US PR-8. Instruction Manual. - approved

Transcription

1 US GB PR-8 Instruction Manual - approved

2 Preface 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. 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 regulations. The design of the equipment presented in this manual may be changed without prior notice

3 Contents 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

4 A. Safety 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

5 A. Safety A2. Safety signs Blue with white symbol. Directive - Prescribes a specific obligation Yellow with black symbol. Warning - Warning for danger. 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: 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. Warning: Sparks from welding could start a fire. 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

6 A. Safety A3. Placement of safety signs - 5 -

7 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 Volt / 60 A 3 phase Volt / 60 A 3 phase Volt / 40 A 3 phase Volt / 40 A Cable area: 20mm 2 per conductor 10mm 2 per conductor > 380Volt 6mm 2 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

8 C. Function selection C1. Operating modes Front panel 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. C2. Control pushbuttons (modes 1-5) 7. Ten LEDs (four green, three orange and three red). For indication of power output. 8. See below. + - v s 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

9 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. s + - v Push S to select operating mode. Push + Plus to select program. Push Minus to select program. Push V to reset alarm signals. Pressure gauge Air Main On/Off switch Pressure Regulator Welding cables Cooling air Trigger connection & measurement - 8 -

10 D. Operation 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 performed. D2. Mode selection There are six different operating modes, each with ten programs. Select the required operating mode by pressing the S pushbutton. Select the required program and/or output power using the + pushbutton. Description of operating cycles: Operating Mode 1 (swaging, heating graphite arc tool) Current flows when the operator presses the trigger. Current stops when the operator releases the trigger. Operating Modes 2, 3 and 4 (washer, stud and single-sided welding) When pressing the trigger, the welding cycle starts and stops automatically. Keep the pressure on the tool until the machine shows the goahead signal. Operating Mode 5 (C and X tongs, double-sided spot welding) Pressing the trigger starts the following programmed sequence: - Current flows after a half-second delay when the operator presses the trigger. This is referred to as the squeeze sequence. - The welding electrodes close. - Welding current flows. - The electrodes are held closed to ensure a reliable spot weld. Nut Release the trigger to release the welding electrodes and move them to the next position. Turn the nut on the rear of the pneumatic cylinder to adjust the width of opening of the tongs. Turn the nut anti-clockwise to increase the opening and clockwise to decrease it

11 D. Operation D2. Mode selection (continued) Operating Mode 6: Automatic and special programs At Power On of the machine it is possibly to see the default calibration value for a short time in the display. If the calibrationvalue set from the factory is to be changed, se instructions below. NOTE! Do the calibration in Mode 6 with 1 diode ON. It s always better to calibrate at low power. Select the required program by pressing the + or - button until the correct program is shown on the display. Calibration for AC1 and AC2 Important! Concerns the two programs, whose text on the display start with AC1 and AC2. - Press the + and pushbuttons at the same time. - The display shows CALIBRATION. - Push the trigger on the tong. - Read the message on the display. If there is no error message (such as CLEAN ELECTRODES ), and if a value of µohm is shown, conditions are correct. - Finish calibration by pressing V or if the value needs to be changed press + or - to get the correct value. Store the new value by pressing S. The text MEM is displayed and finish calibration by pressing V. Now it is possible to use AC1 (metal thickness mm) or AC2 ( mm) and let the PR-8 compensate for different metal thickness. The display and the beep indicate the quality of each weld (correct spot weld, defective spot weld, too high power). Signals during operation: Acoustic signals allow the operator to concentrate on the welding, telling him of the quality of the welds. 1. Strident signal: correct weld. 2. Muffled signal: defective weld (see E1, Welding problems). Further information in all cases is shown on the display. Why changing the calibration Value? Depending of how powerful the main supply is there is sometimes a need for a change of the calibration value. If the machine is to powerful: Increase the calibration value with 10 units and test. If the machine is to weak: Reduce the calibation value with 10 units and test. Only for AC1 and AC2-10 -

