Operating Instructions
Serial Number _______________
International Welding Technologies, Inc.
2650 Egg Harbor Road
Lindenwold, NJ 08021
(856) 435-8004 phone
(856) 435-4004
fax
www.internationalwelding.com
Revision 2
1
It is prohibited to transmit or reprint this document, as well as to utilize or disclose
its contents, unless this has been expressly granted by International Welding
Technologies, Inc. (herein also referred to as IWT). Non-compliance with this
regulation is liable to compensation. All rights reserved, particularly in the case
of a patent grant or GM registration.
We certify that the contents of this pamphlet correspond to the hard and software
described. Deviations, however, cannot be excluded, so that we cannot warrant
for absolute compliance. The data in this documentation, however, have been
verified regularly and necessary corrections will be incorporated in future
impressions. We appreciate any suggestions for improvement.
International Welding Technologies, Inc. – All rights reserved
Subject to technical alterations
2
Contents
1. General ....................................................................................................................... 5
1.1 Introduction to stud welding ........................................................................................ 5
1.2 Application .................................................................................................................. 6
1.3 Information on the product .......................................................................................... 6
1.4 Serial Plate ................................................................................................................. 7
1.5 Information on documentation .................................................................................... 7
1.5.1 Information on operating instructions .................................................................. 7
1.5.2 Conduct in the case of malfunctions ................................................................... 8
1.6 Contacts and service address .................................................................................... 8
2 Description of the stud welder ................................................................................ 9
2.1 Capacitor discharge technology ................................................................................. 9
2.2 Stud welder set-up ...................................................................................................... 10
2.3 Dimensions ................................................................................................................. 11
2.4 Technical Data ............................................................................................................ 12
2.5 Block Diagram ............................................................................................................ 13
3 Safety Instructions ..................................................................................................... 14
3.1 Description of reference signs in the operating instructions........................................ 14
3.2 Staff qualification and training..................................................................................... 15
3.3 Dangers in case of non-compliance with safety instructions....................................... 15
3.4 Safety-conscious working ........................................................................................... 15
3.5 Safety instructions for the operator/user ..................................................................... 16
3.6 The following should be observed before starting the system .................................... 16
3.7 Before starting to weld… ............................................................................................ 17
3.8 Safety precautions at installation site.......................................................................... 17
3.9 Working with the stud welder ...................................................................................... 18
3.10 Safety instructions for maintenance, inspection and assembly works ...................... 18
3.11 Unauthorized retrofit and spare parts production ...................................................... 19
3.12 Inadmissible operating methods ............................................................................... 20
3.13 Storing the stud welder ............................................................................................. 20
4 Installation of stud welder ........................................................................................ 21
5 Initiation ....................................................................................................................... 22
5.1 Exterior components ................................................................................................... 22
5.1.1 Front view ........................................................................................................... 22
5.1.2 Rear view ............................................................................................................ 22
5.2 Operating elements .................................................................................................... 23
5.3 Connection elements .................................................................................................. 23
5.4 Display elements ........................................................................................................ 24
Revision 2
3
5.5 Fuse elements ............................................................................................................ 25
5.6 Preparation for initiation .............................................................................................. 26
5.6.1 Ground connection ............................................................................................. 26
5.6.2 Connect stud welding pistol ................................................................................ 26
5.6.3 Mains supply connection .................................................................................... 26
5.7 Gun Setup ................................................................................................................. 27
5.8 Operation ................................................................................................................... 29
5.9 Welding parameters.................................................................................................... 29
5.10 Reverse polarity ........................................................................................................ 30
5.11 Modular circuitry ....................................................................................................... 30
6 Quality control ............................................................................................................ 31
6.1 General ....................................................................................................................... 31
6.2 Demands on the company .......................................................................................... 31
6.3 Proof of qualification ................................................................................................... 31
6.4 Type and scope test ................................................................................................... 31
6.4.1 Standard work test .............................................................................................. 31
6.4.2 Simplified work test ............................................................................................. 32
6.5 Test execution ............................................................................................................ 32
6.5.1 Production of samples ........................................................................................ 32
7 Maintenance ............................................................................................................... 33
7.1 Stud welder................................................................................................................. 33
7.2 Replacement of components ...................................................................................... 33
7.3 Part list........................................................................................................................ 33
7.4 Wiring diagram ........................................................................................................... 33
7.5 Fuses .......................................................................................................................... 33
8 Trouble shooting ........................................................................................................ 34
8.1 Trouble shooting the LYNX4 ....................................................................................... 34
8.2 Causes of poor or erratic welds .................................................................................. 35
8.3 Trouble shooting poor welds ....................................................................................... 36
9 Warranty……………………………………………………………………………………….37
Supplement for Insulation Welding .................................................................................... 38
4
1
General
1.1
Introduction to stud welding
Your new stud welding equipment is carefully constructed of the finest
components and materials available. Used properly, this equipment will
give you years of efficient service.
The system incorporates the latest in engineering advances, for
completely reliable end welding of mild steel, stainless steel, aluminum,
copper and lead free brass fasteners.
A careful study of this manual will enable you to understand how the
welder operates to insure proper performance under all operating
conditions.
You have purchased a product which:
•
•
•
•
•
Conforms to machinery directives 2006/42/EC
Conforms to low voltage directives 2006/95/EC
Complies IEC 60974 for ARC welding equipment
Conforms to IPC-A-610-Class II
RoHS Compliant
Before putting the stud welder into operation, always observe the
following:
•
•
•
•
Store the operating instructions in a place accessible to every
operator
Ensure that the respective operator has read and understood the
operating instructions prior to installation. Each operator should
confirm this by signature
Prevent the stud welder being operated by unauthorized persons
Only trained personnel must operate the stud welder.
MORTAL DANGER
Revision 2
Persons with pacemakers must not operate the stud welder and must
not stay in the vicinity of the stud welder while it is running. Ensure
that the stud welder is not operated near electronically sensitive lifesupporting equipment, such as in intensive care units in hospitals.
