JAVAC 11244-X User manual

INSTRUCTION MANUAL
We have the right to improve and update the machine.
The picture and the content are just for your reference.
11244-X
SM081175-V.1.0

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1. Mechanical/Electrical/Illustration of Working Principle data
Electrical Data
SN——Series number
CE，EN，ISO——Certification standards
Uin—— rated supply voltage
U20——range of rated ac no-load voltage and number of adjustable steps
I1（max）——max input welding current
I2（max）——max output welding current
Duty——Duty cycle
Weight——weight of the welding equipment
2. CD stud mode
2-1. Summary
The machine is for Capacitor Discharge Stud Welding ,the weld able range is Ø3- Ø8mm. Stud materials are soft
steel, stainless steel, aluminum, titanium (Ti), brass and copper screw. Stud Welding time is about
3/1000s-6/1000s,the time is very short, so the welding heat can not damage the base metal, even the base metal is
sheet metal.
2-2. Matters need attention
(1) Input power is AC110 / AC220 / AC380≥15A
(2) Turn "off " the switch, when not use the machine.
(3) Make sure turn "off " the switch, when connect or remove the cables of the machine.
(4) The machine maintenance and repair must turn "off " the switch after 5 minutes.
(5) The stud clamp is inside the stud welding torch. The inside diameter of stud clamp must suitable the stud screw.
Do not use worn stud clamp.
(6) Stud welding may to cause welding arc and metal spatter, protect your self with appropriate safety garments
and goggles.
(7) Make sure there are no flammable materials work area.
(8) The machine must use special stud screw, so must use original spares.
(9) Pleases contact the manufacturer ,as following situations:mechanical failure, reduce or increase the torch cable,
change the standard equipment.
MODE
L

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2-3. Stud welding and spot welding
2-3-1. stud welding （Diagram 1）
Contact type:
When mounting the stud, the stud extend the three support legs about 2mm. Confirm the stud welding position.
Press the support legs on the work piece steady. Make sure the work piece is smooth and clean. Press the torch
trigger, the stud screw will be welded on the base metal immediately. Check the stud welding strength. If the
strength is not enough, please adjust the torch pressure. The work process is electric discharge, stud welding and
recharge, repeat the steps.
Traditional method ，such as rivets, lock screw and common welding, they must damage the base metal. But the
stub welding does not damage the base metal.
2-3-2. Spot welding
Diagram 2
This is special spot welding function. It does not heat affect the back of work piece.
The back of the work piece is good appearance.
2-4. Stud welding visual test
Please refer to the picture as follow, and assessment the stud welding results.
If the stud welding results are not good. Please refer to Part 2-7, and adjust the charge voltage, torch head pressure
or torch head height, according as the standard.(Note: only adjust one part at a time.)
1.Voltage not enough
2.Correct voltage
3.Too high voltage
1. Washer contact to work piece
2. Discharge-arc
3. Finish welding
1.The stud screw press the
base metal
2. electric discharge,
start arc
3. Stud welding
complete

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EA R TH
EA R TH
EA R TH
EA R TH
EA R TH
2-5. Stud welding trouble
The following situation may cause the trouble, please remedy them before use the machine.
(1) The earth cable and the metal are not good connection.
(2) Torch cable or earth cable is winding.
(3) The diameter of screw clamp and stud screw is not suitable. Or screw clamp is worn.
(4) The base metal dirty, rusty, paint or other problem interfere with electricity conductibility.
(5) The torch is not suitable for the base metal or stud screw (material or diameter).
(6) The stud screw and the base metal are not good connection (Keep the stud screw connect the base metal
vertically).
(7) The stud welding voltage is not correct.
(8) The capacitor is damage, or capacitance is not enough.
(9) Welding torch movement is abnormal. (The support foot is abnormal)
(10) Stud screw extends too long or too short from the stud clamp.
(11) Base metal distortion or move, when welding.
(12) Method for connect the earth cable:
①Cable must connect the base metal directly, and must connect more than two earth cables.
②The earth cable must connect on the diagonal position of the base metal.
(refer to the diagram as follow)
◎correct connection
◎incorrect connection
2-6. Welding mode, torch and earth cable choice
There are 3 welding mode for the machine
（1）Steel washer welding: use quick puller slide hammer ,h type puller for the steel car body,
please mount Euro and Japanese type torch to socket “1 ”and control socket “4” , mount
earth cable to socket “2”.Select “torch” for switch “5”.
（2）Aluminum stud welding: please mount stud welding torch to socket “1” and control socket
“4”, mount earth cable to socket “2”.If use complete set stud welding torch with earth
cable ,it is also the same. Please mount earth cable to socket “2”.Select “torch” for switch
“5”.
（3）Brass electrode/ carbon electrode heating：

