Antech AN-350 User manual

OPERATION MANUAL FOR THE SCD SERIES-CAPACITOR
DISCHARGE STUD WELDING MACHINE
▓SERIES :SCD —
▓MODEL#:AN—350
▓SERIAL#:AE0
▓DATE :
ANTECH ELECTRONICS LTD.
030-056-01-001
Please read this manual carefully before
using this welding machine

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
10/2000 ANTECH ELECT.LTD.
1
Thank you for choosing Antech welding equipments.
Please read this manual carefully before the installation and operation of
the SCD series stud welding machine. Do not hesitate to contact us if you have
queries.
The SCD series of stud welding machines is another high quality product
developed by Antech Electronics Ltd. It is built with a dedicated AN-350
controller that provides stable outputs regardless of any input voltage and
temperature changes. The internal memory supports three (3, or up) set of program
parameters. The SCD series stud welding machines are equipped with either quality
German or Japanese stud welding guns to provide superb performance and
reliability. It is thus a perfect alternative to the expensive import stud
welding machines.
Please advise if any errors are found concerning the contents and printing
of this manual.
CAUTION
DANGER, HIGH VOLTAGE

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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CAUTIONS
1. Ensure that the welding machine is properly grounded before operations, to
avoid electric shock.
2. Be aware of high voltage
The power thyristors, transformers, capacitors and some components might
carry high voltages. It is advised that the supply to the welding machine
be disconnected before opening the chassis for service and maintenance.
3. Ensure that the start switch or welding gun trigger is in the off position
before turning on the power to the welding machine.
4. Do not operate the welding machine if the chassis is open.
5. Any service, repairing and maintenance should only be performed by qualified
technicians. ( Be cautious when dealing with high voltage components, such
as the thyristers, transformers and capacitors )
6. The working environment should be free of corrosive gas, vapor and excessive
dust. Keep the control unit from contacts of water and grease.
7. Do not place heavy loads on top of the control unit.
8. Keep working condition clean, free of dust and dry. Check cable connections
and screw joints in a regular basis.
9. No smoking and fire hazardous material is near by the welding machine.
10. Sparks might be produced in the welding process. It is strongly recommended
that protection materials, especially safety glasses, be worn to prevent
bodily injuries.

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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INDEX
1: Introduction ………………………………………………………………………… 4
2: Specifications ……………………………………………………………………… 4
3: Installations ………………………………………………………………………… 4
4: The Control Unit …………………………………………………………………… 7
5: The Stud Welding Gun ………………………………………………………………… 1 4
6: Stud Welding Procedure ………………………………………………………………23
7: Welding Tips …………………………………………………………………………… 24
8: Maintenance …………………………………………………………………………… 25
9: Diagnostics …………………………………………………………………………… 26
10: Parameter List ……………………………………………………………………… 27
Diagram 1: Connection diagram SCD capacitor stud welding machine
Diagram 2: SCD series stud welding

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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1. INTRODUCTION:
The SCD series Stud Welding Machines are designed for tip ignition stud
welding of stud/nails. The stud weld is completed in a very short period of time.
This helps to prevent thin workpieces from damage and distortion due to the heat
generated during the welding process. As a result, the SCD series stud welding
is suitable for a wide range of applications.
It is easy to perform maintenance and repairing as all the major parts are
housed in a single chassis, except the welding gun and cables. Based on a lot
of expertise, experience and continuous improvements, the SCD series of stud
welding machines have been developed to meet the requirements of the welding
industry. It is suitable for the stud welding of stainless steel, mild steel,
aluminum, copper … etc.
It is our endeavor to maintain a high quality control policy so that our
products will satisfy all our users in the welding industry.
2.SPECIFICATIONS:
Model: SCD-60 SCD-80 SCD-100
Input voltage 220V± 15%, single phase, 50/60Hz
Weld stud range Φ2~Φ6
M3~M6( ※Al. M5)
Φ2~Φ8
M3~M8( ※Al. M6)
Φ2~Φ10
M3~M10( ※Al. M8)
Capacitance( µF) 66,000 99,000 132,000
Output voltage,
(capacitor voltage)
30~175V
Ambient temperature -10℃~55℃
Relative humidity 20%~ 90%
Dimensions 455 (D) X 350 (W) X 450 (H)
Stud weld gun type ESP-9 / ESP-6 / H100/ TSK310
※For aluminum (Al.), recommend to use CD-Stud gun type ESP-9
3. INSTALLATIONS:
3.1 Setup:
Follow the following steps for proper setup:

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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3.1.1 Place the welding machine on a solid and stable platform.
3.1.2 If necessary, u se a250VD.C.isolation meter to check the isolation between
the input power lines and the chassis. The resistance should be greater
than 2 MO .( due to t he internal electronics, the control circuit wiring
should be disconnected for proper measurement of isolation) .
3.1.3 Connect the input power plug to a suitable and safe power socket. Proper
grounding is mamdatory.
3.1.4 For pneumatic welding gun systems:
(1)Connect the pedal/push button switch to the connector on the front of
the control unit;
(2)Clean the air hoses and assembly, and then connect the air outlet from
the air-compressor to the air inlet on the right hand side of the
welding machine;
3.1.5 Output Power Selection:(to be set according to customer requirements)
There are three selections of output power ranges, as shown in Figure 1.
The selections can be made with the position of the copper bars at the
back of the control unit:
???出小能量接法
短路?片 短路?片
???出中等能量接法
短路?片 短路?片
???出最大能量接法
短路?片
?一 外部接?柱?接示意?
Short circuit copper bar
Small power output
connection method
Short circuit copper bar
Short circuit copper bar
Short circuit copper bar
Short circuit copper bar
Middle power output
connection method
Largest power output
connection method
Figure 1: Output Power Selection Method

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
10/2000 ANTECH ELECT.LTD.
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接地??
焊???
接地??
FUSE
焊???
ANTECH ELECT.LTD
SCD-80
電源線
S/P
POWER
S/P13
2VALVE
WELDREADY RUN VALVE
C
工件
焊槍
?二焊机外部?接?
3.2 Exterior Connections:(See Figure 2)
3.2.1 Connect the stud welding gun cable to the corresponding( -) fast-on socket
at the left of the front panel of the welding machine. Turn right and ensure
that they are tightened properly;
3.2.2 Connect the control wires of the welding gun to the 4-pin socket on the
front of the control panel, tighten the connection with the mounting ring
of the plug;
3.2.3 Connect the earth cables to the earth( +) fast-on connector on the front
panel. Turn clockwise to tighten the connection properly;
3.2.4 Connect the earth cables to the work piece by clamps respectively.
? NOTE: 1.As welding current may go up to8000A, it is essential to maintain tight
connections for all welding gun and earth cables;
2.To achieve satisfactory welding results, use both earth cables for the
connection of the work piece. They should placed in a diagonal
positions, as shown in Figure 3;
Welding torch
W
ork piece
W
elding
gun
cable
Welding gun
G
round cable
G
round cable
W
elding gun cable
Power
cable
Figure 2: Outer Cable Connection of Welding Machine

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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◎Correct positions ◎Incorrect positions
Figure 3: Connection of earth cables to the work piece
3. Make sure that the side, rear and bottom panels of the chassis are
free of obstacles that might block the airflow for cooling.
Check again to confirm correct wirings before switching on the power.
4.THE CONTROL UNIT:
4.1 Features:
The AN350 Capacitor Discharge Welding Controller is used as the control unit.
It is microcontroller based providing 3 series of program welding parameters,
Overheat indication, Discharge thyrister diagnostics( Open-circuited /
Short-circuited ) indication 、Capacitor over-voltage indication and
protection, Under-voltage indication and Parameter lock (optional)
features.
4.2 Major components:
The control unit is mainly composed of the following parts: the main
transformer, capacitors, thyristers, input filter, charging resistor and
an AN350 controller.
4.3 Basic features of the control unit:
4.3.1 Controller: AN-350
4.3.2 Control features:
Timing Control : Pre-squeeze Time: 1-99 cycles
Hold Time: : 0-99 cycles
Voltage Control: Capacitor Voltage : 30V~175V
Weld Counter: Number of welding: 0~9999
Preset Counter: Number of welding to stop: 0~9999
接地
接地
接地
接地
接地
Ground
Ground
Ground
Ground
Ground

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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S/P
POWER
S/P
ANTECH ELECT.LTD
SCD-80
FUSE
23
1
C
WELDREADY RUN VALVE
VALVE
保?
?源??
?源?? 程序???? AN-350控制盒
快速接?
焊?插座
接?插（有气缸??
种焊?之焊机用）
Diagnostics : Discharge thyrister O/C & S/C alarm
Capacitor over and under-voltage alarm
Transformer and thyrister over-heat alarm
System Parameters: (S0), used for the fine tuning and running conditions
of the welding system.
□NOTE: For 50 Hz line frequency, 1 cycle = 20 msec.
4.3.3 Operating Specifications:
Input Voltage: Single phase 220V± 15%,
50/60Hz( automatic frequency detection)
Solenoid Voltage : DC24V± 10%
Ambient Temperature : -10℃~55℃
Relative Humidity : below 90%
Parameter Display: 4 X 7-segment LED display
Indicators : Spot LED
4.4 Descriptions of the Control Unit:(See Figure 4)
Fuse
Power switch
AN-350
Control box
Power cable inlet
Welding torch
socket
Quick socket
Logical
selection
Figure 4: Descriptions of the Control Unit
Connecting socket
(for stud welding
machine with air
tank only)