5
WARNING
Keep sufficient distance from electronic devices. When stud welding,
highly intensive electromagnetic fields are created which may
permanently damage these devises (e.g. television sets).
•
•
1.2
Observe the safety instructions in Section 3.
Call a doctor in case of an accident.
Application
4
The IWT stud welder LYNX Modular Stud Welding System allows you to
weld pins and threaded studs sizes #4 through 5/16” as well as various
fastening elements made of steel, stainless steel, aluminum, copper and
lead free brass.
The visible side of the work piece is spared to a large extent from
pressure marks or deformations, so that even thin sheet metals down to
0.060 thick retain their decorative appearance.
If you need consultation or assistance in solving problems, please
contact either our parent company or our field engineers.
1.3
Information on the product
Manufacturer: INTERNATIONAL WELDING TECHNOLOGIES, INC.
2650 Egg Harbor Road
Lindenwold, NJ 08021
Tel: 856-435-8004
Fax: 856-435-4004
4
Product Designation: LYNX Modular Stud Welding System
Country of Origin: USA
6
1.4
Serial Plate
The serial plate is located on the rear side of the stud welder. It contains
information regarding the manufacturers name, address, country of
origin, product designation, method of welding, date of manufactured,
production number and main connection values.
1.5
Information on documentation
The following operating instructions are supplied with the LYNX4 stud
welder:
•
•
•
•
•
1.5.1
4
Operating instructions for the LYNX Modular Stud Welding
System
1,2,3 Quick Setup Guide to Gap Welding
4
LYNX Control PCB schematic
4
LYNX fault indicator list
4
LYNX Insulation Supplement
Information on operating instructions
The contents of these operating instructions are neither part of any
former or existing arrangement, pledge or legal relationship nor are
designed for modifying the latter. All obligations of INTERNATIONAL
WELDING TECHNOLOGIES, INC. result from the respective contract of
sale (invoice), which also comprises the complete and generally valid
warranties. These contractual warranty terms are neither extended not
restricted by the implementation of these operating instructions.
WARNING
Do not carry out any activities on the stud welding system without
specifically knowing the operating instructions or the respective part.
Ensure that only qualified personnel familiar with the operating
instructions and the necessary technical activities (training!) operate
the system.
Revision 2
7
1.5.2
Conduct in the case of malfunctions
If malfunctions occur, first try to detect and eliminate the causes
according to the list in Section 8 “Troubleshooting”. In all other cases,
contact our service department.
If you require service, please make sure that you supply the following
information:
•
•
•
•
•
•
•
Customer number
Product designation
Serial number
Year of construction
Options
Material of stud and work piece
Stud dimensions
This information will help us both to save time and unnecessary costs,
e.g. caused by delivering the wrong spare parts.
1.6
Contacts and service address
If you have any questions regarding the operation of the stud welding
system, retrofits or if you require service, please contact your responsible
service office or the following address:
INTERNATIONAL WELDING TECHNOLOGIES, INC.
2650 Egg Harbor Road
Lindenwold, NJ 08021
Tel: 856-435-8004
Fax: 856-435-4004
www.internationalwelding.com
8
2
Description of stud welder
2.1
Capacitor discharge technology
4
The LYNX Modular Stud Welding System with tip ignition operates
according to the principle of capacitor discharge as defined in the
American Welding Society Welding Handbook and in DVS Leaflet 0903
(German Welding Society). This system uses the abrupt discharge of a
capacitor bank to generate an electric arc.
Stud tip or gun foot
touches work piece.
Stud lifts off and
drops under spring
pressure. Arc is
initiated
Stud immerses into
weld pool. Material
solidifies rapidly.
Note the final picture in the sequence above; in order for a weld to be
good, it should have an even fillet completely around it. Any voids at all
indicate a weakness in the weld zone that could only cause weld failure
later. Also, the stud should appear to penetrate the parent material -- it
should never appear to be 'sitting on top' of the weld.
What actually happens during a capacitor discharge weld? The work
surface (or ground) is connected to one side of the capacitor bank. The
stud, through the collet, gun, and an electronic switching device (SCR) is
connected to the other side of the capacitor bank. When the stud is
placed against the work surface, only the tip touches. When the trigger is
squeezed, the switching device conducts, and the capacitor bank is
shorted out through the tip of the stud. Because of the high welding
current, the tip disintegrates and an arc is established. The arc melts the
interface surfaces, and the spring pressure of the gun combined with
velocity of the gun spindle movement pushes the stud into the parent
material to complete the weld. The process lasts about 1 - 3
milliseconds.
Revision 2
9
To make a good weld occur, two things are needed: heat and pressure.
A weld must have sufficient heat to melt the weld zone, and enough
pressure to provide good fusion.
4
In the LYNX Modular Stud Welding System, heat is easily regulated by
the voltage on the capacitor bank. The length of weld cable used also
affects the heat. You should always use the supplied cables; otherwise
the weld arc is too erratic. Pressure is controlled by protrusion; the
amount of stud that extends beyond the gun's foot and the spring
pressure setting on the gun. It gap welding, adjustment made to the
spring will influence the velocity at which the stud is propelled to the
work. It should be mentioned that the more pressure the weld has, the
shorter the weld time will be. This will result in a cooler weld with less
penetration and less reverse side marking.
Besides heat and pressure, some of the other aspects of capacitor
discharge welding should be mentioned. Grounding is very important.
The ground connections must be clean and tight, but it must also be
positioned properly. Whenever the weld consistently "blows" to one side
(referred to as “arc blow”), the grounding is usually inadequate.
Another important subject is polarity. Straight polarity is when the work
surface is positive and the gun is negative. Whenever the work is clean,
straight polarity is used. On the other hand, reverse polarity (work
surface is negative) is used for welding brass or whenever impurities
such as galvanizing are present (see Section 5.9 for a discussion of
polarity).
2.2
Stud welder set-up
4
The standard pistol to be connected to the LYNX Modular Stud Welding
System is the IWT-G1 gap gun or IWT-C1 contact gun. See additional
information on the weld guns in Section 5.
