Pro Spot PR-113 Instruction manual

PR-2000
High Frequency Inverter
Resistance Spot Welder
Instruction Manual
Version 2.0n 2/23/2010
PR-2000
Table Of Contents
Quick start instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety
2.0
2.1
2.2
2.3
Safety & Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Warnings and important notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3.2 Overheat protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Installation
3.1
3.2
3.3
3.4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Packaging and delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Welder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Connection of electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.4.1 Electrical Plug / Extension cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.5 Connection of pneumatic air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Operation
4.1 Before you begin welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2 About your welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2.1 Welder Overview & Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2.2 Getting familiar with your welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2.3 PR-2000 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2.4 Indications on the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.3 Turning on the welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.4 Choosing the weld mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.5 Setting the pneumatic air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.6 Setting the weld current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.7 Setting the weld time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.8 Setting the default weld programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5 Double-Sided Welding
5.1 PS-500 Double-Acting Spot Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.1.1 PS-500 Component Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.1.2 Using the Double-Acting Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.2 Extension Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.2.1 Switching to extension arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.2.2 Extension Arms and Welding Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.3 PS-500 Electrode Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.4 Removing Welding Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.5 Welding Electrode Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.6 Wheel House Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.7 X-Adapter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5.7.1 Attaching the X-Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5.7.2 Using the X-Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5.7.3 X-Adapter Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Copyright © Pro Spot International, Inc. 2005-2009
PR-2000
Table Of Contents
6 Single-Sided Welding
6.1 Single-Sided Welding Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.2 Single-Sided Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.3 Stud Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.4 Nut Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.5 Dent Pulling with Spot Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.6 Moulding Clip Rivet Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.7 Dent Pulling with Washers and Slide Hammer with Hook . . . . . . . . . . . . . . . . . . . .27
6.8 Contact Shrinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.9 Carbon Rod Shrinking / Stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.10 Stitch Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.11 Pro Pull Dent Pulling (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6.11.1 Selecting Pro Pull Weld Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6.11.2 Pro Pull Component Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6.11.3 Pro Pull Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
6.11.4 Dent Pulling with Pro Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
6.11.5 Paintless Dent Pulling With Pro Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Copyright © Pro Spot International, Inc. 2005-2009
Page 2
PR-2000
Quick start instructions
WARNING! Before turning the welder on, make sure it is connected
to proper electricity by certified people. Connect air to the air inlet on
back panel.
ATTENTION! Avant d'allumer le soudeur, vérifiez qu'il est connecté
à l’électricité par des personnes certifiées. Connectez l’air à
l'entrée d'air au panneau arrière.
Figure 1.1
Figure 1.2
1. Turn the Power Switch on the front panel ON.
2. Connect Air to the air inlet located on the back panel.
3. During the test procedure a “Push Help to change language” prompt appears
on the display screen . Click the Help button to acces the System settings screen
where the language can be changed. Select desired language by clicking the
“Change Language” button, then exit.
4. After test procedure, the software defaults to HSS/Galv. Two Sided weld mode.
5. The welder is now ready to operate. Make sure air pressure is set at 90 PSI.
Place the welding gun at the weld area and press the lower trigger button to weld.
The upper weld button is for spreading the electrodes open for better access.
6. There are 6 different power levels pre-programmed into the PR-2000. The software defaults to 0.7mm weld program. That is the thickness of one of the two layers of metal you are welding . To chage between pre-set power settings press
Navigation button, Up (fig. 1.1). The programs will switch between 0.7, 1.0, 1.2,
1.5, 2.0 and 2.5mm.
7. To go to the next weld mode: “Mild Steel” press the Navigation button, Right
(fig. 1.2). The same weld power levels are available in each weld mode. Navigate
with the Right and Left arrow buttons and select weld power with the “Next
Program” button (Navigation button, Up).
8. Press the “Help” button anytime for instructions.
Copyright © Pro Spot International, Inc. 2005-2009
Page 3
PR-2000
1 Introduction
Congratulations on acquiring your new PRO SPOT PR-2000 welder!
Team Pro Spot looks forward to supporting you.
You have a welder and support group that will increase your productivity. The integrated features, ease of use,
speed and quality welds that your PR-2000 offers will become an important part of your business.
The following information will be needed when you call Pro Spot:
* MODEL TYPE: PR-2000
* SERIAL NO:________________
The serial number is located on the back of the unit.
For parts or service contact your local distributor,
Local number: ____________________________
or in the U.S. call: Toll free:1-877 PRO SPOT or 1-760-407-1414
for a customer service representative.
Visit Pro Spot On-Line: www.prospot.com E-mail: info@prospot.com
NOTE: You can now order parts online at: prospot.com/store/
The PR-2000 Spot welder is used by body shops to
duplicate the welding procedure used by the car manufacturers. Use of the equipment that is contrary to the
instructions in this manual can cause personal injury
and/or machine damage.
Note: This instruction manual provides advice as well
as instructions for installation, operation, maintenance
and troubleshooting.
IMPORTANT! Read this manual carefully to
become familiar with the proper operation of
the welder. Do not neglect to do this as
improper handling may result in personal
injury and damage to the equipment.
Pro Spot International, Inc. can in no way be held
responsible for intentional or unintentional damage, and
consequent unlimited loss of profit, loss of income, loss
of business opportunity, loss of use, etc. that originates
from incorrect use of this equipment ir its use in a manner not intended.
Warranty
Pro Spot International, Inc. offers a two-year guarantee
from the date of delivery of the new welder. This guarantee covers material defects and assumes normal care
and maintenance.
The guarantee assumes that:
• the equipment is correctly installed and inspected
• the equipment has not been altered or rebuilt without
approval from Pro Spot International, Inc.
• genuine Pro Spot International, Inc. spare parts are
used to make repairs.
• operation and maintenance has been carried out
according to the instructions in this manual.
All claims on warranty must verify that the fault has
occurred within the guarantee period, and that the unit
has been used within its operating range as stated in
the specifications. All claims must include the product
type and serial number. This data is stamped on the
name plate.
Copyright © Pro Spot International, Inc. 2005-2009
IMPORTANT! Lisez ce Mode d’Emploi
attentivement afin de vous familiariser avec
le bon fonctionnement du soudeur. Ne
négligez pas de le faire puisque
une mauvaise manipulation peut conduire a
des blessures et dommages à l'équipement.
The drawings in this manual are presented for illustrative purposes only and do not necessarily show the
design of the equipment available on the market at any
given time. The equipment is intended for use in accordance with current trade practice and appropriate safety
regulations. The equipment illustrated in the manual
may be changed without prior notice.
The contents in this publication can be changed without
prior notice.
