user manual v4
Contents
1. nw l 205184 gt 105184 x HOLDVINOD Un 8 180 6 D zodtotdr 1041014 5 82d a 3dWOd JY eune d z ZHOLDVLNOD jode 71 IS shueinoo Un Q MION 12016 NY auneld m 61096 2NV18 75096 LYJNYO 45 1 096 HION LAIG CH3WWVOJSNVHL 21 La qe LYOLDVLNOD aqno vzexe 1nepuofsip 242. To purge the SD card insert the SD card in the reader of your PC and in the menus click on Options and Purge SD Card Beware during a purge operation the reports that have not yet been imported in the software will be automatically imported Filling the information of a report The following information can be automatically added on each report Operator Brand Vehicle model Registration First registration Chassis number Operation Remarks To fill this data select a report and enter this information in the header of the report Print a report To print a report select the report and click on icon A print preview appears Click on icon Export in PDF format To export a report in PDF format select a report and click on icon gl A print preview appears Click on icon i Example of report Company name JBDC Phone number 00 33 2 34 55 78 88 Address 134 Boulevard des loges Fax number 00 332 34 56 78 81 Email c antactieibdc ip code 53841 Website www ibdc cam City SAINT BERTHEY IM Operator Vehicle make RENAULT Jab number 099 Vehicle mo del MEGANE Report date 28 03 2013 Chassis Nr 12354235 Operation REAR FENDER Registration 113AMZ35 Remarks Comments First Registration 03 04 2007 SN 1109003480 Settings Measurements p ns Date Hour Intensity d Force Tenes L2 EN X ow Cdempmi 2 26 05 2015 17 34 C damp 1 Sp
3. Do not use in the open air AN Do not use the product under water projections IP21 s People wearing pace makers should not approach this product Risk of interference and disturbance of pace makers near of the product Caution Strong magnetic field People wearing active or passive implants must be informed Use eye protection or wear safety glasses Body protection must be worn Hand protection must be worn Risk of burns 10 DECLARATION OF CONFORMITY JBDC confirm that the product described within this manual conforms to the following directives Low Voltage Directive 2006 95 CE in respect of the harmonized norm EN 62135 1 Electromagnetic Compatibility Directive EMC 2004 108 CE in respect of the harmonized norm EN62135 2 Machine Directive 2006 42 EC in respect of the harmonized norm EN 60204 1 22 SPOT 10 000 C D 11 WARRANTY 1 The warranty is valid for one year only when the certificate of warranty has been filled correctly by the seller 2 The warranty covers every default or manufacture vice for one year as from the purchase date spare parts and labourforce 3 THE WARRANTY DOESN T COVER THE VOLTAGE ERRORS damage due to a bad use dropped product dismantling or any more issue due to the carriage 4 The warranty doesn t cover any issue due to a maintenance of the clamp or the generator 5 The warranty doesn t cover the normal wear and tear of the spare parts e g cables clamps etc In case
4. management ERROR 8192 30 1 98 27 Overheating Current too low _ 23784788 17 32 current too low Insufficient air pressure Different events might cause the appearance of error messages They can be classified in three categories The messages that warn the user of overheating or a lack of electrode force or welding current etc These messages appear on the screen and remain until a key is pressed the defects that correspond to a bad installation air pressure electrical power supply The messages that inform of major failures such as material failure These defects cause the display of an error message that blocks the machine The thermal protection makes use of a thermistor on the diode bridge which block the use of the machine and displays the message overheating If the welding current obtained during the welding spot is 6 less than the current setting the machine displays once the welding spot is performed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the actual measured welding current This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the button on the clamp If the machine cannot deliver the requested current then the following message appears The welding spot is not performed
5. mode the single sided gun will be limited to steel sheets of thickness 1 5mm maximum With the single sided gun the operator can choose between a variety of tools monopoint welding star welding stud welding rivet welding washer welding carbon shrinking stitch welding The selection of the tool is performed using the and keys In manual mode the maximum permitted welding current is 9 kA during a period that will not exceed 600 ms This is why it is not possible to select higher values for these parameters Select the thickness of the sheets to be welded on the machine using the and keys It is possible to modify the parameters for current and time in manual mode Pressing during 2 seconds the key takes back to the standard mode The highlighting allows to select the parameter to adjust Each parameter can be adjusted using the and keys The up and down keys allow to move from one parameter to the next WARNING The clamp and the gun of the unit are connected to the same current source This means that when you use one of these 2 tools there is also power on the second tool The tool which is not used must therefore be placed on its stand on the trolley clamps stand located on the side of the trolley and gun stand located on the T Shape balancer In case these instructions are not respected severe damage can occur to the generator tools Sparks and metal projections can occur SPOT 10 000 C Error
