Cutlass Fasteners Signus PHM-1A User manual

PHM-1A GAP CD WELD GUN MANUAL
COPYRIGHT CFI 2009 email: [e-mail] PAGE - 1 -
Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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PLEASE READ THIS OPERATION AND MAINTENANCE MANUAL
CAREFULLY BEFORE USING YOUR NEW CUTLASS STUD WELDER.
MODEL : SIGNUS
PART NO. : PHM-1A
SERIAL NO. :

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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WARRANTY
The electrical and mechanical components of the Cutlass Stud Welders are thoroughly
performance inspected prior to assembly in the Welder. The assembled Welder is completely
performance checked. The Welder is delivered to you in perfect electro-mechanical condition.
All parts used in the assembly of the Welder are fully warranted for a period of three (3)
months from the date of delivery.
Under this warranty, the manufacturer reserves the right to repair or replace, at its option,
defective parts which fail during the warranty period. Notice of any claim for warranty repair or
replacement must be furnished to the manufacturer, by the purchaser, within five (5) days after
the defect is first discovered. The manufacturer does not assume any liability for paying
shipping costs, or for any labor or material furnished where such costs are not expressly
authorized in writing.
We do not warrant the Cutlass Stud Welders, parts or accessories against failures resulting
from misuse, abuse, improper installation, normal wear and tear, maladjustment or use not in
accordance with the operating instructions furnished by the manufacturer. Cutlass shall never
be liable for any consequential damages.

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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SUGGESTED SAFETY PRECAUTIONS
In any welding operation, it is the responsibility of the welder to observe certain safety rules to insure his personal
safety and to protect those working near him.
Reference is directed without endorsement or recommendation, to ANSI Z49.1, Safety in Welding and Cutting,
and to AWG Publication A6, 1-66 Recommended Safe Practices for Gas-Shielded Arc Welding.
1. Always treat electricity with respect. Under open circuit conditions, the welding machine output may be
dangerous.
2. Do not work on live circuits and conductors. Disconnect the main power line before checking the machine or
performing any maintenance operations.
3. Ensure the welding machine cabinet is properly grounded to a good electrical ground.
4. Do not stand in water or on damp floors while welding or weld in the rain. Avoid wearing wet or sweaty
clothes when welding.
5. Do not operate with worn or poorly connected cables, and do not operate weld gun with loose cable
connections. Inspect all cables frequently for insulation failures, exposed wires, loose connections and repair
as needed.
6. Do not overload weld cables or continue to operate with hot cables.
7. Do not weld near flammable materials or liquids, in or near atmospheres, or on ducts carrying explosive
gases.
8. Do not weld on containers which have held combustible or flammable materials, or on materials which give
off flammable or toxic vapors when heated, without proper cleaning, purging, or inerting.
9. Ensure adequate ventilation is provided when welding in confined spaces.
10. Never look at the electrical arc without wearing eye shields.
11. Always use proper protective clothing, gloves etc. Never weld close to a bystander who is unaware of the
possible dangers of ultraviolet light and weld splatter on their eyes.
12. Installation, servicing and trouble shooting should only be done by qualified personnel, familiar with this type
of equipment.

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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The SIGNUS CD stud welding system consists of the power unit (LBS-075), ground cables,
welding gun (PHM -1A), a suitable chuck (collet) and welding stud.
The PHM-1A is a GAP welding gun for welding studs with ignition tips. Due to the very short
welding time (compared to contact CD welding) the PHM-1A is ideal for welding to very thin
work pieces and allows welding to Aluminum without inert gas.
With the recommended settings shown on pages 9 and 10, other materials can also be
welded.
THE GAP CAPACITOR DISCHARGE STUD WELDING PROCESS
A stud is first pushed into the weld chuck or collet. The gun is then placed in a vertical position on the
workpiece. When the trigger button is pressed the gun automatically lifts the stud off the surface. When
the maximum set lift is achieved the lifting solenoid is turned off and the welding current is switched on.
The spring in the gun forces the stud towards the workpiece.
When the ignition tip hits the workpiece surface, a very high current is discharged. This vaporizes the
ignition tip and an arc is generated which melts the face of the stud and an approximately equal area of
the workpiece. The stud then dips into the molten weld pool, the arc is extinguished and the weld pool
solidifies. The welding process lasts about 1-3 milliseconds.
The weld gun is pulled off the weld stud. The SIGNUS recharges and a new stud can be fitted in the
weld chuck and the weld sequence repeated.
The higher the lift setting, the shorter the weld time (see the chart on page 9 for suggested settings). It
is recommended that the workpiece is 0.020” (0.5mm) minimum thickness.

