Pro Spot PR-111 Bedienungsanleitung

Punktschweißgerät

Resistance

Spot Welder

Kurzanleitung

Instruction Manual

Version 1.0

PR-111, PR-112 & PR-113

Inverter

Plasma Cutter

Series

Pro Spot training and services

Pro Spot Distributors and Sub-Distributors are carefully se-

lected and are well trained in the collision repair industry. We offer

technical and service education at our world wide training facilities at

regular intervals so your local distributor will always be up to date and

able to pass on the latest in spot welding technology to our custom-

ers.

Customer service is an important part of any investment and

our distributors and sub-distributors will be there to support your

technical and service needs. We have a great customer service re-

cord, we intend to keep it that way.

About Pro Spot

Pro Spot International, Inc., based in Carlsbad, California, manufactures resistance spot welding equipment

specializing in applications for the collision repair industry. The company began in 1986. The company owns and manages

an on site machine shop, research & development department, a fabrication facility and production lines for the various

welders.

Pro Spot International exports its products worldwide, export sales are managed through our headquarter ofﬁce.

The company owns numerous patents for our ingenious application tools, machines, and procedures.

Pro Spot is certified by CASE and a member of the ICAR Industry Training Alliance

Pro Spot International, Inc. U.S.A.

www.prospot.com

5932 Sea Otter Place

Carlsbad, CA 92010

Phone: +1 760-407-1414

Toll free (US only): 877- PRO SPOT

Fax: 760-407-1421

E-Mail: [email protected]

Contact Information

CAUTION!

BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE

PLASMA CUTTER, READ THE CONTENTS OF THIS MANUAL CAREFULLY, PAYING PAR-

TICULAR ATTENTION TO THE SAFETY RULES.

In the event of these instructions not being clear, please contact your supplier.

CONGRATULATIONS ON YOUR NEW PURCHASE!

YOU ARE NOW IN THE POSSESSION OF ONE OF THE SAFESTAND MOST TECHNOLOGI-

CALLYADVANCED PLASMA CUTTERS ON THE MARKET.

FOLLOW OUR SUGGESTIONS AND YOU WILL BE GUARANTEED SAFE AND PROBLEM-

FREE OPERATION.

Your plasma cutting unit is ¿tted with sophisticated safeguards which block

functioningandthereforethecuttingoperationsuntilallthesafetyconditions

arepresent.Theplasma cutting technique requiresdangerouslyhighvoltage

for pilot arc starting and during cutting, therefore the following safety rules

must be observed with great care.

ELECTRICITY

1-Makesurethat the unit is earthed and that thesupplylinehasanadequate

earth connection.

2-Make sure that the work bench has a satisfactory earth connection.

3-Avoid contact between the metal bars being cut and bare skin or damp

clothes.

4-Do not lean on the piece being cut or hold it in your hands.

5-Do not carry out cutting operations in damp environments or on wet surfaces.

6-Do not use the unit if the torch or cables appear damaged.

7-Always turn the unit off before replacing the electrode, the nozzle or the spreader tip of the torch.

8-Always switch the unit off and remove the power cable from the mains socket before carrying out

any maintenance inside the unit.

EYE AND BODY PROTECTION

One of the hazards during the cutting process is the emission of electromagnetic waves due to the

electric arc. The length of these waves ranges from infrared to ultraviolet. If these rays hit the eyes,

they can cause various complaints such as conjunctivitis, burns to the retina, deterioration of sight,

etc. Moreover a high concentration of ultraviolet rays can burn the skin. It is, therefore, extremely

important that the operator uses adequate safety equipment and clothing, such as:

SAFETY RULES AND GENERAL WARNINGS

INTRODUCTION

CAUTION!

Repairs, maintenance and operation of the unit should be carried out by trained personnel

who are aware of the risks caused by the high voltage needed to operate the plasma cutting

unit. The operator should work in compliance with current standards and abide by all safety

regulations.

CAUTION!

If during the cutting operation a slight electric shock is felt, stop work immediately and do not

use the unit until the fault has been discovered and resolved.

1-Split or leather gloves

2-Split or leather aprons

3-Shin-guards

4-Safety shoes

5-Safety mask (or even better helmet) large enough to cover the whole

of the face, equipped with safety lenses able to ¿lter all the radiation and

reduce the intensity of the light absorbed by the eye.