This publication contains information that is protected by
copyright laws. No part of this publication may be reproduced, stored in a system for information retrieval or be
transmitted in any form, in any manner, without
Pro Spot International, Inc.’s written consent.
Conformity with directives and standards:
PR-2000 complies with CE standards.
1 Introduction
Page 4
PR-2000
2 Safety
2.0 Safety & Environmental Specifications
The PR-2000 Spot welder is designed for indoor use - Protection Degree IP21S.
The PR-2000 Spot welder is designed to operate from -10º C to 40º C.
The unit may be stored and transported in an ambient temperature from -20º C
to +55º C. The unit can be operated at 95% Relative Humidity (RH). For operation above 1000m consult the manufacturer. Do not operate the unit on a slope
of more than 10º. The unit mets the requirements of IEC|EN60974-1 2005 third
edition and UL60974-1 2nd edition. E.M.C. classification is C1SPR11.
NOTE: Heating tests were performed at room ambient temperature and the duty
cycle at 40º C has been determined by simulation.
2.1 General
The PR-2000 Spot welder has been designed and is tested to meet strict safety
requirements. Please read the following instructions carefully before operating the
PR-2000 and refer to them as needed to ensure the continued safe operation of
the welder
Information provided in this manual describes the suggested best working practices and should in no way take precedence over individual responsibilities or
local regulations.
The PR-2000 Spot Welder is designed to comply with all applicable safety regulations for this type of equipment. During operation, it is always each individual’s
responsibility to consider:
• Their own and other’s personal safety.
• The safety of the welder through correct use of the equipment in accordance
with the descriptions and instructions provided in this manual.
By observing and following the safety precautions, users of the PR-2000 Spot
welder will ensure safer working conditions for themselves and their fellow workers.
2.2 Warnings and important notices
The following types of safety signs are used on the equipment and in Pro Spot’s
instruction manuals:
Caution.
Attention!
Read instruction manual.
Lire Mode d’Emploi.
!
!
Prohibited.
Prohibits behaviour that
can cause injury.
Interdit.
Interdit aux comportements
qui peuvent provoquer des blessures.
Command.
Calls for a specific action.
!
Commande.
Appelle à une action spécifique.
Warning.
Notice of personal injury risk and
or damage to equipment.
Warning.
Some parts of the welder may become
hot after prolonged use.
Copyright © Pro Spot International, Inc. 2005-2009
2 Safety
!
Avertissement.
Avis de risque de blessure personnelle
et / ou d’endommager l'équipement.
Avertissement.
Certaines parties du soudeur peuvent devenir
chaudes après une utilisation prolongée.
Page 5
PR-2000
The following warnings and important notices are used in the instruction manual:
WARNING! Do not operate or place
the welder near water, in wet locations
or outdoors. Risk for injuries or damage
to the welder.
ATTENTION! Ne pas faire fonctionner le soudeur
près de l'eau, en voie humide , ou à l’éxterieur .
Risque de blessures ou de dommages au
soudeur.
WARNING! Do not place the welder on
unstable or uneven ground. The welder
might tip causing personal injuries or
serious damage to the welder.
ATTENTION! Ne placez pas le soudeur sur un sol
instable ou irrégulière. Le soudeur peut basculer
causant des lésions corporelles ou des dommages
graves au soudeur.
WARNING! All electrical connections
must be made by a qualified electrician.
Risk for electrical shock.
ATTENTION! Toutes les connexions électriques
doivent être faites par un électricien qualifié.
Risque de choc électrique.
WARNING! Loose cables and hoses
present tripping risks. Risk for injuries.
ATTENTION! Câbles et tuyaux lâches présentent des
risques de déclenchement. Risque de blessures
WARNING! Make sure to use welding
goggles when spot welding. The sparks
might otherwise injure the eyes.
ATTENTION! Veuillez utiliser des lunettes de soudeur
sur place. Les étincelles pourraient autrement blesser
les yeux.
WARNING! Sparks from welding
could start a fire. Risk for injuries.
ATTENTION! Étincelles de soudure pourrait provoquer
une incendie. Risque de blessures.
WARNING! Risk for damage to materials
close to the weld, e.g to glass or textiles.
ATTENTION! Risque de dommages aux matériaux à
proximité de la soudure, par exemple verre ou textiles.
WARNING! For proper cooling efficiency,
never operate the welder without connecting
it to the compressed air source.
ATTENTION! Pour refroidissement efficace, ne jamais
soudeur sans attacher à la source d'air comprimé.
WARNING! All service and maintenance
must be carried out by Pro Spot service
personnel and service support. Risk for
electrical shock.
ATTENTION! Tout le service et l'entretien doivent être
effectués par personnel et soutien de service Pro
Spot. Risque de choc électrique.
WARNING! Unplug the welder from the
wall outlet before servicing, cleaning or
maintenance. Risk for electrical shock.
ATTENTION! Débranchez le soudeur de la prise
murale avant l'entretien, ou nettoyage. Risque de
choc électrique.
IMPORTANT! The PR-2000 welder may only be
used by qualified personnel. The user of
the welder must have knowledge of spot welding
and of alignment of collision-damaged vehicles.
IMPORTANT! Le soudeur PR-2000 peut seulement être
utilisé par personnel qualifié. L'utilisateur du soudeur
doit avoir une connaissance de soudage par points et
l'alignement des véhicules endommagés par collisions.
IMPORTANT! Do not turn off the welder
while cooling is activated!
IMPORTANT! N'éteignez pas le soudeur pendant que le
refroidissement est activé!
IMPORTANT! The air must be clean and
free from oil and moisture. Use filter.
IMPORTANT! L'air doit être propre et sans huile et
humidité. Utilisez un filtre
Copyright © Pro Spot International, Inc. 2005-2009
2 Safety
Page 6
PR-2000
2.3 Safety devices
When the Spot Gun is used continuously, the welding cables and the power transformer get hot. To prevent the welder from malfunctioning due to overheating, it is
cooled using the built-in air system.
2.3.1 Cooling
Figure 2.1
Figure 2.2
PR-2000 features an air cooling system that cools all four welding cables.There
are two different Cooling Modes: "AUTO" (default) and "MANUAL". In the "AUTO"
mode, the air cooling system turns on automatically after 15-30 welds and forced
air starts to flow through the cable. In the "MANUAL" mode the cooling system
operates continuously.
To switch to “MANUAL” mode:
1) Restart the software and press “HELP” button while start-up screen is displayed. “System Settings” screen will display (fig. 2.1).
2) Select “System Settings” by pressing the Navigation button, Up (fig. 2.2).
3) Select “Manual Cooling” by pressing the Navigation button, Down (fig. 2.3).
AIR COOLING will activate.
