stud welding products StudPro 2500 Operation Manual Download Page 5 | Manualshive

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5

5

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

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Summary of Contents for StudPro 2500

Page 1: ...50 Downey CA 9459 Washburn Rd Downey CA 90242 Phone 800 252 1919 Fax 562 862 3022 Hayward CA 2391 American Ave Hayward CA 94545 Phone 510 782 7883 Fax 510 782 7918 Renton WA 927 Thomas Ave SW Renton W...

Page 2: ...un 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 Setup and Welding 9 15 5 Testin...

Page 3: ...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 we...

Page 4: ...lays 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 C...

Page 5: ...erates 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...

Page 6: ...s 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 re...

Page 7: ...g 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 e...

Page 8: ...he 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...

Page 9: ...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...

Page 10: ...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 t...

Page 11: ...ly one ground clamp but certain applica tions will require an additional dual clamp SET UP AND WELDING CONNECTING THE GROUND CLAMP Attach the clamp of the welding ground lead to the work piece Prior t...

Page 12: ...he 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 y...

Page 13: ...ill show you the tension setting during the ad justment SET UP AND WELDING Adjustment Screw Tension Indicator SELECTING THE SPRING LOAD The proper spring pre load setting on the stud gun will vary dep...

Page 14: ...hing 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 t...

Page 15: ...10 8 110 130 10 125 160 1 4 160 190 Diameter Voltage DC 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...

Page 16: ...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 tha...

Page 17: ...T 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 bas...

Page 18: ...5 Stud Welding Procedure 5 8 Checking the Quality of the Weld TESTING YOUR SETTINGS When you have performed all of the presets as discussed in this manual it is recom mended that you perform several t...

Page 19: ...n of the welding gun for ease of movement 5 Stud Welding Procedure 5 8 Checking the Quality of the Weld TESTING YOUR SETTINGS When you have performed all of the presets as discussed in this manual it...

Page 20: ...Weld 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...

Page 21: ...tion 5 Stud Welding Procedure 5 8 Checking the Quality of the Weld INSPECTING THE WELD Visually inspect the weld A good weld will result in an all around weld with a small visible amount of weld surro...

Page 22: ...22 23 CD Gun Exploded View...

Page 23: ...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 B...

Page 24: ...003 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 P...

Page 25: ...25 22 Internal Components 1 107 0031 Control Panel Mount 2 107 0002 Camlock Panel Mount 3 TWE01017 Voltage Adjustment Knob 1 2 3...

Page 26: ...PRICE 1 4 1 1 4 033 781 3 50 3 8 1 1 8 033 782 3 50 1 2 1 033 783 3 50 5 8 7 8 033 784 3 50 3 4 3 4 033 785 3 50 7 8 5 8 033 775 3 50 1 1 2 033 776 3 50 1 1 8 3 8 033 777 3 50 1 1 4 1 4 033 778 3 50...

Page 27: ...5 8 CI 018 062 18 00 10 X 3 4 CI 018 075 18 00 10X 1 CI 018 100 18 00 1 4 X 1 4 CI 025 025 18 00 1 4 X 3 8 CI 025 037 18 00 1 4 X 1 2 CI 025 050 18 00 1 4 X 5 8 CI 025 062 18 00 1 4 X 3 4 CI 025 075...

Page 28: ...22 00 STUD LENGTH PART NO PRICE 1 4 TO 5 8 500 017 017 16 00 3 4 TO 1 1 8 500 017 018 16 00 1 1 4 TO 1 5 8 500 017 019 16 00 1 3 4 TO 2 1 8 500 017 020 16 00 BOTTOM LOAD STUD DIA PART NO PRICE 4 112...

Page 29: ...PART NO PRICE 039 464 45 00 K B ADAPTORS PART NO PRICE 033 750 47 00 K N ADAPTORS MISCELLANEOUS ADAPTORS PART NO DESCRIPTION PRICE MT 0008 TEMPLATE TUBE 96 00 1 4 1 2 ARC STUDS MT 0012 TEMPLATE TUBE 1...

Page 30: ...0ff can be made Kit Contains 1 torque meter 5 stud adapter M3 to M8 1 allen key 4 mm 1 parameter table Torque Bending Test Description Application Non destructive test method for studs welded with tip...

Page 31: ...t 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 initi...

Page 32: ...022 Hayward CA 2391 American Ave Hayward CA 94545 Phone 510 782 7883 Fax 510 782 7918 Renton WA 927 Thomas Ave SW Renton WA 98057 Phone 425 656 9787 Fax 425 656 9786 Phoenix AZ 3535 East Wier Ave Ste...

Page 33: ...rd CA 94545 Phone 510 782 7883 Fax 510 782 7918 Renton WA 927 Thomas Ave SW Renton WA 98057 Phone 425 656 9787 Fax 425 656 9786 Phoenix AZ 3535 East Wier Ave Ste 4 Phoenix AZ 85040 Phone 602 305 9350...

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