Related Manuals for Car-O-Liner CR510
Summary of Contents for Car-O-Liner CR510
- Page 1 Instruction Manual CR510, CR530 and CR500 Double Action Medium Frequency Spot Welder (35201, rev 3) 2006-03, ENG...
- Page 2 “the welder” concerns all welders. given time. The equipment is intended for use in accordance with current trade practice and Car-O-Liner AB can in no way be held responsible appropriate safety regulations. The equipment for intentional or unintentional damage, and conse-...
- Page 3 CR500 range Car-O-Liner AB Conformity with directives and standards CR500 range is designed and manufactured Car-O-Liner AB, which is an EN-ISO 9001 accrediteddevelopment and manufacturing organisation. The CR500 range complies with the following standards: UL 499, CAN/CSA-C22.2 No. 88-1958 (R1992) – Intertec Testing Services ...
- Page 4 Car-O-Liner AB CR500 range 35201, ENG - rev. 3, 2006-03...
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Page 5: Table Of Contents
Setting up the C-tong................28 4.6.1 Rotating the yoke ..............30 4.6.2 Changing the electrodes ............30 4.6.3 Changing the yoke ..............32 OEM CR510, 530 ................33 Multi-function gun applications ............33 4.8.1 Carbon rod shrinking .............. 33 4.8.2 Dent pulling................34 4.8.3 Welding of clip rivets .............. - Page 6 Car-O-Liner AB CR500 range 4.8.4 Welding of screws and ground screws ........36 4.8.5 Welding of nuts ...............37 4.8.6 Stitch welding................38 4.8.7 Fitting the multi-function gun ..........40 4.8.8 Grounding the welding object when using tools .....41 4.8.9 Single sided spot welding ............42 Using external accessories ..............46...
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Page 7: Introduction
CR500 range Car-O-Liner AB 1 Introduction 1.1 General The CR500 range are medium frequency spot welders that is designed for Multi-function gun [2] body shops to duplicate the welding procedure used by car manufacturers. It consists of a welder unit [1] fitted with a multi-function gun [2] and a c-tong Welder unit [1] [3]. -
Page 8: Welder Cr500 Range
Main switch Display Holder for ground lead C-tong Holder for multi- function gun Holder for dent puller Multi-function gun Pressure gauge Figure 1.1 CR500 range Water filling On/Off button Water level Figure 1.2 CR510, CR530 35201, ENG - rev. 3, 2006-03... -
Page 9: Control Panel
CR500 range Car-O-Liner AB 1.2.1 Control panel The control panel comprises the display, the pressure regulator and the pressure gauge.The welding programs are set on the display and the pneumatic air pressure are set on the pressure regulator. 1.2.2 Multi-function gun The multi-function gun is used for the following weld programs: ... -
Page 10: X-Tong
Car-O-Liner AB CR500 range 1.2.4 X-tong The x-tong is used for Two sided spot welding. Triggers Welding cables Electrodes 1.3 Marking The name plate is at the rear of the welder unit. Name plate Figure 1.3 The name plate of CR500 range. -
Page 11: Safety
2.2 Warnings and important notices The following types of safety signs are used on the equipment and in Car-O-Liner’s instruction manuals: Prohibited Prohibits behaviour that can cause injury. Command Prescribes a specific responsibility or action. - Page 12 Car-O-Liner AB CR500 range The following warnings and important notices are used in the instruction manual: WARNING Warning (in bold type) is used in this manual to indicate a possible danger that could lead to personal injury. An instruction is normally given, followed by a short explanation plus the possible effect if the instruction is not followed.
- Page 13 CR500 range Car-O-Liner AB WARNING! It is very important to turn the handle firmly to fasten the yoke. WARNING! All service and maintenance must be carried out by Car-O- Liner service personnel and service support. Risk for electrical shock. WARNING! Never remove any covers or perform any work to the welder without unplugging the welder from the wall outlet.