Figure 2.3
2.3.2 Overheat protection
Figure 2.4
The built-in overheat protection is designed to prevent damage to the welder
caused by overheating. The system will automatically shut off the welder when a
pre-programmed temperature is reached (fig.2.4). DO NOT turn off the welder! It
needs the cooling air to cool the machine faster. Wait until the display returns to
normal (usually 4-8 min.) Shorter duty cycles (due to short weld times and “rest”
periods between welds) will allow the cooling system to function better and may
prevent the auto-shut-off. (Consistently check weld strength by performing
destructuive tests).
IMPORTANT! Do not turn off the welder while the cooling system is
activated!
IMPORTANT! N'éteignez pas le soudeur pendant que
le système de refroidissement est en marche!
IMPORTANT! If the thermal breaker has switched off the welder,
please contact Pro Spot's authorized service personnel
IMPORTANT! Si le disjoncteur thermique a éteint le soudeur,
contactez le personnel de service recommandé par PROSPOT.
Copyright © Pro Spot International, Inc. 2005-2009
2 Safety
Page 7
PR-2000
3 Installation
3.1 General
The PR-2000 Spot welder is inspected and tested prior to leaving the factory to
guarantee consistent quality and the highest possible reliability. Follow the installation tips and operating instructions below to ensure user safety and proper
welder performance.
WARNING! Do not operate or place the welder near water, in wet
locations or outdoors. Risk for injuries or damage to the welder.
ATTENTION! Ne pas faire fonctionner le soudeur près de l'eau, en zone
humide ou à l'extérieur. Risque de blessures ou de dommages au soudeur.
WARNING! Do not place the welder on unstable or uneven
ground. The welder might fall causing personal injuries and damage to
the welder. Do not operate on a slope of more than 10º.
ATTENTION! Ne placez pas le soudeur sur un sol instable ou irrégulier. Le
soudeur peut tomber causant des dommages graves au soudeur.
Ne pas utiliser sur une pente de plus de 10º
IMPORTANT! It is the responsibility of the owner to ensure that
the equipment has been installed as specified in the instructions provided. It is also the owner's responsibility to ensure that the welder
is inspected in accordance with applicable regulations before it is
put into service. Do not use for thawing out frozen water pipes (17.1)
IMPORTANT! Le propriétaire doit s’assurer que l'équipement a été installé
conformément aux instructions fournies. Le propriétaire est egalement
responsable de l’inspection du soudeur conforment à la réglementation
applicable avant qu'il ne soit mis en service. Ne pas utiliser pour dégeler
les conduites d'eau congelées (17.1)
A grounded electrical plug must be installed (refer to section 3.4 “Connection of
electrical supply”).
3.2 Packaging and delivery inspection
Check the contents of the shipping container against the packing list, consignment note, or other delivery documentation to verify that everything is included
and in the correct quantity. Check the PR-2000 Spot Welder carefully to make
sure that no damage has occurred during transport. If anything is damaged or
missing, the welder may be unsafe to use till the part is repaired or replaced. If
anything is missing, please contact your supplier. Remove all packaging material
from the welder.
3.3 Welder assembly
For your convenience, PR-2000 welder ships fully assembled.
Due to differences in wiring codes and connection methods, no electrical plug
comes with the welder. Consult a certified electrician for proper installation of the
electrical plug.
Insert the support arm (boom) as shown in Figure 3.1
Figure 3.1
Copyright © Pro Spot International, Inc. 2005-2009
3 Installation
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PR-2000
3.4 Connection of electrical supply
The PR-2000 Spot Welder requires one of the following voltage / frequency combinations:
208-240V 50/60 Hz
400-420V 50/60 Hz
U.S.A., Canada, Japan OR
Europe, Australia
Note: Make sure that the facility supply voltage and frequency are the same as
shown on the welder name plate (see section 4.2 “About your welder”).
The power supply must have a ground connection. The supply must also be
protected as follows:
The 208-240V 3-Phase or Single-Phase require 60A breaker.
The 400V and 420V supply require a 32A slow blow fuse (Circuit
breaker 32D).
WARNING! All electrical connections must be made by a qualified
electrician. Risk for electrical shock.
ATTENTION! Toutes les connexions électriques doivent être
faites par un électricien qualifié . Risque de choc électrique.
1. Connect the green wire to ground.
Note: Make sure that the supply cable is at least 6 AWG at 208V and 400 V.
The PR-2000 is rated for over voltage category III and polution degree 3.
3.4.1 Electrical Plug / Extension cords
2. If an extension cord is used with the welder, ensure that the length of the
extension cord does not exceed 10 m (30 ft) and it meets the specifications of
Item 1 above. The cord must also be grounded. Consult
an electrician for safe and proper installation of the electrical plug.
NOTE: When connecting the welder to Single-Phase input power, install Red and
White wires. Connect Green to earth ground! Leave out the black wire. Insulate
and store the black wire properly.
3.5 Connection of pneumatic air supply
The PR-2000 Spot welder must be connected to a pneumatic air network.
(100 PSI to 130 PSI)
1. Connect the PR-2000 to the air supply via the threaded input port at
the rear of the welder using a standard connector.
2. If not already set, adjust the air pressure setting on the welder front panel to
60 PSI (4-5 bar) (refer to section 4.5 “Setting the pneumatic air pressure”).
IMPORTANT! The air must be clean and free from oil and
moisture. Use a filter.
Figure 3.2
IMPORTANT! L'air doit être propre sans huile et
humidité. Utilisez un filtre.
Air supply port
Copyright © Pro Spot International, Inc. 2005-2009
3 Installation
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PR-2000
4 Operation
4.1 Before you begin welding
Before you begin welding, be sure to read and understand the following instructions.
The Pro Spot PR-2000 is a state-of-the-art Inverter Resistance Spot Welder that
was designed for the collision repair industry. It duplicates the welding procedure
used by the car manufacturers. It is important to understand the design and function of this welder before operating it.
ELECTRICITY ONLY: The PR-2000 uses only electricity to create the welds
unlike the MIG welder which uses an arc from a feeding wire to build a weld
nugget using inert gas and the feeding wire material.
PRESSURE: The PR-2000 has a built in air cylinder that compresses the DoubleSided Gun’s welding tips together automatically when triggered. The compression
is an important part of a good resistance weld. The pressure is adjustable from
the Control Panel. The optimum welding pressure varies between 60-90 PSI (46.5 BAR). 90 PSI seems to be a common starting pressure. As a rule, increase
pressure with thicker metals but remember that too much pressure could
decrease the resistance of the metal between the electrodes, resulting in poor
weld penetration.
