HTP Quick Spot II User manual

HTP Quick Spot II Part #60501
Owner’s Manual
America Inc.
HTP America, Inc. • 180 Joey Drive • Elk Grove Village, IL 60007
1-800-USA-WELD •847-357-0700 •FAX: [phone] •www.usaweld.com
Transgun
Squeeze Type
Resistance Welder

1
Introduction
Congratulations on your purchase of an HTP Quick Spot II
Squeeze-Type Resistance Spot Welder. Squeeze-Type
Resistance Spot Welding (S-TRSW) is one of the most widely
used welding processes in the metal fabricating industry today.
Your Quick Spot has been designed specifically for automotive
repair applications such as welding steel and HSLA steel body
panels up to a maximum thickness of .078" (14 ga).
To get the most from your HTP Quick Spot, read the following
manual carefully.
Electrical Connection
Your Quick Spot will only operate when PROPERLY connected
to 220-volt single-phase power wired for a minimum of 30
amps. All electrical connections should be done by a qualified
electrician in accordance with the National Electrical Code and
local codes and ordinances. When connecting your Quick Spot,
the yellow-green wire MUST BE CONNECTED TO GROUND
OR SERIOUS INJURY MAY RESULT.
Electrical Specifications
Input Voltage 220 Volts 50/60 Hz
Input Amperage 30 Amps
Output Amperage 6300 Amps
KVA @ 50% 2.5
Maximum KVA 14
Index
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installing Spot Welding Arms . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Components and Adjustments . . . . . . . . . . . . . . . . . . . . 4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjusting the Spot Welding Pressure . . . . . . . . . . . . . . . . . . . 5
Operating Your Quick Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Weld Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Spot WeldingArms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2
Safety Suggestions
1) Squeeze Type Resistance Spot Welding (STRSW) produces
very strong magnetic fields. People wearing pacemakers
should not operate, nor be in the vicinity of a STRSW
welder in use.
2) The strong magnetic fields produced by the
Versa Spot 7000 may attract magnetic materials that are in
the vicinity of the welder. Do not operate the machine in
the vicinity of any magnetic materials.
3) The strong magnetic fields produced by the
Versa Spot 7000 may damage watches and computers.
4) Connect the machine to an electrical supply according to
local electrical codes. Be sure the machine is properly
grounded.
5) Disconnect the machine from the power source during
installation, inspection and maintenance operations.
6) Disconnect the machine from the power supply and air
supply when servicing the Pneumatic Clamp or replacing
Tongs or Electrodes.
7) Do not operate the machine in wet conditions! Do not
operate the machine while standing on a wet floor. Electric
Shock can KILL!
8) Always wear eye protection when operating your Quick
Spot II.
9) To avoid fire, do not weld on wood, plastic tile, or carpeted
floors. Concrete or masonry floors are safest.
10) Do not weld on drums, barrels, tanks or other containers
until they have been cleared as described in AWS Standard
A6.01.
12) Provide adequate ventilation in the welding area at all
times. Do not weld on galvanized zinc, Cadmium or lead
beryllium materials unless POSITIVE sufficient ventilation
is provided. These materials produce toxic fumes.
13) Exposed, electrically hot conductors or other bare metal in
the welding circuit, or ungrounded electrically hot
equipment can fatally shock a person whose body becomes
a conductor. Do not stand, sit, lie, lean on or touch a wet
surface when welding.
14) Frequently inspect cables for wear, cracks, damage and
loose connections. Replace those with excessively worn
insulation to avoid a possible lethal shock from bared cable.
For more information, refer to the following standards and
comply as applicable.
1. ANSI Standard Z49.1 SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society,
2051 NW 7th St., Miami, FL 33125.
2. ANSI Standard Z87.1 SAFE PRACTICE FOR
OCCUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY 10018.
3. America Welding Society Standard A6.0 WELDING AND
CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
4. NFPA STANDARD 51. OXYGEN-FUEL GAS SYSTEMS
FOR WELDING AND CUTTING, obtainable from the
National Fire Protection Assoc., 470 Atlantic Avenue,
Boston, MA 02210.
5. NFPA Standard 51B. CUTTING AND WELDING
PROCESSES, obtainable same as item 4.
6. CGA PAMPHLET P-1. SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 500 Fifth Avenue, New
York, NY 10036.
7. OSHA Standard 29 CFR, Part 1910, Subpart Q WELDING,
CUTTING AND BRAZING.