10
2.3
Dimensions
4
The LYNX Modular Stud Welding System is a powerful but lightweight
system that is easily carried into the work place. The base unit weighs
20 lbs. The dimensions are:
12” Wide x 12” Long x 5” High
12”
5”
12”
Revision 2
11
2.4
Technical Data
3
Description
LYNX Modular Stud Welding System
Welding range
#4/12ga through 5/16”
Material
Steel, Stainless Steel, Aluminum, Copper,
Lead Free Brass
Welding Method
Capacitor Discharge Tip Ignition
Standard Pistol(s)
IWT-G1 gap, IWT-C1 contact or IWT-Ci
insulation gun
Current Source
Capacitor Bank
Charging Capacity
81,000 micro Farad
Charging Voltage
50 – 195 V adjustable
Welding Time
0.001 – 0.003 seconds
Welding Duty Cycle
Up to 20 studs per minute
Mains Supply
110 or 220 VAC 50/60 Hz. Switchable on the
main board
Fuses
2 x 16A slow blow, 250 V
Welding Cable
#2 highly flexible weld cable
Ground Cables
Two, #2 highly flexible weld cable
Weight
26 lbs
Color
Blue
Subject to technical change without notice.
12
2.5
Revision 2
Block Diagram
13
3 Safety instructions
These operating instructions contain basic instructions that have to be
complied with during installation and/or operation. It is therefore
absolutely necessary that the operator and responsible specialist staff
read these operating instructions prior to assembly and initiation. They
must always be available at the installation site.
Not only the general "safety instructions" listed under this main item, but
also the special safety instructions e.g. for high temperatures, voltages,
etc. listed under the other main items have to be complied with.
3.1 Description of reference signs in the operating instructions
The non-observance of safety instructions can cause damage to the
operator and observers. The safety instructions of this manual are
marked with the general symbol for danger safety symbol in
compliance with DIN 4844-W9
Warning of electrical voltage is specifically marked with the safety
symbol in compliance with DIN 488-W8.
14
In addition to these symbols, the words “DANGER TO HEALTH” or
“MORTAL DANGER” refer to the degree of a possible danger.
Safety instructions the non-observance of which may endanger the
machine and its functions are marked with the terms
"CAUTION" or "WARNING".
General instructions are marked with the hand symbol.
3.2 Staff qualification and training
The staff responsible for operation, maintenance, inspection and
assembly must have the respective qualification for carrying out these
works. Field of responsibility, competence and the supervision of staff
has to be exactly regulated by the user. If your personnel do not have the
necessary knowledge they must be trained and instructed. If necessary,
this can be done by the manufacturer/supplier on behalf of the welding
equipment user. Furthermore, the user must ensure that the contents of
the operating instructions are fully understood by the staff.
3.3 Dangers in the case of non-compliance with safety instructions
The non-compliance with safety instructions may not only endanger
persons, but also the welding system and its environment. Any noncompliance with safety instructions may result in a complete loss of
damage claims.
Non-compliance with safety instructions may have the following consequences:
•
•
•
Failure of important system functions
Failure of prescribed methods for maintenance
Danger to persons through electric, mechanic, thermal and
acoustic influences
3.4 Safety-conscious working
The safety instructions listed in this manual, existing national accident
prevention regulations and possible international working, operating and
safety regulations of the user must be complied with.
Revision 2
15
3.5 Safety instructions for the operator/user
When stud welding, danger may result from
•
•
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•
electric current
optical radiation
harmful substances (smoke)
acoustic shock
spraying sparks
You are therefore obliged to restrict the dangers to an inevitable degree
and to point these dangers out to the operator and other persons
involved.
MORTAL DANGER
Persons with pacemakers must neither operate the stud welder nor
stay near it.
3.6 The following should be observed before starting the system...
Before starting the system, pay attention to the following information:
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•
•
•
•
•
•
•
Do not touch live electrical parts.
Juveniles under the age of 16 years must not operate the stud
welding system.
Read all of the operating instructions before starting the system.
Only qualified personnel are allowed to operate the system.
Prevent unauthorized use of the system by children or
unqualified personnel
Wear non-combustible, closed working clothes.
Wear a leather apron to protect your clothes from welding
spatters that are generated during the welding process.
Wear head protection when carrying out welding work above
your head
MORTAL DANGER
16
When welding, do not wear clothes soiled with easily combustible
substances such as oil, gasoline and thinners, etc.
•
•
•
•
•
•
•
•
•
Wear gauntlet gloves made of leather.
Never wear rings, watches nor electrically conductive jewelry.
Wear protective goggles to protect your eyes from welding
spatters and flashes of light that are generated during the
process.
Wear ear protection. Capacitor discharge generates a loud bang.
Disconnect input power before installing or servicing this
equipment according to OSHA 29 CFR 1910.147
Turn off all equipment when not in use.
Do not use worn, damaged, undersized or poorly spliced cables.
Do not drape cables over your body.
Welding on closed containers, such as tanks, drums, or pipes
can cause them to blow up. Sparks can fly off from the welding
arc. The flying sparks, hot work pieces, and hot equipment can
cause fires.
3.7 Before starting to weld...
•
Check the state of all cables.
•
Immediately replace defective cables and cable connections.
•
Ensure that the air apertures of the housing are not covered.
Heat accumulation may damage the stud welder.
•
Look around for potential safety or fire hazards.
3.8 Safety precautions at installation site
Revision 2
•
When placing the stud welder on tables or similar workshop
furniture, ensure that the stud welding system stands firmly and
that the table can bear its weight.
•
Make sure mains socket and stud welder are properly grounded.
•
Comply with fire prevention regulations and do not weld in
hazardous locations.
•
Make sure room is well ventilated or extract welding fumes, if
necessary.
17
DANGER TO HEALTH
When welding, fumes and suspended matters may be generated.
