US GB PR-8 - Pro 4 - Pro Spot PR-8 GB/US/2000-08 PRO SPOT A2. Safety signs Blue with white symbol....

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Transcript of US GB PR-8 - Pro 4 - Pro Spot PR-8 GB/US/2000-08 PRO SPOT A2. Safety signs Blue with white symbol....

  • Instruction Manual

    PR-8

    2000-08

    US

    GB

    - approved

  • - 1 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    Preface

    The photographs and drawings in this manual are merely illustrative and do not necessarily represent the actual appearance of equipment available. The equipment is designed to be used in accordance with established practices and in observation of applicable safety re- gulations. The design of the equipment presented in this manual may be changed without prior notice.

    You have just bought a Pro Spot PR-8.

    The use of microprocessor control in our vehicle body welding equipment has many benefits. It means, for example, that a wide range of features is available to the operator.

    The microprocessor is programmed in the same way as an ordinary computer. It includes software that enables the operator to control energy input to suit the particular application or conditions. Repair work quality can be checked with an acoustic signal, while a display helps the operator to control and set up the machine.

    Read this instruction book to appreciate how versatile the Pro Spot PR-8 is.

  • - 2 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    A. Safety A1 Warnings, important notes

    and information 3 A2 Safety signs 4 A3 Placement of safety signs 5

    B. Installation B1 Connection to the power unit 6 B2 Maintenance 6

    C. Function selection C1 Operating mode 7 C2 Control pushbuttons (modes 1-5) 7 C3 Control pushbuttons (mode 6),

    automatic program 8

    D. Operation D1 Welding tools 9 D2 Mode selections 9

    - Swaging, heating – graphite arc tool 9 - Washer, stud and single-sided welding 9 - C & X tongs, double-sided spot welding 9 - Automatic control and special programs 10

    D3 Fitting the welding device 12 D4 Fitting the earth connection 14 D5 Welding gun with single electrode 15 D6 Setting the welding current 16

    E. Trouble shooting E1 Welding problems 17 E2 Error list 18

    F. Technical specification F1 Technical data 19 F2 Block Diagram 20 F3 Diagram 21

    G. Spare parts 23

    H. C-tong Situations 27

    Contents

  • - 3 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    A1. Warnings, important notes and information

    Follow these safety rules to ensure safety for the operator and other persons.

    In addition to the safety signs shown on page 5, the following warnings and important notes will be found elsewhere in these instructions.

    Warning! Make sure you know where fire extinguishing equipment is.

    Important! Risk of damage to materials close to the weld, e.g. glass or textiles.

    Important! Ensure that all electrical equipment within the working area is disconnected. Beware risk of interference.

    Important! When in Operating Mode 4, the earth connection must be made to the supporting body sheet and not to the part to be welded.

    Important! The user must have the necessary knowledge for use of this equipment.

    REMEMBER GENERAL FIRE SAFETY! Pay attention to the fire safety regulations. Welding is always classified as a fire risk operation. Welding where there is flammable or explosive material is strictly forbidden. Remove flammable material from the immediate vicinity of the welding site. Fire extinguishers must always be on site where welding is taking place. NOTE: Sparks may cause fire many hours after completion of welding.

    WATCH OUT FOR THE MAIN VOLTAGE! Take care of the cables - the connection cable must not be compressed, touch sharp edges or hot work pieces. Faulty cables are always a fire risk and highly dangerous. Do not locate the welding machine on wet surface.

    A. Safety

  • - 4 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    A2. Safety signs

    Blue with white symbol. Directive - Prescribes a specific obligation

    Yellow with black symbol. Warning - Warning for danger.

    A. Safety

    Warning: Appropriate eye protection must be worn when using this equipment.

    Protective gloves, clothing and shoes must be worn when using this equipment.

    Warning: Risk of tripping: loose hoses, cables etc.

    Undamaged safety signs must always be positioned at the places indicated.

    If any sign is damaged or missing, the user must ensure that it is immediately replaced by a new sign. Safety signs are available as spare parts.

    Warning: All electrical work on the power unit (connec- tion, service and installation) must be performed only by authorized personnel. Disconnect the supply before per- forming any service or installation work.