12 D. Operation D2. Mode selection (continued) The Automatic Control System. The machine monitors the resistance of the weld as the weld current builds up, stopping the current when a correct weld has been achieved. The machine generates an error signal when a defective weld has been made. ACE program suits best when there is a lot of similar welding points (same thickness) to weld, the program will compensate for the temperatur raise (transformer, cables and tong) and put out more power. AC1 / AC2 program is more sensitive and need a calibration (ref. D2). The program works good when welding different sheet thickness. Special program Select the special program by pressing the + button. The selected program will be shown on the display (1)

13 D. Operation D3. Fitting the welding device 1) Stud holder: Two sizes of stud holders are supplied with the PR-8. Select the correct holder to suit the size of stud to be welded, and fit it using the brass nut supplied. 2) Conducting probe (graphite arc): Fit this in the same way as the stud holders. The welding devices, studs and washers can be stored on the tool chart. 3) Tongs for double-sided welding: The tongs can be connected to the same welding cables, which means that they can be changed without having to change the cables

14 D. Operation D3. Fitting the welding device (continued) 4) The welding electrodes, the wheel, the slide-hammer electrode and the rivet holder all feature a conical shank and can be fitted on the same adapter. 5) The slide-hammer tool (for pulling out dents) is intended to be screwed directly into the welding gun handle. Make sure that the locating pin fits into the corresponding groove. Select the particular part to suit the work. See the Welding Devices section

15 D. Operation D4. Fitting the earth connection a) For Operating Modes 1, 2 and 3 - Carefully grind an area of 7 x 4 cm and temporarily secure the earth connection to the workpiece with a clamp. - Grind an area of 7 x 4 cm on the body sheet, choosing an area where it is flattest. See diagram A. - Spot-weld an earth connection stud in the centre of the ground area, using Operating Mode 3, level 7 or 8. Make sure that the stud cannot be twisted or broken off. - Secure the earth connection to the stud with the hand bolt. Part (1) SUPPORTING SHEET IMPORTANT! (For Operating Modes 1, 2 and 3): The earth connection must be secured to the part to be welded, and not to the metal beneath it. Make the connection as close to the working area (1) as possible. b) For Operating Mode 4 - Carefully grind an area of 7 x 4 cm on the load-carrying part of the body and temporarily secure the earth connection to it with a clamp. (1) - Grind an area of 7 x 4 cm on the loadbearing body sheet, choosing an area where it is flattest. See diagram B. Part SUPPORTING SHEET - Spot-weld an earth connection stud in the centre of the ground area, using Operating Mode 3, level 7 or 8. Make sure that the stud cannot be twisted or broken off. IMPORTANT! (For Operating Mode 4): The earth connection must be secured to the supporting part that is to be welded to the new part. Make the connection as close to the working area (1) as possible

16 D. Operation D5. Welding gun with single electrode (Operating Mode 4). The use of a microprocessor in the BOSS+V4 means that the operator needs only set the required value of the current before starting to use the equipment. However, some basic welding rules need to be followed if best use is to be made of the machine: - Do not weld on the body sheet to which the earth connection is made. (See section D4 on the earth connection.) - When performing spot welding, start with the spot furthest away from the earth connection and work towards the earth connection. - Make sure that the two body plates to be welded are in good metallic contact with each other. - Press the electrode against the body sheet by hand pressure. Note: Insufficient hand pressure and too high a welding current can burn a hole in the metal and damage the electrode. Make sure that you are using the correct combination of pressure and current. - Wait for about a second after conclusion of welding before removing the gun, to allow time for the weld to fuse. - Reposition the welding gun and repeat the operation. - Clean and sharpen the electrode tip carefully, particularly if poor contact has caused the metal to stick to the tip of the electrode. (Probably due to excessive current and/or too low hand pressure.) - Let the machine and welding cables cool down if they overheat and/or if an overheating alarm is generated. Tong (Operating Mode 5-6). The starting time of the welding cycle, a half second squeeze sequence, gives the possibility to stop the cycle if bad positioning. Important! Risk of damage to materials close to the weld, e.g. glass or textiles. 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

