OPERATION MANUAL - Stud Welding Products, Inc. Manual_Updated.pdfOPERATION MANUAL MODELS TWE-250...

OPERATION MANUAL

MODELSTWE-250TWE-321TWE-375

TRU‐WELD EQUIPMENT COMPANY

6400 N. HONEYTOWN ROAD

SMITHVILLE, OHIO 44677

(330) 669‐2773

MODELSStudPro 2500StudPro 3125StudPro 3750

Downey, CA9459 Washburn Rd.Downey, CA 90242Phone- 800.252.1919Fax- 562.862.3022

Hayward, CA2391 American Ave.Hayward, CA 94545Phone- 510.782.7883Fax- 510.782.7918

Renton, WA927 Thomas Ave. SWRenton, WA 98057Phone- 425.656.9787Fax- 425.656.9786

Phoenix, AZ3535 East Wier Ave., Ste. #4Phoenix, AZ 85040Phone- 602.305.9350Fax- 602.305.4890

Toll free customer support: 1.800.252.1919

22

CONTENTS

Section Description Pages

1 Introduction 3

2 External Features 4‐5

3 Safety 6‐8

4 Setup and Welding 9‐15

5 Testing Weld Settings 16

6 Inspecting The Weld 17

7 CD Stud Gun Views 18

8 CD Stud Gun Exploded View 19

9 CD Stud Gun Parts List 20

10 CD Controller Exploded View 21

11 CD Controller Parts List 22

1 Introduction 3 2 External Features 4-5 3 Safety 6-8 4 SetupandWelding 9-15 5 TestingWeldSettings 16-19 6 TypesofFractures 20 7 ArcBlowEffect 21 8 CDStudGunExplodedView 22 9 InternalComponents 23-25 10 CDAccessoreis 26-29 11 TorqueBendingTest 30-31 12 CDGunSetUp’s 32-33

33

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 materi‐

als with little or no reverse‐side marking.

The equipment consists of a control unit, a welding hand gun, and all necessary inter‐

connecting cables.

THE PROCESS

Capacitor Discharge (CD) stud welding is a form of welding in which the energy re‐

quired 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 du‐

ration 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 con‐

tact at the time of the discharge of the capacitors. As the capacitors discharge, melt‐

ing 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.

INTRODUCTION

44

FRONT PANEL

1. 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 (‐)

EXTERNAL FEATURES

1

4

2

5 6

3

1

2

3

654

55

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 Hertz @10 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.

EXTERNAL FEATURES

ON/OFF Switch

15Amp Fuse

Power Supply Fan

AC Cord

ON/OFF Switch

15Amp Fuse

Power Supply Fan

AC Cord

66

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 any‐

one 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 incom‐

ing 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 elec‐

trical 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.

SAFETY

77

FIRE

During welding, small particles of hot metal can be expelled. Ensure that no combus‐

tible materials are near the welding area.

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 com‐

bustible 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.

SAFETY

FIRE HAZARD FROM SPARKS

88

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.

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.

SAFETY

AUTHORIZEDPERSONNEL ONLY

99

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 110 VAC @ 60Hz 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 con‐

nector.

Ground Cable Socket

SET-UP AND WELDING

Ground Cable Socket

ON/OFF Switch

Fuse

Power Cord (110 VAC)

1010

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 con‐

nector.

Welding Gun Power Connector

Welding Gun Control 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.

SET-UP AND WELDING

Welding Gun Control Cable Connector

Welding Gun Power Connector

1111

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 applica‐

tions will require an additional dual clamp.

SET-UP AND WELDING

13

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 applica‐tions will require an additional dual clamp.

SET-UP AND WELDING

12

14

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 deter‐mines how much of the stud is engaged in the collet.

• The CI (Collet Insert) which is a single part and the amount of the stud that is en‐gaged is predetermined.

• Standard Adjustable Chucks have an adjustable internal screw to manually adjust for the engagement of the stud.

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.