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Page 14: Safety Signs
CR500 range IMPORTANT! If the thermal breaker has switched off the welder, please contact Car-O-Liner authorized service personnel. IMPORTANT! It is the responsibility of the owner to ensure that the equipment has been installed as specified in the instructions provided. It is also the owner’s responsibility to ensure that the welder is inspected in... -
Page 15: Placement Of Safety Signs
CR500 range Car-O-Liner AB WARNING Appropriate protection (protective gloves, visor, clothing and shoes) must be worn when using this equipment. WARNING Sparks from welding could start a fire. WARNING! All electrical connections must be made by a qualified electrician. Disconnect the supply before performing any service or installation work. -
Page 16: Cooling
The welding cables are cooled by compressed air blowing through the cables. The cable cooling system is controlled by electrovalves sending compressed air from the pneumatic air network. CR510 and CR530 are also equipped with water cooling of electrodes and yokes. -
Page 17: Installation
CR500 range Car-O-Liner AB 3 Installation 3.1 General The welder is inspected and checked prior to leaving the factory to guarantee consistent quality and the highest possible reliability. Instructions for instal- lation, with general tips and directions, are provided as follows. -
Page 18: Connection Of Electrical Supply
Car-O-Liner AB CR500 range 3.4 Connection of electrical supply The CR500 range requires one of the following voltage/ frequency combina- tions: 230 V ±10 %, 50-60 Hz, 3-phase 400 V ±10 %, 50-60 Hz, 3-phase 460 V ±10 %, 50-60 Hz, 3-phase The required voltage and frequency is preset upon leaving the manufacturer. -
Page 19: Connection Of Pneumatic Air Supply
IMPORTANT! If the heater is used in temperatures below freezing point, Car-O-Liner´s recommended antifreeze agent must be used. 1. Loosen the lid on the top of the water tank. 2. Fill the water tank with water mixed with antifreeze. -
Page 20: Mount Yoke And Electrode (C-Tong)
Car-O-Liner AB CR500 range NOTE: Do not fill up the tank entirely to allow space for the hot water to expand. 3.7 Mount yoke and electrode (C-tong) To mount the yoke and electrode, see section 4.6 "Setting up the C-tong". -
Page 21: Operation
CR500 range Car-O-Liner AB 4 Operation 4.1 Before you begin welding Before you begin welding, be sure to read the instructions in this instruction manual and that you understand them. Be sure to follow the car manufactur- ers instructions as well, for example welding parameters. -
Page 22: Quick Start Instructions
Figure 4.4. 3. Select a welding program, refer to Figure 4.2. Two sided Multi-function Air puller Fender edge spot welding gun applications CR510, 530 CR500 DA Carbon rod Dent pulling Welding of clip Welding of Welding of Welding of... -
Page 23: Turning On The Welder
CR500 range Car-O-Liner AB 4.2.1 Turning on the welder Turn the main switch to position “1”. Once the welder is ready for use, the “Two sided spot Main welding” application is shown on the display. This switch application is only displayed the first time the welder is started. -
Page 24: Setting The Weld Programs
“Up” “Switch” “Down” Display “Left” “Right” “Automatic/Manual” “Save” Figure 4.3 The CR500 range control panel “Up” “Down” “Switch” Display “Save” “Left” “Right” “Automatic/Manual” Figure 4.4 The CR510 control panel 35201, ENG - rev. 3, 2006-03... -
Page 25: Saving The Personalized Settings
CR500 range Car-O-Liner AB The weld programs are selected as follows: 1. Use the button “Switch“ to select what kind of gun to use. The chosen gun is shown in the upper left corner of the display. If you have chosen the “Multi-function gun application”, continue at instruction 2. -
Page 26: Recalling The Personalized Settings
Car-O-Liner AB CR500 range The second line in the “Save” menu (marked with 1-5) contains the person- alized settings that have been previously saved. NOTE: A total of five (5) options can be saved. 4. Make sure that the field “1-5” is active. -
Page 27: Setting The Weld Program
CR500 range Car-O-Liner AB 11. Scroll the five options in the “Save” menu, by clicking on the buttons “Up“ and “Down“ . 12. Move to the field “Recall” by clicking on the buttons “Left“ “Right“ . 13. Recall the personalized settings by clicking on the button “Up“ . -
Page 28: Setting Up The C-Tong
Car-O-Liner AB CR500 range 4.6 Setting up the C-tong IMPORTANT! Adjust the time and the power according to the thickness of the metal sheet. Max 5-6 mm Max 6-8 mm Sphericle 1. Be sure to use a yoke that is suited to the actual welding object. For 120°... - Page 29 CR500 range Car-O-Liner AB NOTE: By releasing the trigger within half a second, the weld cycle can be interrupted. NOTE: By default, the c-tong is set to both close the electrodes and make a weld when the trigger is pressed once. The welding sequence can be changed so that the c-tong closes when triggered once and makes a weld when the trigger is pressed twice.