6. of breakdown please return the unit to the JBDC factory JBDC with the following certificate of warranty validate by the seller and explicative note of the breakdown After the warranty our After sales service provides the repairs by acceptance of the quotation ATTENTION We remind you that we do not accept any product return with carriage cost not included JBDC S A V 5 134 Bd des Loges 4159 53941 SAINT BERTHEVIN cedex FAX S A V 02 43 01 23 75 CERTIFICATE OF WARRANTY Seller stamp Reference of the unit Purchase date Seller Name Company Valid for one year as from the purchase 23 U 12 CIRCUIT DIAGRAM SPOT 10 000 C 55 2NV18 INV s m Z SSIOA 5 5 59 Z BESI Y SA 2NV 18 aus 66025 91 01615 si Ly 0615 LAW 14514 s3 14V2 18656 S60ES LOS LEN addeu la ee 5 4 unal dvo QuvO8A3 870167404 NI 2 gt zi 23 13101514 S EN 431402 19V2 10676 2 z un EE 9113 101518 2 LLLES ZZ t 8 2 addeu ES LI gt 5 3ONId 2 un 2 32NId adden 9
7. too low Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the welding current measured during the spot is 6 less than the setting the machine will display when the spot is completed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the B button on the clamp Multisheet mode This mode allows to precisely specify the thickness and type of each sheet of an assembly of 2 or 3 sheets Using the up and down keys in the circle allows to select the MODE MULTI 23 6 parameters for each sheet When the parameters for each sheet are highlighted the sheet thickness and type of steel parameters can be adjusted using the and keys in the circle The parameters to be adjusted in this mode are The thickness of each sheet to be welded to choose between the values 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 mm The type of steel for each sheet coated steel HTS steel UHTS steel BORON steel In order to activate sheet 3 press the up and down keys in the circle to highlight sheet 3 then use the and keys in the circle to select the s
8. EMEDIES The metal surface has not been Check the preparation of the prepared properly surface The caps are worm Change the caps The spot weld is poor quality Check the arm that has been installed in the software Check the system pressure Insufficient air pressure min 7 bar The clamps have pierced the Change the caps metal The arm fitted is incorrect 5 The metal surface has not been Check the preparation of the 5 prepared properly surface Check the stability of the Electrical supply problem power supply Lack of power on C clamp Caps dirty or damaged Change the caps The machine has been used Refer to the Heating The generator has gone into intensively Tongtable p 18 amp 19 Thermal Protection Mode Insufficient cooling Air pressure Check the system pressure too low min 7 bar Bad Earth connection Farn connection cable oponer aun Insufficient tightening of the chuck Check the tightening of the P 9 Or accessories chuck or accessories The consumables are damaged Replace the consumables U Check the tightening of the chuck the chuck exit and the sheath Check the Earth connection The spot is poor guality Bad Earth connection ls Insufficient tightening of the chuck accessories The gun over heats 21 SPOT 10 000 C D 9 ICONS Caution Read the user manual before use A 905 Separate collection required Do not throw in a domestic dustbin
9. Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the welding current measured during the spot is 690 less than the setting the machine will display when the spot is completed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the B button on the clamp Pressing during 2 seconds the key takes back to the standard mode SPOT 10 000 C Use of the single sided gun 4 Connect the copper plate to the generator s earth cable e Firmly fix the earth plate as near as possible to the welding area In case of monopoint welding with the single sided gun always fix the earth plate on the sheet that is not in contact with the welding electrode such that the welding current will flow the 2 sheets to be welded Select the GUN tool using s key or pulling the gun s trigger 4 The default parameter is star welding in standard mode A let the inertia hammer at the end of the gun if this one is hung to the balancer ope STANDARD 25 04 05 11 54 MANUAL 4 04 68 11 54 The single sided gun can be used in standard or manual mode In normal