When the legs and foot piece are in place, insert the stud to be welded into the col‐let. 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.

SET-UP AND WELDING

Foot Piece

Collet

Leg Piece

12

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 deter‐

mines how much of the stud is engaged in the collet.

• The CI (Collet Insert) which is a single part and the amount of the stud that is en‐

gaged is predetermined.

• Standard Adjustable Chucks have an adjustable internal screw to manually adjust

for the engagement of the stud.

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.

When the legs and foot piece are in place, insert the stud to be welded into the col‐

let. 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.

SET-UP AND WELDING

Foot Piece

Collet

Leg Piece

1313

SELECTING THE SPRING LOAD

The proper spring pre‐load setting on the stud gun will vary depending on the se‐

lected 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.

This spring pre‐load adjustment is made by turning the screw insert in the back of the

stud gun with a screwdriver. On the bottom of the back cap of the stud gun is the

indicator numbered 1 thru 5, which will show you the tension setting during the ad‐

justment.

SET-UP AND WELDING

Adjustment Screw

Tension Indicator

15

SELECTING THE SPRING LOAD The proper spring pre‐load setting on the stud gun will vary depending on the se‐lected 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.

This spring pre‐load adjustment is made by turning the back cap of the stud gun. On the side of the stud gun is the indicator numbered 1 thru 5, which will show you the tension setting during the adjustment.

SET-UP AND WELDING

Adjustment Cap

Tension Indicator

Location of adjustment on back of the gun.

1414

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 diame‐

ter and material, you can now power on the welder.

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.

SET-UP AND WELDING

ON/OFF SWITCH

FUSE

ON/OFF Switch

FUSE

1515

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.

Approximate voltage staring points are listed below. Fine tuning the voltage to meet

your requirement for your specific application is recommended.

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.

SET-UP AND WELDING

Diameter Voltage (DC)

14 ga. 50‐75

12 ga. 75‐110

#8 110‐130

#10 125‐160

1/4” 160‐190


14 ga. 35‐50

12 ga. 50‐75

#8 75‐100

#10 100‐120

1/4” 120‐140

MODEL TWE‐321 & 375

3/8” (TWE‐375) 160‐200

5/16” 140‐160

Voltage Adjustment Knob

MODEL STUDPRO 2500

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.

Approximate voltage staring points are listed below. Fine tuning the voltage to meet

your requirement for your specific application is recommended.

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.

SET-UP AND WELDING


14 ga. 50‐75

12 ga. 75‐110

#8 110‐130

#10 125‐160

1/4” 160‐190


14 ga. 35‐50

12 ga. 50‐75

#8 75‐100

#10 100‐120

1/4” 120‐140

MODEL TWE‐321 & 375

3/8” (TWE‐375) 160‐200

5/16” 140‐160


MODEL 3125 & 3750

(3750)


16

18

TESTING YOUR SETTINGS When you have performed all of the presets as discussed in this manual, it is recom‐mended 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 press‐ing 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.

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.

TESTING WELD SETTINGS

1717

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

SET-UP AND WELDING

TESTING YOUR SETTINGS

When you have performed all of the presets as discussed in this manual, it is recom‐

mended 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 press‐

ing 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.

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.


1818

CD 2301 Order No. BA 92-12-0231A Issue 05.01.10 31

5.8.1 Visual Inspection

A visual inspection must be carried out with each welding element.

Condition Possible cause Corrective actionsGood welded jointLow spatters around the weld without outer flawsThe weld pool forms a collar around the flange of about 1 - 1,5 mm

- Correct parameters - None

Cold weld poolGap 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 poolMany spatters around the weld

- Heat input too high- Plunging speed too low

- Reduce charging voltage- Increase plunging speed

One-sided weld poolOne-sided spatter collarWeld 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

Visual Inspection

5 Stud Welding Procedure

5.8 Checking the Quality of the Weld
















1919

32 CD 2301 Order No. BA 92-12-0231A Issue 05.01.10

5.8.2 Bending Test

You can purchase from SWP a bending device with inserts for various diameters of thewelding elements.