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Page 30: Rotating The Yoke
Car-O-Liner AB CR500 range 4.6.1 Rotating the yoke The yoke can be rotated 360° to attain maximum reach when performing two sided spot welding. To set the angle of the yoke: Yoke 1. Loosen the yoke by turning the handle counter-clockwise. - Page 31 CR500 range Car-O-Liner AB Changing the yoke electrode on CR500 DA The yoke electrode is placed in a coned hole that runs through the end of the yoke. The yoke electrode can be removed using a mandrel: Coned hole 1. Place the mandrel so that its tip touches the yoke electrode that is fitted in the hole at the yoke.
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Page 32: Changing The Yoke
Car-O-Liner AB CR500 range Changing the cap 1. Turn off the water cooling. 25. Grab the piston electrode at the end and hold the electrode in place with a 16 mm wrench (5/8"). 2. Twist the cap off with a suitable tool. -
Page 33: Oem Cr510, 530
CR500 range Car-O-Liner AB 4.7 OEM CR510, 530 Prepared for OEM weldning parameters. 1. Use the buttons “Up” and “Down” to select Make. 2. Use the buttons “Left” and “Right” to step to model function. 3. Use the buttons “Up”... -
Page 34: Dent Pulling
Car-O-Liner AB CR500 range 4. Check the chosen power by performing a strength test (refer to Lock nut Carbon rod section 4.12 "Performing strength tests"). 5. Fit the multi-function gun with a carbon rod) refer to section 4.8.7 "Fitting the multi-function gun"). -
Page 35: Welding Of Clip Rivets
CR500 range Car-O-Liner AB 4.8.3 Welding of clip rivets Welding of clip rivets is a multi-function gun application. The clip rivets are included with the CR500 range at delivery. 1. Select the “Multi function gun” application, refer to section 4.2.3 "Setting the weld programs". -
Page 36: Welding Of Screws And Ground Screws
Car-O-Liner AB CR500 range 4.8.4 Welding of screws and ground screws Welding of screws is a multi-function gun application. The screws are in- cluded with the CR500 range at delivery. 1. Select the “Multi function gun” application, refer to section 4.2.3 "Setting the weld programs". -
Page 37: Welding Of Nuts
CR500 range Car-O-Liner AB 4.8.5 Welding of nuts Welding of screws is a multi-function gun application. The screws are in- cluded with the CR500 range at delivery. 1. Select the “Multi function gun” application, refer to section 4.2.3 "Setting the weld programs". -
Page 38: Stitch Welding
Car-O-Liner AB CR500 range 4.8.6 Stitch welding Stitch welding is a multi-function gun application that is used to easily make several welds in a row. 1. Select the “Multi function gun” application, refer to section 4.2.3 "Setting the weld programs". - Page 39 CR500 range Car-O-Liner AB WARNING! Make sure to use welding goggles when stitch welding. The welding torch might otherwise injure the eyes. 11. When the stitch welding is completed, release the trigger. Wait for half a second until the stitch electrode is removed from the sheet.
