KENT STUD WELDING CO., LTD DA-1600i User manual

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
1
DA-1600i Stud Welding Machine
DA-2000i Stud Welding Machine
DA-2500i Stud Welding Machine
Operate Manual
KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
2
Content
1. Preface------------------------------------------------------------------------------ Page 3
2. Introduction---------------------------------------------------------------------- Page 4
3. Tech parameter------------------------------------------------------------------ Page 5
4. Safety-------------------------------------------------------------------------------- Page 6
5. Operation-------------------------------------------------------------------------- Page 8
6. Welding quality------------------------------------------------------------------ Page 10
7. Maintenance and troubleshooting--------------------------------------- Page 14
8. Diagram ---------------------------------------------------------------------------- Page 16
9. Guarantee-------------------------------------------------------------------------- Page 17

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
3
1. STUD WELDING INTRODUCTION
Stud welding: It is a method to weld metal fasteners onto working piece. It has advantages like high speed,
high strength, heat affected zone is small, less pollution etc. It is widely used in such industries as automobile,
boiler, steel structure and ship industries.
It can be used to weld thread fasteners, normal pin, open pin and bolt, which is made by low carbon steel,
low alloy steel, stainless steel, cooper and etc.
Welding current (A) can be chose 50-100 times of stud Dia. I = (50-100) d（A）
Welding time (Ms) can be chose 50-150 times of stud Dia. T= (50-150) d (ms)
According to our experience, following is the data for low carbon steel bolt welding. For other material, you need
to do welding test.
STUD
DIRECT WELDING
THROUGH DECK WELDING
CURRENT
TIME
CURRENT
TIME
ф10
600A
1.20S
——
——
ф12
800A
1.12S
——
——
ф13
900A
1.00S
700A
1.40S
ф16
1300A
1.20S
1000A
1.70S
ф19
1600A
1.30S
1400A
1.90S
ф22
1900A
1.40S
1700A
2.00S

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
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Principle of DA serial arc stud welding machine:
a. Put the stud inside ceramic ring, and contacted with work piece.
b. Start of welding torch switch, welding torch lift automatically, and arc creates high temperate bath.
c. Welding torch push stud into high temperate, stud and work piece are combined.
d. Break ceramic ring, stud welding is finished.

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
5
2. TECH PARAMETER
2.1 Model instruction
DA –2000i Inverter type
Max current
Draw arc stud welding
2.2 Tech parameter of DA serial stud welding machine
Model
DA—1600i
DA—2000i
DA—2500i
Range of stud
Φ4mm—Φ20mm
Φ4mm—Φ24mm
Φ4mm—Φ28mm
Welding current
200A—1600A
300A—2000A
300A—2500A
Welding time
0.1S—3.0S
0.1S—3.0S
0.1S—3.0S
Welding speed
Φ20 10pcs/min
M22 10pcs/min
M28 10pcs/min
Input
AC 3~380V 50/60Hz
AC 3~380V 50/60Hz
AC 3~380V 50/60Hz
Input power
50KW
60KW
80KW
Power switch
100A
125A
160A
Safety grade
Ip21
Ip21
Ip21
Cooling type
F
F
F
Out dimension
（L x W x H）
850×368×560mm
890×398×680mm
890×398×680mm
Weight
98kg
126kg
135kg
NOTE:
1. Power cable and torch cable can be extended, but the current will be
lower when cable getting longer.
2. The parameter is tested when input power and torch cable is within
requirement. If tech parameters have too much different on spot, please
check input power, but not voltage.
3. According to safety requirement, please use 5 cores power cable, Install
leakage protection box. This machine does not use zero line.

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
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3. Safety
3.1 Worker safety.
a.
The welding operator must have qualification to hold a Studs Welding Operator’s
Certificate and must strictly follow the Specifications on Welding Operator’s
Operating Safety for purpose of safety of the welding operator and the other
people.
b.
The operator must properly wear Personal Protective Equipment (PPE) such as dry
insulated shoe, insulated gloves; welding operator’s working clothing, helmet, or
goggles etc.
c.
Don’t wear metallic ornaments such as necklace, ear ring, and watch etc.
d.
The persons wearing heart defibrillators or unsuitable for approaching the strong
magnetic field shall keep away from equipment and electrical cables in the process
of welding.
e.
The equipment shall be connected to the power supply box with leakage protection
function.
f.
Follow the other relevant provisions of safety to ensure personal safety.
g.
All the electrical connections and cables shall be kept in a good order. Especially,
the chucks must well contact with the welding studs for prevention of too relaxed
chucks and of injury due to arc generation of bonding face.
h.
Please immediately seek medical care and notify the insurance company or local
safety supervision authority in case of safety accidents.