The bending test serves as an easy work sample and as a check for the selected weldingparameters. 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 chapter5.

You don’t need to test all studs. It is sufficient to carry out studtests 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 andelectrically 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.


















2020

CD 2301 Order No. BA 92-12-0231A Issue 05.01.10 33

Type of fracture Possible cause Corrective actionsBase material buckling - Correct parameters - none

Fracture in the welding elementabove 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

Bending Test



INSPECTING THE WELD




voltage.









SET-UP AND WELDING TYPES OF FRACTURES

2121

34 CD 2301 Order No. BA 92-12-0231A Issue 05.01.10

5.8.3 Arc Blow Effect

A so called arc blow effect can occur with unproportionally distributed ground connec-tions in relation to the base material mass, varying material distribution, or welding atthe edge of a work piece. This is an undesired deflection of the arc. It causes a single-sided melting of the stud material, increased pore formation, and undercuts in thewelding area.

The arc blow effect is proportional to the current and can be influenced by symmetricinstallation of the ground clamps, by fitting of compensation masses, or by rotating thewelding gun around its vertical axis (applies for welding guns with external weldingcable).

Arc blow effects and some corrective actions(according to standards, see appendix)

Cause Corrective action



INSPECTING THE WELD




voltage.









SET-UP AND WELDING ARC BLOW EFFECT

22 23

CD Gun Exploded View

23

20

Internal Components

1.

2.

1. TWE01013 ‐‐‐ CD Rocker switch

6. 5. 4.

3.

2. TWE01012 ‐‐‐ CD 15 Amp Breaker

3. TWE0851CD ‐‐‐ AC Inline Filter

4. TWE01004 ‐‐‐ Capacitor (2)

5. TWE103621‐005 ‐‐‐ CD Capacitor Bracket

6. TWE103621‐006 ‐‐‐ CD Capacitor Bridge Link

24 21

Internal Components

1. 2.

1. TWE01001 ‐‐‐ PC Board

6. 5. 4. 3.

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. 8. 10. 11.

7. TWE01019 ‐‐‐ CD Terminal Block

8. TWE01006 ‐‐‐ Main Wire Harness

9. TWE01014 ‐‐‐ Power Relay

10. TWE01005 ‐‐‐ CD Main Transformer

10. TWE01008 ‐‐‐ CD Power Resistor

9.

25 22

Internal Components

1. 107‐0031 ‐‐‐ Control Panel Mount

2. 107‐0002 ‐‐‐ Camlock Panel Mount

3. TWE01017 ‐‐‐ Voltage Adjustment Knob

1. 2. 3.

2628

13

CAPACITOR DISCHARGE ACCESSORIES

ONE PIECE CONTACT/MAGNETIC CHUCK

PART NO. PRICE039 613 36.00

“B” COLLETS PROTECTOR

STUD SIZE PART NO. PRICE14 GA X 12 GA 028 837 23.0010 GA 028 838 23.00BODY ONLY 028 836 20.0012 GA INSERT 028 834 4.0010 GA INSERT 028 835

“B” STOP

STUD STOP PART NO. PRICE1/4 1 1/4 033 781 3.503/8 1 1/8 033 782 3.501/2 1” 033 783 3.505/8 7/8 033 784 3.503/4 3/4 033 785 3.507/8 5/8 033 775 3.501” 1/2 033 776 3.501 1/8 3/8 033 777 3.501 1/4 1/4 033 778 3.501 3/8 (BUTTON STOP) 1/8 033 779 3.50UNIVERSAL 033 780 3.50

SHORT BUTTON STOP

UNIVERSAL “B” STOP

MAGNETIC CHUCK

PART NO. DESCRIPTION PRICE035 301 COMPLETE ASSY 49.00017 633 MAGNET ONLY 40.00029 615 CONDUCTOR PLATE 20.00039 609 INSUL. TUBE 9.00039 610 INSUL. DISC 9.00SCREW 10 32 X 7/8 9.00