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Page 40: Fitting The Multi-Function Gun
Car-O-Liner AB CR500 range 4.8.7 Fitting the multi-function gun The multi-function gun can be fitted with a number of tools. The most com- Tool holder Lock nut Dent puller Carbon rod Rivet holder Stitch electrode Screw holder mon tools are: Fit the multi-function gun with tools as follows: 1. -
Page 41: Grounding The Welding Object When Using Tools
CR500 range Car-O-Liner AB 4.8.8 Grounding the welding object when using tools To ensure personal safety and quality weld nuggets, the welding object must be grounded. This is done as follows: 1. To achieve good contact, remove paint, primer and rust by grinding the area onto which the ground connector shall be connected. -
Page 42: Single Sided Spot Welding
Car-O-Liner AB CR500 range 4.8.9 Single sided spot welding Single sided spot welding is used where two sided spot welding cannot be used. Single sided spot welding can be used on both galvanized and stainless steel sheets. IMPORTANT! Single sided spot welding is not permitted on supporting frameworks of a vehicle. - Page 43 CR500 range Car-O-Liner AB 5. Set the welding time. 6. Set the welding power. IMPORTANT! Adjust the time and the power according to the thickness of the metal sheet. 7. Before welding on a vehicle, check the set welding program by performing a strength test (refer to section 4.11 "Performing...
- Page 44 Car-O-Liner AB CR500 range Fitting the multi-function gun with a single side electrode Lock nut Single spot 1. Thread the lock nut on the multi-function gun counter-clockwise to electrode open the tool holder on the gun. Normally, the nut can be opened by hand, but if the nut is stuck it can be opened with the notch below the dent puller holder (see Figure 4.8).
- Page 45 CR500 range Car-O-Liner AB 5. Place a new electrode into the electrode holder. This can be done by hand. Grounding the welding object when performing single sided spot welding 1. To achieve a good contact, remove paint, primer and rust by grinding the area on the inner body sheet onto which the ground connector shall be connected.
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Page 46: Using External Accessories
Car-O-Liner AB CR500 range 4.9 Using external accessories External accessories, such as an air puller, can be connected to the CR500 range. These external accessories, the trigger contact and the power supply connector for external accessories are not included with the welder at delivery. -
Page 47: Setting Up The Trigger Function
CR500 range Car-O-Liner AB 4.10.1 Setting up the trigger function The closing sequence of the c-tong can be changed. By default, the c-tong is set to both close the electrodes and make a weld when the trigger is pressed once (Single function). But, the welding sequence can be changed so that the c-tong closes when triggered once and makes a weld when the trigger is pressed a second time (Double function). -
Page 48: Setting Up Current Control / Energy Control
Car-O-Liner AB CR500 range 4.10.4 Setting up Current control / Energy control The “Control” application allows the user to set wether the welder should use “Current control” or “Energy control”. When using CC, “Current control”, the welder automatically compensates the power losses (due to increased heat in the welder) by keeping the current constant. -
Page 49: Performing Strength Tests
CR500 range Car-O-Liner AB 4.10.7 Performing strength tests The aim of spot welding is to restore the vehicle to its former condition. It is therefore important that the weld nuggets have sufficient quality. The quality of the weld nuggets are checked with strength tests. When performing these tests, one ensures that the set weld current and weld time is sufficient. -
Page 50: Service And Maintenance
Car-O-Liner AB CR500 range 5 Service and Maintenance WARNING! All service and maintenance must be carried out by Car-O- Liner service personnel and service support. Risk for electrical shock. WARNING! Never remove any covers or perform any work to the welder without unplugging the welder from the wall outlet. -
Page 51: Daily
CR500 range Car-O-Liner AB 5.2.1 Daily Check the condition of the c-tong, air connections and air hoses to prevent overheating and malfunction due to poor cooling. Check the condition of the welding cables. Do not use faulty cables! ... -
Page 52: System Information
This message appears after a set Check that the electrode shape and size is number of welds. maintained. If not, exchange the cap (CR510 and CR530) or dress the electrode. To confirm the message, press any key to return to the chosen program/welding. -
Page 53: Troubleshooting
CR500 range Car-O-Liner AB 6 Troubleshooting The troubleshooting instructions in this chapter will help you to quickly find and correct the most common faults that may occur when using the welder. The error message list is useful in interpreting any error messages shown on the display of the welder. -
Page 54: Fault Tracing Tables
Insufficient connection between the Clean the metal from any rust, color etc. metalsheets. To confirm the message, press any key to return to the chosen program/welding. (The message locks the system function). Insulation (CR510, CR530) 35201, ENG - rev. 3, 2006-03... - Page 55 Check the water level. Make sure that the unit is switched on. To confirm the message, press any key to return to the chosen program/welding. (The message locks the system function). Waterflow (CR510, CR530) Figure 6.1 Possible welder unit faults 35201, ENG - rev. 3, 2006-03...