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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CD STUD/BASE METAL COMBINATION WELDING CAPABILITIES
* Generally full strength results, depending upon the combination of stud size and base metal.
BASE MATERIAL
STUD MATERIAL
MILD STEEL
1008-1010
STAINLESS
302, 304, 305
ALUMINUM
1100, 5356, 6061
BRASS
70/30, 65/35
MILD STEEL
1006-1030
Excellent
Excellent
-------------
Excellent
MEDIUM CARBON STEEL
1030-1050
Good*
Good*
-------------
Good*
GALVANIZED DUCT
Excellent
Excellent
-------------
Excellent
STRUCTURAL STEEL
A-36, A-108
Excellent
Excellent
-------------
Excellent
STAINLESS STEEL
405, 410, 430, AND 300 SERIES
EXCEPT 303
Excellent
Excellent
-------------
Excellent
LEAD FREE BRASS,
ELECTROLYTIC COPPER,
LEAD FREE ROLLED COPPER
Excellent
Excellent
-------------
Excellent
MOST ALUMINUM ALLOYS OF
THE 1100, 3000, 5000, AND 6000
SERIES
-------------
-------------
Excellent
-------------
DIE-CAST ZINC ALLOYS
Good*
Good*
Excellent
Good*
Welding studs with ignition tip can be positioned
exactly on center punch marks or scribed lines.
Since the welding process is started by the ignition
tip, marking must be performed carefully.
The weld cannot ignite on a center punch mark
which is too deep. Should the weld start the weld
strength may still be questionable.
Therefore make sure the depth of the center punch
mark does not exceed 0.012” (0.3mm).

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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The electrical and mechanical parameters of the weld are set using the voltage control knob on the
front of the welder and by adjusting the lift distance of the welding gun.
WELD GUN SETUP
ADJUSTING THE PHM-1A WELD GUN
The welding time depends on the stud speed . It is adjusted indirectly via the lift mechanism in the gun.
The greater the lift is, the higher the speed of the welding stud as it returns to the workpiece, and hence
the shorter the welding time.
The lift is set with the rear cap on the back of the weld gun:
Turning the rear cap clockwise will increase the
lift, thereby reducing the weld time.
Turning the rear cap counterclockwise will reduce
the lift, thereby increasing the weld time.
To prevent damage to the adjusting mechanism,
never use force to turn the rear cap at the limits of
the adjustment.
1/8”
1/16 -1/8”
LEG
FOOTPIECE
WELD
STUD
The weld chuck should be adjusted as shown. For longer
studs, as much of the stud should be held as possible.
This may require complete removal of the adjusting screw.
Seat weld chuck firmly in the front of weld gun and attach
leg and footpiece assembly. Set leg depth so
approximately 1/8” of stud/chuck protrudes beyond the
footpiece.

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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Turn the rear cap clockwise to approximately
maximum lift. Place the gun in the welding position
on a flat surface as shown.
Turn the rear cap counterclockwise until the stud
and footpace lie flat on the surface. This setting is
called “zero lift”.
Find your material combination and the diameter of
the welding stud in the following chart. Then set the
lift by turning the rear cap clockwise by the specified
value.
NOTE: One revolution of the rear cap corresponds
to 1.0mm (0.040”) lift
Place the weld gun perpendicular to the
workpiece as shown. Apply pressure to the
gun so the footpiece lies firmly on the
workpiece.
Hold gun steady and pull trigger when stud is
in required position. After weld cycle withdraw
gun from stud. Pull gun straight back so weld
chuck is not damaged.
Inspect weld and adjust settings as required.
WORKPIECE
MATERIAL
STUD MATERIAL AND DIAMETER
MILD STEEL
STAINLESS STEEL
ALUMINUM ALLOY
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
STEEL
1.5-2 1.5-2 1.5-2 1.5-2 1.5-2
1.5-2 1.5-2 1.5-2 1.5-2 1.5-2
-----
STEEL GALVANIZED
1.5-1.5-1.5-1.5-1.5-
2.5 2.5 2.5 2.5 2.5
1.5-1.5-1.5-1.5-1.5-
2.5 2.5 2.5 2.5 2.5
-----
STAINLESS STEEL
1.5-1.5-1.5-1.5-1.5-
2.5 2.5 2.5 2.5 2.5
1.5-1.5-1.5-1.5-1.5-
2.5 2.5 2.5 2.5 2.5
-----
ALUMINUM ALLOY
-- ---
-----
3-3.5 3-3.5 3-3.5 3-3.5 -
WORKPIECE
SECTION THRU
FOOTPIECE