    Warning: Sparks from welding could start a fire.

  • - 5 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    A3. Placement of safety signs

    A. Safety

  • - 6 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    B. Installation

    B1. Connection to the power unit

    Warning: All electrical work on the power unit (connection, service and installation) must be performed only by authorized personnel. Disconnect the supply before performing any service or installation work.

    Make sure that the voltage shown on the machine rating plate is the same as that of your supply.

    Connect the equipment to a supply socket capable of supplying the power required

    The main supply cable must be of such a size as to ensure that it does not overheat when the equipment is in use.

    USA / Canada Other countries Supply protection: Circuit Breakers Residual Current Device

    Voltage/Power: 3 phase 208-240Volt / 60 A 3 phase 208-240Volt / 60 A 3 phase 400-440Volt / 40 A 3 phase 400-440Volt / 40 A

    Cable area: 20mm2 per conductor 10mm2 per conductor > 380Volt 6mm2 per

    conductor

    Degrees of protection: IP 23 IP23

    Connection to the compressed air system

    The equipment requires a compressed air supply at 6-8 bar. This must be clean, oil-free and moisture-free air.

    Connect the Pro Spot PR-8 to the compressed air system via the connection on the rear panel of the machine, using a standard compressed air connector.

    The Pro Spot PR-8 is now ready for use.

    B2. Maintenance The amount of use and the working environment should be taken into consideration when planning the frequency of maintenance of the machine. Careful use and preventive maintenance will help to ensure trouble free operation.

    Daily maintenance: Check the condition of tongs, air connections and air hoses to prevent overheating and mailfunction due to bad cooling.

    Check the condition of tongs and welding cables, do not use faulty cables!

    Make sure that the main connection cables in use are safe and according to laid down regulations. The repair and mounting of main connection cables should be carried out by an authorized electrician.

    Clean all oxidized parts of the tongs, electrodes and connections and tighten the loosened ones.

    Regular maintenance: Pro Spot service repair shops make regular maintenance.

    Cleaning the machine

    Checking and maintenance of connections, welding tools and electric connections.

    Checking of main cable and plug.

    Damaged parts or parts in bad condition are replaced by new ones.

    Maintenance testing. Operation and performance of the machine are checked.

  • - 7 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    The Pro Spot PR-8 has six operating modes, as follows:

    1. Swaging (graphite arc tool) for thermal straightening of damaged bodywork.

    2. Washer welding for slide-hammer tool (pulling out dents.)

    3. Stud welding for welding various types of studs, rivets, etc.

    4. Single-sided spot welding for welding body parts without tongs.

    5. Tongs (double-sided spot welding) for welding with C or X tongs.

    6. Automatic Control and special programs.

    C. Function selection

    C2. Control pushbuttons (modes 1-5)

    7. Ten LEDs (four green, three orange and three red). For indication of power output.

    8. See below.

    C1. Operating modes Front panel

    7. 8.

    1. 2. 3. 4. 5. 6.

    Press + Plus to increase output power. NB: When operating in Mode 3, text will be shown on the display for rivets, studs etc.

    Press – Minus to decrease output power.

    Acknowledge/cancel messages or faults with V (reset).

    Press S to select operating modes.

    ” + ”

    ” - ” ” v ” ” s ”

  • - 8 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    C. Function selection

    C3. Control pushbuttons in Mode 6, Automatic Program

    Don’t forget to connect the welding cables and control cable. When using tongs, connect the air hose on the welding cable to the air supply connection on the front panel.

    Push S to select operating mode.

    Push + Plus to select program.

    Push – Minus to select program.

    Push V to reset alarm signals.

    ” + ” ” - ” ” v ”

    ” s ”

    Air Main On/Off switch

    Pressure Regulator

    Welding cables Cooling air

    Trigger connection & measurement

    Pressure gauge

  • - 9 -

    Pro Spot PR-8

    GB/US/2000-08 PRO SPOT

    D. Operation

    Nut

    D1. Welding tools

    The PR-8 has two 150 mm² screened, air-cooled welding current cables, with connectors for the welding tool to be used.

    Select the welding tool(s) that is/are suitable for the repair work to be pe