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Page 56: Dismantling And Salvage
Car-O-Liner AB CR500 range 7 Dismantling and Salvage IMPORTANT! For the sake of the environment, it is important that the equipment is dismantled in an environmentally friendly way. To limit strain on the environment and its natural resources, it is important that the various parts of the welder are recycled. -
Page 57: Technical Specifications
CR500 range Car-O-Liner AB 8 Technical Specifications CR510 CR500 DA CR530C CR530X Supply voltage 230 V ±10 %, 50-60 Hz, 3-phase 230 V ±10 %, 50-60 Hz, 3-phase 400 V ±10 %, 50-60 Hz, 3-phase 400 V ±10 %, 50-60 Hz, 3-phase 400 V ±10 %, 50-60 Hz, 3-... - Page 58 Car-O-Liner AB CR500 range 35201, ENG - rev. 3, 2006-03...
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Page 59: Spare Parts And Accesories
Tool box CR500 range (The items marked with • are included in the CR500 range Tool box.) Allen key 5 mm • 31076 Plastic box • 35476 C-tong holder CR500 DA/CR510 34702 Holder for dent puller 32962 and grounding connector Front wheel 34158... -
Page 60: Spare Parts For The Multi-Function Gun
Car-O-Liner AB CR500 range 9.2 Spare parts for the Multi-function gun Object Quantity Part No: Lock nut 32556 Multi-function gun housing, 139 40 03 004 1 pair Trigger 139 40 03 005 Screw 33076 Micro switch 33077 Screw M4×10 33213... - Page 61 CR500 range Car-O-Liner AB 32318 Screw holder Ø 5-6 mm • Rivet holder Ø 3-5 mm • 32319 Carbon rod holder • 32873 Contact tip for dent puller • 32504 Carbon rod Ø 10 mm • 32322 Single spot electrode L50, length 50 mm (domed) •...
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Page 62: Spare Parts For The C-Tong
Yoke locking handle 33086 Electrode L40, length 40 mm • CR500 DA 31060 Electrode L80, length 80 mm • CR500 DA 31058 Cap holder 40, CR510, CR530 C 34885 Cap holder 80, CR510, CR530 C 34886 Caps 34921 (The items marked with • are included in the CR500 Tool box.) -
Page 63: Spare Parts For The X-Tong
CR500 range Car-O-Liner AB 9.4 Spare Parts for the X-tong Object Quantity Part No: X-tong, compl. 34918 Arm, 120 mm 34920 Caps, x-tong 34919 35201, ENG - rev. 3, 2006-03... - Page 64 Profitable Alignment Processes to the Automotive Industry, including Technical Development, Training and Service. Over 40 000 Car-O-Liner Collision Repair Systems are in use world- wide. Car-O-Liner runs operations of its own in Scandinavia, USA, UK, France, Germany, Thailand and China and sells through local distributors in more than 60 countries.