Make sure the electrodes are aligned in both the horizontal
direction as shown in Fig. 2 and the verticle direction as shown
in Fig. 3. Manually close the electrodes to be sure they come
together squarely. It is possible to lock the arms closed by
screwing an M6 bolt into the case as shown in Figure 4 to make
it easier to adjust the spot welding arms. Be sure to remove the
locking bolt to release the arms prior to operation.
Tighten the 2 allen screws in the brass sleeves securely,
but DO NOT OVERTIGHTEN! Tighten the allen screws
which hold the electrodes in the spot weldng arms as tight as
possible. We recommend you use a 3/8” drive 5mm allen
socket for this purpose.
Using a paint marker, mark the electrodes where they mate with
the arms (see Figure 5). This way, if the electrodes happen to
slip in the arms, it will be obvious. If slippage occurs,
eventually there will not be enough clamping pressure because
the arms will not close completely. When this happens, the
machine will arc between the electrodes and the panels and
blow a hole in the panels. Should you notice the electrodes
slipping, realign the arms and tighten the allen bolts securely.
Install all arms in the same manner.
To make it easier to reinstall the arms, it is recommended to
mark the arms with a paint marker where they are inserted into
the quick spot. See Figure 6.
Figure 5 Figure 6
3
Installing The Spot Welding Arms
Select the spot welding arms which you want to use for your
spot welding application. In this instance we will be installing
the standard arms (#673151) which came with your quick spot.
Using a 5 mm allen wrench, remove the two M6 x 15 allen
bolts from the brass sleeve which retains the arms (See Fig 1).
Put a light coating of a high pressure grease or anti seize
compound on the threads and under the heads of these bolts and
re-install them in the brass sleeve, but do not tighten.
Included in the box with your Quick Spot was a package which
has the #673151 arms, a 5mm allen wrench, a 6mm allen
wrench, an M6 locking bolt, and a handle. The handle can be
installed in three different positions, right, left, and top. Install
the handle on the pneumatic clamp in the best position for the
specific job.
Once again, put a light coating of high pressure grease or anti
seize compound on the threads and under the heads of the two
M6 X 20mm allen bolts which hold the electrodes into the spot
welding arms. Slide the electrodes into the spot welding arms
and tighten slightly. Install the arms in your quick spot and
tighten slightly. (See Fig. 2).
Figure 2
Figure 3
Figure 4
Figure 1

Main Components and Adjustments
Figure 7
1) Moveable Welding Arm – this is the spot welding arm
which moves
2) Lifting Eye Hole – an M8 lifting eye can be inserted in this
hole should it be desired to suspend your Quick Spot from
a counterweight.
3) Welding Lever – depressing the welding lever lowers the
moveable welding arm, brings it in contact with the panel,
depressing the micro switch (5), which activates the
welding power.
4) Electrode Pressure Adjusting Screw
Use a 6mm allen to adjust the electrode pressure. The pressure
can be adjusted from 85 lbs to 265 lbs
4
5) MicroSwitch – when the welding lever (3) contacts the
Micro Switch, the welding current starts.
6) Input Power Cable – make sure the input power cord is
connected to the correct power supply.
7) Fixed Welding Arm – This is the spot welding arm which is
fixed. Usually you will position the fixed arm against the
panel to be welded, and then bring the moveable arm in
contact with the other side of the panel to make a weld.
8) Right/left/center adjustable hand grip – the hand grip can be
postioned on the right, left, or center depending on the job
requirements. It can not be positioned in the center if the
lifting eye is in use.
Figure D