CAUTION!

A further hazard for eyes is the risk of splinters or particles which may be deta-

ched during the cutting operations or during grinding,

brushing or hammering away of the scale.

Always wear goggles or protective shields with transparent lenses during

these operations to prevent splinters or other foreign bodies from entering the eye.

IMPORTANT:safety screensshouldbe installed around the cutting area toprotect other people, who

may be working in adjacent areas, from the radiation given out by the arc.

FIRE HAZARDS

1-Prevent sparks or hot scale from producing Àames

2-Remove inÀammable or combustible materials from the cutting area.

3-Make sure that ¿re-¿ghting equipment is located near the work area.

4-Situate the unit in an area where the air can be sucked in and exhausted from the grilles on the panel

CAUTION!

Do not cut fuel or lubricant containers even if these are empty.

Do not cut containers or casings which contain inÀammable material.

Never cut in environments which are polluted by inÀammable gas or combustible liquid va-

pours (such as petrol).

CUTTING FUMES AND GASES

Harmful fumes and metallic powders are produced during the cutting operation. Metals which are

painted or coated or which contain mercury, cadmium, zinc, lead and graphite may produce harmful

concentrations of toxic fumes during cutting.

To protect the operator or other persons from exposure to possible toxic fumes, fume respirators

should be worn and work areas should be adequately ventilated.

When working in enclosed environments, suction units should be ¿tted below the cutting area.

CAUTION!

When halogenated solvents or degreasing agents are present, the material to be cut should

be cleaned properly to prevent the formation of toxic gases. Some chlorinated solvents may

decompose in the presence of the radiation given out by the arc and may generate phosge-

ne gas.

CAUTION!

Never, under any circumstances, look at an electric arc without eye protection.

NOISE

Noise is generated during the cutting process. The noise level depends on the cutting parameters used.

CAUTION!

Noise can damage hearing

Wear adequate hearing protection.

BURNS

The operator should be adequately protected during cutting operations. This should be routine practice.

CAUTION!

Do not point the torch jet at people or foreign bodies.

EMC

Before installing the plasma cutting unit, carry out an inspection of the surrounding area, observing

the following guidelines:

1-Make sure that there are no other power supply cables, control lines, telephone leads or other

equipment near the unit.

2-Make sure that there are no radio receivers or television appliances.

3-Make sure there are no computers or other control systems.

4-Make sure that there is no-one with a pacemaker or hearing aid in the area around the unit.

5-Check the immunity of any other equipment operating in the same environment. In certain cases

additional protective measures may be required.

Interference can be reduced in the following ways:

1-If there is interference in the power supply line, an E.M.C. ¿lter should be inserted between the

mains and the unit.

2-Theoutputcablesoftheunitshould be shortened; these should be kept close together and stretched

along the ground.

3-All the panels of the unit should be correctly closed after carrying out maintenance.

GENERAL INFORMATION

PLASMA ARC AND BASIC PRINCIPLES FOR THE PERFORMANCE OF PLASMA CUTTING

¥Plasma is a gas that is heated to an extremely high temperature and ionised so that it becomes

a conductor of electricity.

¥This cutting procedure utilises the plasma to transfer the electric arc to the metal workpiece,

which is melted by the heatand then separated.

¥The torch uses compressed air from a single source, for both the plasma and cooling and pro-

tective gas.

¥The start of the cycle is determided by an arc, called the pilot arc, which is struck between the

mobile electode(negative polarity) ab dthe torch nozzle (positive polarity) due to the short circuit

between these two elements.

¥When the torch is brought into direct contact with the workpiece to be cut (connetcted to the

positive polarity of the power source) the pilot arc is transfered between the electrode and the

workpiece itself thus striking a plasma arc, also called cutting arc.

¥The duration of the pilot arc is set in the fatcory at 3 seconds; if the transfer has not been made

within this time, the cycle is automatically stopped except for the cooling air which is kept on.

A source of clean, dry air or nitrogen must be supplied to your plasma cutting unit. The supply pres-

sure must be between 72.5 and 150 psi (5 and10.3 bar). The Àow rate is approximately 3.5 cu.ft./

min. (100L/min.). Failure to observe these precautions could result in excessive operating tempera-

tures or damage to the torch.