Beware of fumes detrimental to health, particularly when using
surface-treated materials. If possible, only weld in rooms that are
higher than 10 ft. As per VBG 15, special regulations are applicable
for narrow rooms.
3.9 Working with the stud welder
•
Comply with all accident prevention regulations which apply to
the operation of your stud welder
One of the accident prevention regulations
applicable for stud welders is VBG15 "Welding, cutting and similar
working methods". For more information, contact the Employer's
Liability Insurance Association.
DANGER TO HEALTH
When welding, do not wear clothes soiled with easily combustible
substances such as oil, grease and paraffin oil, etc.
If an accident happens,
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•
18
switch off the stud welder and disconnect it from the mains supply
call a 911.
3.10 Safety instructions for maintenance, inspection and assembly works
Only carry out maintenance
works when stud welder has
been switched off and
unplugged—follow
lockout/tagout procedures.
The user must ensure that all maintenance, inspection and assembly
work is carried out by authorized and qualified technical personnel.
Generally, only work on the system when it has been switched off and
after having disconnected it from the mains supply. It is necessary to
comply with the procedure for stopping the stud welding system
described in the operating instructions (chapter 3.13).
Immediately after having completed your work, re-install and activate all
safety and protective devices.
3.11 Unauthorized retrofit and spare parts production
The system may only be retrofitted and modified after consultation with
the manufacturer. Original spare parts and accessories authorized by the
manufacturer guarantee safety. The use of other parts may result in the
cancellation of warranty for any consequences thus caused.
Revision 2
19
3.12 Inadmissible operating methods
Limit values
Working safety of the stud welding system supplied can only be
guaranteed when the stud welder is used in accordance with its purpose.
The limit values indicated in the chapter "Technical data" must never be
exceeded.
3.13 Storing the stud welder
•
Switch off the mains switch (chapter 5.1.2, item 8) located at the stud
welder's rear side.
•
Disconnect the mains plug from the socket.
•
Disconnect:
- the ground cables (chapter 5.1.1 , item 4)
- the control cable (chapter 5.1.1, item 6)
- the welding cable (chapter 5.1.1, item 5)
from the stud welder.
20
•
Roll up the cables without buckling them.
•
Make sure stud welder cannot be used by unauthorized persons.
•
Check the welding cable and connections of the stud welder for
damage such as burn-off, mechanical wear etc. and have damaged
parts replaced by IWT customer service.
4 Installation of stud welder
•
Only install the stud welder on an even surface. The four anti-vibration
pads located on the bottom of the stud welder guarantee its anti-skid
position and serve as vibration dampers.
•
Although the stud welder is resistant to environmental influences, it
should be protected against dampness and dust.
Under no
circumstance should the unit be placed next to a grinding station.
Metallic particles will be drawn into the enclosure though the fan.
•
The stud welder should not be place in close proximity to any high
frequency welding equipment, share a common ground and/or common
power supply. Doing so could damage sensitive electronics and will void
the stud welder’s warranty.
•
Please pay particular attention to the bearing strength of the workshop
furniture and ensure a safe and stable position.
•
Make sure there is sufficient free space around the louvers.
•
Install the stud welder close to the welding location.
•
Ensure correct connected loads with mains operation.
•
The electrical connecting cable used for mains operation is of adequate
length. Additional extension cables cause a voltage drop, possibly
leading to unit disturbances.
•
Do not use extension cords unless approved by the manufacturer.
•
Ensure sufficient ventilation of the working room when operating the
system.
•
Never hoist or suspend the machine by its carrying handle.
The housing of stud welder LYNX corresponds to safety class IP 21,
IEC 60974-1. Please observe that this system of protection is not
suitable for being operated or transported in the rain.
Revision 2
21
5
Initiation
5.1
Exterior components
5.1.1
Front View
1
2
3
7
4
4
5
6
Item
1
2
3
4
5
6
7
5.1.2
Rear View
10
8
22
Description
Voltage Control Knob
Voltage Display
Informational Display
Ground Connectors
Gun Weld Cable Connector
Gun Control Cable
Connector
Voltage Reference Chart
9
Item
8
9
10
Description
Power Socket/Switch
Serial Plate
Cooling Louvers
5.2
Operating elements
•
Mains switch (Section 5.1.2., Item 8)
The mains switch is located at the rear of the stud welding unit and
serves to switch the stud welder on and off.
•
Voltage control knob (Section 5.1.1., Item 1)
The voltage control knob is located on the front of the stud welder.
This knob functions to increase or decrease the capacitor charge
voltage. Refer to the chart on the front of the stud welder to
determine the approximate voltage for different fastener diameters.
Turning the knob clockwise will increase the voltage. Turing the
knob counter-clockwise will cause the stud welder to discharge
excess voltage to internal resistors and recharge to a lower setting.
WARNING
Repeatedly charging and discharging the capacitors quickly using
the voltage control knob may damage the unit. Allow the unit’s
internal fan sufficient time to cool the resistors upon discharge.
•
5.3
Connection Elements
•
Revision 2
Voltage chart (Section 5.1.1., Item 7)
The voltage chart located on the front panel of the stud welder
provides the approximate voltage settings for steel and aluminum
fasteners. These numbers are approximate starting values and the
actual voltage should be adjusted either up or down for your
particular application. Please note that voltages are provided for
“flanged” fasteners. Voltages for mini-flange, DIN, or non-flanged
fasteners will be lower.
Ground cable connector (Section 5.1.1., Item 4)
4
There are two ground cable connectors on the front to the LYNX
Modular Stud Welding System. Insert each cable connector into the
ground socket and twist in a clockwise direction to tighten. Ensure
these connectors are tight. These cables provide the return path
for the welding current. For good grounding, attach each ground
23
cable to the work piece. When possible, weld between the ground
cables to minimize the affects of “arc blow” on weld quality.
5.4
•
Weld cable connector (Section 5.1.1., Item 5)
The welding pistol weld cable connector attaches to the front of the
unit in the gun connector socket. Insert the connector into the socket
and twist in a clockwise direction to tighten. Ensure this connector
is tight.
