Car-O-Liner CR35 User manual

(rev. 0) 2006-04, ENG
INSTRUCTION MANUAL
CR35 Spotter
Movable Dent fixer

This manual refers to the following spot welders CR-35.
This manual is supplied by CAO-O-LINER without any guarantee. CAR-O-LINER reserves
the right to apply to this manual, at any time and without notice, modifications due to
typing errors, inaccuracy of contents or improvements of the programs and devices.
In any case, possible modifications will be integrated in the subsequent editions of this
manual. In no case CAR-O-LINER will be liable for direct, indirect, extraordinary,
accidental or consequential damage caused by the use or the inability to use the spot
welder or this documentation.
Copyright © 2006 CAR-O-LINER
Box 7
SE-736 21 Kungsor - Sweden
All rights reserved. First edition 2006. Printed in Sweden.
p. 2

CAR-O-LINER p. 03
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
CONTENTS
Notes and precautions ………………………………….p. 04
Definition of the terms …………………………………..p. 05
Features of the machine and general information……p. 05
Technical specifications and performances ………….p. 06
Packing-Unpacking-Storage …………………………...p. 07
Installation ………………………………………………..p. 08
Electrical connection .………………………………….. p. 09
MicroDigital 1 welding control……………..………... p. 10
Start-up ………………………………………………….. p. 11
Limit of use ……………………………………………… p. 11
Environment ……………………………………………..p. 12
Starting the machine ……………………………………p. 12
Easy Start ………………………………………………...p. 12
Handling ………………………………………………….p. 13
Maintenance ……………………………………………..p. 13
Scheduled maintenance ………………………………. p. 14
Extraordinary maintenance …………………………….p. 14
Emergency ……………………………….………………p. 15
Disassembly-Disposal …………………………………. p. 15
Troubleshooting …………………………………………p. 16
CR 35 (spotter) spare parts …………………………… p. 17
KS spare parts …………………………………………..p. 18
MR spare parts …………………………………………. p. 19
Multipoint spare parts ………………………………….. p. 20
CR 35 electric diagram …………………………………p. 21

CAR-O-LINER p. 04
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
NOTES AND PRECAUTIONS
Have the electrical connections made by qualified personnel in compliance with the
relevant Laws and safety Codes. Make sure that the power box is properly connected to
the grounding system and that it is complying with the CEI EN 60 204/1 Standard.
W A R N I N G
Do not use cables with damaged insulation, loose connecting terminals or inadequate
section.
Do not operate the spot welder in a humid or wet environment or in the rain.
Always disconnect the machine from the supply systems during installation or checking
and maintenance operations.
Bring flammable materials or substances to a sufficient distance (at least 10 meters) from
the working area.
It is extremely dangerous to weld (spot weld) containers or tanks which have contained
liquid or gaseous substances or combustibles, because explosions may occur.
During spot welding, and especially when welding galvanized, painted or oil contaminated
metal, smoke will be produced. Make sure there is an adequate air change or a suitable
extraction systems.
Always protect your eyes with special safety glasses, wear gloves, apron and protective
clothing without metal accessories.
During welding operations the machine generates magnetic fields. Pay attention to the
attraction of iron bearing working residues.
Watches as well as other mechanical, electric and/or electronic devices can be damaged.
WARNING: Persons with pacemakers or other cardiac devices must absolutely not
use the machine.
The operator must have adequate knowledge and training in the use and the resistance
welding procedure with this machine.
Do not allow unauthorized persons to access the working area; avoid that more then one
person works simultaneously on the same machine.
The spot welder is equipped with balancing and movable mechanisms. Therefore all
precautions must be taken to avoid hazardous situations.

CAR-O-LINER p. 05
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
DEFINITION OF THE TERMS
Refer to the UNI EN 292 Standard for the definition of the terms used in this manual.
FEATURES OF THE MACHINE AND GENERAL INFORMATION
MOVABLE RESISTANCE WELDING STATION
Main components and controls:
Mobile trolley of metal tubes and frame with wheels.
Welding gun with plait cables covered with a special bushing.
Electro-pneumatic operation of welding gun closure.
Manometer unit for welding pressure regulation at the electrodes.
MICRO DIGITAL 1, synchronous, with pulses, heating and welding current regulation.
SCR-diode power unit.
This machine has been manufactured in compliance with the following regulations:
Machine Safety Directive 89/392/CEE, 91/368CEE, 93/44/CEE, 93/68/CEE
89/336/CEE Directive, electromagnetic compatibility.
73/23/CEE Directive, low voltage electric material.
EN 50063 Standard, building and installation of resistance welders.
UNI EN 292/1 and 292/2 Standard, machinery safety.