10. SPOT 10 000 C USER MANUAL va TABLE OF CONTENTS 1 PRESENTATION SAFETY RECOMMENDATIONS AND GENERAL 2 2 DESCRIPTION uU vU OR UE DEMENS DS E E 3 18061 3 Rear eer 3 E 3 TINS TALIA TIO cp 4 4 OPERATION sa 5 Key ees 5 SEO Te Ce CLA dev 6 7 USEOF THE single sided nn 8 9 Welding SDOtS OU 10 Recording features identification mode user s parameters bp 10 12 ina anda 13 SPOT Save SOT 13 14 5 PRECAUTIONS ANDSERVIGING iso ia Ur Dex vuU Ex vi rci exta Vcr lere oan 15 Relacement Of caps electrodes Con pA UN anon petes ovn unto 15 Cleaning or replacement OF welding 00165 minus E Nes cian ll 15 purge or threbpneumaglic oc oci tco eS ODE DOC ORAN CUR i 15 maintenance Ofthe generator s cis os duco uos dec d da i a exu a da xa NEN ET I X a I Iu e I a 15 Replacement and adjustment of C arms eeeeesse eee ne
11. after making the last spot with the gun SPOT 10 000 C 4 EQUIPMENT OPERATION Key definition F g move NORMAL mmm HLE THLE Pression 6 1 bar key Pressing this key allows to select the tool that will be used either clamp or single sided gun The clamp adjustment mode allows to close the clamp and apply the programmed force on the electrodes with any current flowing This mode is used to adjust the arms Pressing this key 2 seconds allows coming back to normal mode from the other modes Pressing this key 2 seconds brings the spot counter to zero when it is displaved Pressing briefly twice this key erases the report that is displayed on the screen when in the visualisation mode Pressing briefly this key when in program saving mode erases the selected program Save a report More details can be found on this function in the corresponding chapter The record key saving function enables or disables the report The visualize key allows to read the sequence of spots performed Use of the advanced modes The MODE key allows to navigate through 3 different modes STANDARD MODE MULTISHEET MODE MANUAL MODE A long press on the MODE key allows to enter the configuration mode where the language and date can be edited and the sound alarm activated for current too low or low pressure messages The up and down keys in the circle allow to select the param
12. and the message must be acknowledged to perform a welding spot If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Insufficient Pressure Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the actual measured clamping force is too low then the machine will display the following message Low Pressure 23 84 08 Insufficient pressure 297647608 13 51 low pressure 664 443 4 320 M SPOT 10 000 C Welding spot counter A welding spot counter allows to count the number of spots performed with the same caps If the welding spot is performed without any problem the following message appears The counter is displayed on the top left corner of the screen Pressing the key for two seconds resets this counter to zero after the caps have been replaced If more than 200 welding spots are done with the same caps then the machine will display a warning message In this case the warning message Do control caps is also recorded in the traceability report You can define the threshold number of spots 200 by default POINTS 3 04709 13 108 POINTS 2a0 21 04 88 17 03 OK Do control caps Lose 6x 443 aon Tens 6 04 F 187 320 ms 320 ms Recording features The log report allows t
13. ation vehicle make vehicle model vehicle identification CHASSIS NUMBER number required when entering the repair order To exit the screen you must press the mode key for 2 seconds Then you must put the SD card that contains the program into your BP card reader REGISTRATION VEHICULE MAKE List of screens that allow you to enter a repair order When a job number has already been created it can not be changed or deleted on the BP To remove it you must use the software SPOT SAVE PC You can create up to 100 job numbers Display Job number Display User ID User ID NAME Job number NAME Keys left and right moves the cursor in the field The up and down buttons allow you to change the letters or numbers The short press the Esc key clears the field The mode button allows scrolling fields for the modification or reading Display Registration optional Display Vehicle make optional REGISTRATION VEHICULE MAKE 11 SPOT 10 000 C Display Vehicle model optional Display Chassis number optional VEHICULE MODEL Chassis number catalogue When consulting jobs with the View key gt the screen CATALOG appears The page number is displayed 13 maxi Keys left and right are used to change the page The up and down keys are used to select the next or previous Job number The mode key allows displaying the selected repair order L 1 1 1 1 1 The mode