•
Control cable connector (Section 5.1.1., Item 6)
The welding pistol control cable connector attaches to a four-pin
connector on the front of the stud welder. This connector provides
the gun trigger signal and “foot on work” indicator for gap mode
welding.
•
Mains connector (Section 5.1.2., Item 8)
The mains connector is located in the rear of the stud welder. Use
the mains cable supplied to connect the stud welder to the power
supply. The stud welder is configured at the manufacturer to use a
12 Amp, 120V 50/60 Hz supply.
Display elements
4
The LYNX Modular Stud Welding System is equipped with seven
indicator displays:
•
•
•
•
•
24
Charge voltage (Section 5.1.1., Item 2)
This three panel RED digital LED displays the actual charge voltage
on the capacitor bank.
“Power” on light
This AMBER single LED indicates the power switch is on and is
connected to the mains.
“Capacitors at charge” ready light
This GREEN single LED indicates that the capacitor have
successfully charged to the correct voltage as determined by the
voltage selection knob.
“Fault” light
This RED single LED indicates a fault with the stud welder. A solid
fault light indicates safety circuit activated. A blinking fault light
indicates transformer has overheated. See section 8.1
“Stud on work surface” light
The GREEN “stud on work surface” indicator is used to indicate a
complete electrical path from the stud to the welding system. When
this light is activated, the unit is ready to weld a fastener. This
•
indicator is used in contact welding mode.
“Foot on work surface” light
The GREEN “foot on work surface” indicator is used to indicate a
complete electrical path for gun foot piece to the welding system.
When this light is activated, the unit is ready to weld a fastener in
gap mode.
The operator will note that when welding with an
IWT-G1 gap gun, the “stud on work surface” LED will initially be
activated, then when the trigger is pulled the “foot on work
surface” LED will be activated. When welding with an IWT-C1
contact gun, only the “stud on work surface” LED will be
activated.
•
5.5
Weld complete light
The GREEN “weld complete” indicator is a momentary LED that is
activated at the end of the weld cycle after the gun is removed from
the welded fastener. This LED indicates that the weld has been
completed successfully with the selected energy being completely
discharged within the time requirements. This LED indicates the
base unit is working as designed.
Fuse elements
4
The LYNX Modular Stud Welding System is protected by the following
fuses:
Mains fuse:
Charging fuse:
Control fuse:
Fuse for Fan:
2 x 16A 250 V slow blow
10A 250 V slow blow
2A 250 V slow blow
2A 250 V slow blow
MORTAL DANGER
Always replace fuses with the correct replacement value. Do not use
oversized fuses that may damage the unit.
Revision 2
Always disconnect the stud welder from the mains power supply
when replacing fuses or servicing the stud welder.
25
5.6
Preparation for initiation
Connect the stud welding pistol and the ground cables to the stud welder
as indicated in Section 5.3.
5.6.1
Ground connection
•
•
•
Connect the ground cables into the indicated ground sockets.
Turn the connectors clockwise until they stop.
Connect the quick clamps to the work piece.
Ensure optimum contact with work piece.
5.6.2
Connect stud welding pistol
•
•
•
•
5.6.3
Connect welding cable of the stud welding pistol into the indicated
socket.
Turn the connector clockwise until it stops.
Connect the control cable connector into the four-pin socket.
Turn the screw connector on the outside of the plug to secure the
plug to the socket.
Mains supply connection
4
Connect the power cable supplied with the LYNX Modular Stud Welding
System into the rear of the unit. Connect the three prong plug into a
grounded shock proof supply. Do not use an extension cord with this
unit.
26
5.7
Gun Setup
Figure 5.1 on the next page depicts the optimal set-up for the fastener in
the chuck. To set the stud in the chuck, loosen the backstop screw until
1
the fastener extends approximately /8 inch from the front of the chuck.
Tighten the back-stop locking nut to preserve this setting. For fasteners
longer than 1-½ inch, back the stop all the way out to obtain as much
engagement in the chuck as possible.
If you are welding to aluminum, the set-up of the gun will be as
depicted in Figure 5.2. First follow the directions for Figure 5.1. Then
fully insert the chuck into the gun and tighten the chuck-locking nut.
Loosen the two legs by releasing the four (4) set screws in the faceplate.
1
Adjust the legs so that only the flange (approximately /32 inch) of the
fastener is observed beyond the brass ring. Tighten the four (4) set
screws in the legs. Finally, adjust the spring pressure at the slot screw in
the rear of the gun. The pressure should be set to +.
If you are welding to mild (carbon) or stainless steel, the set-up of
the gun will be as depicted in Figure 5.3. First follow the directions for
Figure 5.1. Then fully insert the chuck into the gun and tighten the
chuck-locking nut. Loosen the two legs by releasing the four (4) set
3
screws in the faceplate. Adjust the legs so that approximately /32 inch of
the fastener is observed beyond the brass ring. Tighten the four (4) set
screws in the legs. Finally, adjust the spring pressure at the slot screw in
the rear of the gun. The pressure should be set to -. The gun set-up is
now complete.
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27
Fig 5.1
Fig 5.2
Fig 5.3
28
5.8
Operation
Switch on the mains switch. The unit will power all LED’s and run a
quick diagnostic check. The amber LED will then illuminate indicating
line voltage (110VAC or 220VAC). The digital LED on the front panel will
indicate the charge voltage. Once the charge voltage is reached, the
“ready” LED will light.
Adjust charging voltage by means of the front panel knob. Refer to the
table on the front panel to establish approximate voltage setting for the
selected fastener.
Position the weld pistol with a fastener in the gun on the work piece. The
“stud on work” LED will be lit.
Depress to trigger on the welding gun. In gap mode only, the “foot on
work” light will activate. Pull the trigger rapidly to discharge the unit.
After the stud is welded, remove the gun from the stud by pulling the gun
away perpendicular to the work surface. The “weld complete” light will
activate momentarily and the unit will recharge. Upon successful
recharge, the “ready” light will turn on.