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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4.4.1 Power Switch:
Used to connect or disconnect power to the welding machine;
4.4.2 Program Series Selector:
Used to select the series of programmed parameters( S1, S2, S3);
4.4.3 AN-350 Controller:
AN-350 Controller is the main processor of the welding machine. It is
used for the control of the welding sequence, status indications and
parameter setup and storage.
4.4.4 Fuse( 5A):
For the over-current protection of the welding gun.
4.4.5 4-pins Socket:
Used for the connection of the control wires of the welding gun.
4.4.6 Input Power port:
4.4.7 Fast-on Socket( -):
Used for the connection of the Welding gun cable.
4.4.8 Fast-on Socket( +):
Used for the connection of the earth cables.
4.5 Descriptions of the AN-350 Operator Panel and Indictors: (See Diagram 5)
1. Power Indicator( POWER)
2. Ready Indicator( READY)
3. Weld Ready Indicator( RUN)
4. Solenoid Indicator( VALVE)
5. Welding Indicator( WELD)
6. Program/Parameter Display
7. Program Button( S/P)
8. Clear Button( C)
9. Increment Button( +)
10. Decrement Button( -)
Diagram 5: AN-350 Operator Panel
107 8 9
ANTECH ELECT.SYSTEM CANADA
VALVE
1 432
S/P
S/P
S/P
6
C
VALUE
C
POWER RUNREADY
5
WELD

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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4.5.1 Power Indicator( POWER):
This LED lights up when power is applied to AN-350;
4.5.2 Ready Indicator( READY):
This LED lights up when the control unit has passed self-diagnostics after
power on;
4.5.3 Weld Ready indicator( RUN):
The AN350 controller will start charging the capacitors when it passes
self-diagnostics. This LED lights up when the capacitor voltage has been
charged to the preset value and it is ready for welding;
4.5.4 Solenoid Indicator( VALVE):
This LED indicator lights up when the solenoid is energized;valid only
if the welding gun is driven by solenoid.
4.5.5 Welding Indicator( WELD):
This LED lights up when welding is in progress;
4.5.6 Program/Parameter Display:
This 4 X 7 -segment LED display is used to show the series number, program
number and parameter values.
NOTE: Series #0 parameters are for internal use only. Do not change;
4.5.7 Program Button( S/P):
Press this button in a row to follow a sequence showing the series number,
parameter number and parameter values. The following example demonstrates
the display sequence for series #1；

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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S1
P1
=XX
P3
=XX
P5
=XXX
P8
=XXXX
P9
=XXXX
4.5.8 Clear Button( C):
Press the Clear button to exit from any display mode to the ‘rdy’ mode;
4.5.9 Increment Button( +):
Press this button once would increase the display value by one (1), if
allowed;
4.5.10 Decrement Button( -):
Press this button once would decrease the display value by one (1), if
allowed;

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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4.5.11 Descriptions of AN-350 features:
( 1) S1-S3: series 1 to 3, user program parameters, set as required:
( S1-S3) Parameter #
Descriptions Range
P1 Pre-squeeze Time
1~ 99 cycle
P3 Hold Time 0~ 99 cycle
P5 Capacitor voltage
30~ 175V
P8 Weld Counter 0~ 9999
P9 Preset Counter 0~ 9999
( 2) S0: System parameters, read only, do not changes the values:
SO Parameter #
Descriptions
P1 Capacitance
P2 Maximum capacitor voltage
P3 Charging current
P4 Charging resistor
P5 Delay between charging & discharging
P6 Solenoid starting time
P7 Discharge delay time
P8 Software version
P9 DIP switch positions
P10 Input line voltage
P11 Current Capacitor voltage
P12 Capacitor voltage setpoint
4.6 Descriptions of display messages:(7-segment LED display)
4.6.1 General messages:
Up : Powering (up),self diagnostics in progress
Chrg: (Charge) Charging in progress
Rdy : (Ready) for Welding
On : Welding in progress( Stud gun trigger has been pulled)
Off : Welding completed(release trigger,and it will be back to“ rdy”)
Cntr: (Counter)The Weld counter has reached the Preset counter value
4.6.2 Fault messages:
E01: AN-350 cable to driver board is open or overheated
E03: Discharge fault
E04: Charging fault
E05: Capacitor over-charged