CAR-O-LINER p. 06
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
TECHNICAL SPECIFICATIONS AND PERFORMANCES
Table of general technical data:
DIMENSIONS CR 35 Spotter
Head WxLxH mm 130x350x205
Welding cable with easy start gun mm 3000
Earth cable mm 2000
Cable section mm² 50
Weight Kg 18
ELECTRICAL specifications CR 35 Spotter
Nominal power at 50% KVA 2
Input voltage (*) 1ph V/Hz 230/50
Secondary no-load voltage V 7
Secondary short-circuit current KA 2.8
Secondary welding current KA 2,5
Duty cycles % 5
Rated power KVA 16
Fuses A 16
MECHANICAL FEATURES CR 35 Spotter
Noise level (ISO 7779) dBA <65
Ambient temperature °C 55÷35
Air humidity % <90
Fig. 1
CAR-O-LINER p. 07

MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
PACKING
The spot welder is packed in a sturdy cardboard box.
When shipped in a container by sea, the spot welder is sealed with salt resistant plastic
material.
On request, the spot welder is delivered on a pallet with wooden case and fastened with
steel strips.
UNPACKING
Remove the panels of the wooden case (if provided).
Remove the steel strips.
Remove the protective plastic material.
Remove the cardboard box.
CAUTION: The packing materials – wood, nails, plastics, cardboard etc. – must not be left
within the reach of children, as they could be a source of danger.
The packing materials must be subdivided and disposed of in compliance with the
applicable Codes.
STORAGE
The spot welder must be stored at a temperature between 0 and 40 °C in a dry place,
protected from weather and far from heat sources.
The spot welder must be moved with care, avoiding shocks and dropping which could
damage the machine.
CAR-O-LINER P. 08
MOVABLE SPOT WELDER

This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
INSTALLATION
PRECAUTIONS AND CHECKS
CAUTION: During all installation and connection operations, the machine must be
absolutely isolated from the power supply line.
CAUTION: Installation must be made by qualified personnel in compliance with the
applicable regulations and in accordance with the instructions of the manufacturer.
CAUTION: Before connecting the machine to the mains supply, make sure that the data
on the nameplate of the spot welder correspond to the voltage and frequency of the mains
supply available on site.
Electrical safety of the spot welder is obtained only when connected to an efficient
grounding system made in compliance with the applicable Regulations.
Have qualified personnel check the system for functional efficiency.
The Manufacturer cannot be held liable for possible damage caused by absence or
inefficiency of the grounding system.
Check that the installed power on the electric supply meter as well as the cables of the
electrical plant are adequate for the rated power of the spot welder.
CAUTION: In case the user makes modifications, alterations or changes of the spot
welder or integrates it in a plant, any liability of the Manufacturer decays and the user is
obliged to remove the CE label.
The non-observance of the above instructions will render the safety system provided by
the Manufacturer ineffective, causing serious risks of personal injuries and material
damage.
CAR-O-LINER p. 09
MOVABLE SPOT WELDER

This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
ELECTRICAL CONNECTION
The electrical connection of the spot welder to the mains must be made by qualified personnel.
The electrical connection must be made in compliance with the prescriptions of the EN 50063 CEI
26-6 and CEI 64/8 Standard - installation of resistance welders (spot welders) - to a grounded
power box provided with a differential circuit breaker having an adequate capacity for the power of
the spot welder (tab.1, p.6, Electrical Features) and complying with the CEI EN 60204/1
Standards.
Make sure that the size of the electrical line (conductor section) and the capacity of the fuses are
adequate.
Caution: The spot welders are SINGLE PHASE and provided with a power cord with two
leads, plus a third lead intended only for connection to the grounding system; therefore
they can be connected to a single phase power supply, or to a three phase power supply of
which only two of the three available phases will be used.