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Please mount Euro and Japanese type torch to socket “1” and control socket “4” , mount earth cable
to socket “2”.Select“carbon electrode heating” for switch “5”.
If use brass electrode heating function, please mount brass electrode(round or iron electrode) on the
torch. If use carbon electrode heating function, please mount carbon electrode on the torch.
The cable connection, please refer to above the diagram.
1) For stud welding-torch without earth cable
AC 110V/ 230V 15A Please confirm the input voltage before connect to power supply
INPUT CABLE
CONNECT TO
THE BACK OF
THE MACHINE
EARTH CABLES （TWO CABLES）
STUD WELDING TORCH CABLE
CONTROL CABLE
STUD WELDING TORCH
WORK PIECE
Stud torch without earth cable
Need to use two earth cables
4
5
2
1
3

5
2) For stud welding-torch with earth cable
3) For spot welding
EARTH CABLE （ONE CABLE）
STUD WELDING TORCH CABLE
CONTROL CABLE
STUD WELDING TORCH
WORK PIECE
Stud torch with earth cable
Only use one earth cable
EARTH CABLES (ONE OR TWO CABLES)
SPOT WELDING TORCH CABLE
CONTROL CABLE
SPOT WELDING TORCH
WORK PIECE
Spot welding torch
Use one earth cable or two earth
cable.

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4) carbon electrode heating (optional function, only for carbon heating type machine)
Operation suggestions
The machine is different from traditional spot welder, it use patent power source design. The peak output
current is over three times of traditional welder and the welding current is reduce to several msec. So it can
greatly reduce welding heating effect for the car body and keep good surface. But caused by high welding
current, if the output circuit is poor contact, it may burn black the work piece. It need good conduction and
good contact.
Please note the following suggestion:
1) Polish and clean the work piece, whatever welding point or earth connection point.
2) The earth cable need to good contact and close to the welding point. Use two earth clamp, when aluminum
stud welding. The welding point should be between the two earth clamp and keep equi-distance. It can
avoid to arc deflection and improve the success rate of the welding.
3) Polish and clean the washer and electrode.
4) When use quick puller slide hammer or h type puller, make sure screw tight all conductive parts.
5)Press the torch, washer, electrode on the work piece with more strength, when welding operation. It is good
for conduction. Please don’t welding with weak pressure contact.
EARTH CABLES (ONE OR TWO CABLES)
SPOT WELDING TORCH
CABLE
CONTROL CABLE
SPOT WELDING
TORCH
WORK
PIECE
Spot welding torch
Use one earth cable or two earth
cable.

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2-7. Controls on generator front panel
A——There is two mode for choice
Auto mode: after the welding torch and earth cable short circuit
or contact for 0.5s,the machine will output.
Manual mode: trigger on the torch, the machine will output.
B——Welding parameter save
Finish adjust welding mode and welding power, the user can
press "save”for save the setting.
C\D——welding function selection
Choice the welding mode, the system will auto match welding
power. And the power indicator display the power level 1-10 on
the right side.
E\F——Output power adjustment
The larger number the higher output power.
There are 10 level for welding power. In general operation, the
user only choice welding mode, the system will auto match welding
power. But the user can adjust it by themself. After adjust the welding setting, it will don’t cover the system
recommended setting. Till to press ”save”, the machine will save customer setting and cover the recommended
setting.(Keep to press the two buttons for 2 second, the welding setting will be recover factory defaults.)
G——Socket for work clamp
H——Control socket for torch
I——Socket for torch
J——Power switch
K——Input power cable (Confirm the power voltage before use)
L——Ground connector for the machine case
M——Discharge indicator
When the indicator is light up, it means the machine charge is
finish, The machine can welding operation.After discharge
operation, the discharge indicator will light off for a few moment.
When the discharge indicator is light off, it means the machine is
charging. The time of light off will increase, following of the more
setting power. If in manual mode, the user trigger on the torch
Φ4~5 steel stud
round washer/tab shooter
quick puller slide hammer
star washer/steel tab
triangle washer/ American stud
Φ 4~5 aluminum stud (optional function, only
for ALU type machine)
A
B
G H I
C D E F
M
N
O
J
P
K
L

