Pro Spot AL-5 Bedienungsanleitung

Aluminum Dent

Pulling System

Instruction Manual

Version 1.02

AL-5

Capacitor Discharge

TABLE OF CONTENTS

GETTING FAMILIAR WITH YOUR WELDER - READ BEFORE USING 1

AL-5

CREATING A PROPER GROUND

GETTING FAMILIAR WITH YOUR GUN 2

GETTING READY TO WELD

WELDING INSTRUCTIONS

IDENTIFYING COMMON ISSUES

WELDER PARTS LIST

WELDER GUN PARTS LIST

WARRANTY REGISTRATION

WARRANTY

Getting Familiar with your Welder

AL-5

Voltage Adjustment

Knob

ON / OFF Switch

(Not Shown)

ON / OFF Switch

Grounding Plate

Overheat Light

(OH)

Over Voltage Light

(OV)

Ground Light

(GRD)

Ready Light

Power Light

(ON)

Ground

Cable 1

Ground

Cable 2

Ground

Cable 3

Positive

Cable 4

AL-5

Page 1

Input Cable

AL-5 Stud Gun

Rear View

Input Cable

Front Panel Zoom

Overheat Light

(OH)

Over Voltage Light

(OV)

Ground Light

(GRD)

Ready Light

Power Light

(ON)

Ground

Cable 1

Ground

Cable 2

Ground

Cable 3 Positive

Cable 4

Voltage Adjustment

Knob

ON / OFF Switch

(Not Shown)

Input Cable

Grounding Plate

AL-5 Stud Gun

Getting Familiar with your Gun

AL-5

Page 2

Trigger

Switch

Stud Electrode

Electrode Shaft

Set Screws

Adjustable Electrode

Pressure Knob

Command

Cable

For Trigger

Positive

Cable

Stud

Trigger

Switch

Electrode Shaft

Set Screws

Adjustable Electrode

Tension Knob

Ground Pins (3)

Command

Cable

For Trigger

Positive

Cable

Welding Stud

Ground Plate

Clean surface, weld a stud using the AL-5.

Place the ground plate on top of the stud, use

a wing nut or similar to tighten the plate to the panel.

The closer the ground to the weld location, the better.

Ground Clamp

Alternative method to achieve ground.

Clean surface on work piece and use ground

clamp in this location. The closer the ground

to the weld location, the better.

Additional Grounding for AL-5

Instructions

Weld a stud near the work area where the

dent removal will take place.

Make sure the area where the copper is

touching is clean and free of paint and dirt.

Make sure the adapter is flush with the panel.

Push down the gun so that at least two of

the three ground pins are contacting the panel

to allow for good ground. When good contact

has been made, push the trigger.

Place the ground plate on top of the stud, use

a wing nut or similar to tighten the plate to the panel.

Insert the stud into the electrode. The stud

should extend 1/8” or 3mm from the electrode.

Alternative method to achieve ground.

IMPORTANT: The result of stud welding is directly

dependant on how good the ground contact is. Keep

the ground in close proximity to the work area.

1/8” (3mm)

Creating A Proper Ground

AL-5

Page 3

Point Do Not Use

Pressure

The Arc melts the point Base of stud is

fused to the panel

Getting Ready To Weld

AL-5

To Weld:

Insert a threaded stud into the matching electrode holder.

Place the gun in a perpendicular 90° position to the weld area.

Figure 3

AL-5

Page 4

Figure 1

When the stud is placed on the panel, the GRD (ground) Light should turn on and indicate that the

ground circuit is complete. If the voltage setting is changed, the ready light will go out until the

correct capacitor voltage has been verified. Once the correct capacitor voltage has been verified,

the light will turn on again.

In normal operation, the indicator light

on the front panel should be as

follows:

GRD

READY

READY and ON

lights are illuminated

when the welder is on.

The point on the stud creates an arc and the pressure on the stud collapses the point and melts

the base of the stud to the panel. All of this occurs in milliseconds to create a proper weld, if the

time were longer it could damage or blow a hole in the panel.

NO GAP

Setting the Weld Voltage:

4mm

5mm 70-110

6mm 80-130

60-90

Thickness: Set weld knob to:

Aluminum

Welding Instructions

AL-5

Page 5

AluminumAluminum

Place stud in

desired location.

Do not apply pressure

to gun yet.

Squeeze and hold trigger.

Again, do not apply pressure

to gun yet.

With trigger still squeezed, apply

downward pressure until

the gun fires and the weld

has been made.

Aluminum

1. Make sure the point ONLY touches the surface.

GOOD! Stud flush to electrode. GOOD.

2. Make sure the point ONLY touches the surface

GOOD! Stud can extend 1/8”(2mm) from electrode. OK.

3. Point and head of stud touches the surface. BAD!

4. Head of stud touches the surface. BAD!

5. Electrode touches surface. BAD!

6. No point on stud. BAD! Will not work.

Point. GOOD! No Point. BAD!

