Pro Spot AL-5 User manual

Aluminum Dent
Pulling System
Copyright © Pro Spot International, Inc. 2005-2011
Instruction Manual
Version 1.02
AL-5
Capacitor Discharge

TABLE OF CONTENTS
GETTING FAMILIAR WITH YOUR WELDER - READ BEFORE USING 1
Copyright © Pro Spot International, Inc. 2005-2011
AL-5
CREATING A PROPER GROUND
GETTING FAMILIAR WITH YOUR GUN 2
GETTING READY TO WELD
3
WELDING INSTRUCTIONS
4
IDENTIFYING COMMON ISSUES
5
WELDER PARTS LIST
6
WELDER GUN PARTS LIST
7
WARRANTY REGISTRATION
8
WARRANTY
9
10

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
Copyright © Pro Spot International, Inc. 2005-2011
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
Copyright © Pro Spot International, Inc. 2005-2011
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
Copyright © Pro Spot International, Inc. 2005-2011
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
90
Copyright © Pro Spot International, Inc. 2005-2011
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:
OV
OH
GRD
READY
READY and ON
lights are illuminated
when the welder is on.
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
Copyright © Pro Spot International, Inc. 2005-2011
AL-5
Page 5
1.
2.
3.
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.
1.
3.
5.
4.
6.
2.
Point. GOOD! No Point. BAD!
Copyright © Pro Spot International, Inc. 2005-2011
AL-5
Page 6
Identifying Common Issues
AL-5

Copyright © Pro Spot International, Inc. 2005-2011
AL-5
Page 7
39
37 40
38
Parts List
AL-5
OV
OH VOLTAGE
GRD
READY
ON
Copyright © Pro Spot International, Inc. 2005-2011
AL-5
Page ??
14
13
3
2
5
5
15
7
6
23
29
4
17
1
22
11
10
9
8
19
21
18
12
20
28
27
39
30
37
35
36
38
24
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.
1
23 1
24 2
25 2
26
27
28
29
30
31
1
1
1
1
1
1
4
4
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-????
34
35
36
37
38
1
1
1
1
NUT
XX-????
S-250
80-5155
52-3503 NYLON SHOULDER WASHER
32
34
33
CABLE CLAMP
CORD GRIP
1
1
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
30
29
3
2
5
5
18
7
6
8
25
4
32
1
24
17
16
15
14
21
23
20
26
31
28
10
9
11
12
35
13
22
27
34
33
36

Copyright © Pro Spot International, Inc. 2005-2011
AL-5
Page 8
Parts List
AL-5 Gun
Copyright © Pro Spot International, Inc. 2005-2011
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
BOLT MX XX
BOLT MX XX
M6 FLANGE NUT
GROUND CABLE
TRIGGER CABLE
1
21 1
22 1
23 1
24 1
25
26
27
1
1
1
GUN DECAL
28 2
723 16 93215
21 12 422 14 10 56
13
18 19
28
20
8
24
26
21
27
25 1
17
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
19
14 73213 17 10 418 12 856
11
16
1
15
20
21