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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4.7 Descriptions of the AN-350 controller operations:
The adjustment of program parameters:
( 1) Press the (S/P) button,and then choose the series number by pressing
the (+) or ( -) buttons. For example,series #2( shows S2 on display);
( 2) Press the (S/P) button to accept the series #. And then press the (+)
or (-) buttons to select Parameter #, i.e. P1, P3, P5, P8, P9;
(3)Press the (S/P) button to accept the parameter # and the current value
of the parameter will be shown. And then press the (+) or (-) buttons
to select Parameter value;
(4)Press the (S/P) button to accept the value and it will be saved to the
internal memory of the controller. The display will show the next
parameter on the list. Repeat step (4) to change the value of the
parameter, if necessary, until all parameters have been updated;
( 5) It is absolutely necessary to press the (S/P) button for the controller
to accept the value even though only one parameter is required to be
updated;
( 6) Press the (C) button to exit from any display state and it will be back
to the ready (rdy) state for welding operations.
4.8 The following is a typical example of parameter setting:
Set the pressuring time of series #2 be 20 units, holding time be 10 units,
charging voltage be 100V, welding parameter be 0.
Display
Display
Display
Display
Display
Display
Display
Display
Display
Press
Press
Press
Press
Press
Press once
or
Press once or more
Press once or more
or

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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5. Stud Welding Guns:
5.1 The selection of Stud welding guns:
5.1.1 According to the applications, there are two types of Stud welding guns :
the Gap method and the Contact method Stun welding guns.
( 1) For the Gap method welding guns, the discharge of current is made
at the moment after the stud is pulled away from the work piece with
a gap maintained between them, as shown in Figure 6:
Diagram 6: Gap Method Stud Welding Procedure
Gap method stud welding is suitable for welding of mild steel,
stainless steel, aluminum and titanium .. etc.?
1.?????/??? 2.??……???? 3.????
Display
Press
Press once or more
or
Display
Display
Display
Display
Display
or
Press
Press
Press
Press
Press once or more
Setting complete. Press
and
once to go back to stand by mode.
3.Studweldingcomplete
2. Discharge current,
arc generated
1. Stud weldingwork piece

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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( 2) For the Contact method, the discharge is made through the contact
maintained under pressure between the tip of the stud and the work
piece, as illustrated in Diagram 7:
Contact method is suitable for the stun welding of various materials,
such as mild steel, stainless steel .. etc
5.1.2 Depends on the material and size of studs, there are three different stud
welding guns available for selection:
Stud Gun Descriptions
Model ESP 9
Type Gap method
Suitable for Mild steel, Stainless
Steel, Aluminum .. etc
Diameter
M3~M8/Φ2~Φ8
Length 5mm~50mm
Stud
Material
Mild steel, Stainless
Steel, Aluminum .. etc
Length of Gun cable
4 meter
Gap adjustment type
Automatic ( when
trigger is pulled)
1.?????/????? 2.??……???? 3.????
?七 接触式种焊?工作方式
ESP9
支?腳
（共三支） 前面蓋套 外殼
夾頭
??螺母
焊?????
握把
控制電? 焊接電?
Diagram 7: Contact Method Stud Welding Procedure
3.Studweldingcomplete
2. Discharge current,
arc generated
1. Stud welding work piece
Casing
Welding
cable
Control
cable
Handle
Switch ON/OFF
Supporting arm
(totally 3) Front
Locking nut
Chuck

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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焊???
??
??螺母
支??
??
控制?? 焊接??
?簧加?
力???
外?
Model ESP 6
Type Contact method
Suitable for Mild steel, Stainless
Steel .. etc
Diameter
M3~M8/Φ2~Φ8
Length 5mm~50mm
Stud
Material
Mild steel, Stainless
Steel .. etc
Length of Gun cable
4 meter
Adjustment type Preset gap adjustment
Model H-100
Type Contact method
Suitable for Mild steel, Stainless
Steel .. etc
Diameter
M3~M10/Φ2~Φ10
Length 5mm~45mm
Stud
Material
Mild steel, Stainless
Steel .. etc
Length of Gun cable
6 meter
焊接電?
??螺母
夾頭
控制電?
焊?????
握把
前面蓋套
支??
(共三支)外殼
后部?套
H-100
Pressure Adjustment
method
By spring and/or stud
tip adjustments
Model HP-TSK310
Type Contact method
Suitable for Mild steel? Stainless
Steel, Aluminum .. etc.
Diameter
Φ3~Φ8
Length 6mm~30mm
Stud
Material
Mild steel? Stainless
Steel, Aluminum .. etc.
Pressure Adjustment
method
By adjustment of aft
spring and pressure
button
外殼
前面蓋套
焊机????
握把
支?腳
(共三支)
夾頭
??螺母
控制電? 焊接電?
ESP6
Casing
Welding
cable
Control
cable
Handle
Switch ON/OFF
Supporting arm
(totally 3)
Front
Locking nut
Casing
Welding
cable
Control
cable
Handle
Switch ON/OFF
Supporting arm
(totally 3)
Front
Locking nut Aft cover
Casing
Welding
cable
Control
cable
Supporting arm
Locking nut
Switch ON/OFF
pressure
adjusting
button
Chuck
Chuck
Chuck