14. ation from the file The key p allows to recover a report previously saved and to read it on the screen Before visualizing a report the record must be stopped by pressing the key The mode key allows to exit the report visualisation mode To erase the content of a report display it on the screen Then press the key using the visualize key The following message appears on the screen Rs ICE Fas Observation 30704708 14 25 NS X C Ika 1 3 4 5 6 8 9 1 4 5 When the triangle sign is displayed pressing key a second time definitively erases the contents of the report displayed on the screen The triangle sign disappears from the screen after 3 seconds 10 SPOT 10 000 C Identification mode If the identification mode is set to ON then you should enter LANGUAGES all required fields of the repair order to the welding points if DATE AND TIME the machine will issue the defect identification To enable and disable the identification mode insert an SD A card reader in the identification of BP instead of the SD card nanc that contains the programs The screen below setup is activated by pressing for 2 seconds on the mode button AUTO MODE SUPERVISION When the SD card identification is inserted and you select identify ON THEN supervision following screen appears This screen allows you to make the fields registr
15. dle A Types of arms for the C clam Jr 34 qH 106 mm RC2 57 mm Ref 051065 Ref 051072 E 08 Nj 8 bar 300 daN 8 bar 300 daN 8 bar 300 daN 8 bar 120 daN C clamp overheatin Nombre de points avant la premi re coupure thermique 1 8mm 3mm ACIER _ 48 39 36 2 18 62 48 44 75 47 The time for cooling the clamp can reach 15mn Number of spots between 2 stops due to overheating default 18mm 2mm 25mm 3mm 16 14 10 8 13 12 10 8 28 0 8mm 1mm 1 2mm ACIER 56 4 32 20 UHE 32 2 18 15 12 10 9 EE NN 39 16 SPOT 10 000 D 6 ASSEMBLY INSTRUCTIONS 8 x12 M8 x85 8 100 M6x20 M8 4 4 4 Z E X30 X1 X1 X6 X26 SPOT 10 000 C 4 8 12 6 M6x20 1 t le 1 M8x85 1 M8x100 18 U GL SPOT 10 000 C 7 TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS O 400V 3 phases earth 50 60Hhz Permanent input current IN 8 32 5 RAR THERMAL CHARACTERISTICS Ambient temperature range DOC 45 C Transport and storage temperature range 209 70 Hygrometry Altitude 2000m Thermal protection on the rectifier 70 C OE 0 0 02 MECHANICAL CHARACTERISTICS O CC PNEUMATIC CHARACTERISTICS o 20 SPOT 10 000 C D 8 TROUBLESHOOTING ANOMALIES CAUSES R
16. ed program in the list of saved programs The mode key allows to exit the program selection mode and makes the machine enter the manual mode where the parameters and the tool saved in the program are recalled To disable a progam simply change the value of a parameter in the manual mode standard mode or mutisheet mode or simply change tool by pressing key Zi 12 SPOT 10 000 C SD memory card SD card reference 050914 This card allows the user to transfer files from the machine to a PC to collect log reports in order to keep traceability of his work and possibly show it to an insurance company Update welding parameters new menu languages A copy of the SPOT SAVE software to collect and edit the traceability reports is stored on the SD card copy of the user manual is also stored on the SD The memory space will allow saving the characteristics of more than 1 000 welding spots The machine can operate without any SD card in manual mode only If the memory card is not inserted in the card reader then the following message is displayed Important Switch off the machine insert the SD card and switch the machine ON again The machine shall be switched off before removing the Insert SD card SD card from the reader indeed data on the SD card can be destroyed SPOT SAVE SOFTWARE FOR PC The purpose of this software is to allow the user to edit or save reports of the welding spots perfo
17. eter to modify sheet thickness type of steel arm used The and keys allow to modify the parameter 22 4 gt INVERTER microprocessor CONTROL 25 07 07 15 30 1 5 mm C3 400 mm e ial 2 4 Saving parameters The save key m allows to save an user s welding parameters mode sheet thickness welding current welding time or electrode force The open key y allows to call back previously saved welding settings The machine automatically goes to manual mode recalling the saved parameters current welding time force and the tool used clamp or gun 5 Steel sheet thickness This setting allows to select the thickness of the steel sheets to weld The sheet thickness can be adjusted using the and keys in the circle position 5 The thickness can be selected amongst the following preset values 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 mm 6 Type of steel sheet This setting allows to select the type of steel sheet to weld amongst 4 families coated steel HTS steel UHTS steel BORON steel This setting can be adjusted using the and keys in the circle position 5 Arm used When a clamp is used the user should specify the type of arm which is used on the clamp so that the machine will adjust automatically the air pressure to get the requested electrode force SPOT 10 000 C Use of the pneumatic clamps When using a pneumatic clamp always di