CURRENT: Another important aspect of a weld is the current applied through the
work piece. A weld is created when a large current is transferred through the layers of sheet metal. The resistance in the metal causes the area to heat up and
fuse the sheets together in a nugget.
WELD PROGRAM: Maintaining the air pressure after the current shuts off makes
the weld cool down under pressure resulting in a harder, stronger weld. This feature is built in to the PR-2000's weld control program and is engaged automatically during a weld cycle.
TIME: The Timer controls the duration of the current applied during the weld
cycle. The ideal is to get a weld that uses higher current and shorter time to control heat buildup.
Copyright © Pro Spot International, Inc. 2005-2009
4 Operation
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PR-2000
4.2 About your welder
4.2.1 Welder Overview & Technical Specifications
The welder is supplied with one of the following voltage and frequency combinations:
Input voltage:
1 or 3 phase
208-240V 50/60 Hz. OR
400-420V 50/60 Hz.
The actual voltage and frequency is stated on the rear panel name plate.
Open circuit output voltage 20v max. E.M.C. classification is C1SPR 11.
Note: For 1-phase installation leave out black wire.
Welding amperage:
Cable length:
Electrode Pressure:
Cooling system:
Welding cable cooling:
Microprocessor program:
Weight (standard):
9500A max (3-phase)
6300A max (1-phase)
8’ (2.5m) standard
At 7 bars (90 PSI)-280 DaN (616 Lb)
Air (2 fans)
Air cooling
Digital control
213lb (97kg)
The name plate is at the rear of the welder unit.
The required voltage is indicated with a check mark.
Welding output is rated at 15V.
4.2.2 Getting familiar with your welder
Air
Pressure
Gauge
Control Panel
Air
Pressure
Regulator
Input Voltage Phase Indicator LED
Lights should illuminate when circuit
breaker on the rear panel is "ON".
(2 lights for 1 phase or 3 lights for 3
phase)
Power Switch
Cable Holder Bracket
Figure 4.1 PR-2000-Front View
Name Plate shows:
Input voltage,
Serial number, etc.
R
WELD CABLES CONFIGURATION
Cooling Fan
1
Single-Sided Weld Gun cable
2
Single-Sided ground cable
3
Two-Sided spot gun cable
4
Two-Sided ground cable
AIR HOSE AND COMMAND CABLE CONFIGURATION
5 Air Supply to 2-sided spot gun (compress)
6 Air Supply to 2-sided spot gun (release)
7 Command cable 1-sided gun
8 Command cable 2-sided spot gun
Figure 4.2 PR-2000-Back View
Input Voltage Cable.
Consult certified electrician
for installation of proper plug and voltage.
Copyright © Pro Spot International, Inc. 2005-2009
4 Operation
Air Input
Connect filtered air
100 PSI 7 BAR (min)
Page 11
PR-2000
4.2.3 PR-2000 Control Panel
Figure 4.3 The PR-2000 Control Panel
4.2.4 Indications on the Control Panel
When two sided welding is selected, a spot gun graphic appears in the upper-left
corner of the display screen (fig. 4.4).
Figure 4.4
Figure 4.5
When single sided welding is selected, a single sided gun graphic appears in the
upper-left corner of the display screen (fig. 4.5).
4.3 Turning on the welder
1. Toggle the circuit breaker on the front panel to “ON”. Three lights on the
front panel should illuminate indicating 3-phase installation, 2 lights for 1phase installation (fig. 4.5.1)
2. The display will go through the start-up procedure and automatically default to
Two-Sided welding.
Figure 4.5.1
3. The PR-2000 is now ready to use.
IMPORTANT! Make sure to read the instruction manual before operating
the welder. Only trained personell should use this welder.
IMPORTANT! Assurez-vous de lire le Mode d’Emploi avant d'opérer
le soudeur. Seules, les personnes qualifiées devraient utiliser ce
soudeur.
Copyright © Pro Spot International, Inc. 2005-2009
4 Operation
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PR-2000
4.4 Choosing the weld mode
The PR-2000 is a multi-functional resistance spot welder. It is equipped with a
four weld cable system for your convenience. Two of the weld cables are connected to the Two-Sided Spot Gun and the other two are connected to the SingleSided Weld Gun.
Figure 4.6
To select a weld mode, press the respective mode button (fig. 4.6)
Once the welding mode is selected, a group of related weld programs become
available to the user (see section 4.8 “Setting the default weld programs”)
4.5 Setting the pneumatic air pressure
Pneumatic air is used for:
- forcing the spot gun to close and open.
- cooling the welding cables that are connected to the spot gun.
The air pressure is regulated with the air regulator, and the set pressure is indicated on the pressure gauge. Default pressure is 90 PSI.
Change the air pressure as follows:
1. Unlock the pressure regulator by pulling on the adjustor knob till it snaps into
the unlocked position.
2. Turn the pressure regulator knob clockwise to increase or counter-clockwise to
decrease the air pressure.
3. Lock the pressure regulator by returning the knob to the lock position.
4.6 Setting the weld program
The PR-2000 features 6 different strength weld power modes. It defaults to
0.7mm program. To change weld program press “Next Program” (fig. 4.7).
The program box indicates the weld power (thickness).
For example, when welding two HSS Galv. metals that are 1.2mm thick, you
should use the 1.2mm program.
Figure 4.7
If more power is desired, press “Next Program” to reach the next level.
4.7 Setting the weld time and current
The time and current automatically change with each respective weld power
mode.
Referring to fig. 4.8: The top value indicates the time duration that will be applied
during the weld and the bottom value indicates the weld power in weld amperage
that will be applied during the weld.
Figure 4.8
Copyright © Pro Spot International, Inc. 2005-2009
4 Operation
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PR-2000
4.8 Setting the default weld programs
There are 15 weld programs featured in the PR-2000 Spot Welder. Ten of these
programs are associated with the Single-Sided Gun and five are associated with
the Two-Sided Spot Gun.
Two-Sided Programs
1
2
4
3
5
Single-Sided Programs
6
7
8
9
10
11
12
13
15
14
1
HSS Steel / Galv. Steel Welding
10
Nut Welding
2
Mild Steel Welding
11
Bolt Welding
3
Weld Bonding
12
Stitch Welding
4
Boron Steel
13
Carbon Rod Shrinking
5
Custom Program
14
Rivet Welding
6
Single-Sided Spot Welding
15
Washer Welding
7
Pro Pull Dent Removal
8
Pulling
9
Contact Shrinking
The welding programs are selected on the Control Panel. Select the welding program by using the Left and Right navigaton buttons (fig. 4.9)
Figure 4.9
The selected program is indicated by a highlighted black box over the program
name (fig. 4.10).