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5.2 Stud Gun Adjustments:
5.2.1 Gun assembly of ESP 9/ ESP 6 stud guns:( Figure 8)
2mm
Figure 8: ESP 9/ESP 6 gun assembly
Item Descriptions Item Descriptions
1 Chuck 4 Stud stop’s fixing nut
2 Tightening nut 5 Stud stop’s tightening nut
3 Adjustable stud stop 6 Supporting foot
( 1) Chuck:
The chuck is used for the holding of the stud/nail and for the
discharge current to go through its contact with the stud for welding.
It is therefore critical that the size of the stud and the chuck are
matched. Otherwise, unsatisfactory welding results could be produced
and the stud & gun assembly would be damaged prematurely;
□Note: 1.When using new chucks, ensure that the bottom part of the
stud/nail is tight with inserted;

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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2.Check the contact from time to time and use a pair of pliers
to tighten it when necessary ;
3.Replace the chuck if worn out after a long period of
operations.
( 2) The chuck’s tightening nut:
Used to fix the position of the chuck from shifting;
( 3) Adjustable stud stop:
The adjustable stud stop is used to support the position of the stud
when inserted into the chuck. This helps the provide a consistent
position for studs of various lengths;
( 4) Stud stop’s fixing nut:
Allows the adjustment and fixing of the stud stop’s position;
( 5) Stud stop’s tightening nut:
After the position of the stud stop has been fixed, it is used to
tighten up the stud stop in order to prevent it from shifting;
( 6) Supporting feet:
The three supporting feet determines a stable surface. This helps to
maintain a stable and vertical stud position relative to the work
piece.
5.2.2 Setup of the gap for type ESP 9 stud gun:
Although the gap of type ESP 9 stud gun is adjusted automatically, it is
also necessary to setup the chuck in order to weld properly.
( 1) Unscrew the tightening nut of the chuck;
( 2) Place a stud/nail into the chuck;
( 3) Use the adjustable stud stop, adjust the space between the chuck face
and the stud flange to be 2mm minimum;
( 4) Tighten the adjustable stud stop to the chuck,and then place the chuck
to the welding gun;
( 5) Place the head of the gun on the nylon setting gauge in such a way
that all the supporting feet would make a contact with the setting
gauge, as shown in Figure 9;

OPERATION MANUAL FOR SCD( AN-350) SERIES CAPACITOR DISCHARGE STUD WELDING MACHINES
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Figure 9: Setting Gauge Gap Adjustment
(6)Unscrew the tightening nut and move the chuck until the tip of the
stud touches the lower part of the setting gauge;
(7)Use the dedicated nut driver( Stud gun accessory) to tighten the
tightening nut of the chuck carefully.
□Note: 1.The above procedure is for standard gap setup;
2.If the surface of the work piece is slightly contaminated,
reduce the gap (relative to standard gap) which allows a
longer welding time and intensifies degassing;
3.Turn the chuck to adjust the gap:
- Turn to the right: greater gap( shorter welding cycle)
- Turn to the left: smaller gap( longer welding cycle)
Tighten the chuck after gap adjustment
5.2.3 Adjustment of type ESP 6 welding guns:
The adjustment of type ESP 6welding guns is similar to the one for type
ESP 9 welding guns. Setup for standard gap first,and then re-adjust the
gap to change the welding cycle and degassing power according to test
result.
5.2.4 The type H-100 welding gun:
( 1) Installation of the chuck:(As shown in Figure 10)
?用套筒板手 ?? ?杆
????螺母
?十 H-100型种焊???安?
Chuck
Chuck locking nut
Stud stop
Figure 10: Installation of Stud Chuck (Model H-100)
Box type spanner