CAR-O-LINER p. 10
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
WELDING CONTROL.
Micro Digital 1 microprocessor-controlled welding control.
Machine starting is made switching the light button. The default operative mode is manual.
To change in automatic mode it is necessary to switch on the machine and pressing at the same
time the button on the gun.
1) “MR” WELDING SELECTOR
Activates the “MR” welding function. Welding time of 1 at 10 cycles, current at 100%.
2) TIP WELDING SELECTOR
Activates the tip welding function. Welding time of 1 at 10 cycles, cold welding, current at 85%.
3) PULSE HEATING SELECTOR
Activates the metal heating function with a copper electrode and pulse process. Heating current of
30% at 100%.
4) CARBON ELECTROD HEATING SELECTOR
Activates the heating function for metal heating operations using the carbon electrode. Heating
current of 15% at 60%.
5) WELDING OR HEATING SELECTOR
Activates the welding function with single spot process for screws, rivets and so on, and heating of
the metal with a copper electrode. Welding or metal heating time of 5 at 30 cycles, current at
100%.
5 1
2
3
4

CAR-O-LINER p. 11
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
START-UP
WARNING: Remember some safety precautions to be taken in order to avoid hazardous
situations.
The operator must have adequate knowledge and training in resistance welding
procedures (spot welding) with this type of spot welder.
Do not allow unauthorized persons to access the working area.
Avoid that more then one person works simultaneously on the same spot welder.
The spot welder is equipped with mobile elements, welding arms and electrodes.
CAUTION:
Do not wear magnetic metal objects as rings, bracelets, watches etc. during welding
operations, because these objects can be violently attracted by the magnetic field
generated by the spot welder or considerably overheated due to the Joule effect and
cause burns.
The operator must wear safety glasses, gloves and an apron to protect himself against
burns, cuts in the hands and sparkling incandescent particles.
Note: The individual protective systems must be in compliance with the applicable
Regulations.
LIMIT OF USE
This spot welder has been designed, dimensioned and manufactured for resistance
welding on thin steel sheet (fig.1, p.6, Electrical Features). Any use with different welding
procedures, non-iron metals, different sheet thickness or with more duty cycles as
indicated may affect proper operation and cause damage to the spot welder.
Therefore the machine must be destined only for the use foreseen and described in this
manual, any other use is to be considered improper and may cause hazards to the
operator's safety and material damage.
The manufacturer cannot be held liable for possible personal injuries or material damage
arising from improper or unreasonable use.

CAR-O-LINER p. 12
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
ENVIRONMENT
Working ambient temperature: 5°C to 35°C.
Working air humidity: lower than 90%..
STARTING THE MACHINE
WARNING: The first start-up of the spot welder must be made by qualified personnel.
Before performing any welding operation, checks and adjustments must be made.
Make sure the electrical connection has been made properly and in compliance with the
applicable regulations.
Check the diameter and the good state of the welding electrode tips.
Turning on: operate (close) the main switch, the display and the red LEDs indicate that the
spot welder is properly energized.
Turning off: Operate (open) the main switch. The spot welder and the display turn off.
WARNING: The spot welder must be used by trained personnel.
WELDING WITH MANUAL GUN
Welding gun with manual start switch. All the welding operations are controlled
pushing the switch an the gun.
WELDING WITH GUN EASY START
The use of TOP CAR 28 is to make easy by a special electronic circuit of automatic
start, that consent the use of a gun with out start switch, this makes welding easyer
and all heating operations. Easy start, begin the welding cycle after 3/10 sec from
the contact electrode-metal sheet.

CAR-O-LINER p. 13
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
HANDLING
CAUTION: Use particular care in handling and positioning the spot welder in the shop
during the welding operations.
The spot welder is equipped with moving elements, therefore all precautions must be
taken to avoid dangerous situations to arise.
The spot welder must be moved and positioned using the appropriate handle.
Do not allow unauthorized persons to access the working area; avoid that more then one
person works simultaneously on the same machine.
Before operation check the machine for level and stable positioning.
MAINTENANCE
WARNING: Never remove the panels of the spot welding machine and access the interior
without having previously removed the power cord from the power supply box.
WARNING: Possible checks inside the spot welding machine, performed when energized,
can cause heavy electrical shocks generated by direct contact with current carrying parts.
WARNING: Maintenance must be performed by qualified personnel.
CAR-O-LINER p. 14
MOVABLE SPOT WELDER