In any welding mode there are 6 power level programs: 0.7mm - 2.5mm. To
switch between programs press the “Next Program” button (fig. 4.7).
Figure 4.10
Some programs require a double-weld in one cycle (fig. 4.11). Those welds automatically deliver Weld 1, programmed delay, then Weld 2. This is a very sophisticated weld feature for controlling exact temperature into the weld area and to preheat it.
Figure 4.11
Note: Two-Sided welding mode and Program No. 1 are set by default
when the PR-2000 is turned on.
Note: Mode recto- verso de soudage et le programme de soudage n °
1 sont définies par défaut lorsque le PR-2000 est allumé.
Copyright © Pro Spot International, Inc. 2005-2009
4 Operation
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PR-2000
5 Double-Sided Welding
5.1 PS-500 Double-Acting Spot Gun
The spot gun is used for the following weld programs:
• Two-Sided spot welding - HSS Galvanized steel, Mild steel, Weld Bonding,
Boron Steel, Pulse welding and OEM, Custom Modes
(see section 4.8 “Setting the default welding programs”)
5.1.1 PS-500 Component Diagram
PS-302
C-Arm
F-44
Release Trigger Switch
F-44
Weld Trigger Switch
Weld Shaft
PS-103-CM
20mm Shank
PS-025
Welding Cap
PS-1101-CM
60mm Shank
PS-5203
Clamping Handle
Figure 5.1 PS-500 Spot Gun - Component Diagram
5.1.2 Using the Double-Acting Gun
Push this button to open electrodes wide.
Copyright © Pro Spot International, Inc.
2005-2009
Push this button to close electrodes and weld.
5 Double-Sided Welding
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PR-2000
5.2 Extension Arms
The Pro Spot PR-2000 comes with a variety of extension arms to accomodate
any welding job situation.
Please refer to fig. 5.3 for details on what welding electrodes to use with each
extension arm.
NOTE: Extension arms marked “optional ” are available from your local
distributor or online at www.prospot.com
REMARQUE: Bras d'extension portant la mention «facultatif» sont
disponibles chez votre Distributeur régional ou en ligne à
www.prospot.com
PS-302:
C-Arm
PS-52-5/8:
Wheel House Arm
PS-403 (optional):
C-X Adapter
PS-305:
508mm Extension Arm
PS-503-W (optional):
600mm Extension Arm
Figure 5.2 PR-2000 Extension Arms
5.2.1 Switching to extension arms
Loosen the handle and pull off the C-arm...
Copyright © Pro Spot International, Inc.
2005-2009
Now, insert the extension arm and tighten the handle.
5 Double-Sided Welding
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PR-2000
5.2.2 Extension Arms and Welding Electrodes
Different extension arms require the use of different welding electrodes.
Use charts in fig. 5.3 and 5.4 to determine the correct combination of extension
arms and welding electrodes.
IMPORTANT! Using incorrect welding electrodes with extension arms
may result in weak welds and/or damage to your welder.
IMPORTANT! Utiliser des électrodes de soudage inexactes avec le bras
d'extension peut donner des soudures faibles et / ou endommager votre
soudeur.
A
A
B
C
B
C
PS-302
PS-1101-CM
PS-103-CM
PS-52-5/8
PS-1101-CM
PS-1133-5/8
PS-403
see Sec. 5.7.3
see Sec. 5.7.3
PS-305
PS-1101-CM
PS-129-CM
PS-503-W
PS-1101-CM
PS-128-CM
Figure 5.3 Extension arm - Welding electrode configuration chart
Figure 5.4 Welding electrode selection chart
NOTE: PS-025 Welding Caps can be purchased in packages of 15 from
your local distributor or online at www.prospot.com
REMARQUE: Des bouchons de type PS-025 peuvent être achetés en
paquets de 15 chez votre distributeur local ou en ligne à
www.prospot.com
Copyright © Pro Spot International, Inc.
2005-2009
5 Double-Sided Welding
Page 17
PR-2000
5.3 PS-500 Electrode Alignment
Use the set screws (A, B, C) to align the electrodes. Ex: to move electrode down,
loosen screw (C) and tighten screws (A and B).
Figure 5.5 Electrode Alignment
CORRECT
WRONG
IMPORTANT! Always maintain proper electrode alignment. Not doing
so may result in weak, substandard welds!
IMPORTANT! Toujours maintenir l'alignement des électrodes appropriées.
Ne pas le faire entrainerait des soudures faibles, de qualité
inférieures!
Copyright © Pro Spot International, Inc.
2005-2009
5 Double-Sided Welding
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PR-2000
5.4 Removing Welding Electrodes
Removing Extension Arm Electrode
The extension arm electrodes can be easily removed by lightly tapping them
with a pin and hammer as shown in fig. 5.6
Removing Piston Electrode
Figure 5.6a: Removing
Piston Electrode
To remove the piston electrode:
1. Grip piston electrode with a set of pliers or vise-grips (fig.5.6a).
2. Rock the pliers back and forth to loosen the electrode from the holder.
3. Remove the electrode
Note: Vise-Grips shown in fig. 5.6a are specially designed to hold round
objects without damaging or scarring them. You can purchase a set from your
local distributor or online at: www.prospot.com
IMPORTANT! Do not attempt to remove the electrode by hitting it.
This could damage the electrode and the spot gun.
Figure 5.6b: Removing
Welding Cap
IMPORTANT! N'essayez pas de retirer l'électrode en la frappant.
Cela pourrait endommager l'électrode et le “pistolet”.
Removing Welding Caps
To remove a welding cap:
1. Hold piston electrode with a set of pliers or vise-grips.
2. Grip welding cap with another set of pliers or wedge side cutters between
cap and shank as shown in fig. 5.6b
3. Twist the two to loosen and remove the welding cap.
NOTE: An optional welding electrode cap removal tool is available,
which makes cap removal easy (fig. 5.6c). You can order the cap
removal tool from your local distributor or online at: www.prospot.com
REMARQUE: Un outil optionnel pour enlever le bouchon est disponible,
pour faciliter le retrait du bouchon (fig. 5.6c). Vous pouvez commander cet
outil chez votre distributeur local ou en ligne à l'adresse: www.prospot.com
Figure 5.6c: Optional Weld
Cap Removal Tool
Welding Cap
Piston Electrode
Extension Arm
Electrode
Pin
Figure 5.6 Removing Welding Electrodes
Copyright © Pro Spot International, Inc.
2005-2009
5 Double-Sided Welding
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PR-2000
5.5 Welding Electrode Maintenance
To maintain structurally-sound welds it is important to keep your welding
electrodes clear from build-up. It is also important to maintain a 6mm weld
nugget diameter. Clean electrodes with a file and periodically replace welding caps as explained in Section 5.4 “Removing Welding Electrodes”
WARNING! The electrodes may be hot. Use caution when handling
them.
