Related Manuals for Car-O-Liner CTR12000
Summary of Contents for Car-O-Liner CTR12000
- Page 1 CTR12000 General information and instructions, Part 1 Instruction Manual (ORIGINAL) (41643, rev 2) 2016-10, ENG...
- Page 2 Note This instruction manual provides advice as well as instructions for installation, operation, maintenance The Spot Welder CTR12000 is used by body shops to duplicate the welding procedure used by the car and troubleshooting. manufacturers. All other use of the equipment, or...
- Page 3 Below an example of how the EC Declaration of Conformity for the CTR12000 is outlined. A signed and dated copy of the EC Declaration of Conformity, including serial number, is included in the documentation for the CTR12000. Please contact your distributor if you need a new copy of the Declaration of Conformity.
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Page 4: Table Of Contents
Car-O-Liner Group AB CTR12000 Contents General ................6 About this manual ................. 6 Previous knowledge and experience ............ 6 Use to the intended purpose ..............7 Brief description of the welding machine ..........8 ... - Page 5 Maintenance and upkeep ..........38 Dismantling and salvage ..........40 Service ................41 Spare parts ..............42 Power source CTR12000 ................42 Multifunction gun (Optional) ................45 41643, ENG - rev. 2, 2016-10...
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Page 6: General
1 General About this manual This manual provides information on operating the following appliance: CTR12000 with connection for water cooled C welding gun and optionally available multifunction gun. For further information on special features of our equipment you may perhaps need and that are fully or partly missing in this manual, please contact your local Car-O-Liner distributor. -
Page 7: Use To The Intended Purpose
Use to the intended purpose The resistance spot welding power source CTR12000 has been designed for repair work in body shops: Resistance welding procedure for spot welding, sheet forming with spotter (rivets and washers), local heating of steel plates (carbon electrode) and stitch welding on stainless steel (with multi-function gun being optionally available). -
Page 8: Brief Description Of The Welding Machine
Behind the cover Miniature circuit breaker F1, F2 Residual-current circuit breaker Holder for C-arm, 350 mm Holder for C-arm, 500 mm Accessories storage case Incorporated Trays for welding accessories cooling unit Figure 1.1 CTR12000 41643, ENG - rev. 2, 2016-10... -
Page 9: Welding Power Source
CTR12000 Car-O-Liner Group AB Welding power source The welding power source has the task to control the welding process and to feed the welding gun with welding current, compressed air and cooling wa- ter. The machine has been designed for repair jobs in body shops and must be installed on even floor. -
Page 10: Optional Equipment
The risk of overheating may result from insufficient cooling liquid level or cool- ing circuit interruption. Optional equipment The standard CTR12000 machine is delivered with a C-tong. In principle, the machine can also be equipped with Multifunction gun ... -
Page 11: Safety
CTR12000 Car-O-Liner Group AB 2 Safety Safety instructions In order to ensure safe operation, only qualified staff is allowed to install the machine observing all the instructions mentioned in the section “INSTAL- LATION and ASSEMBLY”. Strictly comply with the safety instructions in the section “MAINTENANCE AND UPKEEP”... -
Page 12: Warning And Danger Signs And Terms
Car-O-Liner Group AB CTR12000 Warning and danger signs and terms This manual mainly uses self-explaining picture symbols (pictographs) for indicating dangers and hazards. In addition, signal words in square brackets are used: “Danger“ indicates an imminently hazardous situation which, if not avoided, DANGER will result in death or serious injury. -
Page 13: Electrical Hazards
CTR12000 Car-O-Liner Group AB An electromagnetic valve generally leads the current to the pneumatic gun. This valve is normally closed and controlled by the mains on/off switch to avoid hazards that may result from a lack of electric but not pneumatic ener- gy. -
Page 14: Hazards From Electromagnetic Disturbances
Car-O-Liner Group AB CTR12000 Hazards from electromagnetic disturbances Electromagnetic disturbances are produced during the operation of welding machines. The welding machines are designed to be used in industrial envi- ronment. Their use in residential premises may cause interference with radio and television reception. -
Page 15: Fires And Explosions
CTR12000 Car-O-Liner Group AB shielding, where necessary, cables, leads and electric equipment in the vicinity of the welding workplace The Spot Welder CTR 12000 uses high currents to heat the welding point. This current is supplied by the transformer through the C-arm to the welding point. -
Page 16: Hazards From Heat
Car-O-Liner Group AB CTR12000 Allow the workpieces to cool down after the welding process! Keep away hot weld metal from combustible materials! Keep children and animals far away from the workplace! Approved fire extinguishers, suitable for the different welding processes, should be nearby and easily accessible. -