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when the discharge indicator will light off ,the machine can output, but the it will reduce output power.
N——Brass electrode/ carbon electrode heating or welding function choice
O——Socket for brass electrode/ carbon electrode heating
P——fuse
2-8. Stud welding torch
2-8-1 torch (as diagram on right)
Torch work principle:
Press the stud screw connects to the base metal.
The welding torch will discharge by contact way.
That applies to :
Soft steel, stainless steel stud screw.
Length of stud screw less than 150mm.
2-8-2 Adjust the pressure and extend distance
1, Stud screw extend 2.0mm from 3 support feet, as the diagram 4 on left
2, Turn left the Spring adjustment, stud welding heat will increase, torch pressure will reduce.
3, Turn light the Spring adjustment, stud welding heat will reduce, torch pressure will increase.
4, When torch pressure is not enough, please remove back cover and spring adjustment, then replace the pressure spring.
2-8-3 Stud screw clamp
Stud screw clamp is the part for keep the stud screw carry welding current. So make sure the diameter of the
clamp in accord with stud screw. When the diameter of the clamp is not suitable to the stud screw, the stud screw
and clamp are easily damaged. That will cause stud welding treble. Please pay attention to the problem.
stud screw clamp setting of torch
Torch head holder
Shell
Screw clamp
3 support feet
Trigger
Handle
Pressure
adjustment
Socket wrench
for adjust
screw clamp
Screw clamp
Gag lever post
Clamp fixed screw
Extend 2mm
Diagram 4
Pressure spring
Spring adjustment

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1. Use socket wrench to lose the clamp fixed screw.
2. Pull out screw clamp and gag lever post.
3. Insert screw clamp and gag lever post to torch head. Make sure the diameter of the clamp is correct and the
length of the gag lever post is correct.
4. Use socket wrench to locking the clamp fixed screw.
Note: When Use new screw clamp, must use pliers to clamp the groove of the screw clamp.
That can make sure the screw camp and stud screw close contact.
2-9. Operating process for stud welding
Note: Protect your eyes and your body when stud welding. Please operate the machine as follow.
2-9-1 preparation for operation
(1)Keep the work piece free of dirt ,oil, paint and rust.
(2)If the base metal is thin, it will dent at pressure .It must add a base plate, when stud welding.
(3)Select suitable stud welding torch, according as material, diameter, length of the stud screw,
(4) Make sure the diameter of the clamp is correct and the length of the gag lever post is correct.
Install the screw clamp and gag lever post in the torch.
(5)Make sure all the cables connect to the machine and workpiece. Connect input cable and turn on.
2-9-2 operate stud welding
(1)Insert the stud screw to screw clamp.
Note: Make sure the stud screw insert to the end of the screw clamp and contact the gag lever post.
(2)Keep the 3 support feet contact the base metal. The torch presses on base metal vertically.
(Diagram 25) Note: Keep H-10torch contact the base metal, after insert the stud screw.
(3)Press torch trigger. Discharge→Stud welding complete.
(4) After stud welding complete, release the trigger, move back the torch vertically. (Diagram 26)
Please test stud welding and setting suitable the welding strength before formal production.
Diagram 24
Screw clamp
Stud screw
Diagram 25
Diagram 26
Stud screw
Screw
clamp
3 support feet
The groove expand in use, the stud screw will loose.
Use pliers to clamp it ,when meet the problem,
That can extend using life of the screw clamp.