17 D. Operation D6. Setting the welding current The operator can increase or decrease the welding current with the + and pushbuttons. The display (1) shows the Operating Mode and program that you have selected. 1. Numbers 1 to 10 represents number of diodes ON. Mode 4 (Diode 4 ON) Prog Display (1) Anmärkning mm Welding of mm mm Welding of mm Weld into 1.5 Welding of 0.7 mot 1.5 mm Weld into 1.5 Welding of 1.0 into 1.5 mm Weld into 2.0 Welding of 0.7 into 2.0 mm Weld into 2.0 Welding of 1.0 into 2.0 mm 7 37 ACE mm ACEnergy 3 for mm welding 8 38 ACE mm ACEnergy 5 for mm welding Weld into 1.5 ACEnergy welding for 1.5 into 1.5 mm Weld into 2.0 ACEnergy welding for 1.5 into 2.0 mm Mode 5 (Diode 5 ON) 1 41 STD PROG TWIN Sheet Thickness mm 2 42 STD PROG TWIN Sheet Thickness mm 3 43 STD PROG TWIN Sheet Thickness mm 4 44 STD PROG TWIN Sheet Thickness mm 5 45 STD PROG TWIN Sheet Thickness mm 6 46 STD PROG TWIN Sheet Thickness mm 7 47 STD PROG TWIN Sheet Thickness mm 8 48 STD PROG TWIN Sheet Thickness mm 9 49 STD PROG TWIN Sheet Thickness mm STD PROG TWIN Sheet Thickness mm Mode 6 (Diode 5 ON and Diod Extra Program ON) GALV Welding of galvanized sheets mm GALV Welding of galvanized sheets mm GALV Welding of galvanized sheets mm GALV Welding of galvanized sheets mm 5 55 AC AC1 Automatic program for sheets 0.5 to 1.9 mm (see D2) 6 56 AC AC2 Automatic program for sheets 1.0 to 3.0 mm (see D2) 7 57 ACE ACEnergy for sheets mm 8 58 ACE ACEnergy for sheets mm 9 59 ACE ACEnergy for sheets mm ACE ACEnergy for sheets mm

18 E. Trouble shooting E1. Welding problems Swaging (Operating Mode 1): Nothing happens when the graphite electrode touches the body sheet: - Make sure that the earth connection is correctly positioned. - Check the power supply to the machine (fuses, MCBs, plugs inserted etc.). - See the section on fault tracing. Washer welding (Operating Mode 2) Severe burning of the metal - Reduce the current. The edge of the washer penetrates into the body sheet: - Reduce the pressure on the washer and reduce the current. Stud welding (Operating Mode 3): The studs do not hold: - Make sure that the stud and the earth contact are on the same body part. - Position the earth connection close to the part to be welded. - Increase the pressure on the stud and increase the current. Note: the current and the pressure must be matched. - Grind the sheet - it may be covered with something that prevents proper current flow. Single electrode (Operating Mode 4) Spot welds are not holding: - Check the earth connection and make sure that it is sufficiently close to the part to be welded. - Make sure that the earth connection is secured to the supporting sheet and not to the part to be welded. - Start by welding the spot furthest away from the earth connection and then work towards the earth connection. - Increase the pressure on the electrode, and increase the current. - Clean and sharpen the tip of the electrode. - Check the power supply to the machine (fuses, MCBs, plugs inserted etc.). - Check that the welding cables are connected to the correct polarity (+ and ). Double electrode (Operating Modes 5 and 6) The electrode burns through the material: - Replace the electrodes if they are too old. - Check the air pressure: must be at least 6 bar. Pressure for C-tong should be 5 bar(73 psi, see table on front panel). - Check to see whether the electrode clamping force is too low. The studs burn through the sheet: - Reduce the current. - Increase the pressure on the stud. - Grind the sheet for better current distribution

19 E. Trouble shooting E2. Error list Error message (welding) 51 = Calculation error 53 = Measurement error 54 = Stop or thyristor fault 55 = Calibration error 56 = Too high power 57 = Resistance error (AC) 58 = Autoblanking not found (AC) 59 = Safety time (AC) Press the V pushbutton and try again. If the same error message recurs, stop using the machine and call for service. Error no. 5 will be displayed if you do not press the V pushbutton. High temperature Allow the machine to cool for a few minutes. Do not turn it off, so that the fan can continue to run and the welding gun can work Test button for the RCD (residual current device). We recommend that you press this button at least once a year to check that the RCD is operating correctly. 2. RCD. The machine incorporates an RCD that protects against earth faults and power failures. If it operates, reset it by turning it on again. 3. MCB (miniature circuit-breaker). Protects against overloads. If it operates, reset it by turning it on again