18. heet thickness and type of steel Pies uit SPOT 10 000 C If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Pressure too low Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the welding current measured during the spot is 6 less than the setting the machine will display when the spot is completed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the B button on the clamp Pressing during 2 seconds the key takes back to the standard mode Gysteel mode The Gysteel mode is optional it can be configured in the setup menu which is activated by pressing the mode button for 2 seconds mode Gysteel on off This mode is identical to the standard mode except that the user can define the elasticity limit of the sheet This limit Re can be identified using a metal tester like Gysteel Vision Re 1 10 refers to mild steels Re 11 18 refers to HSS THSS Re 19 35 refers to UHSS Re 36 99 refers
19. key is used to leave from viewing the report 4 The library management of the SD card can handle SD cards 2 GB Each job has an associated log file xxx dat where xxx id from 001 to 100 In every report the maximum recorded spot welds is 500 the job number and the user id of the file are displayed 4 No The page is shown in the top left All jobs are stored in the catalog GYS It contains the total number of job name of each job and user id max 100 jobs User welding parameter record The saving of user welding parameters allows to save the preferred welding parameters for different users of the machine 20 user profiles can be saved Each of them contains the following settings tool arm welding current welding time electrode force A user can save his preferred parameters for the clamp or single sided gun The save key allows to record the settings currently used in manual mode welding current welding time electrode force The 20 user profiles are then displayed with either an identifier for those that are already used or for those that are still available Use the and keys as well as the up and down keys to enter the identifier When entering a previously used identifier the machine will erase the previous settings saved The Open key allows to access the user profiles previously saved Selecting an empty user profile has no effect Pressing briefly the key erases the select
20. mmable material 5 Do not weld in an atmosphere charged with flammable gas or fuel fumes ELECTRO MAGNETIC COMPATIBILITY DU A Near the spot welding machine check whether there are no other power supply cable no control lines no telephone cables no radio or TV reception appliances no watches no mobile phones no magnetic cards no computers nor any other electronic appliance there are in the surroundings no persons using active medical appliances pacemakers acoustic prosthetics Plan extra protections if other products are to be used in the vicinity of the machine In order to protect the electronic control units on the vehicles it is recommended to disconnect the battery of the vehicle disconnect the airbag control unit disconnect and even remove the electronic control units if they are in the immediate vicinity of the welding area This product is designed to be used in an industrial or professional environment as defined in the CISPR11 publication In a different environment it might be difficult to ensure electromagnetic compatibility 2 SPOT 10 000 C D CE MARKING JBDC testifies that this product has been designed and manufactured in conformity with the following European standards Low Voltage Directive 2006 95 EC in application of the norm EN 62135 1 Electromagnetic Compatibility Directive EMC 2004 108 EC in application of the norm EN 62135 2 Machines directive 2006 95 EC in ap
21. nce on the unit For a use in single sided gun mode it is necessary to check the state of the tools stars monopoint electrode carbide electrode and if they look in bad conditions clean or replace them Replacement of the caps electrodes To guarantee an efficient welding spot it is necessary to replace the caps every 200 spots using the dedicated tool Assemble the caps with copper grease ref 050440 A type caps ref 049987 Ftype caps ref 049970 Bevelled caps ref 049994 Several combinations are possible Warning The caps must be in perfect line If not check that the electrodes are in line cf replacement of arms p 18 and 19 15 SPOT 10 000 C Replacement or adjustment of C Clamp arms Proceed as follows Unscrew the handle A Unscrew the screw maintaining the arm and the clamp B Remove the arm form the clamp C Take another arm and insert it in the clamp put some copper grease on the extremity of the arm Screw to assemble arm and clamp B Screw the handle again C clamp mobile electrode setu Proceed as follows 1 The machine must be switched off 2 Unleashing the movable electrode of the nut by unscrewing the locking handle A 3 Adjust the position of the movable electrode by sliding through the sleeve B 4 opening between the 2 caps C should be about 10 mm 5 Set the movable electrode in the nut tightening the locking han