14

TEMPLATE TUBE ADAPTOR

STUD RANGE PART NO. PRICE14 GA – #6 033 764 18.00

STANDARD SPARK SHIELD

STUD DIA.X DEPTH PART NO. PRICE#4 X 1/4 CI 010 025 18.00#4 X 3/8 CI 010 037 18.00#4 X 1/2 CI 010 050 18.00#4 X 1” CI 010 100 18.00#6X 1/4 CI 013 025 18.00#6 X 3/8 CI 013 037 18.00#6 X 1/2 CI 013 050 18.00#6 X 5/8 CI 013 062 18.00#6 X 3/4 CI 013 075 18.00#6X 1” CI 013 100 18.0010GA X 1/2 CI 014 050 18.0010GA X 3/4 CI 014 075 18.0010GA X 1 CI 014 100 18.00#8X 1/4 CI 015 025 18.00#8 X 3/8 CI 015 037 18.00#8 X 1/2 CI 015 050 18.00#8 X 5/8 CI 015 062 18.00#8 X 3/4 CI 015 075 18.00#8X 1” CI 015 100 18.00#10 X 1/4 CI 018 025 18.00#10 X 3/8 CI 018 037 18.00#10 X 1/2 CI 018 050 18.00#10 X 5/8 CI 018 062 18.00#10 X 3/4 CI 018 075 18.00#10X 1” CI 018 100 18.001/4 X 1/4 CI 025 025 18.001/4 X 3/8 CI 025 037 18.001/4 X 1/2 CI 025 050 18.001/4 X 5/8 CI 025 062 18.001/4 X 3/4 CI 025 075 18.001/4 X 1” CI 025 100 18.005/16 X 3/8 CI 031 037 25.005/16 X 1/2 CI 031 050 25.005/16 X 5/8 CI 031 062 25.005/16 X 3/4 CI 031 075 25.005/16 X 1” CI 031 100 25.003/8 X 1/2 CI 037 050 25.003/8 X 3/4 CI 037 075 25.003/8 X 1” CI 037 100 25.00

COLLETS INSERTS FOR WELD STUDS

CAPACITOR DISCHARGE ACCESSORIES

COLLETS INSERTS FOR WELD PINS

STUD RANGE PART NO. PRICE14 GA – 10 GA 033 769 20.00

VENTED SPARK SHIELD

TEMPLATE I.D. PART NO. PRICE1” DIA. 039 839 333.001 1/4” DIA. 039 840 333.00

STUD DIA.X DEPTH PART NO. PRICE12GA X 1/2 CIP 010 050 18.0012GA X 3/4 CIP 010 075 18.0012GA X 1” CIP 010 100 18.0010GA X 1/2 CIP 014 050 18.0010GA X 3/4 CIP 014 075 18.00

1-3/4”

1/4 DIA

2927

2830

15

STUD SIZE PART NO. OTHER PART # PRICE#6 CDBN 013 500 001 356 17.00#8 CDBN 015 500 001 357 17.00#10 CDBN 018 500 001 366 17.001/4 CDBN 025 500 001 359 17.005/16 CDBN 031 500 001 360 22.004 MM CDBN 004M 500 001 361 22.006 MM CDBN 006M 500 001 362 22.0012 GA CDBN 010 500 001 363 22.00

STUD LENGTH PART NO. PRICE1/4 TO 5/8 500 017 017 16.003/4 TO 1 1/8 500 017 018 16.001 1/4 TO 1 5/8 500 017 019 16.001 3/4 TO 2 1/8 500 017 020 16.00

BOTTOM LOAD

STUD DIA PART NO. PRICE#4 (.112) 016 412#6 (.138) 016 415#8 (.164) 016 416#10 (.189) 004 684

RAM FEED

STUD DIA PART NO. PRICE#4 (.112) 025 016#6 (.138) 025 017#8 (.164) 025 018#10 (.189) 025 019

NON STOCK ITEM / ALLOW 2 WEEKS FOR DELIVERY

KSM / ERICO AIR COLLET

LONG ADJ. STOPS FOR ABOVE

LONG STYLE COLLETS

2-3/8 LONG & KSM

2-3/8”

3/8”DIA.