AL-5

Page 6

Identifying Common Issues

AL-5

Page 7

37 40

Parts List

AL-5

OH VOLTAGE

GRD

READY

AL-5

Page ??

AL-5 Stud Welder

Parts List

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 90-0154 CHASSIS 1

2 90-0157 PLATE, NEUTRAL 1

3 90-0156 PLATE, POSITIVE 1

4 90-0158 BUSS BAR 1

5 90-0159 PLATE, BACKER 1

6 90-0160 CONTACT SCREW 1

7 90-0161 SPACER, BOX CLAMP 4

8 80-5154 LABEL, FRONT PANEL 1

9 CAPACITOR 2

10 TRANSFORMER 1

11 COOLING FAN 110V 1

12 PCB, CAPACITOR DISCHARGE WELDER 1

13 STANDOFF 2

14 STANDOFF 1

15 DIODE 1

16 RUBBER FOOT 4

17 NUT, BRASS 2

18 TRAFIMET CX31 1

19 KNOB 1

20 STRAIN RELIEF 1

21 4 PIN CONNECTOR 2

22 SWITCH

BACKER, CAP. DIS.

23 1

24 2

25 2

90-0155

51-0055

COVER

HANDLE

72-0333

77-2275

82-0101

CB-500/A

ST-18

ST-04

74-8004

52-9540

N-90

63-0031

52-0119

52-1244

63-1360

78-1686

90-0159

P10-12 FUSE HOLDER

FUSE 2A SLOW IEC

COOLING FAN POWER CORD

AL-5 SERIAL TAG

POWER SUPPLY, 9’10” POWER CORD

1/4”-20 X 2” HHCS ZINC

AL-5 COVER SIDE DECAL

FAN FILTER ASSEMBLY

76-1210

PR-2000-80

PR-2000-79

80-5156

69-7035

32 1

GROUNDING PLATE

XX-????

33 1

MX BOLT

XX-????

NUT

XX-????

S-250

80-5155

52-3503 NYLON SHOULDER WASHER

CABLE CLAMP

CORD GRIP

NUT

PLUG

52-2514

63-1357

52-2003

39 FRONT PANEL DECAL

xx-????

52-1903

ITEM NO. PART NUMBER DESCRIPTION QTY

1 90-0154 CHASSIS 1

2 90-0157 PLATE, NEUTRAL 1

3 90-0156 PLATE, POSITIVE 1

4 90-0158 BUSS BAR 1

5 90-0159 PLATE, BACKER 1

6 90-0160 CONTACT SCREW 1

7 90-0161 SPACER, BOX CLAMP 4

8 90-0159 BACKER PLATE 1

9 90-0139 LEG, SUPPORT 3

10 90-0138 SUPPORT, TRIANGLE 1

11 90-0195 GROUND PLATE 1

12 85-0127 GROUND CLAMP 1

13 CB-500 PROCESSOR BOARD 1

14 80-5154 LABEL, FRONT PANEL 1

15 72-0333 CAPACITOR 2

16 77-2275 TRANSFORMER 1

17 82-0101 COOLING FAN 110V 1

18 74-8004 DIODE 1

19 52-9540 RUBBER FOOT 4

20 63-0031 SOCKET 1

21 52-0119 KNOB 1

22 52-1244 STRAIN RELIEF 1

23 63-1360 4 PIN CONNECTOR 1

24 78-1686 SWITCH 1

25 52-3503 NYLON SHOULDER WASHER 4

26 52-1903 CORD GRIP 2

27 52-2003 NUT 2

28 51-0133 PANEL NUT, #8 12

29 ST-18 STANDOFF, BRASS 2

30 ST-04 STANDOFF, PLASTIC 1

31 WL-56 CABLE 2

32 N-90 NUT, BRASS 2

33 N-96 FLANGE NUT 1/4-20 2

34 S-176 FHMS 8-32 X .75 3

35 S-38

90-0155

80-5155

51-0055

80-5154

PHMS 1/4-20 X .5 2

36 CLAMP, 76mm CAPACITOR 2

37 COVER 1

38 AL-5 COVER SIDE DECAL 2

39 HANDLE 2

40 FRONT PANEL DECAL 1

AL-5

Page 8

Parts List

AL-5 Gun

AL-5

Page ??

AL-5 Stud Gun

Parts List

ITEM

NO. Part Number DESCRIPTION QTY.