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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RECOMMENDED CHARGE VOLTAGE
The welding current strength is regulated via the charge voltage of the capacitors in the Signus power
unit. To set the charge voltage, turn the knob on the front panel to the recommended setting from the
following table.
The settings shown below are to be used as a guide only, and we recommend test welding on
scrap material to ascertain optimum weld parameters for a specific application.
**The settings shown above are for standard Flanged welding studs. For Mini-Flanged or Non-Flanged Studs, lower settings will be required.
TEST WELDING
Before making your first weld, check the ground clamp. It is essential that no power be lost through a poor
connection. The surface under the ground should be free from oil, scale, grease and rust. The test should be on
a piece of scrap material similar to the material to be used during actual production.
NOTE: IF WELD APPEARS COLD, DO NOT PLACE GUN ON WELDED STUD AND TRIGGER AGAIN.
DAMAGE TO WELD CHUCK OR CONTROLLER WILL OCCUR.
TOO COLD
COLD
GOOD WELD
TOO HOT
No weld visible
Too much spatter around
head of fastener.
Weld just visible around
head of fastener.
WORKPIECE
MATERIAL
STUD MATERIAL AND DIAMETER
MILD STEEL
STAINLESS STEEL
ALUMINUM ALLOY
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
STEEL
2 3 4 6 8
2 3 4 6 8
-----
STEEL GALVANIZED
3 4 5 7 9-10
3 4 5 7 9-10
-----
STAINLESS STEEL
1 2 3 4 7
1 2 3 5 7
-----
ALUMINUM ALLOY
- ----
- ----
2 3 4 5 -

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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CAUSES OF POOR OR ERRATIC WELDS
1. Loose weld chuck –does not grip stud tightly.
2. Faulty or loose ground connections.
3. Dirty base material (oil, grease, rust etc).
4. Voltage too high or too low.
5. Broken or loose cables.
6. Gun binding –dirt in weld gun preventing free movement.
7. Leg and/or footpiece incorrectly set.
8. Use of center punch.
9. Weld cables coiled.
NOTE: The weld cables and ground cables should be laid out in a straight line or large loops. Poor weld
quality may result if welding cables are closely coiled.
WELDER MAINTENANCE
Your Cutlass welder is designed for long service with minimum care. Ordinary common sense maintenance will
keep it operating efficiently. Following are some tips on preventative maintenance:
1. Treat the welding and control cables with respect. Avoid sharp bends and kinks which may break the cables.
Do not use the cables as a “tow-line” to move controller. Avoid damaging or straining the cables where they
enter the gun or connectors.
2. Ensure unit vents are not obstructed, and that the unit is not covered while in use. Avoid overheating.
3. Keep the welding gun free of dust and dirt. Periodically clean weld splatter from front of gun.
4. The welder should not be placed in close proximity to any MIG or TIG welders, nor should the CD power
source share a common power supply with MIG or TIG equipment. Similarly the main ground connection
from the CD welder to the workpiece should not be linked in any way to MIG or TIG grounds.
FAILURE TO COMPLY COULD INVALIDATE YOUR WARRANTY

PHM-1A GAP CD WELD GUN MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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STANDARD ACCESSORIES
INCH
STUD SIZE
PART NUMBER
2-56UNC
015-509
12GA, 4-40UNC
602-467A
1/8
015-511
10GA, 6-32UNC
602-451A
STUD SIZE
PART NUMBER
8-32UNC
602-452A
3MM
605-111
#10, 3/16
605-101A
4MM
602-423A
0.217
605-112
5MM
605-102
1/4
605-104A
6MM
605-103
5/16
605-105A
8MM
605-105A
3/8
605-106A
10MM
605-106
* LONGER LENGTHS AVAILABLE ON REQUEST
SIZE
„D‟ DIA.
PART NO.
SMALL
7/8”
023-252
MEDIUM
1.160”
023-252M
DESCRIPTION
PART NO.
JIG LOCATING BUSH
D = 7/8”
650-691
NAIL GUIDE
D = 7/8”
601-350
CHUCK DRIFT
000-374
SPARK SHIELD, SML.
D = 1.16”, A =3/16”
999-013
SPARK SHIELD, LGE.
D = 1.16”, A =1/2”
999-018
METRIC
STANDARD
ADJUSTABLE
WELD CHUCKS
CD FOOTPIECE
D
JIG LOCATING BUSH
CHUCK DRIFT
SPARK SHIELD
NAIL GUIDE
D
A
D
* 2.5/8”