5.9
Welding parameters
4
The table on the front of the LYNX Modular Stud Welding System
provides standard values for welding different size fasteners. The
charge voltage is selected based on the diameter of the fastener. These
estimated voltages listed below are for “flanged” fasteners and may not
be appropriate for mini-flange, DIN, or non-flange fasteners. Voltage
should be adjusted for your particular application.
DIA.
STEEL
ALUM
#4/12GA
#6/10GA
55
85
65
90
#8
80
105
#10
100
115
1/4”
135
155
5/16”
175
NA
GUN
(-)
(+)
*When using an IWT-Ci Insulation Gun, please find insulation supplement on page 38
In the above chart, “GUN” indicates the spring pressure setting on the
IWT-G1 gap gun. “-“ indicates decreased spring pressure on the gun
spindle. “+” indicates increased spring pressure on the gun spindle
resulting in greater velocity at the instant the weld is made.
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29
5.10
Reverse Polarity
Sometimes is may be beneficial to use reverse polarity during stud
welding. Reverse polarity is often recommended when welding to brass
material or through galvanized materials.
Normally, straight polarity is used in stud welding. In straight polarity the
work surface is the positive electrode and the stud is negative. Current
flows from the negative electrode to the positive electrode. Typically, the
positive electrode runs approximately 20% hotter than the negative
electrode. This increase in temperature is caused by the electron
bombardment on the position electrode.
Using straight polarity
concentrates the heat on the work and gives maximum penetration into
the base material.
Reverse polarity is used to enhance the welding of galvanized steel
because the current flow is from the work surface to the stud. This
direction in current has a tendency to lift off and expel impurities from the
work surface thereby providing a stronger weld.
4
To initiate reverse polarity welding with the LYNX Modular Stud Welding
System unplug all weld cables from the unit. Then, plug the gun weld
cable into one of the ground sockets. LEAVE THE OTHER GROUND
SOCKET VACANT. Plug one ground cable into the gun weld cable
connector. Alternatively, contact IWT for a “Y” connector so that two
ground cables can be used in this configuration. Now the current is
flowing from the ground to the gun.
5.11
Modular circuitry
4
If your LYNX Modular Stud Welding System has already been
configured for automatic capability, you will find a 15-pin sub-miniature
“D” connector on the rear of the unit. This connector provides inputs
and outputs for use in automation. The following signals are provided:
• External triggering input (pins 1 and 6)
• Capacitors at charge signal (pins 4 and 9)
• Stud on work signal (pins 3 and 8)
• Fastener reload signal (pins 2 and 7)
• Weld complete signal (same as reload)
•
Foot on work (pins 10 and 11)
*Refer to Appendix C for further information regarding this function.
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6
Quality Control
6.1 General
The 0905 DVS Guideline, part 2, of April 1979 is applicable with regard
to quality assurance of stud weld joints. The tests described in this
section are written in simplified terms, following above regulation. They
refer to work tests that are carried out and supervised by the user prior to
and during welding.
6.2 Demands on the company
The company must employ a technical supervisor responsible for
welding matters, as well as qualified operating personnel for stud welding
(see DVS Guideline 0905, part 2, section 4).
6.3 Proof of qualification
In the case of components which documentation must be provided for, or
stud welding works which as per DIN 4100, DIN 4113 are subject to
acceptance, the processing company must submit a certificate of
competence or a proof of qualification for working with stud welding
equipment (see DVS Guideline 0905, part 2, sections 4.1 and 4.2). The
proof of qualification applies in particular to the fastening of structures
that are relevant in terms of safety regulations. When being used in the
building industry, only approved base and stud materials may be used
(for example, see DIN 4100. section 2.1, certificate of approval for
stainless steel ifBT; DIN 4113, part 2).
6.4 Type and scope of test
Provided that the IWT stud welding system is used properly and the
materials are appropriately selected, the strength of the welding joint
(welding zone) will always be stronger than that of the stud or base
material. The best method of quality control for capacitor discharge stud
welding is to destructively test studs that have been welded to the same
base material to be used in actual production.
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6.4.1 Standard work test
Generally, standard work tests have to be carried out and supervised by
the user before welding at a structure and after a certain number of
welds has been made. The number of welds after which a standard work
test is required is agreed upon with the customer.
The standard work test is restricted to the stud diameter, base material
and type of equipment used. It comprises the following tests:
•
Visual inspection (all samples)
•
Tensile test
•
Torque test
•
Bend test
In case of doubt, the test scope should be extended in compliance AWS
Welding Handbook or with DVS Guideline 0905, part 2, section 5.1.1.
6.4.2 Simplified work test
Simplified work tests serve to check the correct setting and function of
the equipment. They are carried out at the beginning of every working
shift and after several hours of interruption.
•
Simplified work tests include:
•
Visual inspection (all samples)
6.5 Test execution
6.5.1 Production of samples
The studs for the work test are welded on a sheet metal using the same
welding positions and edge distances as on the component to be welded
later. If it is possible and sensible from an economical point of view, use
parts that are identical to those used in later production.
The visual inspection serves as a rough check for major defects. The
uniformity of the weld is assessed. When in doubt, tensile and bend tests
should be carried out.
32
7
Maintenance
7.1
Stud welder
The stud welder is constructed in such a way that only a minimum of
maintenance is required. The interior of the stud welder should,
however, be cleaned at regular intervals depending on the environmental
conditions at the location of use. Clean the unit with compressed air
only.
7.2
Replacement of components
Defective components may only be replaced by trained IWT servicemen.
Perfect function of your stud welder can only be guaranteed when
original IWT spare parts are used.
7.3
Fuses
4
The stud welder LYNX Modular Stud Welding System is protected by
the following fuses:
Mains fuse:
Charging fuse:
Control fuse:
Fuse for Fan:
2 x 16A 250V slow blow
10A 250V slow blow
2A 250V slow blow
2A 250V slow blow
MORTAL DANGER
Always replace fuses with the correct replacement value. Do not use
oversized fuses that may damage the unit.