An air regulator is included with the unit with optimum pressure setting set to 65 PSI, 4.5 Bar.

Note: the regulator should never be set above 6 bar.

MANUAL PURGE

Oil in the air is a severe problem and must be avoided.

The unit is also equipped with an air ¿lter which captures

water and oil vapor.

Model 30A - 40A: The vapor collected can be drained

out turning the drain knob located on the air ¿lter. Three

Position Drain knob, select the desired position:

1. Open

2. Open when no air pressure, closed when air pressu-

re. The drain knob should not be left in this position

during cutting operations.

3. Closed

Model 45A: water contained in the ¿lter glass can be drained by pushing upward the drain connector.

Note: The unit will not operate if the input air pressure is below 55 PSI, 3.8 Bar.

POWER SUPPLY CONNECTION

Themachine must be connectedtoaLine-Neutral system witha“PE”protected grounding wire. Check

that the relevant socket terminal is actually connected to the distribution system grounding.

CONNECTION TO GROUND CABLE

Connect the dinse plug to the socket and the work cable clamp to the piece to be cut or to the metallic

workbench. Take following precautions:

¥Verify that there is a good electrical contact particularly if insulated or oxidated coated sheets

are cut.

¥Make ground connections as close as possible to the cutting area. The use of the metallic struc-

tures which are not part of the workpiece, such as the return cable of the cutting current, may

endanger the safety system and give poor cutting results.

¥Do not make a ground connection on the piece which has to be removed.

WARNING!: Before starting the cutting operations verify that the parts are properly assembled

by inspecting the head of the torch as shown on paragraph “Torch Maintenance”

LOCATION AND HANDLING OF THE POWER SOURCE

¥Choose location verifying that there is a good air Àow and no dust, smoke or gas is present.

¥Make sure that obstacles do not prevent the cooling air Àow out of front and rear openings of

the machine.

¥Arrange an open space of at least 5m around the machine.

¥In the case the machine has to be moved, always disconnect the plug from the outlet and gather

the cables and pipes so as not to damage them.

TORCH CONNECTION

COMPRESSED AIR

water contained in the ¿lter glass can be drained by pushing

upward the drain connector.

PR-111:

PR-112/113:

1.ON/FF Switch – In the ON position the machine is ready for normal operation. All system

control circuits are activated. OFF position deactivates control circuits.

2.Output Current Knob - Adjusts the cutting current supplied by the machine according to the

thickness of material/speed.

3.Green LED– Turns ON when input voltage is applied within normal range – blinks slowly

when input voltage goes above 260Vac, or below 180Vac.

4.Red LED–Turns ON when torch is triggered. Blinks quickly during 3 second safety pre-Àow

prior to pilot arc ignition. Blinks slowly if cutting arcs not initiated after 3 second pilot arc

ignition.

5.Yellow LED– Turns ON when the thermal protection is activated. Blinks slowly when the

under pressure protection is working (the pressure is under 3,8 Bar).

6. Air regulator - Adjusts the input air pressure - pull upward to unlock - nominal air pressure

setting is 4,5 Bar. Note: the regulator should never be set above 6 Bar.

7.Compressed air connection

8. Input cord

9. Work cable with clamp

10. Torch (with a trigger security cap)

FUNCTIONS

30A - 40A MODEL

PR-111

45A MODEL

1.ON/FF Switch – In the ON position the machine is ready for normal operation. All system

control circuits are activated. OFF position deactivates control circuits.

2.Output Current Knob - Adjusts the cutting current supplied by the machine according to the

thickness of material/speed.

3.Digital Ammeter - when unit is on views the set cutting current when unit is on, during pilot

arc time views the pilot arc current and during cutting views the cutting current.

4.Green LED – Turns ON when input voltage is applied to the machine.

5.Red LED –Turns ON when pilot or cutting arcs are initiated.

6.Yellow LED – Turns ON when the thermal protection is activated or when voltage exceeds

with compressed air

7.Yellow LED – Turns on when the under pressure protection is working (the pressure is under

3,8 Bar) or when voltage exceeds without compressed air.

8.Torch Gas Purge Button – Allows to remove any condensation that may have accumulated

in the torch and leads while the system was shut down.

9. Air Pressure Gauge – shows the input air pressure

10.Air regulator - Adjusts the input air pressure - pull upward to unlock - nominal air pressure

setting is 4,5 Bar. Note: the regulator should never be set above 6 Bar.