22. nnen nnn nnn nnn nnn nhu nnne nnn nnn n nnn nnn 16 6 ASSEMBLY INSTRUCTIONS artic a 17 19 Z nECHNICAECBHARAGTIERISTIGS E saved Ducum d NG 20 Oc TROUBLESHOOTING 5 uiid O I ar 21 Fe TECON o 22 DECLARATION OF CONEOR MET Y n na 22 iE pid Pluta 9 23 S CIRCUIT DIAGRAM e 24 Autres langues disponibles sur la carte SD Other languages available on the SD card Weitere auf SD Karte verf gbare Sprachen 08 07 2014 V4 SPOT 10 000 C Thank you for your choice Before installing and using the product or before maintenance please read carefully the following safety recommendations in order to avoid accidents to the users and damage of the welding process JBDC cannot be held responsible for the damages occurring to persons or belongings following the use of the machine in the following circumstances Modification or disabling of safety elements Non respect of the recommendations written in the user manual Modification of the characteristics of the product Use of accessories other than the JBDC accessories or accessories not adapted to the machine Non respect of the regulations and particular dispositions in the country where the machine is installed 1 PRESENTATION SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS This product has been designed to ca
23. o save the characteristics of the welding spots performed with the clamp It is available from all modes by simply pressing the keys located below the icon REPORTING The user welding parameters mode is also available from all modes by pressing the keys below the icon MEMORY LOG report o 17128 Recording a report allows to save the characteristics of a series of welding spots and save them on the SD memory card such that they can be transferred to any standard PC JBDC provides a software to read the SD card and edit reports This SPOT SAVE software is stored in the SD card together with a copy of the user manual Name of 2 5 report By default this function is disabled at the start of the machine Pressing the key the mode key allows to start recording the selected log file Pressing again the record key will stop the record The log file thus created contains an identifier entered by the user as well as for each welding spot performed the tool used the arms used and the settings of the machine welding current and electrode force It also contains the possible error messages that have been displayed during the record I low P low Use the and keys as well as the up and down keys to enter the identifier If a previously existing identifier is entered the machine will save the new welding spot characteristics at the end of the file without erasing any inform
24. ot 14 SPOT 10 000 C 5 PRECAUTIONS AND SERVICING User training Operators must have an appropriate qualification for the use of the machine in order to get the best of the unit and to make Satisfying work e g car body repair training Preparation of the parts to assemble It is essential to grind clean and to accost the part to be welded In case of a protection application first verify that it is conducting by testing a sample Single sided qun welding Before repairing a vehicle check that the car manufacturer authorizes the welding process you have chosen Purge of the pneumatic filter Regularly drain the dehumidifier filter placed on the rear side of the unit Generator maintenance The maintenance and the repair of the current generator must be done by an appointed and JBDC trained technician Any maintenance operation done by another person will cancel the warranty conditions JBDC cannot be held responsible for damages or accidents which happen subsequently to operations performed by people exterior to JBDC Cleaning or replacement of the welding tools Any welding tool is degraded after a certain period of use However all tools must stay clean in order to get the best performance of the unit When using the unit in pneumatic clamp mode check the good state of the CAPS electrodes flat rounded or bevelled If this is not the case clean them with sandpaper fine grain or replace them see refere
25. perations in very wet areas or on a wet floor Do not weld with worn out cables Make sure that there is no isolation defect nor stripped cables nor loose connections and that there is no cooling liquid leaks 7 Before performing any control or maintenance operation switch off and disconnect the unit directly from the plug EYE AND BODY PROTECTION 1 During the welding process the operator must protect himself from possible projections of steel in fusion with clothes like leather gloves welding aprons safety shoes welding helmets or glasses for filtering radiations and projections Similarly during grinding or hammering operations the operator must wear eye protection 2 The tightening force of the clamp can reach 550 daN Keep away all body parts from the mobile elements of the clamp to avoid any risk of squeezing of fingers in particular 3 Do not wear rings watches or jewellery which are current conductors and can cause serious burns 4 All the protection boards must be in good condition and maintained in place Never look at a welding arc without any eye protection Protect the environment near the product against projections and reflections FIRE 1 Make sure that the sparks will not cause fire especially near flammable material 2 Check that fire extinguishers are near the operator 3 Use the product in a room with extractor fans 4 Do not weld on combustible or lubricant containers even empty nor on containers containing fla
