Pro Spot PR-205 User manual

All Info Copyright © Pro Spot International Inc.
Instruction Manual
Version 1.0
PR-205
SYNERGIC MIG/MAG
WELDER

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 tend to keep it that way.
About Pro Spot
-
Pro Spot International, Inc. U.S.A.
www.prospot.com
5932 Sea Otter Pl.
Carlsbad, CA 92010
Phone: [phone]
Toll free (US only): 877- PRO SPOT
Fax: [phone]
E-Mail: [email protected]
Contact Information
Pro Spot is certified by CASE and a member of the ICAR Industry Training Alliance
Pro Spot International, Inc., based in Carlsbad, California, manufactures resistance spot welding equipment spe-
cializing 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.
All Info Copyright © Pro Spot International Inc.1

Table of Contents
1.0 SAFETY INFORMATION 3
1.1 Introduction 3
1.2 Personal Protection 3
1.3 Fire Prevention 3
1.4 Electric Shock 4
1.5 Noise 4
1.6 Electromagnetic Compatibility 4
1.7 Gas Cylinders 4
2.0 INSTALLATION RECOMMENDATIONS 5
2.1 Location 5
2.2 Ventilation 5
2.3 Voltage Requirements 5
2.4 Safety Instructions 6
3.0 INTRODUCTION 6
4.0 PR-205 Basics 7
5.0 STICK WELDING (MMA) 9
5.2 Getting Ready For MMA Welding 9
6.0 MIG/MAG WELDING 9
6.1.1 Torch Connection 9
6.1.2 Installing Welding Wire 9
6.1.3 Replacing The Wire Liner 10
6.1.4 How To Choose The Wire Liner 10
6.1.5 Gas Cylinder And Regulator Connection 11
6.1.6 MOG Welding (No Gas/Flux Core) 11
6.1.7 MIG/MAG Welding 11
6.2 MIG/MAG And No Gas Manual Welding 11
6.3 Automatic MIG/MAG/MOG Welding 12
6.4 Aluminum Welding 12
7.0 PROTECTION GASES GUIDE 13
8.0 WELDING HINTS AND MAINTENANCE 13
9.0 TROUBLESHOOTING 14
NOTES 16
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SAFETY INFORMATION
1.0
1.1INTRODUCTION
1.2 PERSONAL PROTECTION
1.3 FIRE PREVENTION
Make sure this manual is carefully read and understood by the welder, and by the maintenance personell.
Welding processes of any kind can be dangerous not only to the operator but to any person situated near
the equipment, if safety and operating rules are not strictly observed.
Fire and explosion can be caused by hot slag, sparks or the welding arc.
Arc rays can injure your eyes and burn your skin. The welding arc produces ultra violet and infra red
light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
Gases and fumes produced during the welding process can be dangerous and hazardous to your health.
• Wear closed, non-ammable protective clothing, without pockets or turned up pants, gloves and
shoes with insulating sole and steel toe. Avoid oily greasy clothing.
• Wear non-ammable welding helmet with appropriate lter lenses designed to shield the neck
and the face, also on the sides. Keep protective lens clean and replace them when broken, cracked or
spattered. Position a transparent glass between lense and welding area.
• Weld in a closed area that is not open to other work areas.
• Never look at the arc without correct protection to the eyes. Wear safety glasses with the side shields
to protect from ying particles.
• Keep an approved re extinguisher of adequate size and type in the welding area. Inspect it regularly
to ensure that it is in proper working order.
• Remove all combustible materials from the working area. If you can not remove them, protect them
with re-proof covers.
• Ventilate welding areas adequately. Maintain sufficient air ow to prevent accumulation of explosive
or toxic concentrations of gases.
• Do not weld on containers that may have held combustibles.
• Always check welding area to make sure it is free of sparks, slag, or glowing metal and ames.
• The work area must have a reproof oor.
• Adequate exhaust ventilation must be used in the area. It should be provided through a mobile fume
extractor or through a built-in system on the workbench that provides exhaust ventilation from the
sides, the front and below, but not from above the bench so as to avoid raising dust and fumes. Local
exhaust ventilation must be provided together with adequate general ventilation and air circulation,
particularly when work is done in a conned space.
• Welding process must be performed on metal surfaces thoroughly cleaned from rust or paint, to avoid
production of harmful fumes. Parts degreased with a solvent must be dried before welding.
• Be very careful when welding any metal which may contain one or more of the following:
Antimony Beryllium Cobalt Manganese Selenium Arsenic Cadmium
Copper Mercury Silver Barium Chromium Lead Nickel
Vanadium
• Remove all Chlorinated solvents from the welding area before welding. Certain chlorinated solvents
decompose when exposed to ultraviolet radiation to form phosgene gas (nerve gas).
All Info Copyright © Pro Spot International Inc.3

SAFETY INFORMATION
1.0
1.4 ELECTRIC SHOCK
1.5 NOISE
1.6 ELECTROMAGNETIC COMPATIBILITY
1.7 GAS CYLINDERS
Noise can cause permanent hearing loss. Welding processes can cause noise levels that exceed safe limits.
You must protect your ears from loud noise to prevent permanent loss of hearing.
Before installing your welder, carry out an inspection of the surrounding area, observing the following
guidelines:
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Treat them
carefully. Cylinders should be secured by a chain at all times. The cylinder cap should be on all cylinders
when not in use.
• To protect your hearing from loud noise, wear protective ear plugs and/or other suitable ear protection.
• Noise levels should be measured to make sure the decibels (sound) do not exceed safe levels.
• Make sure that there are no other power supply cables, ccomputer lines, telephone cables or other
equipment near the unit.
• Make sure that there are no radio recievers, television or computers near the unit.
• People with pace-maker or hearing-prosthesis should keep far from the power source.
! In particular cases special protection measures may be required.
Interference can be reduced by following these suggestions:
• If there is interference in the power source line, an E.M.T. lter can be mounted between the power
supply and the power source.
• The output cables of the power source should be not too long, keep together and connected to ground.
• After maintenance all the panels of the power source must be securely fastened in place.
• These welders use only inert or non-ammable gases for welding. It is important to choose the
appropriate gas for the type of welding being performed.
WARNING: ELECTRIC SHOCK CAN KILL!
• A person qualied in First Aid should always be present in the working area; If a person is found
unconscious and electric shock is suspected, do not touch the person if she or he is in contact with
cable or electrical wires. Disconnect power from the machine, then use First Aid. Use dry wood or
other insulating materials to move cables away from the person, if necessary.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Make sure the main power line is properly grounded.
• Do not coil the torch or the ground cables around your body.
• Never touch or come in physical contact with any part of the input power circuit and welding current
circuit.
ELECTRIC WARNING
• Repair or replace all worn or damaged parts.
• Extra care must be taken when working in moist or damp areas.
• Install and maintain equipment according to local regulations
• Disconnect power supply before performing any service or repair.
• Should you feel the slightest electrical shock, stop any welding immediately and do not use the welder
until the problem has been found and corrected.
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