ATTENTION! Les électrodes peuvent être chaudes. Soyez prudent
lors de leur manipulation .
5.6 Wheel House Arm
The wheel house adapter allows access to hard to reach areas such as
the wheel house
PS-52-5/8:
Wheel House Arm
PS-1101-CM:
60mm Electrode Shank
Copyright © Pro Spot International, Inc.
2005-2009
PS-1133-5/8:
Electrode
5 Double-Sided Welding
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PR-2000
5.7 X-Adapter (optional)
C-TYPE GUN
The advantage of the C-Type Spot Gun is that when making vertical pinch
welds on quarter panels, rocker panels, door pillars, etc., the spot gun is
positioned perpendicular to the work area. Easy to reach! Easy to use!
X-TYPE GUN
The X-type design is used on certain applications where the C-type can’t reach.
90% of all welding needs can be done with the C-type but for some radiator support and truck bed pinch welds, the X-Adapter works better. This new invention
from Pro Spot makes it possible to weld where you never could before!
5.7.1 Attaching the X-Adapter
1
2
3
A
Loosen the handle and pull
out C-arm...
4
C
B
Follow instructions in Sec. 5.4
to remove piston electrode
Insert the X-Adapter onto the
gun.Tighten handle (A).
5
D
D
Insert the Tapered Electrode (B)
into the Shaft (C). Apply air
(carefully) to put pressure on the
electrodes so that Tapered
Electrode seats firmly in the shaft
before tightening the Collar (D)
set screw.
Tighten the Collar (D) set screw.
IMPORTANT! Do not tighten the Collar before the inserting Tapered
Electrode into the shaft. The collar is designed to prevent the Tapered
Electrode from falling out of the Shaft when the gun is fully opened.
IMPORTANT! Ne serrez pas le collier avant de glisser l’Électrode rétrécie
dans le tube. Le collier est conçu pour empêcher l’ Électrode rétrécie de
tomber du tube quand le pistolet est complètement ouvert.
Copyright © Pro Spot International, Inc.
2005-2009
5 Double-Sided Welding
Page 21
PR-2000
5.7 X-Adapter (optional) cont.
5.7.2 Using the X-Adapter
Push the upper switch to open electrodes wide.
Push the lower switch to close electrodes and weld.
5.7.3 X-Adapter Configurations
X Adapter
(PS-404)
90° Electrode - Upper
(PS-411)
PS-024
Welding Cap
45° Electrode - Upper
(PS-421)
Collar
(PS-407)
90°Electrode - Lower Pivot Axle
(PS-412)
(PS-406)
Figure 5.7 90° Arm Set
Copyright © Pro Spot International, Inc.
2005-2009
Tapered
Electrode
(PS-405)
45°Electrode - Lower
(PS-422)
Figure 5.8 45° Arm Set
5 Double-Sided Welding
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PR-2000
6 Single-Sided Welding
6.1 Single-Sided Welding Overview
ground plate
Figure 6.1
Figure 6.1b
The Single-Sided Weld System allows the operator to carry out
welding tasks using a Single-Sided Weld Gun. The Single-Sided
weld procedure requires contact only from one side compared to
two sides in Two-Sided welding. A ground plate must be connected to the panel to be welded for it to work (fig. 6.1).
You can also use an optional magnetic ground plate to easily attach the ground
cable to the metal (fig. 6.1b).
NOTE: Make sure the ground plate is clamped firmly in place on the
inside of a clean metal surface as near as possible to the weld location.
Do not attach the ground to the metal you're about to weld on. When
performing other weld tasks such as dent pulling, etc., the ground
attachment location becomes less critical.
REMARQUE: Assurez-vous que la plaque de terre est fixée solidement
en place à l'intérieur d'une surface métallique propre aussi près
que possible du lieu de soudure. N’attachez pas la plaque de metal
que vous êtes sur le point de soudre . Quand vous effectuez d'autres
tâches de soudures comme la traction d’impacts, etc le lieu de la prise
de terre devient moins critique.
In the Single-Sided weld mode the following weld procedures are available for the
PR-2000:
Single-Sided Welding
Carbon Rod Shrinking
Stitch Welding
Washer Welding
Nail Welding
Bolt and Nut Welding
Rivet Welding
Contact Shrinking
Spot Hammer Dent Pulling
Pro Pull Dent Removal
Figure 6.2 Single-Sided applications
Copyright © Pro Spot International, Inc.
2005-2009
6 Single-Sided Welding
Page 23
PR-2000
1. Make sure the welder is turned on. Push the Single-Sided weld mode button
(fig 6.3). Single Sided Weld Programs will display on the screen (fig. 6.5).
Figure 6.3: Selecting Single -Sided
weld mode
2. Use the navigation buttons, Left or Right to select desired weld program (refer
to section 4.8 “Setting the default weld program” or fig.4.9). The display screen
shows the currently selected program (fig. 6.4).
Single-Sided Programs
1
Figure 6.4
2
3
4
5
6
7
8
9
10
Figure 6.5 PR-2000 Single Sided Weld Programs
Copyright © Pro Spot International, Inc.
2005-2009
1
Single-Sided spot welding
2
Pro Pull Dent Removal
3
Dent Pulling
4
Contact Shrinking
5
Nut Welding
6
Bolt Welding
7
Stitch Welding
8
Carbon Rod Shrinking
9
Rivet Welding
10
Washer Welding
6 Single-Sided Welding
Page 24
PR-2000
6.2 Single-Sided Spot Welding
Single-Sided spot welding is used where Two-Sided spot welding cannot be used.
Important: The Single-Sided spot welding is not permitted on supporting
frameworks of a vehicle. It is only permitted for cosmetic purposes.
Figure 6.6
Figure 6.9
Important: Le soudage de Côté Unique par points n'est pas autorisée sur
les cadres de soutien d'un véhicule. Il est seulement permis à des fins
cosmétiques.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
3. Fit the Single-Sided Gun with Single-Sided electrode (fig.6.9).
4. Grind between the inner and the outer body sheets to remove paint, primer and
rust. This ensures good electrical contact when performing Single-Sided welding.
5. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
6. Apply about 33-44 lbs of pressure on the Single-Sided gun and push the trigger
to weld. Reposition and weld again.