5
Control Panel
1. Welding Mode – depressing this button will allow you to
select between:
a) Pulse Welding – the pulse welding mode is recommended
for HSLA steel, galvanized steel, and panels which have a
weld thru primer between them. For unibody collision
repair, you should select the pulse welding mode. When
the Quick Spot is in the pulse welding mode, the welding
current will be a series of pulses of current instead of one
continuous burst.
b) Continuous Welding – the continuous welding mode is
good for clean sheet metal. It can also be used for
restoration on older vehicles.
If lights a and b flash alternately, the duty cycle of your
Quick Spot II has been exceed. Once the duty cycle has been
exceeded, the machine will not weld until it has cooled down.
You can expect to make 3 welds per minute when the machine
is set for a thickness of 1mm + 1mm in the continuous welding
mode.
2. Panel Thickness Selector – the correct panel thickness must
be selected!! When spot welding 3 or more panels together,
set the thickness to the combined thickness of the panels.
a) each panel measures 0.6mm (.024" or 24 ga) thick for a
combined thickness of 1.2mm (.048")
b) each panel measures 0.8mm (.030" or 22 ga) thick for a
combined thickness of 1.6mm (.060")
c) each panel measures 1.0mm (.040") thick for a combined
thickness of 2.0mm (.080")
d) each panel measures 1.2mm (.048" or 18 ga) thick for a
combined thickness of 2.4mm (.096")
e) each panel measures 1.5mm (.060" or 16 ga) thick for a
combined thickness of 3.0mm (.120")
f) each panel measures 2.0mm (.078" or 14 ga) thick for a
combined thickness of 4.0mm (.156")
3. Spot welding time – allows you to "fine tune" the spot
welding time. Based on the appearance of the weld it is
possible to increase or decrease the weld time from the
default setting.
Adjusting the Spot Welding Pressure
The spot welding pressure can be adjusted to different values by
using the following chart for different length spot welding arms.
The pressure is adjusted by turning the pressure adjusting screw
(Fig 7, #4) using a 6mm allen wrench.
Arm Length Pressure in Pounds
4 3/4" 265 220 175 135 85
10" 170 120 95 70 50
13 3/4" 100 85 70 50
20" 60 55 40
23
1
A
FEDCBA
B

6
Operating Your Quick Spot II
You are now ready to use the machine to spot weld. Keep in
mind the unit must pass an electric current through the panels to
operate. Paint tends to be an insulating material. When you are
preparing the panel and vehicle, it is important to keep this in
mind. Proper preparation of the panel/vehicle is essential for
maximum strength of the welds.
Plug the unit into the correct power source. Using the the
welding mode switch, select either Pulse Welding (A) or
Continuous Welding (B). Pulse Welding is preferred for
unibody repairs.
Machine Thickness in Thickness in Closest Maximum Maximum
Setting Inches per panel Millimeters per Gauge Combined Combined
for 2 panels panel for 2 panels Thickness (in) Thickness (mm)
0.6 + 0.6 0.024 0.6 24 0.048 1.2
0.8 + 0.8 0.030 0.8 22 0.060 1.6
1.0 + 1.0 0.039 1.0 20 0.078 2.0
1.2 + 1.2 0.047 1.2 18 0.094 2.4
1.5 + 1.5 0.059 1.5 16 0.118 3.0
2.0 + 2.0 0.078 2.0 14 0.156 4.0
From the vehicle manufacturer, or using a micrometer,
determine the thickness of the panel you will be welding.
Using the Panel Thickness Selector, set the machine to the
correct thickness of the panel. If you are welding more than
two panels, set the machine to the combined thickness of all the
panels you will be welding. For example, if you were welding
3 panels which were .024" thick, (combined thickness = 3 x
.024" or .072") the machine would be set to 1.0 + 1.0, because
the maximum combined thickness of that setting is .078".
(See Table 1)
Figure 10
3
5
1
2
4
Table 1
Setting the machine for a thicker panel than you are actually
welding will result in more heat input in to the panel. Setting
the machine for a thinner panel than you are actually welding
will not produce a weld with optimum strength. SET THE
MACHINE FOR THE CORRECT THICKNESS!
When fitting the panel on the vehicle, there can be no gaps.
If there is a gap between the panels, the spot welder will blow a
hole in the two panels. Use vise grips to make sure the panel fit
is correct.