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2-10. Maintenance
(1)The machine and torch must to keep away from dust, humidity, rain.
(2) Avoid vibration, when move the machine.
(3) Do not put the machine reversely, protect the machine.
(4)Clean the dust and check the screw, which can keep the machine in good condition.
(5)Turn off the switch, when not use the machine.
2-11. Select stud screw
Metal: soft steel, stainless steel, aluminum, titanium (Ti), brass ,copper
(1) Model F S TP
(2) Dimension outside thread-------- thread diameter * total length
internal thread --------screw diameter * total length - thread diameter
(3) Normal AL stud: The embossment is in the center of stud’s end face. The top face of embossment is
smooth. The size and height of the embossments are good consistency. The end face of stud is smooth.
Defective AL stud: The embossment is not in the center of stud’s end face. The top face of embossment
is not smooth. The size and height of the embossments are unevenness. The end face of stud is coarse.
total length
total length
total length
thread
diameter
screw
diameter
Coarse
Defective Al stud
Smoot
h
Normal Al stud

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3. Safety precautions
WELDING CAN BE HARMFULTO YOURSELFAND OTHERS. The user must therefore be educated
against the hazards, summarized below, deriving from welding operations. For more detailed information, order
the manual.
ELECTRIC SHOCK - May be fatal.
Install and earth the welding machine according to the applicable regulations.
Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.
Isolate yourselves from both the earth and the work piece.
Make sure your working position is safe.
FUMES AND GASES - May be hazardous to your health.
Keep your head away from fumes.
Work in the presence of adequate ventilation, and use ventilators around the arc to prevent gases from forming in
the work area.
ARC RAYS - May injure the eyes and burn the skin.
Protect your eyes with welding masks fitted with filtered lenses, and protect your body with appropriate safety
garments.
Protect others by installing adequate shields or curtains.
RISK OF FIREAND BURNS
Sparks (sprays) may cause fires and burn the skin; you should therefore make sure there are no flammable
materials in the area, and wear appropriate protective garments.
NOISE
This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding procedure may
produce noise levels beyond said limit; users must therefore implement all precautions required by law.
PACEMAKERS
The magnetic fields created by high currents may affect the operation of pacemakers. Wearers of vital electronic
equipment (pacemakers) should consult their physician before beginning any arc welding, cutting, gouging or spot
welding operations.
EXPLOSIONS
Do not weld in the vicinity of containers under pressure, or in the presence of explosive dust, gases or fumes. . All
cylinders and pressure regulators used in welding operations should be handled with care.
ELECTROMAGNETIC COMPATIBILITY
This machine is manufactured in compliance with the instructions contained in the harmonized standard，and must
be used solely for professional purposes in an industrial environment. There may be potential difficulties in
ensuring electromagnetic compatibility in non- industrial environments.
IN CASE OF MALFUNCTIONS, REQUESTASSISTANCE FROM QUALIFIED PERSONNEL.
4. Trouble shooting
The machine with three protection function. If the machine is abnormal, please refer to the following:
1) Over heat protection
There is a aux transformer inside the machine. The aux transformer is with thermal switch. The temperature
of the transformer will rise following the machine work duty. If the machine is over duty and over heat,
the“auto”and “manual” indicator on front will light up, the machine will stop output. In general, the machine
duty cycle is enough to car body repair. If the machine over heat protection on low work duty, please check
the fan.

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2) Short circuit protection
After the machine output power, if the torch and earth cable are keeping short circuit, the machine will stop
charge. The torch and earth cable need to open circuit, the machine can charge and welding again.
3) Over current protection
In current sample is without this function. But we plan to add fuse in future. If the fuse is broken, it means
the machine is abnormal and over current, please contact to the after service.
No power
1. Check the source power.
2. Check the input cable.
3. Check the main switch.
4. Please contact to the manufacturer.
No weld
1. Check the output cable for torch & earth
2. Check the connection for torch & earth.
3. Check power fuse
4. check transformer, maybe over heat
5. Please contact to the manufacturer.
Fan is not working
1. Check the power of fan.
2. Check the fan, maybe something stuck in the fan.
3. Please contact to the manufacturer.