Note: Make sure that Single-Sided electrode is clean. If it isn't, use a file
or tip dresser to clean it. If the weld cap shows considerable wear, it
should be replaced (refer to section 5.4 “Removing Welding Electrodes”)
6.3 Bolt Welding
Remarque: Assurez-vous que l ‘électrode Côté Unique est propre. Si
ca ne l’est pas, utilisez une lime pour le nettoyer. Si le bouchon de
soudure est considerablement usé, il devrait être remplacé (voir la
section 5.4 "Enlèvement d’Electrodes de soudage»)
Many of today's car bodies come with factory equipped threaded studs. After a
collision, the studs may be lost or do not accompany the replacement part. With
the PR-2000, threaded studs can be welded-on in factory style. This type of stud
is also common throughout the car body for attachments of interior, tail lights,
door moldings, etc.
Figure 6.10
Tip: A threaded stud can also be used to fasten the ground clamp directly
to the panel, minimizing the area needed for grinding.
Suggestion: Un goujon fileté peut également être utilisé pour fixer la pince
directement sur le panneau, ce qui réduit la surface nécessaire au broyage.
Figure 6.12
Copyright © Pro Spot International, Inc.
2005-2009
Studs are held in place during welding with magnetic adapter electrode.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Bolt Welding Program by pressing the Left or Right Navigatioin Buttons
(fig. 4.9). Make sure that Bolt Welding graphic appears on the screen (fig. 6.10)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit Single Sided gun with the magnetic stud adapter (fig. 6.12).
5. Insert stud into the adapter (fig. 6.12).
6. Prepare the surface area by removing paint and primer.
7. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
8. Position single sided gun over work area and push the trigger to weld.
9. Repeat as needed.
6 Single-Sided Welding
Page 25
PR-2000
6.4 Nut Welding
Weld-on nuts are common throughout the car body for attachments of interior, tail
lights, door moldings, etc. and are applied with ease using the PR-2000.
Tip: Different size nuts are available from your local Pro Spot distributor
or on the web at Pro Spot online store.
Figure 6.13
Figure 6.15
Suggestion: Des ecrous de différentes tailles sont disponibles chez votre
distributeur local Spot Pro ou sur le web à la boutique Pro Spot en ligne.
Nuts are held in place during welding with a shrinking electrode.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Nut Welding Program by pressing the Left or Right Navigatioin Buttons
(fig. 4.9). Make sure that Nut Welding graphic appears on the screen (fig. 6.13)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit Single-Sided gun with the Shrink Electrode (fig. 6.15).
5. Prepare the surface area by removing paint and primer.
6. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
7. Press weld-on nut to the metal with Contact Shrinking electrode, apply some
pressure and push the trigger to weld.
8. Repeat as needed.
6.5 Dent Pulling with Spot Hammer
Spot hammer dent pulling is used to repair dents on a vehicle body. The spot
hammer welds directly onto the work area and pulls the dent.
Tip: The replaceable welding tip should last for over one thousand welds.
Contact your local distributor to order replacement tips, or order on the
web at Pro Spot online store.
Figure 6.16
Figure 6.18
Suggestion: Le bout de soudage remplaçable devrait permettre d’accomplir
plus de milles soudures. Contactez votre distributeur local pour commander
pointes de rechange, ou commandez sur la Web Pro Spot au magasin en ligne.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Spot Hammer Program by pressing the Left or Right Navigatioin Buttons
(fig. 4.9). Make sure that Spot Hammer graphic appears on the screen (fig. 6.16)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit Single-Sided gun with the spot hammer (fig. 6.18).
5. Prepare the dent surface area by removing paint and primer.
6. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
7. Position the spot hammer tip at the bottom of the dent and push the
trigger to weld the electrode onto the metal.
8. Pull out a dent then release by twisting the hammer.
9. If needed, reposition, weld, and pull again.
When more pulling power is needed, simply increase the current.
Note: Check spot hammer tip periodically to make sure it is in good
working order. If the tip looks worn, replace it with a new one.
Remarque: Contrôlez le bout du marteau périodiquement pour s'assurer
qu'il est en bon état de marche. Si le bout semble usé, le remplacer par un
nouveau.
Copyright © Pro Spot International, Inc.
2005-2009
6 Single-Sided Welding
Page 26
PR-2000
6.6 Moulding Clip Rivet Welding
Figure 6.19
Figure 6.21
This function will weld on factory type clips for the window moulding. The clips
that hold the moulding do not, usually, come on the replacement parts.
Rivets are held in place during welding with magnetic adapter electrode.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Rivet Welding Program by pressing the Left or Right Navigatioin Buttons
(fig. 4.9). Make sure that Rivet Welding graphic appears on the screen (fig. 6.19)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
3. Fit Single-Sided gun with the magnetic rivet adapter (fig. 6.21).
4. Insert rivet into the adapter (fig. 6.21).
5. Prepare the surface area by removing paint and primer.
6. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
7. Position Single-Sided gun over work area and push the trigger to weld.
8. Repeat as needed.
6.7 Dent Pulling with Washers and Slide Hammer with Hook
The slide hammer with hook (optional) can be used in conjunction with washers
to repair car body dents.
Tip: You can purchase a slide hammer with hook from your local Pro Spot
distributor or on the web at Pro Spot online store.
Figure 6.22
Figure 6.24
Suggestion: Vous pouvez acheter un marteau glissant avec crochet chez votre
votre distributeur local Pro Spot ou sur le web à la boutique Pro Spot en ligne.
Washers are held in place during welding with magnetic adapter electrode.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Washer Welding Program by pressing the Left or Right Navigatioin
Buttons (fig. 4.9). Make sure that Washer Welding graphic appears on the screen
(fig. 6.22)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit Single-Sided gun with the magnetic washer adapter (fig. 6.24).
5. Insert washer into the adapter (fig. 6.24).
6. Prepare the dent surface area by removing paint and primer.
When welding on washers, you only need to clean the area where the washer
touches the metal since the grounding system is connected through a separate
cable.
7. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
8. Position the washer at the bottom of the dent and push the trigger to weld the
washer onto the metal.
9. Hook the washer with the slide hammer and pull out the dent.
10. Repeat as needed.
Tip: You can, also, pull multiple washers by welding on a row of washers
at the bottom of the dent, inserting a rod through the washers and pulling
the rod with the slide hammer with hook.
Suggestion: Vous pouvez, également, obtenir plusieurs rondelles par soudage
sur une rangée de rondelles au bas de la Bosselure, en insérant une baguette
a travers les rondelles et en tirant la tige avec le marteau glissant avec crochet.
Copyright © Pro Spot International, Inc.
