BDI S100 STINGER User manual

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QUICK START
GUIDE
For the complete S100 manual go to:
https://bditest.com/S100-Manual

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1. Connect the lug on the red cable from the bonder handle to the smaller terminal. Then install and hand-tighten the
wing nut again. Do not over tighten.
2. Line up the 3-pin connector from the handle with the receptacle on the panel. Twist the barrel of the connector to
secure it.
3. Use either cable with the magnetic clamp or the mechanical clamp. Connect clamp to bare, clean steel. To activate
the magnetic clamp, place it on a bare, clean steel surface then turn the switch to ON.
4. Insert the battery pack into the handle in the orientation shown in the drawing below until the pack snaps into place.
Charge the battery pack before use.

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STANDARD S100 KIT
INITIAL SETUP
1. Connect the black ground cable lug to larger stud on Stinger™ top panel. Thread on the ¼-20 wing nut for a
firm hand-tight.
S100 Stinger™ Spot Bonder
Bonding Handle and 5 ft Cables
1x Straight Bonding Tip
Magnetic Grounding Clamp
With 5 ft Cable
Mechanical Grounding Clamp
With 5 ft Cable
1x Milwaukee® M12™*
REDLITHIUM™ 3.0 Battery
Milwaukee® M12™ Lithium-Ion
Battery Charger
* M12 and REDLITHIUM are registered trademarks to the Milwaukee Electric Tool Corporation.

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OVERVIEW (SWITCH PANEL)
START BONDING!
1. Power on by pressing the Power button momentarily (no. 1 in the table above).
2. Check battery charge level by pressing the Li-Ion Battery button (no. 2 in the table above).
3. Set bonding energy to 35 joules. See Operations Manual for details on adjusting the settings and
verifying bond quality.
4. Make sure ground clamp is on a bare, clean spot of steel, near work area.
5. Firmly press bonding tip to the sensor’s bonding shim. Double check the sensor is in correct
position.
6. Squeeze trigger to create a spot-bond. See Operations Manual for additional details on verifying
the strength of a spot-bond.
7. Move tip to next location in bonding pattern and repeat step 5 through 6.
8. When finished, press the Power button to tun o.
CONTROLS CONNECTORS
1 POWER BUTTON 5 3-PIN CONTROL CABLE
2 LI-ION BATTERY BUTTON 6 POSITIVE ELECTRODE LEAD
3 BOND INTENSITY CONTROLS 7 GROUND TERMINAL
4 DISPLAY
ERROR CAUSE SOLUTION
bA Lo Very low battery
– Check battery charge level
– Change to battery with full charge
– If ambient temperature is cold, make sure the battery itself is warm
rE Resistance error
– Bonding resistance greater than 1 ohm
– Ensure all connections are properly made and tight
– Check all wingnuts and cables
– Ensure proper surface prep at gage location
– Ensure proper contact between the bonder-to-gage and gage-to-specimen
– Place the discharge tip firmly in contact with the material to be bonded
before pressing the trigger
REFER TO THE S100 STINGER™ OPERATIONS MANUAL ON OUR WEBSITE AT:
HTTPS://BDITEST.COM/S100-STINGER-MANUAL
TO LEARN MORE ABOUT THE S100 AND FOR WARRANTY INFORMATION, WARNINGS AND PRECAUTIONS, AND
DETAILED INSTRUCTIONS ON HOW TO OPERATE IT.
THE S100 STINGER™ IS MANUFACTURED BY BDI | MADE IN THE USA
FOR SUPPORT:
Email: [e-mail]
Or call: +1.303.494.3230
COMMON ERROR MESSAGES