OPERATION MANUAL MODELS TWE-321 TWE-375. Toll free customer support:

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1 OPERATION MANUAL MODELS StudPro TWE i TWE-321 TWE-375 Downey, CA 9459 Washburn Rd. Downey, CA Phone Fax Hayward, CA Phoenix, AZ 2391 American TRU WELD Ave. EQUIPMENT 3535 East Wier COMPANY Ave., Ste. #4 Hayward, CA Phoenix, AZ N. HONEYTOWN ROAD Phone Phone Fax SMITHVILLE, Fax- OHIO (330) Toll free customer support: Renton, WA 927 Thomas Ave. SW Renton, WA Phone Fax

2 CONTENTS Section Description Pages 1 Introduction 3 2 External Features Safety Setup and Welding Cup Head Welding Testing Weld Settings Types of Fractures 22 8 Arc Blow Effect 23 9 CD Stud Gun Exploded View Internal Components CD Accessoreis Torque Bending Test CD Gun Set Up s

3 INTRODUCTION The complete range of the capacitor discharge equipment is compact, portable stud welding equipment. The units are specifically designed to enable a small diameter range of ferrous and nonferrous weld studs to be welded to light gauge metal materials with little or no reverse side marking. The equipment consists of a control unit, a welding hand gun, and all necessary interconnecting cables. THE PROCESS Capacitor Discharge (CD) stud welding is a form of welding in which the energy required for the welding process is derived from a bank of charged capacitors. This stored energy is discharged at the base of the specially designed CD stud and it fuses the stud to the base material. The time of the weld is determined in such a short duration that no burn through marking is made on the finish side of the material. CONTACT In contact CD welding, the stud is placed under spring pressure on the material to be welded. When the capacitors are discharged, the special tip of the CD stud melts and the spring pressure forces the stud to fuse with the base material. GAP In gap CD welding, the stud is placed onto the material to be welded. As the stud gun is engaged, the stud lifts from the base material and then returns to the point of contact at the time of the discharge of the capacitors. As the capacitors discharge, melting the tip of the weld stud, the pressure created by the movement of the stud to the base material by the stud gun fuses the stud to the base material. 3

4 EXTERNAL FEATURES FRONT PANEL Weld Voltage Selector rotate to change to required voltage. 2. Welding Voltage Digital Display displays selected voltage. 3. LED Lights Charging (capacitors are being charging to desired voltage), Ready (unit is ready to weld), Reset (indicates an error and unit should be turned off). 4. Welding Ground Cable Connector (+) 5. Stud Gun Control Connector 6. Welding Stud Gun Cable Connector ( ) 7. Ground Cup Head 4

5 EXTERNAL FEATURES REAR PANEL 1.On/Off Switch 2.Fuse Holder (10 amp) 3.AC Power Cord 4.Manufacturer Model Number and Serial Number Plate WARNING! This unit operates from a 110 VAC 60 amp circuit. Do not obstruct the ventilation fan, as this may cause unit to over heat. Do not remove any portion of the unit housing without first disconnecting the unit from the power supply. ON/OFF Switch 15Amp Fuse Power Supply Fan AC Cord 5

6 SAFETY PROTECT YOURSELF AND OTHERS! Read the safety notices before using welder. ELECTRICAL No portion of the outer cover of the welding controller should be removed by anyone other than qualified personnel. Always disconnect the unit from the main power prior to removing cover. This equipment contains a transformer power supply system, which is energized by AC current and transforms the AC to DC current. Due to potential dangerous electrical input and output the equipment must be disconnected from all incoming power when servicing. Capacitors store electrical energy. Check for residual charge before performing any maintenance. Do not use fluids to clean electrical components as these may penetrate the electrical system and cause shorts. Connection of the unit into service must be in accordance with the setup procedures as detailed in this manual. Operation of this equipment must be in accordance with all local, regional, and national safety codes. 6