26. plication of the norm EN 60204 1 2 DESCRIPTION OF THE MACHINE Front panel SD card reader Display board for communication with the user Rear panel 32 A D curve circuit breaker Pneumatic filter connection to the pneumatic network system C clamp A Close Weld push button C arm Locking Unlocking C Lever Mobile electrode Handle must be loosened to rotate the arm around its axis or to change it SPOT 10 000 C 3 INSTALLATION Before use Several verifications are necessary before using the unit to ensure good performance of the machine Here are the verifications to do Check the electrical line voltage it should be 400V 3 phases with a 32 A delayed circuit breaker curve D or fuse of aM type the cross section of the cable going from the main electrical board to the socket where the machine will be plugged it should be 4x6 mm2 If this cable is longer than 10m use a conductor size of 10mm2 If you use an electrical extension cord use a 6mm conductor size 10mm if electrical line extension cord total length is superior to 10m ned a 3 phase earth plug minimum 32A on the supply cable power suppry SPOT 10 000 C CABLE PHASE 3 EARTH CONNECTION 3 PHASES 400 50 Hz Be careful in order to avoid voltage drops which can generate bad welding spots you must never have overloaded electrical lines nor supply cable diameters which cross sec
27. r corresponds to the name of the report in the spot welding machine This identifier is displayed in the Active tab When all the reports have been imported it is possible to perform a search edit or archive each report To visualize the characteristics of welding spots in a report select the report the characteristics of each spot appear in a table To perform a search fill the search field and click on icon Al To edit a report select the report and click on icon E To archive a report select the report and click on icon Beware the imported reports cannot be deleted if they have not been previously archived Visualize log reports of welding spots To visualise log reports click on the Archive tab The reports are sorted by year and month To visualise the characteristics of the welding spot performed select a report the data corresponding to each welding spot appears in a table For the archived reports it is possible to perform a search edit or delete a report Beware a report which is archived and then deleted will be imported again in the next import operation in case the SD card has not been blanked To perform a search fill the search field and click on icon 2 To edit a report select the report and click on icon To delete a report select the report and click on icon 13 SPOT 10 000 C Purge of the SD card A purge operation on the SD card will erase all the reports previously saved on the SD card
28. rmed on a car body repair with a SPOT 10000 machine equipped with an SD card reader In order to use this software the PC Personal Computer must be equipped with an SD memory card reader Language selection The software proposes several languages By default the following languages are available French English German Spanish Dutch Danish Finnish Italian Russian Swedish Turkish To select a language click on Options and then on Languages in the menus Beware once the language is selected the user should exit and enter again the SPOT SAVE software for the new language to be considered User identity In order to customize the information that appears on the reports the user should fill some data in the software To enter this data click in the menus on Options and then on Identity A new window then appears with the following information Company name Adress Postal code Town Telephone Fax Email Website Logo This information will then automatically be displayed on the reports Import log reports saved on the SD card In order to import on the PC log reports of welding spots performed with the SPOT 10000 machine insert the SD memory card in the card reader of your PC and then start the SPOT SAVE software Then select the reader where your memory card is inserted and click on the import icon When the import is completed the welding spots performed are sorted by an identifier of the repair order This identifie