1 PS-3202 HANDLE, 3 PIECE 1

2 90-0132 BUSHING, SHAFT 1

3 90-0133 SHAFT, ELECTRODE 1

4 90-0135 PLATE, SPRING 1

5 90-0136 BUSHING, JACK SCREW 1

6 90-0137 JACK SCREW 1

7 90-0138 SUPPORT, TRIANGLE 1

8 90-0139 LEG, SUPPORT 3

9 90-0172 NUT, LOCK 1

10 C-CLIP 1

11 SWITCH 1

12 MICRO SWITCH 1

13 STRAIN RELIEF 1

14 SPRING 1

15 1/4 X 1.0 DOWEL PIN 1

16 TIP ASSY 1

17 CABLE CLAMP 1

18 PLUG 1

19 CORD GRIP 1

20 NUT

POSITIVE CABLE

BOLT MX XX

M6 FLANGE NUT

GROUND CABLE

TRIGGER CABLE

21 1

22 1

23 1

24 1

GUN DECAL

28 2

723 16 93215

21 12 422 14 10 56

18 19

25 1

SR-13

78-0594

78-0867

52-1611

51-0314

50-5501

52-2514

63-1357

S-176

S-44

80-5003

WL-05

WL-56

M-108

52-2003

52-1903

ITEM NO. Part Number DESCRIPTION QTY.

1 PS-3202 HANDLE, 3 PIECE 1

2 90-0132 BUSHING, SHAFT 1

3 90-0133 SHAFT, ELECTRODE 1

4 90-0135 PLATE, SPRING 1

5 90-0136 BUSHING, JACK SCREW 1

6 90-0137 JACK SCREW 1

7 90-0172 NUT, LOCK 1

8 SR-13 C-CLIP 1

9 78-0594 SWITCH 1

10 78-0867 MICRO SWITCH 1

11 52-1611 STRAIN RELIEF 1

12 51-0314 SPRING 1

13 M-108 1/4 X 1.0 DOWEL PIN 1

14 50-5501 TIP ASSY 1

15 52-2514 CABLE CLAMP 1

16 63-1357 PLUG 1

17 WL-56

80-5003

CABLE 1

18 SHCS 1/4-20 X .625 1

19 GUN DECAL 2

????

20 POSITIVE CABLE 1

WL-05

21 TRIGGER CABLE 1

14 73213 17 10 418 12 856

Andere Handbücher für AL-5

Inhaltsverzeichnis

Andere Pro Spot Schweißsystem Handbücher

Pro Spot

Pro Spot AL-5 Bedienungsanleitung

Pro Spot

Pro Spot Hybrid Series Kurzanleitung

Pro Spot

Pro Spot PR-155 Bedienungsanleitung

Pro Spot

Pro Spot SP-2 Bedienungsanleitung

Pro Spot

Pro Spot PR-3 AUTO Bedienungsanleitung

Pro Spot

Pro Spot SP-5 Bedienungsanleitung

Pro Spot

Pro Spot PHS-101 Bedienungsanleitung

Pro Spot

Pro Spot i4s Bedienungsanleitung

Pro Spot

Pro Spot IONSTAR 14883 Bedienungsanleitung

Pro Spot

Pro Spot PR-8 Bedienungsanleitung

Pro Spot

Pro Spot PR-1.6 Bedienungsanleitung

Pro Spot

Pro Spot i4 Bedienungsanleitung

Pro Spot

Pro Spot PR-205 Bedienungsanleitung

Pro Spot

Pro Spot NP-3 Bedienungsanleitung

Pro Spot

Pro Spot PR-111 Bedienungsanleitung

Pro Spot

Pro Spot SP-5.3 Bedienungsanleitung

Pro Spot

Pro Spot PR-2000 Bedienungsanleitung

Pro Spot

Pro Spot PHS-101 Bedienungsanleitung

Pro Spot

Pro Spot i5 Bedienungsanleitung

Pro Spot

Pro Spot i4s Bedienungsanleitung

Pro Spot

Pro Spot SP-5 DP Bedienungsanleitung

Beliebte Schweißsystem Handbücher anderer Marken

Berner

Berner PLASMACUT 54 Bedienungsanleitung

Forney

Forney 210 Bedienungsanleitung

Thermal Arc

Thermal Arc 400S Bedienungsanleitung

Lincoln Electric

Lincoln Electric HANDYMIG 170I Bedienungsanleitung

GYS

GYS PROTIG 201 AC/DC Bedienungsanleitung

TAFA

TAFA 30*8B35 Bedienungsanleitung

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Bedienungsanleitung

ESAB

ESAB Buddy Arc 145 Bedienungsanleitung

CIGWELD

CIGWELD 636804 Kurzanleitung

Red-D-Arc

Red-D-Arc DC-400 Bedienungsanleitung

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 Bedienungsanleitung

Elettro

Elettro HI-MIG 3000 SYNERGIC Bedienungsanleitung

Sonics

Sonics H520T Bedienungsanleitung

Miller

Miller Big Blue 400D Bedienungsanleitung

NewArc

NewArc RT2000 Kurzanleitung

Hypertherm

Hypertherm powermax1000 Bedienungsanleitung

Lincoln Electric

Lincoln Electric POWER WAVE I400 Bedienungsanleitung

Everlast

Everlast POWER MTS 221STi Bedienungsanleitung