7 SAFETY FIRE During welding, small particles of hot metal can be expelled. Ensure that no combustible materials are near the welding area. FIRE HAZARD FROM SPARKS PERSONAL SAFETY Arc rays can burn your eyes and skin. Wear protective clothing and eye protection when welding. Loud noises from welding can damage hearing. Wear earplugs or other protective gear, if applicable. Fumes and gases expelled during welding can be hazardous to your health. Make sure welding is done in a well ventilated area. Hot metal splatter can cause fires and burns. Wear protective clothing, free of combustible materials. Have a fire extinguisher nearby and know how to use it. MAINTENANCE All cables must be inspected regularly to ensure that no danger exists from worn or damaged insulation or unsafe electrical connections. Take special note to the cables near the stud gun this is where maximum wear occurs. Worn cables not only produce inconsistent welds, but can overheat or spark. 7

8 SAFETY TRAINING Use of this equipment must be limited to authorized personnel only. They must be adequately trained, and have read and understood everything in this manual. The manual must be available to operators at all times. AUTHORIZED PERSONNEL ONLY INSTALLATION Select a site for the equipment which is capable of supporting the weight of the equipment, which is clear from traffic routes where people may trip over cables, or they may be damaged by other equipment or vehicles. Do not hang connecting cables over sharp edges or have near heat sources. DISPOSAL The equipment, in its entirety or as components/parts may be disposed of as general industrial waste or scrap. None of the components used in the manufacturing of the CD Welders are toxic, carcinogenic, or otherwise harmful to your health. 8

9 SET-UP AND WELDING POWERING UP THE EQUIPMENT Setup the equipment power supply (Control Unit) and connect to the main power, making certain of the proper voltage requirement of the particular unit. Capacitor Discharge (CD) units generally require Hz incoming power. Refer to the safety recommendations before plugging this unit in. ON/OFF Switch Fuse Power Cord (110 VAC) CONNECTING THE WELDING LEADS Connect the welding ground cable into the (+) terminal mount socket on the front of the welding unit. ***NOTE the cable end plug has a flat which aligns with a dot on the panel mount socket. Secure the connector into the panel mount socket, and then turn it clockwise until it locks into proper position. Failure to do so could result in damage to the connector. Ground Cable Socket For Cup Head to Ground Cable Socket 9

10 SET-UP AND WELDING CONNECTING THE WELDING LEADS Connect the welding stud gun power cable into the ( ) terminal panel mount socket (designated by the gun symbol) on the front of the welding unit. ***NOTE the cable end plug has a flat which aligns with a dot on the panel mount socket. Secure the connector into the panel mount socket, and then turn it clockwise until it locks into proper position. Failure to do so could result in damage to the connector. Welding Gun Power Connector Welding Gun Power Connector Welding Gun Gun Control Cable Cable Connector Connect the weld gun control cable into the center panel 2 pin socket. **NOTE the plug has a large pin and a small pin that match the socket on the unit. This is to prevent incorrect connections. Push the plug firmly into the socket and twist clockwise to secure the plug into the correct position. 10

11 SET-UP AND WELDING CONNECTING THE GROUND CLAMP Attach the clamp of the welding ground lead to the work piece. Prior to securing the clamp, make certain that the contact area is free of rust, paint, grease, or any other impurities to ensure a good ground connection. NOTE***Most applications will require only one ground clamp, but certain applications will require an additional dual clamp. NOTE***Most applications will require only one ground clamp, but certain applications will require an additional dual clamp. 11

12 SET-UP AND WELDING SELECTING THE PROPER STUD COLLET (STUD HOLDER) The collet is selected to the proper diameter that you are welding. There are three styles of collets; The B collet which is a two piece assembly (collet and insert). The insert determines how much of the stud is engaged in the collet. Adapter is required. The CI (Collet Insert) which is a single part and the amount of the stud that is engaged is predetermined. Adapter is required. Euro Collets have an adjustable internal screw to manually adjust for the engagement of the stud. For cup head pins use cup head pin collet The choice between these systems is usually a matter of personal preference. Inserting the selected collet into the stud gun is a simple task. Place the collet into the front holder of the stud gun and set the locking screws to hold it in place. After inserting the collet, mount the two legs and foot piece onto the stud gun. The collet should be centered through the opening of the foot piece. Foot Piece Magnetic Chuck Collet Leg Piece Cuphead Pins When the legs and foot piece are in place, insert the stud to be welded into the collet. Adjust the leg and foot piece by sliding it into position until approximately 1/8 of the stud protrudes from beyond the foot piece. Lock legs in place with the set screws. No foot piece or legs required when welding cuphead pins. 12