29. rry out the following operations in car body workshops Spot welding on metal sheets with a pneumatic clamp Welding of metal sheets with a single sided gun Welding of nails rivets washers and studs Repair of bumps and impacts impacts of hail with the option quick repair GENERALITIES 1 The operators must have followed up an appropriate training 2 The repair and maintenance operations can only be performed by qualified personnel 3 The operator is responsible for the respect of the car manufacturer s recommendations regarding the protection of the car electrical and electronic equipments car computer car radio alarm air bag etc 4 Before any repair or maintenance operation the compressed air supply must be disconnected and depressurized 5 The electrodes arms as well as the other secondary conductors can reach a very high temperature and remain hot very long after having stopped the machine Pay particular attention to the risks of serious burns 6 It is necessary to make a regular preventive maintenance on the machine MAIN SUPPLY Check whether the unit is correctly connected to the earth and that the connection to the earth is in good condition Check whether the workbench is connected to the earth coupler Make sure that the operator has no contact with the metal parts to be welded without any protection or with wet clothes Avoid being in contact with the welding part Do not make any spot welding o
30. sconnect the earth cable used in single sided gun mode from the vehicle C clamp Clamp adjustment The key allows to switch from one tool to the next and also MANUAL allows to enter the clamp adjustment mode The clamp adjustment mode allows to close the clamp and apply the selected electrode force without delivery of any current The clamp remains closed as long as the button on the clamp is pressed This mode allows to check the alignment of the electrodes and the good positioning of the caps Pressing during 2 seconds the key takes back to the standard mode This mode is the default mode when the machine starts It allows to easily perform a welding spot by selecting The tool to be used The thickness of the sheets to be welded to choose from 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 The type of steel to be welded Coated steel HTS steel UHTS steel BORON steel and the arm used Pressing the up and down key in the circle allows to navigate from one parameter to the next thickness type of steel arm used Each parameter can be adjusted by pressing the and keys in the circle Pressure Pressing the close weld button allows to perform a welding spot using the selected parameters If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Pressure
31. tion are not large enough Also the mains plugs must not be too far from the circuit breaker If the machine is not sufficiently supplied it is not possible to ensure a good welding quality Check that the air compressed network can deliver a minimum of 7 bar dry air then connect the compressed air network on the back of the machine The machine must not be used on an air compressed network with a pressure inferior to 3 bar Assembling clamp stand and earth cable Arm stand Assemble the arm stand on the right side of the machine 9 Depending on the arm used position the clamp either using the hook or using the clamp handle Earth cable Assemble the copper plate on the extremity of the earth cable This earth cable is to be used only with the single sided gun Starting the machine Switch ON the circuit breaker The electronic card starts a test and initialisation cycle of the parameters during a period of about 10 seconds At the end of this cycle the machine is ready to be used Cooling of the welding cables The clamp and single sided gun cables are cooled by blown air Cooling of the clamp cable The air is blown into the clamp cable when the user presses the trigger The air continues to be blown into the cable three minutes after the last welding spot Cooling of the gun cable The air is blown into the gun cable when the user presses the trigger The air continues to be blown into the cable three minutes
32. to boron steel 4 Thickness of metal sheets 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 4 The arm type which is used The parameters of thickness elasticity type of arm can be highlighted using the A or V keys And adjusted using and keys Pressing the close welding button allows to perform a welding spot using the parameters displayed Pressing during 2 seconds the key takes back to the standard mode Manual mode This mode allows the user to manually select the welding parameters following instructions from a manufacturer for example MANUAL The settings proposed by default in the manual mode correspond to the settings automatically selected by the standard mode thickness and type of sheet electrode force arm The parameters can be adjusted using the and keys in the circle The up and down keys allow to navigate from one parameter to the next Welding current 2000 to 10000 A by steps of 100 A Display is in kA thousand amps 150 daN Welding time from 100 to 850 ms by steps of 10ms Display in 5 s milliseconds Electrode force from 100 to 500 daN by steps of 5 daN 97 1 1 Display in decaNewtons arm used on the clamp arm number and length If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Pressure too low
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