Always disconnect the stud welder from the mains power supply
when replacing fuses or servicing the stud welder.
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34
7.4
Part list
7.5
Wiring Diagram
8
Trouble Shooting
8.1
Trouble shooting the LYNX4
There are a few basic rules to follow when trouble shooting any C.D.
welding system. They are as follows:
•
•
•
When approaching a welder the studs "aren’t sticking," stand
back and look at the entire situation. More often than not the
problem will be something simple, such as wrong polarity, bad
grounding, coiled cables, etc.
After you have determined that the welder has everything it
needs externally to work, examine the cables. This is the part of
the welder that receives the most wear and naturally is most
subjected to failure. If possible, switch the cables and use a set
that you are certain is good.
Only after you are certain that the trouble is with the stud welder,
unplug the ground and gun cables before proceeding. It is
possible for a defective cable to keep the unit from charging up
its capacitor bank.
Another point to be aware of before actually trouble shooting the system
is that it's a common misconception that whenever the welds are
inconsistent, it is the fault of a defective control unit. This is rarely the
case -- if the welder is defective, it will very seldom fire at all.
Usually when inconsistency occurs, it means that the set-up is marginal,
or there may be a problem in the parent metal. This would account for
the differences in the welds. Review Section 8.2 below.
If the problem cannot be corrected by adjustments on the control, look at
the gun. Is there enough engagement of the stud within the collet or
chuck, and is it tight? If nothing is apparent on the outside of the gun,
check it internally. Is it able to move back and forth freely in the bearing?
Very seldom is the problem in the control. Almost the only thing that
could cause inconsistency in the control unit would be a loose
connection that would be readily apparent, such as arcing on the
capacitor buss bars or at the connections.
Remember, before suspecting the equipment, step back and look at the
whole situation. Often it isn't anything that cannot readily be corrected by
proper set-up.
If, after observing all of the preliminary pointers, it is obvious there is a
defect within the system, contact an authorized IWT service center for
information on servicing your system.
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8.2
Fault Light Indications
4
The LYNX Modular Stud Welding System is powered by an intelligent
microcontroller which can notify the operator if a problem occurs during
the welding, with a fault code. Most fault codes will reset themselves
within a few seconds, while others will require the operator to power
down the machine. If particular fault code continues, please contact an
authorized IWT service center for information on servicing your system.
Fault
Safety
Actuated
Fault
High
Temperature
Fault
Ready
X
X
Low 28V
Fault
Charge Fault
Discharge
Fault
Gun Not
Removed
Fault
X
X
X
LEDs
Stud
X
X
X
X
X
Foot
Weld
Complete
X
X
X
X
X
X
X
X
X
X
*A HIGH TEMPERATURE FAULT (fast blinking fault light) indicated that the transformer is over it’s operational
temperature. In this case do not turn the machine off. Instead let the internal cooling fan cool the transformer
until it automatically resets.
36
8.3
Causes of poor or erratic welds
1. Loose collet. The collet does not grip the stud tightly.
Solution: Change collet
2. Not enough engagement of the stud in the collet.
Solution: Remove the collet from the gun, loosen the back-stop so
that approximately 1/8” of the stud is protruding from the collet, and
reinstall the collet in the gun.
3. Faulty or loose ground connection
Solution: Repair or tighten ground connectors
4. Poor surface condition
Solution: Grind the surface to be welded. Grind through mill scale or
anodizing.
5. Broken or loose cables
Solution: Repair cables
6. Dirt in gun/gun binding
Solution: Clean gun with compressed air, soft cloth and WD-40™
7. Incorrect Polarity
Solution: Change cable hookup as described in Section 5.9.
8. Use of center punch
Solution: Do not use punches that leave a deep indentation. Do not
use permanent markers or grease pencils. Use a graphite pencil or
scribe line only.
9. Cables coiled
Solution: Uncoil cables
10. Arc Blow
Solution: In severe cases there will be no melting under one edge of
the flange while the opposite side appears excessively hot. The
principle cause of arc blow is a magnetic field induced by current
flow during the weld. It occurs most often in long, narrow strips of
metal or near edges of sheets or plates. In some cases, a change in
grounding position will correct the problem. Always try to weld
between the two ground cables provided.
11. Incorrect fastener stick-out
Solution:
Adjust the backstop and/or foot piece so that
approximately 3/32” of the fastener sticks beyond the foot piece to
weld aluminum or 1/8” of the fastener sticks beyond the foot piece to
weld steel.
12. Incorrect spring pressure
Solution: Set spring pressure to “-“ for steels and to “+” for
aluminum.
13. Poor stud quality
Solution: Use only IWT’s pre-cleaned fasteners to assure quality.
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8.4
Trouble shooting poor welds
1. Weld too hot
• Decrease voltage
• Set protrusion as indicated in Section 5.7
• Increase spring pressure
2. Weld too cold
• Increase voltage
• Set protrusion as indicated in Section 5.7
• Decrease spring pressure
3. Arc blow
• Use double ground cables
• Change ground cable position
4. Weld not perpendicular
• Use supplied foot piece
• Use template adaptor
• Use tripod legs (available through IWT)
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9
WARRANTY
IWT’s mechanical components are warranted against manufacturer’s defects in material and workmanship for a period of one
(1) year from the time of shipment from IWT’s facility. IWT’s electrical components are similarly warranted for a period of one
(1) year from the time of shipment from IWT’s facility. IWT’s sole obligation under this warranty is limited to repairing the
product or, at its option, replacing the product without additional charge, provided the item is properly returned to IWT for
repair as described below. The provisions of this warranty shall not apply to any product that has been subjected to tampering,
abuse, improper setup or operating conditions, misuse, lack of proper maintenance, or unauthorized user adjustment. IWT
makes no warranty that its products are fit for any use or purpose to which they may be put by the customer, whether or not
such use or purpose has been disclosed to IWT in specifications or drawings previously or subsequently provided, and
whether or not IWT’s products are specifically designed and/or manufactured for such a purpose.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. ALL OTHER WARRANTIES,
INCLUDING, BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, WHETHER EXPRESSED, IMPLIED, OR ARISING BY OPERATION OF LAW, TRADE USAGE, OR COURSE OF
DEALING, ARE HEREBY DISCLAIMED. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON
THE FACE HEREOF.