7
Fig 13 shows a typical rear quarter panel, with 5 main areas for
spot welding. As mentioned above, paint is an electrical
insulator. Each main spot weld area has one spot weld circled.
It is necessary to have FOUR CLEAN SIDES OF METAL in
each circled area. The first spot weld in each area should be
where you have four clean sides of metal. Once that spot
weld is in place, it is only necessary to remove paint from
panel/vehicle in the area where the electrodes will contact.
Paint or weld through primer can be present on the mating
surfaces of the panel/vehicle, since the welder will now
establish a ground through the first spot weld, which was made
through the four clean sides of metal. However, for optimum
results it is storngly advised to remove the any paint, under-
coating, or sealant from between the two panels. These
contaminents could effect the quality of the weld nugget.
A good tool for paint removal is a fibertex abrasive pad.
The second spot weld should be placed next to the first as
opposed to the other end of the panel. This way, the electricity
has to flow a shorter distance to the first weld which is
providing the ground. The third spot weld should be placed
close to the second, and so on. However, the welds should not
be placed closer than 3/4” together.
In the “REST” Position, the welding lever is fully up, and the
spot welding arms are completely open. As you compress the
welding lever, the jaws begin to close. When the electrodes
touch, the compression cycle begins, however, the welding
current has not yet started. Further compression of the welding
lever will force the end of the welding lever to contact the micro
switch and start the welding current. You will hear the
transformer hum and feel your Quick-Spot vibrate as the
welding current is activated. The timer will automatically stop
the welding process. Maintain pressure on the Welding lever
for 1 to 2 seconds more to allow the welding nugget to solidify.
In order to operate properly, your Quick-Spot must transfer the
welding current from the bottom spot welding tong, into the
bottom side of the lower panel, through the lower panel, into the
top of the lower panel, into the bottom of the upper panel,
through the upper panel, into top of the upper panel, and finally
into the top spot welding tong, completing the electrical circuit.
What this means is BOTH SIDES OF BOTH PANELS MUST
BE CLEAN TO ALLOW THE WELDING CURRENT TO
PASS THROUGH THEM. If they are not clean, then your
Quick-Spot will not work correctly.
We always advise you make sample spot welds to test the
strength of the spot weld. When pulling the two spot welds
apart, one should always tear a hole in one of the panels if the
spot weld is good and strong.
Testing the Welds
We recommend testing the spot welds with either scrap panels
from the vehicle which you are working on, or using test panels
which HTP has available. The test panels are 1" wide x 3" long
18-gauge steel and are available 25 pieces at a time.
Fabricate a weld tester from the drawing below, or purchase a
67000-WT from HTP America. Mounting one of the panels in a
vice, and bend the other panel, so the weld tester can be rolled
around the panel like a sardine can. When rolled, a hole must
be pulled in one of the panels.
67000-WT HTP Spot Weld Tester