13 SET-UP AND WELDING SELECTING THE SPRING LOAD The proper spring pre load setting on the stud gun will vary depending on the selected application. Generals rules of application would be; mild steel or stainless steel usually in the 1 to 2 range, depending on the stud diameter and the thickness of the base material. Aluminum and other nonferrous metals would require settings from 3 to 5 depending on the diameter of the stud and base material thickness. Adjustment Cap Adjustment Screw Tension Indicator Tension Indicator This spring pre load adjustment is made by turning the screw insert in the back of the This stud spring gun with pre load a screwdriver. adjustment On is the made bottom by turning of the back the back cap cap of the of stud the stud gun gun. is the On indicator the side of numbered the stud gun 1 thru is the 5, which indicator will numbered show you the 1 thru tension 5, which setting will during show you the the adjustment. tension setting during the adjustment. Location of adjustment on back of the gun. 13

14 SET-UP AND WELDING READY FOR WELDING When you have completed all of the previous steps to prepare for welding, including connecting the stud gun and ground cables to the unit, attaching the ground cable(s) to the work area, setting up and adjusting the stud gun for the selected stud diameter and material, you can now power on the welder. ON/OFF Switch ON/OFF SWITCH FUSE FUSE The controller ON/OFF switch is located on the rear of the unit in the upper right hand corner. Below this switch is the 15amp fuse holder for the system. 14

15 SET-UP AND WELDING VOLTAGE SELECTION Selecting the required weld voltage is achieved by turning the selector knob. The voltage range is from 35VDC to 200VDC. The voltage is determined by the diameter of the stud and the base material. Voltage Adjustment Knob Knob Approximate voltage staring points are listed below. Fine tuning the voltage to meet your requirement for your specific application is recommended. MODEL STUDPRO 2500i Diameter Voltage (DC) 14 ga ga Cuphead Pin # # / NOTE***when welding cupped head insulation pins, set the DC Voltage to 35 volts to begin and increase as necessary. Adjust the spring pressure on the CD gun between #1 and #3 as necessary. 15

16 Cup Head Welding (A) (B) (C) Connect Male Ground Camlok To Cup Head Ground Camlok Receptacle On Unit (See Location A) Connect Male Gun Control To The Female Gun Control Receptacle On Unit. (See Location B) Connect Male Gun Camlok To The Female Gun Camlok Receptacle On Unit. (See Location C) 16

17 Cup Head Welding Insert Magnetic Chuck Into The Supplied B Adapter And Tighten The Set Screws. (See Figure Above) Set Spring Pressure Between #1 And #2 By Turning The Back Cap. (See Figure Above) Set The Voltage. Recommended Voltage Setting For Cup Head Pins Is Between 70 And 100 Volts. 17

18 TESTING WELD SETTINGS TESTING YOUR SETTINGS When you have performed all of the presets as discussed in this manual, it is recommended that you perform several test welds with the same diameter stud and base material that you will be using. This will verify that all of the settings are correct to the results you desire. Welding is done by placing the stud into the collet, and pressing the stud gun to the work piece, compressing the spring. This is why the stud must protrude beyond the foot piece at least 1/8. Holding the gun perpendicular to the work piece, and aligning the stud to the desired position on the work piece, press down so that the foot piece is flush with the work piece (spring compressed), and depress the trigger. Cuphead pin welding When welding cuphead pins there will not be a foot piece to hold the gun perpendicular this must be done manually. Press down on the work piece so the gun shaft is at approx. ½ of it s max travel (springs will be compressed properly) and depress the trigger. When removing the stud gun from the welded stud, always lift the stud gun vertically from the welded stud in order to maintain the proper tension of the collet. Spreading the collet when lifting the stud gun from the welded stud will shorten the life of the collet and will eventually create an undesirable weld. 18

19 TESTING WELD SETTINGS INSPECTING THE WELD Visually inspect the weld. A good weld will result in an all around weld, with a small visible amount of weld surrounding the flange of the stud. Too much splatter and the weld is too hot, lower the voltage. No splatter and the weld is too cold, increase the voltage. If you get weld flash to one side of the stud as opposed to an even amount around the base of the flange, this is called arc blow, and can be solved by repositioning the ground clamp or using a dual ground clamp. Proper welded studs can be tested by either torquing or bending the stud. The welded flange of the stud should stay in place using either method, even though the threaded portion of the stud breaks. If the base material is very thin, then a full slug, the diameter of the flange will pull from the base metal for a properly welded stud. CD Stud Welding Steps 19