2005-2009
6 Single-Sided Welding
Page 27
PR-2000
6.8 Contact Shrinking
Figure 6.25
Figure 6.27
Dent pulling with washers creates high spots in the metal. Until now, the common
practice would have been to grind the surface, resulting in a loss of sheet metal
thickness. With the PR-2000, use the shrinking tip instead of a grinder to remove
the high spots, leaving a smooth and clean surface that's every bit as thick and
strong as before. Shrinking electrode also acts as a nut adapter (refer to section
6.4 "Nut Welding"). With this electrode you get two convenient tools in one.
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Contact Shrinking Program by pressing the Left or Right Navigatioin
Buttons (fig. 4.9). Make sure that Contact Shrinking graphic appears on the
screen (fig. 6.25)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit Single-Sided gun with the contact shrinking electrode (fig. 6.27).
5. Prepare the surface area by removing paint and primer.
6. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
7. Position the contact shrinking electrode over the high spot, apply some pressure and push the trigger to weld.
8. Repeat as needed.
6.9 Carbon Rod Shrinking / Stretching
Carbon Rod is used to shrink or stretch metal on a vehicle. The carbon rod can
also be used on sharp dents caused by such things as hail.
Figure 6.28
Figure 6.30
Copyright © Pro Spot International, Inc.
2005-2009
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Carbon Shrink Program by pressing the Left or Right Navigatioin
Buttons (fig. 4.9). Make sure that Carbon Shrink graphic appears on the screen
(fig. 6.28)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit the Single-Sided Gun with Carbon Electrode (fig. 6.30).
5. Clean the metal surface area.
6. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
7. Position carbon rod over the work area and push the trigger to start welding.
Keep trigger depressed to continue welding. Move the carbon rod in such a way
as to heat up the entire working area to the appropriate temperature. Release the
trigger to stop welding.
8. Cool the surface with a wet rag or compressed air.
6 Single-Sided Welding
Page 28
PR-2000
6.10 Stitch Welding
The PR-2000 can also be fitted with a stitch weld adapter enabling the operator to
lay staggered bead type welds. While rolling the tip on the sheet metal edge, the
welder will automatically deliver an intermittent or pulsating current.
Figure 6.31
Figure 6.33
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select Stitch Welding Program by pressing the Left or Right Navigatioin
Buttons (fig. 4.9). Make sure that Stitch Welding graphic appears on the screen
(fig. 6.31)
3. Choose weld power level by pressing the “Next Program” button repeatedly.
(refer to section 4.6 "Setting the weld program").
4. Fit Single-Sided gun with the stitch electrode (fig. 6.33).
5. Prepare the surface area by removing paint and primer.
6. Ground the working area (refer to section 6.1 "Single-Sided Welding
Overview").
7. Roll the tip on the sheet metal edge while keeping the trigger depressed. The
welder will automatically deliver an intermittent or pulsating current.
8. Repeat as needed.
This procedure works well on stainless steel, and therefore lends itself well to rust
repair and patching. It's easy to use and can be manipulated to fit any shape or
form you require.
Tip: You can use stitch electrode to weld pulling tabs onto areas that
need to be pulled.
Suggestion: vous pouvez utiliser l'électrode de point à souder en
tirant des onglets sur des endroits qui ont besoin d'être tirés.
Copyright © Pro Spot International, Inc.
2005-2009
6 Single-Sided Welding
Page 29
PR-2000
6.11 Pro Pull Dent Pulling (optional)
e
ll can b
Pro Pu most
to
fitted
ers
ot weld
nce sp
resista nt pullers.
or de
Pro Pull is a patented, innovative tool for fast and accurate dent pulling. It
features paintless dent removal functionality (see sec. 6.3.5 “Paintless Dent
Pulling With Pro Pull”).
rs
te
& Adap
Welder luded.
not inc
6.11.1 Selecting Pro Pull Weld Mode
Figure 6.6 Selecting Pro Pull
weld mode
1. Push the Single-Sided weld mode button (fig 6.3). Single Sided Weld Programs
will display on the screen (fig. 6.5). The PR-2000 software defaults to Single Spot
Weld Mode (fig. 6.6).
2. Select ProPull Welding Program by pressing the Left or Right Navigatioin
Buttons (fig. 4.9). Make sure that Pro Pull Welding graphic appears on the screen
(fig. 6.6)
Make sure the ground plate is clamped firmly in place on the inside of a
clean metal surface as near as possible to the weld location.
NOTE: Do not attach the ground to the metal you're about to weld on.
When performing other weld tasks such as dent pulling, etc., the ground
attachment location becomes less critical.
Assurez-vous que la prise/ plaque de terre est fixée fermement en place à
l'intérieur d'une surface propre de métal le plus près possible du lieu de
soudure.
Remarque: Ne fixez pas la prise the terre a la plaque de metal que vous
êtes sur le point de souder. Lors de l'exécution d'autres tâches comme la
soudure de traction des impacts, etc, la localisation de la prise de terre
devient moins critique.
6.11.2 Pro Pull Component Diagram
Pro Pull comes with three different
Blocking Plates with Quick-Connect design.
Block window size:
2.5"(63mm) x 1.5"(38mm)
PP-10-04
Retrofit point for different end adapters.
Available for most weld guns.
(not included) See prospot.com for more
information.
Large openings for
great visual control
of the pulling area.
Block window size:
1.75"(44mm) x 1"(25mm)
PP-10-03
CLT-55
Electrode
Block window size:
0.75" (19mm) dia.
PP-10-01
N-38
Nut
Copyright © Pro Spot International, Inc.
2005-2009
6 Single-Sided Welding
CLP-75
Removable weld shaft.
The weld current is
transferred through the shaft
and NO CABLE is required
to transfer the current
Page 30
PR-2000
6.11.3 Pro Pull Assembly
C
A
D
approx.
0.7”(17mm)
F
E
1. Attach the Weld Gun (D) to Weld Shaft (C). Secure Lock Bolt (G).
2. Slide weld shaft and gun to standard distance (E).
3. Attach desired block plate (A)
4. Position the weld tip in the “bottom” of the dent, weld, then pull the handle (F)
to initiate the pulling action. Use the shortest weld TIME possible to prevent
extensive weld marks.
6.11.4 Dent Pulling with Pro Pull
1
2
Aim, position & fire!
3
Pull dent with Auto
Blocking.
Twist gun to release tip.
6.11.5 Paintless Dent Pulling With Pro Pull
Glue Adapter for Paintless
Dent Removal
Copyright © Pro Spot International, Inc.
2005-2009
6 Single-Sided Welding
Page 31
NOTES
NOTES
NOTES
Pro Spot international, Inc.
2625 Temple Heights Dr Ste. A
Oceanside, CA 92056
Toll Free: (877) PRO SPOT
Fax: (760) 407-1421
E-mail: info@prospot.com
Web: www.prospot.com
Copyright © Pro Spot International, Inc. 2005-2009