Prima MICROCAR 28 Manuel simple
PRIMA
PRIMA SRL
I – 35020 ALBIGNASEGO / PD
Via Garibaldi, 28
Tel +39 49 8625963
Fax+39 49 8625968
MANUAL INSTRUCTIONS
MICROCAR 28
ATTENTION
Carefully read this manual before using the spot welder.
This manual refers to the following spot welders MICROCAR 28.
This manual is supplied by PRIMA srl without any guarantee. PRIMA srl reserves the
right to apply to this manual, at any time and without notice, modifications due to typing
errors, inaccuracy of contents or improvements of the programs and devices.
In any case, possible modifications will be integrated in the subsequent editions of this
manual. In no case PRIMA srl will be liable for direct, indirect, extraordinary, accidental or
consequential damage caused by the use or the inability to use the spot welder or this
documentation.
Copyright © 2000 Prima srl
Via G. Garibaldi, 28
35020 Albignasego/PD - Italy
All rights reserved. First edition 2000. Printed in Italy.
p. 2
PRIMA p. 03
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
CONTENTS
Notes and precautions ………………………………….p. 04
Definition of the terms …………………………………..p. 05
Features of the machine and general information……p. 05
Technical specifications and performances ………….p. 06
Packing-Unpacking-Storage …………………………...p. 07
Installation ………………………………………………..p. 08
Electrical connection .………………………………….. p. 09
MicroDigital 1 welding control……………..………... p. 10
Start-up ………………………………………………….. p. 11
Limit of use ……………………………………………… p. 11
Environment ……………………………………………..p. 12
Starting the machine ……………………………………p. 12
Easy Start ………………………………………………...p. 12
Handling ………………………………………………….p. 13
Maintenance ……………………………………………..p. 13
Scheduled maintenance ………………………………. p. 14
Extraordinary maintenance …………………………….p. 14
Emergency ……………………………….………………p. 15
Disassembly-Disposal …………………………………. p. 15
Troubleshooting …………………………………………p. 16
Microcar 28 (spotter) spare parts …………………….. p. 17
KSP spare parts …………………………………………p. 18
MR6 spare parts ………………………………………. . p. 19
Multipoint spare parts ………………………………….. p. 20
Microcar 28 electric diagram ………………………….. p. 21
PRIMA p. 04
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
NOTES AND PRECAUTIONS
Have the electrical connections made by qualified personnel in compliance with the
relevant Laws and safety Codes. Make sure that the power box is properly connected to
the grounding system and that it is complying with the CEI EN 60 204/1 Standard.
W A R N I N G
Do not use cables with damaged insulation, loose connecting terminals or inadequate
section.
Do not operate the spot welder in a humid or wet environment or in the rain.
Always disconnect the machine from the supply systems during installation or checking
and maintenance operations.
Bring flammable materials or substances to a sufficient distance (at least 10 meters) from
the working area.
It is extremely dangerous to weld (spot weld) containers or tanks which have contained
liquid or gaseous substances or combustibles, because explosions may occur.
During spot welding, and especially when welding galvanized, painted or oil contaminated
metal, smoke will be produced. Make sure there is an adequate air change or a suitable
extraction systems.
Always protect your eyes with special safety glasses, wear gloves, apron and protective
clothing without metal accessories.
During welding operations the machine generates magnetic fields. Pay attention to the
attraction of iron bearing working residues.
Watches as well as other mechanical, electric and/or electronic devices can be damaged.
WARNING: Persons with pacemakers or other cardiac devices must absolutely not
use the machine.
The operator must have adequate knowledge and training in the use and the resistance
welding procedure with this machine.
Do not allow unauthorized persons to access the working area; avoid that more then one
person works simultaneously on the same machine.
The spot welder is equipped with balancing and movable mechanisms. Therefore all
precautions must be taken to avoid hazardous situations.
PRIMA p. 05
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
DEFINITION OF THE TERMS
Refer to the UNI EN 292 Standard for the definition of the terms used in this manual.
FEATURES OF THE MACHINE AND GENERAL INFORMATION
MOVABLE RESISTANCE WELDING STATION
Main components and controls:
Mobile trolley of metal tubes and frame with wheels.
Welding gun with plait cables covered with a special bushing.
Electro-pneumatic operation of welding gun closure.
Manometer unit for welding pressure regulation at the electrodes.
MICRO DIGITAL 1, synchronous, with pulses, heating and welding current regulation.
SCR-diode power unit.
This machine has been manufactured in compliance with the following regulations:
Machine Safety Directive 89/392/CEE, 91/368CEE, 93/44/CEE, 93/68/CEE
89/336/CEE Directive, electromagnetic compatibility.
73/23/CEE Directive, low voltage electric material.
EN 50063 Standard, building and installation of resistance welders.
UNI EN 292/1 and 292/2 Standard, machinery safety.