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
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3.2 Equipment safety
a.
The equipment shall be connected to the power supply and properly be
protectively grounded by a professional electrician. The power supply shall be
provided with leakage and short circuit protection.
b.
All the electrical cables and distribution boxes must be kept in a good order.
Eliminate all hidden hazards which influencing safety (if any).
c.
An unauthorized person is not allowed to open the equipment.
d.
The space shall be well-ventilated when the equipment is running. The ventilation
grill shall be more than 30m from such obstructions as wall etc.
e.
Dust inside the equipment shall be removed by professionally trained personnel for
ensuring heat dissipation. The interval shall depend on situation of working
environment.
f.
Don’t operate the equipment under a working environment with more flying
metallic powder because metallic powder entering into the equipment may
possibly result in short circuit.
g.
Equipment shall stably be located on a moisture-proof, harm-proof, weather-proof,
well-ventilated, clean, and safe location. Water and metal may possibly damage
equipment shall strictly be prohibited entering into the equipment.
h.
The power supply box shall be switched off (instead of switching off welding
machine only) when the equipment is shutdown, maintenance and repairing or
cleaning for purpose of prevention of electric shock.
i.
Don’t measure, weld or cut this welding machine with a megger, plasma cutter,
argon-arc welding machine etc. with high voltage due to a great deal of electronic
elements provided into the equipment for prevention of equipment damage. Don’t
weld the same working piece together with the other high voltage arcing
equipment either.
j.
This machine is designed for special purpose only.

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
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3.3 Safety of Welding Environment
a.
All the flammable, explosive, and hazard items in the vicinity of welding area shall
be cleaned up. Welding operation must be monitored by exclusively designated
personnel and provided with fire extinguishers. Apply welding operation after all
the hazardous items under the welding area must be cleaned up or after measures
have been taken for the welding operation in the height for prevention of damage
and loss due to falling spark splash.
b.
Ask an inspector for examination before applying welding operation. Apply welding
operation only it can meet the requirements of safety.
c.
Apply welding operation after taking special protective measures under highly
electric-shock, and flammable environment, or under special situation harmful to
health.
d.
Ensure that the working area is well ventilated. Don’t weld on the working pieces
with water accumulated when welding galvanized, nickel-plated, or chrome-plated
pieces having harmful gas volatilization.
e.
Don’t apply welding operation on the enclosed container filling with or ever filled
with hazardous items resulting in explosion or generating harmful gas, except for
taking overall measures of treatment and it is proven for reliability.
f.
Keep away from the objects, such as magnetic card, watch, computer etc, easily
disturbed by electromagnetic field in a safe distance.
g.
The tie-in of working piece must directly be connected to the working pieces
welded and properly contacted. Otherwise, high welding current may pass through
the other approaches to damage the other items.
h.
Simultaneously apply four eyebolts when moving, transporting, and lifting the
equipment. The angle between the steel wire rope shall not be more than 30°.
Ensure that the equipment shall not be attacked by the others and the other
accidents shall not occur at any time.
i.
Carefully follow all kinds of safety provisions on construction sites.

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
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4．Operation
4.1 Structure of front and rear panel
①Input voltage: The voltage of input power.
②Welding current: Only display when welding.
③Welding time: 0-3 second, it is NOT on-time display; need to use test button to check.
④Auto time control: The welding time will be exactly same as setting.
⑤Manual time control: The welding time is controlled by your holding time of torch button
or test button. But it has max limitation. E.g. if you set welding time 2.0s, and switch to
manual, the real welding time only can be controlled within 0-2.0s.
⑥Test: This button has two functions, one is checking time, and another is checking if torch
is broken.

KENT STUD WELDING CO., LTD
No.801, Hongqiao Rd, Wuxi city, Jiangsu province, China
T: [phone]
F: [phone]
10