20 TESTING WELD SETTINGS Visual Inspection A visual inspection must be carried out with each welding element. Visual Inspection Condition Possible cause Corrective actions Good welded joint Low spatters around the weld without outer flaws The weld pool forms a collar around the flange of about 1-1,5 mm - Correct parameters - None Cold weld pool Gap between flange and workpiece - Heat input too low - Plunging speed too low - No sufficient backing of workpiece - Increase charging voltage - Adjust plunging speed correctly - Provide sufficient backing Hot weld pool Many spatters around the weld - Heat input too high - Plunging speed too low - Reduce charging voltage - Increase plunging speed One-sided weld pool One-sided spatter collar Weld pool came out on one side - Arc blow effect - Unsymmetric ground connection - Welding gun put at an angle - Take care for symmetrical ground connection - Put welding gun vertically to the workpiece 20

21 TESTING WELD SETTINGS Bending Test You can purchase from SWP a bending device with inserts for various diameters of the welding elements. The bending test serves as an easy work sample and as a check for the selected welding parameters. The welded joint is stressed by bending in a non-defined way. Bend the welding element with the bending device once by 30. Carry out the test in different directions. The bending test is passed if a crack or a fracture of the welded zone does not occur. Please note the instructions on fault recognition and corrective actions in chapter 5. You don t need to test all studs. It is sufficient to carry out stud tests at random. If the strength of the joint is inadequate, then: check the setting of the stud welding unit check whether the surface of welding element and base material are clean and electrically conductive (must be free from scale, oil, paint, oxide layers) grind off hardened work piece surfaces (e.g. roll hardening). Check the piston of the welding gun for ease of movement. 21

22 TYPES OF FRACTURES Bending Test Type of fracture Possible cause Corrective actions Base material buckling - Correct parameters - none Fracture in the welding element above flange - Correct parameters - none Fracture in the weld metal - Heat input too low - Plunging speed too low - Welding element/base material combination not suitable - Increase charging voltage - Increase plunging speed - Replace welding element or workpiece Backside deformation - Heat input too high - Pressure too high - Contact stud welding not suitable - Workpiece too thin - Reduce charging voltage - Reduce pressure - Use gap stud welding instead of contact stud welding - Adapt thickness of workpiece 22

23 ARC BLOW EFFECT Arc Blow Effect A so called arc blow effect can occur with unproportionally distributed ground connections in relation to the base material mass, varying material distribution, or welding at the edge of a work piece. This is an undesired deflection of the arc. It causes a singlesided melting of the stud material, increased pore formation, and undercuts in the welding area. The arc blow effect is proportional to the current and can be influenced by symmetric installation of the ground clamps, by fitting of compensation masses, or by rotating the welding gun around its vertical axis (applies for welding guns with external welding cable). Arc blow effects and some corrective actions (according to standards, see appendix) Cause Corrective action 23

24 CD Gun Exploded View 24 22

25 Internal Components TWE01013 CD Rocker switch 2. TWE01012 CD 15 Amp Breaker 3. TWE0851CD AC Inline Filter 4. TWE01004 Capacitor (2) 5. TWE CD Capacitor Bracket 6. TWE CD Capacitor Bridge Link 25

26 Internal Components TWE01001 PC Board 2. TWE01002/TWE01003 CD Thyristor /Clamp 3. TWE01011 CD Flyback Diode 4. TWE01010 CD TRIAC 5. TWE01009 CD Bridge Rectifier 6. TWE01015 CD Fan 7. TWE01019 CD Terminal Block 8. TWE01006 Main Wire Harness 9. TWE01014 Power Relay 10. TWE01005 CD Main Transformer 11. TWE01008 CD Power Resistor 26