PRIMA p. 06
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
TECHNICAL SPECIFICATIONS AND PERFORMANCES
Table of general technical data:
DIMENSIONS MICROCAR 28
Head WxLxH mm 145x320x250
Welding cable with easy start gun mm 3000
Earth cable mm 2000
Cable section mm² 50
Weight Kg 13
ELECTRICAL specifications MICROCAR 28
Nominal power at 50% KVA 2
Input voltage (*) 1ph V/Hz 230/50
Secondary no-load voltage V 7
Secondary short-circuit current KA 2.8
Secondary welding current KA 2,5
Duty cycles % 5
Rated power KVA 16
Fuses A 16
MECHANICAL FEATURES MICROCAR 28
Noise level (ISO 7779) dBA <65
Ambient temperature °C 55÷35
Air humidity % <90
Fig. 1
PRIMA p. 07
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
PACKING
The spot welder is packed in a sturdy cardboard box.
When shipped in a container by sea, the spot welder is sealed with salt resistant plastic
material.
On request, the spot welder is delivered on a pallet with wooden case and fastened with
steel strips.
UNPACKING
Remove the panels of the wooden case (if provided).
Remove the steel strips.
Remove the protective plastic material.
Remove the cardboard box.
CAUTION: The packing materials – wood, nails, plastics, cardboard etc. – must not be left
within the reach of children, as they could be a source of danger.
The packing materials must be subdivided and disposed of in compliance with the
applicable Codes.
STORAGE
The spot welder must be stored at a temperature between 0 and 40 °C in a dry place,
protected from weather and far from heat sources.
The spot welder must be moved with care, avoiding shocks and dropping which could
damage the machine.
PRIMA P. 08
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
INSTALLATION
PRECAUTIONS AND CHECKS
CAUTION: During all installation and connection operations, the machine must be
absolutely isolated from the power supply line.
CAUTION: Installation must be made by qualified personnel in compliance with the
applicable regulations and in accordance with the instructions of the manufacturer.
CAUTION: Before connecting the machine to the mains supply, make sure that the data
on the nameplate of the spot welder correspond to the voltage and frequency of the mains
supply available on site.
Electrical safety of the spot welder is obtained only when connected to an efficient
grounding system made in compliance with the applicable Regulations.
Have qualified personnel check the system for functional efficiency.
The Manufacturer cannot be held liable for possible damage caused by absence or
inefficiency of the grounding system.
Check that the installed power on the electric supply meter as well as the cables of the
electrical plant are adequate for the rated power of the spot welder.
CAUTION: In case the user makes modifications, alterations or changes of the spot
welder or integrates it in a plant, any liability of the Manufacturer decays and the user is
obliged to remove the CE label.
The non-observance of the above instructions will render the safety system provided by
the Manufacturer ineffective, causing serious risks of personal injuries and material
damage.
PRIMA p. 09
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
ELECTRICAL CONNECTION
The electrical connection of the spot welder to the mains must be made by qualified personnel.
The electrical connection must be made in compliance with the prescriptions of the EN 50063 CEI
26-6 and CEI 64/8 Standard - installation of resistance welders (spot welders) - to a grounded
power box provided with a differential circuit breaker having an adequate capacity for the power of
the spot welder (tab.1, p.6, Electrical Features) and complying with the CEI EN 60204/1
Standards.
Make sure that the size of the electrical line (conductor section) and the capacity of the fuses are
adequate.
Caution: The spot welders are SINGLE PHASE and provided with a power cord with two
leads, plus a third lead intended only for connection to the grounding system; therefore
they can be connected to a single phase power supply, or to a three phase power supply of
which only two of the three available phases will be used.
PRIMA p. 10
MOVABLE SPOT WELDER
This machine complies with the 89/392/CEE directives and subsequent modifications and
supplements.
WELDING CONTROL.
Micro Digital 1 microprocessor-controlled welding control.
Machine starting is made switching the light button. The default operative mode is manual.
To change in automatic mode it is necessary to switch on the machine and pressing at the same
time the button on the gun.
1) “MR” WELDING SELECTOR
Activates the “MR” welding function. Welding time of 1 at 10 cycles, current at 100%.
2) TIP WELDING SELECTOR
Activates the tip welding function. Welding time of 1 at 10 cycles, cold welding, current at 85%.
3) PULSE HEATING SELECTOR
Activates the metal heating function with a copper electrode and pulse process. Heating current of
30% at 100%.
4) CARBON ELECTROD HEATING SELECTOR
Activates the heating function for metal heating operations using the carbon electrode. Heating
current of 15% at 60%.
5) WELDING OR HEATING SELECTOR
Activates the welding function with single spot process for screws, rivets and so on, and heating of
the metal with a copper electrode. Welding or metal heating time of 5 at 30 cycles, current at
100%.
5 1
2
3
4
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