This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
SCHEDULED MAINTENANCE
Maintenance of components and wear materials must be performed on a regular basis
once a week or more often according to the use and the environmental conditions as
listed below.
Check the welding electrodes every 100 spot welds; restore the original diameter of the tip
(circa 4÷5 mm). Using a fine-grained file, remove iron residues that come off the sheet
metal as well as the craters that have formed.
Check and carefully clean the locking seats of the arms in the gun as well as the
extremities of the welding arms.
Check the state of the power cord and the tightness of the compressed air hoses.
Inspect the spot welder and remove dust and particles that may have deposited on the
various components.
In regular intervals and with a frequency based on the use, at least every 4 months, check
all electrical contacts of the secondary circuit of the spot welding machine. Make sure the
screws are tightened and that there are no traces of oxidation. Inspect all pneumatic
hoses and check the hose clips for perfect seal.
The proper maintenance assures high welding performance of the machine and limits
consumption and current absorption.
In the machine interior, inspect all electric, pneumatic and mechanical components.
Remove dust and particles that may have deposited on the various components.
EXTRAORDINARY MAINTENANCE
Repair and replacement of components of the welding machine, if required, must be
performed by qualified personnel using only original spare parts.
WARNING: Replacement of components with non original spare parts and/or alterations
of the machine causes the decay of any liability of the manufacturer for personal injuries
or material damage that may arise.

CAR-O-LINER p. 15
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
EMERGENCY
FIRE
In case of fire, use only powder extinguishers complying with the applicable Regulations.
WARNING: NEVER USE LIQUID FIRE EXTINGUISHERS, BECAUSE THE MACHINE COULD BE
ENERGIZED.
WARNING: WHEN BURNING, SOME PARTS OF THE MACHINE MAY PRODUCE TOXIC
COMBUSTION GASES OR SMOKE.
DISASSEMBLY - DISPOSAL
CAUTION: If the machine is to be put out of service, provide for disassembly and disposal
according to the applicable Regulations.
Subdivide the different materials:
Metal
Electric material
Electronic material
Plastic and rubber material
ATTENTION: Waste materials must be subdivided and disposed of in compliance with the
applicable Laws.

CAR-O-LINER p. 16
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
TROUBLESHOOTING
Below is a list of possible problems and malfunctions that may occur and the remedies to
eliminate them.
PROBLEM
The spot welder does not
turn on.
Control panel switch
open.
Execution of spot welds
with sparkling of melted
material. Holes and
craters at the welds on
the sheets.
CAUSE
Connection error.
Excessive welding
current or welding time.
Insufficient electrode
pressure.
Electrode tips with metal
residue deposits.
REMEDY
Check connection and
control panel.
Decrease welding current
or welding time.
Clean the electrodes.
Make a correct contact
electrode-metal sheet.

CAR-O-LINER p. 17
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
CR-35 (SPOTTER): SPARE PARTS.
1 90018000 HANDLE
2 20010104 SPOTTER COVER
3 20010106 WELDING CONTROL PANEL
4 20010107 PROTECTION HANDLE
5 90019359 CONNECTING PLUG
6 90019310 FEET
7 20010103 SPOTTER BASIS
8 20010105 WELDING TRANSFORMER
9 90014029 ELECTRIC COIL
10 90019532 TAP FOR TOOLS CONTROL
11 90019037 CABLE HOLDER
12 90019376 POWER SUPPLY CABLE (3x4)
13 90018002 DIODE SCR
14 90018001 ELECTRONIC BOARD
15 90019368 ON-OFF SWITCH
16 90010080 BOARD TRANSFORMER
17 90018003 CABLE BUSHING
18 90018004 CONTROL SELECTION REGULATOR

CAR-O-LINER p. 18
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
“KS” SINGLE POINT: SPARE PARTS.
1 90019364 CONNECTOR
2 90019240 EXTRAFLESSIBLE CABLE (1 X 50mmq x 3000mm)
3 90014312 CABLES HOLDER
4 90016022 SPOTTER HANDLE
5 90016021 ELECTRODES MANDRIN
6 90016020 MANDRIN NUT
7 90019288 MICROSWITCH
8 90019408 GUN CONNECTOR
9 90016024 SLIDE HAMMER

CAR-O-LINER p. 19
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
“MR” GROUND CABLE: SPARE PARTS.
190019240 EXTRAFLEXIBLE CABLE (1x50)
2 90019369 ELECTRIC TERMINAL
3 90019354 M10 NUT
4 90019400 M10 CAP NUT
5 50010302 SLEEVE
6 50010301 "P 10" ELECTRODE
7 90019364 CONNECTOR
8 50010303 SPRING

CAR-O-LINER p. 20
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
MULTIPOINT: SPARE PARTS.
160010303 HEAD FOR ELECTRODES HOLDER
2 60010306 "E 30" ELECTRODE
3 90019350 M8 LEFT NUT
4 60010304 ELECTRODES HOLDER
5 60010305 "P 8" ELECTRODE
6 90019349 GUSSET
7 90013011 M8x30 SPECIAL SCREW