Page 17: Organizational Measures
CTR12000 Car-O-Liner Group AB Organizational measures The user has to provide the required personal protective equipment. All the available safety devices are to be checked at regular intervals. 2.10 Informal safety precautions Always keep the operating manual at the machine location and workplace. In... -
Page 18: Safety Precautions At The Machine Installation Site
Car-O-Liner Group AB CTR12000 All work on the machine’s electrical equipment may be done by qualified electricians only. 2.13 Safety precautions at the machine installation site The machine must be installed on suitable even floor with sufficient bearing capacity and not in the open air. Make sure that the individual mechanical components are safely fastened as prescribed. -
Page 19: Informative Material
Non-observance of the operating instructions for transport, storage, mounting, commissioning, maintenance and retrofitting of the machine. Alteration of the machine without the prior approval of Car-O-Liner; insufficient supervision of machine parts that are subject to wear; improper repair. Foreign objects or an act of God 2.16 Informative material... -
Page 20: Installation
Car-O-Liner Group AB CTR12000 3 Installation Delivery Our welding plants are mostly factory-preassembled and ready to be plugged in, meaning that the welding power source is equipped with 8 m power cable and 32 A plug. Further equipment being part of standard version delivery (other versions see section 3.9):... -
Page 21: Electrical Connection
CTR12000 Car-O-Liner Group AB Keep inflammable materials away from the workplace to prevent fire by spatters of hot molten metal. The room / workplace must have sufficient lighting that is appropriate for the welding jobs to be performed. -
Page 22: Compressed Air Supply
Use a ramp to roll the welder on to the pallet. The welder must be securely strapped to the pallet before transport, in the same way as when it was deliv- ered from the manufacturer! Ramp not provided by Car-O-Liner 41643, ENG - rev. 2, 2016-10... -
Page 23: Storage
Do not overstep this radius, as there is an acute tilting danger by Topview the hanging welding gun. Maximum radius of movement Wheel extension is included in the CTR12000 standard delivery, see supplementary mounting instruction 44131. 41643, ENG - rev. 2, 2016-10... - Page 24 Car-O-Liner Group AB CTR12000 Moving the machine When moving the machine, the welding gun must be fixed at the intended holder (on side of the machine) and must not hang on the balancer. Do not move the machine while the welding gun is hanging on the balancer!
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Page 25: Welding Machine Set-Up
CTR12000 Car-O-Liner Group AB 4 Welding machine set-up Preparing the C-tong for welding operation Different C-arms, as shown left, may be fitted to the C-tong. To fit a C-arm, put the connection shank, to be slightly greased before, into the arm holder of the tong body and lock it by pushing the slide A up. -
Page 26: Motional Mechanism
Car-O-Liner Group AB CTR12000 Motional mechanism 4.2.1 C- Clamps 1. Closing Clamp a. rig, clamp trigger in position 1, closing C- clamp b. release trigger, clamp opens by spring pressure c. work pressure, clamp trigger in pos. 2 d. release trigger, clamp opens by spring pressure e. -
Page 27: Appliance Multifunction Gun (Option)
CTR12000 Car-O-Liner Group AB Appliance Multifunction gun (Option) 1. Pulling hammer for attachments 2. Special chuck for puller ring 3. Carbon electrode 4. Disk electrode 5. Electrode for threaded pin 6. Electrode for finely threaded pin M4 / nail 7. Electrode for trim nipple 8. -
Page 28: Spotting
Car-O-Liner Group AB CTR12000 4.3.1 Spotting The maximum electrode-side sheet thickness is 1.25 mm; the thickness of the sheet on the opposite side should however be higher. Prior to welding, ensure that the sheets are perfectly clean and close lying. -
Page 29: Heating Up Steel Sheets For Shrinking Or Stiffening
CTR12000 Car-O-Liner Group AB 4.3.3 Heating up steel sheets for shrinking or stiffening Small convex dents can be pulled in with the copper electrode D while ap- plying heat (welding current) and pressure at the same time. Larger flat dents or sheet sections, the elasticity of which should be in- creased, can be heated up with the carbon electrode C. -
Page 30: Power Source Set-Up
Car-O-Liner Group AB CTR12000 Power source set-up 4.4.1 Coolant General Due to the increased current load during resistance spot welding, power sec- tion, transformer, rectifier, hose pack and electrodes must be cooled with a cooling liquid. During welding operation, this cooling liquid is made circulating by a circu- lation pump. - Page 31 If the 3 liter canister is used together with 17 liter water to fill up the 20 liter tank in CTR12000, the frost resisting degree will be around -2 C. Transportation of the welder with filled up water tank should only be done if the surrounding temperature is over this value.