LIMITATION OF REMEDY
In no event shall IWT be liable for any incidental, consequential, or special damages of any kind or nature whatsoever. IWT is
in no way liable for any lost profits arising from or connected to this agreement or items sold under this agreement, whether
alleged to arise from breach of contract, expressed or implied warranty, or in tort, including, without limitation, negligence,
failure to warn, or strict liability.
RETURN PROCEDURE
Before returning any equipment in or out of warranty, the customer must first obtain a return authorization number and packing
instructions from IWT. No claim will be allowed nor credit given for products returned without such authorization. Proper
packaging and insurance for transportation is solely the customer’s responsibility. After approval from IWT, the product should
be returned with a statement of the problem and transportation prepaid. If, upon examination, warranted defects exist, the
product will be repaired or replaced at no charge, and shipped prepaid back to the customer. Return shipment will be by
common carrier (i.e., UPS). If rapid delivery is requested by customer, then such transport is at the customer’s expense. If an
out-of-warranty situation exists, the customer will be notified of the repair costs immediately. At such time, the customer must
issue a purchase order to cover the cost of the repair or authorize the product to be shipped back as is, at the customer’s
expense. In any case, a restocking charge of 20% will be charged on all items returned to stock.
FIELD SERVICE
Repairs are ordinarily done at IWT’s, Lindenwold, New Jersey facility where all necessary tools are available. Field service is
only supplied at IWT’s discretion. If field service is required and is performed at IWT’s sole discretion, all relevant expenses,
including transportation, travel time, subsistence costs, and the prevailing cost per hour (eight hour minimum) are the
responsibility of the customer.
UNFORESEEN CIRCUMSTANCES
IWT is not liable for delay or failure to perform any obligations hereunder by reason of circumstances beyond its reasonable
control. These circumstances include, but are not limited to, accidents, acts of God, strikes or labor disputes, laws, rules, or
regulations of any government or government agency, fires, floods, delays or failures in delivery of carriers or suppliers,
shortages of materials, and any other event beyond IWT’s control.
ENTIRE AGREEMENT/GOVERNING LAW
The terms and conditions contained herein shall constitute the entire agreement concerning the terms and conditions for the
limited warranty described hereunder. No oral or other representations are in effect. This Agreement shall be governed in all
respects by the laws of State of New Jersey. No legal action may be taken by any party more than one (1) year after the date
of purchase.
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40
LYNX4 OPERATION MANUAL SUPPLEMENT - WELDING INSULATION PIN
4
The LYNX Modular Stud Welding System is the state of the art welding systems capable of welding pins,
threaded fasteners and insulation fasteners. Depending on your application, your system may have been shipped
with IWT’s Gap (IWT-G1), Contact (IWT-C1), or Insulation Gun (IWT-Ci). This supplement addresses only the
4
setup and operation of the LYNX with the IWT-Ci. Please also refer to Section 5.7 for gap or contact mode
welding.
BACKGROUND/TECHNICAL INTRODUCTION
4
For welding cupped head pins (CHP) and 10GA or 12GA insulation nails, the LYNX is supplied with IWT-Ci
Insulation Gun with 33-ft lead and one 25-ft ground cable. The leads on both the gun and ground cable are
integral to the successful welding of insulation fasteners as discussed below. Since the condition known as “arc
blow” (see section 8.2) is not a concern with insulation fasteners, only one long ground cable is required. The
gauge and length of the gun and ground cables are specifically selected to increase the time of the capacitor
discharge weld pulse. This weld pulse is typically increased from 2 milliseconds to 11 milliseconds using this
special cable set. While many stud welding systems that are designed only for insulation fasteners use internal
resistance to extend this pulse, IWT has chosen to provide an extended cable set thereby providing the operator
with increased working flexibility (up to 50ft working radius).
GUN SETUP FOR INSTALLATION FASTENERS
First determine which type of insulation fastener will be welded and select the appropriate collet supplied with
your gun:
Fastener Type
Cupped Head Pins
10GA Nails
12GA Nails
Appropriate Collet
Magnetic Chuck
#6/10GA Std Chuck
#4/12GA Std Chuck
Part Number
1-CH035301
1-CH500001
1-CH500038
If previously installed, remove the adjustable leg assembly from the gun by loosening 4 set screws in the based
on the assembly (you will not need this foot piece assembly for CHP). Insert the correct collet into your gun and
tighten the locking nut with either a 17mm or 11/16 wrench. If you are welding 10GA or 12GA nails, you may wish
to re-install the adjustable leg set at this point. Set the foot piece so that approximately 3/16” of the nail head
extends beyond the foot piece.
Attach the IWT-Ci Insulation Gun to the locking terminals indicated on the front panel of the unit. Install the
ground cable in either of the indicated ground terminals. Ensure that all connections are tight. Attach the clamp
end of the ground cable to your work piece.
4
Switch the unit on and set the voltage on the LYNX unit as follows:
10GA Nails and 10GA CHP
12GA Nails and 12GA CHP
125-150V
100-125V
You are now ready to weld. Press the gun against your work piece or pierce through the insulation with the CHP.
Once the pin makes contact with the work piece, the “Stud on Work” light will be lit. The gun spring should
compress, however, it is not necessary to “bottom the gun out”. You may now make a weld be depressing the
trigger on the gun. Inspect the weld to ensure the fastener is attached firmly. If necessary, adjust the weld
voltage and/or the gun spring pressure to achieve desired results. Excessive voltage will not produce a
better weld.
See also Section 5.10 for a discussion of reverse polarity welding.
Revision 2
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