11.Input cord

12.Work cable with clamp

13.Torch (with a trigger security cap)

PR-112/113

CUTTING OPERATION

PRELIMINARIES

WARNING: unplug the unit from the power supply before assemble or disassemble piled parts,

single parts, parts of the torch, torch assemblies or cables.

¥Check and follow instructions as foreseen in the paragraphs “Safety and Installation” of the

present instructions manual.

PARTS OF THE TORCH

¥Check the torch for proper assembly. Install proper torch parts for the desired application (refer

to Section called Torch Consumable Parts Selection). NOTE: The power supply will not opera-

te unless the torch shield cup is fully seated against the PIP (Parts in Place) pins in the torch

head.

INPUT POWER

¥Check the power source for proper input voltage.

¥Make sure the power source meets circuit protection and wiring requirements.

¥Plug unit in and close main disconnect switch to supply primary power to the system.

GROUND CABLE

¥Check for a solid ground cable connection to the workpiece.

AUTOMATIC PURGE SYSTEM

30A - 40A model

¥Place the ON/OFF switch to the ON position. The ON light will Àicker momentarily as the system

powers up and then stays on.Activate the torch button to initiate gas purge (pre-Àow) to remove

any condensation that may have accumulated in the torch and leads while the system was shut

down. When the gas purge is complete, pilot arc will be initiated.

45A model

¥Place the ON/OFF switch to the ON position.Activate the torch button to initiate gas purge (pre-

Àow) to remove any condensation that may have accumulated in the torch and leads while the

system was shut down. When the gas purge is complete, pilot arc will be initiated. To cool torch

handle or to further remove condensation in the torch and leads push the torch gas purge button

on the front panel of the unit.

WARNING

Do not initiate pilot arc during adjustment.

CHECKING AIR QUALITY

¥To check air quality, deactivate the torch (post-Àow) and place ¿lter lens in front of the torch.Any

oil or moisture in the air will be visible on the lens. DO NOT initiate pilot arc while checking air

quality.

CUTTING

A. Cutting with a Hand Torch

¥Thetorchcanbecomfortablyheldinonehandorsteadiedwith two hands. Choose the technique

that feels most comfortable and allows good control and movement. Position the index ¿nger or

thumb to press the control switch on the torch handle.

¥For edge starts, hold the torch perpendicular to the workpiece with the front of the tip on the

edge of the workpiece at the point where the cut is to start. - Fig.A. For piercing, angle the torch

slightly to direct sparks away from the torch until the pierce is complete. Fig. B

Fig. A Fig. B

¥For drag cuts keep the torch in contact with the workpiece. For standoff cutting, hold the torch

2-3 mm from the work.

¥With the torch in starting position, press the control switch. After an initial gas purge (pre-air),

the pilot arc will come on and remain on for 3 seconds until the cutting arc starts.

¥Once on, the main arc remains on as long as

thecontrolswitch is held down, unless thetorch

is withdrawn from the work or torch motion is

too slow. Keep moving while cutting. Cut at a

steady speed without pausing. Maintain the

cutting speed so that the arc lag is about 30°

behind the travel direction. Fig. C

If the cutting arc is interrupted, and the torch

triggerisstill pressed, the pilot arc comes back

on automatically for 3 seconds.

¥To shut off the torch simply release the control switch. When the switch is released a post-Àow

will occur. If the torch trigger is pressed during the post-Àow, the pilot arc will restart.

B. Piercing with a Hand Torch

Note: Recommended maximum piercing capacity is 2mm. If necessary to make a cut on a

metal sheet with a tickness more than 2mm without an edge start, make a hole ø 6mm at

least using an electric drill to start cutting.

¥When piercing with a hand torch, tip the torch

slightly so that blowback particles blow away

from the torch tip (and operator) rather than

directly back into it. Fig. B

¥Completethepierce offthe cutting line and then

continue the cut onto the line. Hold the torch

perpendicular to the workpiece after the cut is

complete. Fig. D

¥Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping

the shieldcup in anti-spatter compound will minimize the amount of scale which adheres to it.

C. Grates Cutting

To cut grates it is suggestable to set cutting current between 20 - 34A.

Fig. C

Fig. D

Fig. B

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