- Page 32 Car-O-Liner is not liable for frost damages to the welding machine if these instructions are not followed! b) Distilled water Distilled water is not suitable for serving as coolant in the CTR12000 since it may cause corrosion damages. c) Other coolants or addition agents Car-O-Liner strongly advise not to use other coolants.
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Page 33: Compressed Air Supply
CTR12000 Car-O-Liner Group AB Draining the coolant Prior to longer storage of the welding machine, completely drain the coolant (see chapter Storage). To this aim, proceed in the following order: Switch off the welding machine at the mains switch ... -
Page 34: Machine Start-Up
The yellow pilot lamp B at the top right of the control panel lights up and the CAR-O-LINER logo is displayed on the screen C for about 5 – 10 seconds. During this time, the machine then performs a self-test (initialization). The fan and the circulating pump of the cooling unit both start running (you can hear the noise). -
Page 35: Technical Specifications
CTR12000 Car-O-Liner Group AB 6 Technical specifications 208 V 41643, ENG - rev. 2, 2016-10... - Page 36 Car-O-Liner Group AB CTR12000 460 V 41643, ENG - rev. 2, 2016-10...
- Page 37 CTR12000 Car-O-Liner Group AB 400 V 41643, ENG - rev. 2, 2016-10...
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Page 38: Maintenance And Upkeep
Car-O-Liner Group AB CTR12000 7 Maintenance and upkeep This chapter describes required maintenance work that is obligatory: For ensuring trouble free, safe and efficient performance of the spot welder. For avoiding the causes, mostly quite simple, that lead to impaired welding results. - Page 39 CTR12000 Car-O-Liner Group AB In case of leakage, immediately stop maintenance and eliminate the causes for the leakage. Check the automatic drain system of the water separator. Check manometer gauge for precision. CURRENT-CONDUCTING COMPONENTS Maintenance work on the electric equipment of the machine may be exclu- sively carried out by qualified and trained persons being instructed to do their job in a safe environment.
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Page 40: Dismantling And Salvage
Mechanical components, electrical components, plastic hoses, steel and alu- minium should be sorted for material recycling Battery -The battery in the CTR12000 (control unit) must be recycled or disposed of properly. 41643, ENG - rev. 2, 2016-10... -
Page 41: Service
Any repair on the power source shall be carried out by trained and author- ized staff. If a machine failure makes it necessary - even if the warranty time has al- ready expired contact our Car-O-Liner distributor. 41643, ENG - rev. 2, 2016-10... -
Page 42: Spare Parts
Car-O-Liner Group AB CTR12000 10 Spare parts Appendix A Spare Parts Power source CTR12000 Description Part No: Delivery plate, 3-parts incl. mat 43943 Gun supporter: 43944 Aluminium cap Plastic tube 43945 Transport grip, without screw 43946 43942 Spare key for switch... - Page 43 CTR12000 Car-O-Liner Group AB Appendix B Welding tongs Description Part No: C-tong, type CTR12000, 208V complete with hose pack- 43462 age, without electrode and electrode arms C-tong, type CTR12000, 230V complete with hose pack- 43463 age, without electrode and electrode arms...
- Page 44 Car-O-Liner Group AB CTR12000 41643, ENG - rev. 2, 2016-10...
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Page 45: Multifunction Gun (Optional)
CTR12000 Car-O-Liner Group AB Multifunction gun (Optional) Description Part No: Complete set Spotter (Spot gun with pulling hammer, 41888 workpiece cable and ground cable 2,5 m , delivery plate and accessory box) Spotter (Spot gun with pulling hammer and workpiece... - Page 48 Leading Global Provider of Assured and Profitable Alignment Processes to the Automotive Industry, including Technical Development, Training and Service. Over 55 000 Car-O-Liner Collision Repair Systems are in use worldwide. Car-O-Liner runs operations of its own in Scandinavia, USA, UK, France, Germany, Singapore, India and China and sells through local distributors in more than 60 countries.