20 F. Technical specification F1. Technical data Permissible load : Duty cycle % 2.5% maximum load. Supply voltage : Volt, 60 A : Volt, 40 A : 3 phase, 50/60 Hz Output voltage : 15V Welding current : A (see diagram) Cable length : Up to 3 m (normally 3 m) Welding cable area : 150 mm² Cooling : Air + fan No. of operating modes : 6 No. of programs : 60 Air supply pressure : 5 bar (C-tong), 6-8 bar (X-tong) Degrees of protection : IP 23 Pro Spot PR-8 meets the following directives: ETL and C-ETL Listed Mark, Low Voltage Directive LVD(73/23/EEC), The EMC Directive (89/336/EEC), The Machinery Directive (89/392/EEC)

21 F. Technical specification F2. Block diagram Protect the equipment by means of an RCD where required by local regulations

22 F. Technical specification F3. Diagram Welding current 15KA 10KA 5KA Mains voltage: - High - Medium - Low The actual welding current depends on several factors: supply voltage, cable length and cable cross-sectional area are particularly important. The diagram represents the main functions and processes graphically. Cable length 0 1m 2m 3m 15KA 10KA 5KA 300 mm² 240 mm² 150 mm² The power unit can supply a maximum of 18 ka. However, such a current is seldom necessary, and it requires a cable length of zero. For a welding current of 6-8 ka, which is a normal value for 3+3 steel, 150 mm² cables can be up to 2 m long. Heavier currents require shorter or thicker cables. (The diagram applies for a high mains voltage and low internal impedance.) 0 1m 2m 3m Cable length

23 F. Technical specification F3. Diagram (continued) Intermittence factor 100 % 50 % Welding current 0 % 0 5 KA 10 KA 15 KA xxxxxxxxx dan The intermittence factor is 100% for low currents, and up to 60% for MIG/TIG welding. Spot welding is never performed continuously, which means that its intermittence factor is probably 1-10% (0,6 seconds welding with 6-10 seconds between welds). The Pro Spot PR-8 has a intermittence factor of: 2,5% without getting a overheat. Calculated as follow. In 1 minute it s possibly to make 8 spotwelds. Each weld is 10 cycles = 200ms Duty = (8 * 0,2)/(60-1,6) = 0,027 = 2,7% xxxxxxxxxxxxxxxxxxxxxxx xxxxxxxx dan xxxxxxxxxxxxxxxxxxxxxxxx

24 G. Spare parts Grundsats/Basic set x x 100 x x Pos Part.No. Quant. Description Basic set Puller Single spot gun Nut Electrode holder Pencil tip holder Graphite rod Stud holder diameter Stud holder diameter Rivet holder Stamp electrode Single-spot electrode (dome) Electrode length Stud, 5x14, coarse thread Stud, M6x20 (earth) Clip rivets Cover-plated washer Allen-key Grounding device Hand nut

25 G. Spare parts Pos Part.No. Quant. Description 18 C-tong C-tong yoke yoke Electrode length Electrode length Fender Edge Kit Washer Electrode L80-S Electrode L80/45 -S Electrode L80/ Electrodeholder Electrodeholder Electrode length Electrode -S Fender edge yoke X-tong X-tong Arm L= Electrode L= Arm L= Electrode L= Electrode S Allen key 6mm Sleeve

26 G. Spare parts Pos Part.No. Quant. Description Cables Cable, 150mm 2 3m Cable, 150mm 2 3m Cable, 240mm 2 2,4m Cable, 240mm 2 2,4m - Electrodes Electrode length Electrode length Electrode length Electrode length Electrode length Electrode length Electrode length Electrode -S Accessories Handle yoke yoke Kit Pos. 14, 7,

27 G. Spare parts Pos Part.No. Quant. Description Fender Edge Kit Accessories Washer Electrode L80-S Electrode L80/45 -S Electrode L80/ Electrodeholder Electrodeholder Electrode length Electrode -S Fender edge yoke

28 H. C-tong Situations

29 Pro Spot International, Inc 956 S. Andreasen Dr. #101 Escondido, CA U.S.A. Tel Fax (760) Internet