.
- Connecter le câble de masse à la pièce à usiner aussi
proche que possible de la zone de soudure ou de découpe.
- Ne pas travailler près du générateur.
EXPLOSIONS
· Ne pas souder à proximité de récipients sous
pression ou en présence de poussières, gaz ou
vapeurs explosifs. Manier avec soin les bouteilles
et les détendeurs de pression utilisés dans les opérations
de soudure.
COMPATIBILITE ELECTROMAGNETIQUE
Cette machine est construite en conformité aux indications contenues dans la norme harmonisée IEC 6097410(Cl. A) et ne doit être utilisée que pour des buts professionnels dans un milieu industriel. En fait, il peut y avoir
des difcultés potentielles dans l’assurance de la compatibilité électromagnétique dans un milieu différent de celui
industriel.
ÉLIMINATION D’ÉQUIPEMENTS ÉLECTRIQUES
ET ÉLECTRONIQUES
Ne pas éliminer les déchets d’équipements élec-
triques et électroniques avec les ordures ménagères! Une fois leur cycle de vie terminé, les équipements électriques et électroniques doivent être collectés
séparément et conférés à une usine de recyclage. Nous
recommandons aux propriétaires des équipements de
s’informer auprès de notre représentant local au sujet
des systèmes de collecte agréés.
Des précautions supplémentaires sont à respecter
lorsque l'on travaille en hauteur.
COMPATIBILITE ELECTROMAGNETIQUE
Au Canada, la classication des EMC ne s'applique pas
aux postes de soudage à l'arc.
NORMES DE SECURITE
Pour fournir les conditions et recommandations mini-
males an de protéger les personnes qui travaillent dans
un environnement concerné par le soudage, le coupage
et les techniques connexes, il faut se référer à la norme
CA N/C SA -W117. 2.
EN CAS DE MAUVAIS FONCTIONNEMENT, DEMANDER
L’ASSISTANCE DE PERSONNEL QUALIFIÉ.
1.1 PLAQUETTE DES AVERTISSEMENTS
Le texte numéroté suivant correspond aux cases numérotées de la plaquette.
B. Les galets entraînement l peuvent blesser les mains.
C. Le l de soudure et le groupe entraînement l sont
sous tension pendant le soudage. Ne pas approcher
les mains ni des objets métalliques.
1. Les décharges électriques provoquées par l’élec-
trode le câble peuvent être mortelles. Se protéger de
manière adéquate contre les décharges électriques.
1.1 Porter des gants isolants. Ne pas toucher l’électrode
avec les mains nues. Ne jamais porter des gants humides ou endommagés.
1.2 S’assurer d’être isolés de la pièce à souder et du sol
1.3 Débrancher la che du cordon d’alimentation avant
de travailler sur la machine.
2. L’inhalation des exhalations produites par la soudure
peut être nuisible pour la santé.
2.1 Tenir la tête à l’écart des exhalations.
2.2 Utiliser un système de ventilation forcée ou de déchar-
gement des locaux pour éliminer toute exhalaison.
2.3 Utiliser un ventilateur d’aspiration pour éliminer les
exhalations.
3. Les étincelles provoquées par la soudure peuvent
causer des explosions ou des incendies.
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