27 Internal Components Control Panel Mount Camlock Panel Mount 3. TWE01017 Voltage Adjustment Knob 27

28 CAPACITOR DISCHARGE ACCESSORIES B COLLETS STUD DIA PART NO. PRICE 3 MM CDB 003M GA CDB GA & #4 CDB /8 GA & #5 CDB GA & #6 CDB MM CDB 004M #8 CDB #10 CDB MM CDB 005M MM CDB 006M CDB021 1/4 CDB 025 5/16 CDB 031 3/8 CDB 037 B COLLETS AGM STYLE STUD DIA. PART NO. PRICE 14 GA CDB 008A GA CDB 010A #6 CDB 013A #8 CDB 015A #10 CDB 018A /4 CDB 025A /8 DIA 3/8 DIA. 1-3/8 1-3/16 SOYER COLLETS STUD DIA. PART NO. PRICE #6 CDBS MM CDBS 004M #8 CDBS #10 CDBS MM CDBS 005M MM CDBS 006M /4 CDBS /16 CDBS 031 3/8 CDBS

29 CAPACITOR DISCHARGE ACCESSORIES ONE PIECE CONTACT/MAGNETIC CHUCK PART NO. PRICE MAGNETIC CHUCK PART NO. DESCRIPTION PRICE COMPLETE ASSY MAGNET ONLY CONDUCTOR PLATE INSUL. TUBE INSUL. DISC 9.00 SCREW X 7/ B COLLETS PROTECTOR STUD SIZE PART NO. PRICE 14 GA X 12 GA GA BODY ONLY GA INSERT GA INSERT B STOP STUD STOP PART NO. PRICE 1/4 1 1/ /8 1 1/ / /8 7/ /4 3/ /8 5/ / /8 3/ /4 1/ /8 (BUTTON STOP) 1/ UNIVERSAL SHORT BUTTON STOP UNIVERSAL B STOP 29

30 CAPACITOR DISCHARGE ACCESSORIES COLLETS INSERTS FOR WELD STUDS COLLETS INSERTS FOR WELD PINS 1/4 DIA 1-3/4 STUD DIA. X DEPTH PART NO. PRICE #4 X 1/4 CI #4 X 3/8 CI #4 X 1/2 CI #4 X 1 CI #6X 1/4 CI #6 X 3/8 CI #6 X 1/2 CI #6 X 5/8 CI #6 X 3/4 CI #6X 1 CI GA X 1/2 CI GA X 3/4 CI GA X 1 CI #8X 1/4 CI #8 X 3/8 CI #8 X 1/2 CI #8 X 5/8 CI #8 X 3/4 CI #8X 1 CI #10 X 1/4 CI #10 X 3/8 CI #10 X 1/2 CI #10 X 5/8 CI #10 X 3/4 CI #10X 1 CI /4 X 1/4 CI /4 X 3/8 CI /4 X 1/2 CI /4 X 5/8 CI /4 X 3/4 CI /4 X 1 CI /16 X 3/8 CI /16 X 1/2 CI /16 X 5/8 CI /16 X 3/4 CI /16 X 1 CI /8 X 1/2 CI /8 X 3/4 CI /8 X 1 CI STUD DIA. X DEPTH PART NO. PRICE 12GA X 1/2 CIP GA X 3/4 CIP GA X 1 CIP GA X 1/2 CIP GA X 3/4 CIP STANDARD SPARK SHIELD STUD RANGE PART NO. PRICE 14 GA # VENTED SPARK SHIELD STUD RANGE PART NO. PRICE 14 GA 10 GA TEMPLATE TUBE ADAPTOR TEMPLATE I.D. PART NO. PRICE 1 DIA /4 DIA

31 2-3/8 LONG & KSM LONG STYLE COLLETS 3/8 DIA. 2-3/8 STUD SIZE PART NO. OTHER PART # PRICE #6 CDBN #8 CDBN #10 CDBN /4 CDBN /16 CDBN MM CDBN 004M MM CDBN 006M GA CDBN LONG ADJ. STOPS FOR ABOVE STUD LENGTH PART NO. PRICE 1/4 TO 5/ /4 TO 1 1/ /4 TO 1 5/ /4 TO 2 1/ KSM / ERICO AIR COLLET 7/16 1-1/2 BOTTOM LOAD STUD DIA PART NO. PRICE #4 (.112) #6 (.138) #8 (.164) #10 (.189) RAM FEED STUD DIA PART NO. PRICE #4 (.112) #6 (.138) #8 (.164) #10 (.189) NON STOCK ITEM / ALLOW 2 WEEKS FOR DELIVERY 31