67000-TS Electrode Sharpener Sharpening Electrode
8
Maintenance
Your Quick Spot II needs very little maintenance. As far as the
power source goes, simply blow dry compressed air into the
arms and across the cooling fins to remove any dust which may
have accumulated in the unit.
The spot welding tongs and electrodes must be kept clean
and sharpened. This should be performed any time the
electrodes become contaminated, flattened or out of shape.
HTP has an electrode sharpener #67000-TD which is excellent
for this purpose.
Sharpening Electode
Additionally, any oxidation which forms on the tongs where
they are inserted in the pneumatic clamp, or on the electrodes
where they are inserted in the tongs, should be removed with a
wire wheel.
Trouble shooting
Spot welder is blowing holes or making poor quality welds
1) Gap between the panels – Clamp panels together with
vise grips
2) Electrodes not sharpened – Sharpen electrodes with
#67000-TS
3) Contamination between the panels – Clean between panels
4) Not keeping electrodes perpendicular to the panel – hold the
clamp so the electrodes are perpendicular to the panel
5) Inadequate Clamping pressure – adjust clamping pressure

9
Weld Force Too High
Weld Current Too High
Weld Time Too Long
Weld Force Too Low
Weld Current Too Low
Weld Time Too Short
Electrode Face Too Small
Electrode Face Too Large
Insufficient Electrode Cooling
Electrode Alloy Too Soft
Electrodes Not Flat and Parallel
Electrodes Misaligned
Poor Fit Up
Poor Heat Balance
Weld Spacing Too Close
Weld Too Close To Edge Of Part
Dirty Material
Metallurgy Of Material
Squeeze Time Too Short
Poor Follow-Up
No Speed Regulator On Cylinder
Poor Pressure Regulation
Hold Time Too Short
Transformer Tap Set To Off
No Weld Switch(es) In No Weld
Pressure Switch Open
Temperature Limit Switch Open
Electrodes Do Not Contact Work
Insulated Electrodes/Holders
Shunt Path In Secondary
Excess Ferrous Material In Throat
Emergency Stop Switch Open
Excess
Indentation
Electrode
Mushrooming
Undersized
Weld Nugget
Offset
Weld Nugget
Misshapen
Weld Nugget
Expulsion
At Interface
Cracked Or Poor
Weld Nugget
Discolored
Weld Nugget
No
Weld
Electrodes
Stick To Weld
Expulsion
At Surface
Possible
Cause
Weld
Defect
* If Weld Force is too low, excess heating of the material surface may cause excess indentation.
*
Chart of Weld Defects and Possible Causes

10
L = 4 3/4”
L = 10”
690046
690052
690047 690048
690046
690049 690049
690050
690047
690050
690052
690050
690050
L=20”
L = 13 3/4”
L = 13 3/4”L = 4 3/4”
L = 4 3/4”
Optional Spot Welding Arms
12 3
45
L = 4 3/4”
67
89
Illus # Part # Description
1 673159 Internal Pinch Weld Arms
690052 Electrode (90 Deg)
690046 Electrode (8 1/2”)
2 673152 Straight Arms (Offset Electrode 10”)
690047 Electrode (5”)
690050 Electrode (2”)
3 673156 Long Arms (20”)
690048 Electrode (7 3/4”)
690050 Electrode (2”)
4 673158 External Pinch Weld Arms
690046 Electrode (8 1/2”)
690052 Electrode (90 Deg)
690051
Illus # Part # Description
5 673153 Straight Arms (Center Electrode 13 3/4”)
690049 Electrode (4”)
6 673155 Arms (4 3/4”)
690051 Electrode (Curved)
7 673150 Straight Arms (Center Electrode 4 3/4”)
690049 Electrode (4”)
8 673151 Straight Arms (Offset Electrode 4 3/4”)
690047 Electrode (5”)
690050 Electrode (2”)
9 673154 Arms (13 3/4”)
690050 Electrode (2”)

11
Parts Breakdown
Part # Illus # Description
113585 1 SCR
114070 2 Control PCB
114085 3 Power PCB
122393 4 Microswitch
169034 6 Transformer
690049 8 Electrode L=100MM D.12MM
690050 9 Electrode L=50MM D.12MM
990046 10 Kit Cable Bushing + Ring Nut
482887 11 Pin
322512 12 Handle Cover
212163 13 Screw
322518 14 Bush
522020 15 Upper Arm Clamp
522023 16 Lower Arm Clamp

Wiring Diagram
12