1-1/2”

7/16

2931

16

L

ARCTAPER

I.D.

PARTNO. PRICE044 082 7/8 LONG 17.00033 746 1 9/16 LONG 13.00

B CI ADAPTOR


B N ADAPTOR

PART NO .I.D. PRICE044 083 N B 3/8 ID 28.00044 084 N C 1/4 ID 28.00

ADAPTORS

PART NO. PRICEMT 0003 22.00

THREADED TAPERED ADAPTORS


K B ADAPTORS


K N ADAPTORS

MISCELLANEOUS ADAPTORS

PART NO. DESCRIPTION PRICEMT 0008 TEMPLATE TUBE 96.00

1/4 1/2 ARC STUDS

MT 0012 TEMPLATE TUBE 107.005/8 3/4 ARC STUDS

033 505L L TEC CHUCK 56.00ADAPTOR

033 749 K CI ADAPTORS751 458 049 NS 30 CHUCK ADAPTORS

ADAPTORS

L

3/8 DIA

1/4 DIA

1-7/8

ARCTAPER

3/8 DIA

1-3/4

1/4-20

ARCTAPER

2-3/8

1/4-20

PART NO. DESCRIPTION PRICE

033 505 Chuck Adaptor033 506 Connector Stud

3032

Torque Bending Test

Description

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.

STUD WELDING PRODUCTS, INC.

Check us out on the inDowney, CA9459 Washburn Rd.Downey, CA 90242Phone- 800.252.1919Fax- 562.862.3022


Kent, WA19038 72nd Ave.South Kent, WA 98032Phone- 425.656.9787Fax- 425.656.9786


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 qualityin line to ISO 9000ff can be made.

Kit Contains: 1 torque meter

5 stud adapter (M3 to M8)1 allen key 4 mm1 parameter table

Torque Bending Test

Description

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.


Check us out on the inDowney, CA9459 Washburn Rd.Downey, CA 90242Phone- 800.252.1919Fax- 562.862.3022


Kent, WA19038 72nd Ave.South Kent, WA 98032Phone- 425.656.9787Fax- 425.656.9786


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 qualityin line to ISO 9000ff can be made.

Kit Contains: 1 torque meter

5 stud adapter (M3 to M8)1 allen key 4 mm1 parameter table

3133

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 thetorque wrench. Adjust the test torque in such a way thatthere is no permanent distortion of the welded parts.

As shown in the figure, push the test device onto thestud. A torque is initiated with the torque wrench in adefined distance to the sheet surface. A bending strainof the weld results.

Move the test device forward/up until the device 'clicks' (attaining the nominal torque).

GUN SET UPCD Models

Check us out on the internet www.studweldprod.com or email [email protected], CA9459 Washburn Rd.Downey, CA 90242Phone- 800.252.1919Fax- 562.862.3022





Made in the USA

30mm Template Tube CD Foot

Shaft Extender with “B” Collet

Collet Extender Tri Pod

GUN SET UPInsulation Models

Check us out on the internet www.studweldprod.com or email [email protected], CA9459 Washburn Rd.Downey, CA 90242Phone- 800.252.1919Fax- 562.862.3022





Made in the USA

“B” Collet with CD Foot Piece and Spark Shield Magnetic Chuck with HBS Insulation Push Down

“B” Collet with Collet Protector

“B” Collet with CD Foot Piece Magnetic Chuck

OPERATION MANUAL - Stud Welding Products, Inc. Manual_Updated.pdfOPERATION MANUAL MODELS TWE-250...

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