32 B CI ADAPTOR ADAPTORS K B ADAPTORS 3/8 DIA 1/4-20 1/4 DIA 3/8 DIA PARTNO. PRICE /8 LONG /16 LONG L B N ADAPTOR 1-3/4 PART NO. PRICE K N ADAPTORS 1/ /8 ARC TAPER 2-3/8 ARC TAPER PART NO. PRICE ADAPTORS PART NO. PRICE MISCELLANEOUS ADAPTORS ARC TAPER L I.D. PART NO. DESCRIPTION PRICE MT 0008 TEMPLATE TUBE /4 1/2 ARC STUDS PART NO.I.D. PRICE N B 3/8 ID N C 1/4 ID THREADED TAPERED ADAPTORS MT 0012 TEMPLATE TUBE /8 3/4 ARC STUDS L L TEC CHUCK ADAPTOR K CI ADAPTORS NS 30 CHUCK ADAPTORS PART NO. PRICE MT PART NO. DESCRIPTION PRICE Chuck Adaptor Connector Stud 32

33 STUD WELDING PRODUCTS, INC. Torque Bending Test Application Non-destructive test method for studs welded with tip ignition (CD) and short cycle (SC) process. Torque check of the welded studs for quality assurance. Description A bending torque is applied by a torsion meter onto the stud. This applies a defined stress in the welding zone. The test torque parameters are shown in a table included in this test kit. You can edit the torque at the torque meter by turning the set-up wheel (0-10Nm). Each parameter from the table belongs to the specified stud diameter, the specified material and the sheet thickness of the work piece. These empirical parameters refer to the limit between the elastic and the plastic deformation of the stud or the work piece. For a ratio stud diameter to work piece thickness smaller than 1:2 a plastic deformation of the work piece will occur; for ratios larger than 1:2 the stud will fail. With this tool you can make a fast and easy, non-destructive stud test. A quantitative check of the welding quality in line to ISO 9000ff can be made. Kit Contains: 1 torque meter 5 stud adapter (M3 to M8) 1 allen key 4 mm 1 parameter table Check us out on the in Downey, CA Hayward, CA Kent, WA Phoenix, AZ 9459 Washburn Rd American Ave nd Ave East Wier Ave., Ste. #4 Downey, CA Hayward, CA South Kent, WA Phoenix, AZ Phone Phone Phone Phone Fax Fax Fax Fax

34 STUD WELDING PRODUCTS, INC. Torque Bending Test Instructions Select the test insert depending on stud diameter, push it on a torque wrench and fix it. Depending on the test job, adjust the test torque of the torque wrench. Adjust the test torque in such a way that there is no permanent distortion of the welded parts. As shown in the figure, push the test device onto the stud. A torque is initiated with the torque wrench in a defined distance to the sheet surface. A bending strain of the weld results Move the test device forward/up until the device 'clicks' (attaining the nominal torque).

35 STUD WELDING PRODUCTS, INC. GUN SET UP CD Models 30mm Template Tube CD Foot Collet Extender Tri Pod Made in the USA Shaft Extender with B Collet Check us out on the internet or info@studweldprod.com Downey, CA 9459 Washburn Rd. Downey, CA Phone Fax Hayward, CA 2391 American Ave. Hayward, CA Phone Fax Renton, WA 927 Thomas Ave. SW Renton, WA Phone Fax Phoenix, AZ 3535 East Wier Ave., Ste. #4 Phoenix, AZ Phone Fax

36 STUD WELDING PRODUCTS, INC. GUN SET UP Insulation Models B Collet with CD Foot Piece and Spark Shield Magnetic Chuck with HBS Insulation Push Down B Collet with CD Foot Piece Magnetic Chuck Made in the USA B Collet with Collet Protector Check us out on the internet or info@studweldprod.com Downey, CA 9459 Washburn Rd. Downey, CA Phone Fax Hayward, CA 2391 American Ave. Hayward, CA Phone Fax Renton, WA 927 Thomas Ave. SW Renton, WA Phone Fax Phoenix, AZ 3535 East Wier Ave., Ste. #4 Phoenix, AZ Phone Fax