PR-2000 High Frequency Inverter Resistance Spot Welder Instruction Manual Version 2.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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".
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.
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.
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.
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.
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”.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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).
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.
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.
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").
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.
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).
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.
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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.
