Pro Spot Quality Welding Systems - i4, PR-2000, PR-2, PR-10

Pro Pull Product Support

NOTE: It is suggested that only qualified technicians use these repair guidelines, ignoring to do so could result in a void of your warranty. This information is to be used as a guideline only, and cannot be gauranteed to solve your specific repair issue.

Pro Pull Dent Puller

	1. No Display Screen & No Phase Lamps (Wall and Cabinet Breakers are ON)
	- Check house power level (all phases) at panel, breaker and outlet. - Check wires in plug and supply cable. - Check breaker and cassette terminal strip. - Check harness to PCB and 18VDC. - Check ribbon cable.

	2. No Display Text or No Navigation (Display Screen has power & Phase Lamps are ON)
	Check accidental press of gun trigger. Check software flash card insertion, version and integrity. (Can not swap randomly.) Check Display Brightness adjustment. (See Settings.)

	3. Makes Poor Nugget (Guns weld)
	Check gun setup (squeeze pressure, shank & arm choice, tip condition & alignment). Check metal prep & condition as well as thickness. Check Weld settings and Power profile. Check supply voltage level. (Control voltage drop.)

4. Soft-Start Delay Relay not functioning (No weld either gun)

Confirm click on PCB during 5 second soft-start delay period.
Confirm AC Input voltage and Display.
Check for IGBT buss voltage on PCB indicator and system wiring.
Inspect and check Soft Start Resistor Board.
Jumper the relay harness (temporary) to attempt System fix. (May require cassette swap.)

5. No Squeeze Gun stroke / No Weld (Dent-Pull Gun does weld)

Check gun cable connections and trigger (input) loop continuity (24vdc). (See Command Cable.)
Check pressure & air flow to / through air lines. Disconnect lines at Cabinet & press triggers.
Check solenoid output integrity (24vdc).
Check two-way Gun Solenoid. (Constant stroke air with power OFF means stuck solenoid.)

6. Weld Condition Error Message Issued (No weld at guns.) / Poor voltage or burned part.

Confirm supply voltage to welder. Bridge in high current section generates 300VDC for IGBTs.
Confirm IGBT buss voltage indicators. Soft Start is normally ok.
Confirm PCB 15VDC and IGBT driver integrity (inspect bottom).
Check stud diode array on weld transformer. This is a simple at-gun measurement.
Check IGBTs. Bad diode will damage IGBT// Breaker may trip. // May require cassette swap.

7. Pop Sound Reported in Cabinet ( No Weld either gun & Soft Start Relay OK)

Inspect systems to locate pop source following input voltage check.
Check for loose wiring connections, especially high current paths.
Check for problem with Softstart or IGBT systems. (See also Item #6.)

8. Temperature Error Message Issued or No Air Cooling (Could involve either or both guns.)

Check sensor Display readout (100 C =failure / 30+/-ok) Also see ambient / outdoor temperature.
Check sensor input (25000 +/- ohms). (Sensor failure or temporary overheat will disable welder.)
Check 15VDC and PCB.
Check solenoid output and wiring.
Check 24VDC and PCB.

	9. Cabinet Circuit Breaker Trips
	Check breaker and high current wiring. (See Items #6 & 7.) Check for loose or broken connection. Check Softstart, bridge, IGBT and diode circuits. (Module may conceal burn.)

	10. Facility (wall) ) Breaker Trips
	Check outlet & plug. (Usually a problem outside or near cabinet wall.) (See Items #6 & 7) Check breaker and high current wiring. (See item 9.)