Nu-Tec Systems DUAL-SPOTTER User manual

DUAL-SPOTTER TM
ALUMINUM & STEEL
STUD WELDING SYSTEM
OPERATOR MANUAL
_____________________________________________________
IMPORTANT: BEFORE STARTING THE EQUIPMENT, READ THE ENTIRE MANUAL.
THIS MANUAL MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE
OPERATIVE LIFE-SPAN OF THE MACHINE. THIS EQUIPMENT MUST BE USED SOLELY
FOR WELDING OPERATIONS BY SKILLED TECHNICIANS.
9800-03 01/10/20

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SAFETY PRECAUTIONS - WELDING CAN BE HARMFUL TO YOURSELF AND OTHERS.
1) ELECTRIC SHOCK - May be fatal!
Connect the welding machine to power lines according to applicable and NEMA regulations.
Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.
Isolate yourself from exposed power, earth and the work piece bare metal.
Make certain machine and work piece are grounded to earth per applicable regulations.
2) FUMES AND GASES - May be hazardous to your health! Work in the presence of adequate
ventilation and/or with fume extraction system preventing fume build-up work area.
3) ARC RAYS - May injure the eyes & burn skin! Eye & skin protection must be worn!
Protect your eyes with #5 DIN (min.) filtered lenses and protect your body with appropriate safety
garments when spot welding. Protect others by installing adequate shields or curtains.
4) RISK OF FIRE AND BURNS - Sparks may cause fires and burn the skin! Be certain there are no
flammable materials in the area and wear appropriate protective garments.
5) NOISE - This machine does not directly produce noise exceeding 80dB; however, Users must take
all precautions required by local codes or laws in the event they are below this level.
6) 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.
7) 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.
8) 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.
IF THERE ARE ADDITIONAL QUESTIONS OR CONCERNS, REQUEST ASSISTANCE FROM
YOUR DEALER OR CONTACT FACTORY TECHNICAL SUPPORT @ 704-935-5242

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1. DESCRIPTION OF TECHNICAL SPECIFICATIONS
Uin Rated Supply Voltage
U20 No-load Voltage
I1max Input Current (max.)
I2max Output Current (max.)
Duty Duty-Cycle
2. Summary
The machine utilizes microprocessor capacitor discharge for stud welding with capacity Ø2- Ø6mm. Stud
materials may be mild steel, stainless steel, aluminum, titanium (Ti), brass and copper. Stud Welding time
is about 3/1000s-6/1000s. Given this very short cycle time, the welding heat will not damage or burn-thru
the base metal, even when the base metal is thin sheet.
2-1 Warning
(1) Input power is 115VAC, 1-phase 50/60Hz. Please confirm the correct input voltage.
(2) The stud collet must be installed correctly in the stud welding torch head (see 2.7.2). The inside
diameter of collet must match the stud diameter. Worn or incorrect stud collet can cause damage.
(3) Capacitor discharge stud welding may cause welding arc and metal spatter; therefore operator
must wear appropriate safety goggles and clothing. Exposed skin may result is burns.
(4) Before welding, confirm there are no flammable materials work areas.
(5) The machine must use certified stud screws (from dealer). Alternate studs may cause damage.
(6) Power switch must be in "OFF" position when not in use as capacitors store electrical energy.
(7) Power switch must be in "OFF" position when connect or remove the cables of the machine.
(8) Power switch must be in "OFF" position for 5 minutes before starting work. This is minimum
required time to fully discharge capacitors. Maintenance should be performed by professionals only.
(9) Please contact the manufacturer in the following situations: mechanical failure, reduce or increase
torch cable length, damage to any component and any change the standard equipment.

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2-2. AL & Steel CD Spot Welding
2-2-1. AL Stud Welding
Capacitive discharge aluminum stud welding requires specially designed CD-Studs with arc-tip heads. CD
stud welding requires very clean and contaminate free surface. The process requires the correct extension
from the chuck collet, the correct amount of downward pressure to “push” the stud into the weld pool (torch
head spring setting) along with the correct amount of current (machine power setting) to create the weld
pool. If any of these variables are incorrect for the stud being used. Poor welds may occur.
2-2-2. Steel Spot Welding
1. The stud pressed onto
material - Compression
2. Capacitor discharge
arc melts pin into puddle
3. Completed AL
stud weld

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Set-Up Tab Shooter Tool
Capacitive discharge steel stud welding requires specially designed stud pins with arc-tip or pull tabs. CD
stud welding on steel requires the correct pressure and power setting to “weld” to the surface of the panel
but, due to the extremely short cycle time, there is no distortion, burn-through or oxidation on reverse side
of panel. Given this control, the CD weld is not as strong as traditional transformer resistance weld but is
adequate to pull deformity from panel with correct tools.
Set-Up Dent-Stick puller(optional)
1. Washer contact
to work piece
2. Discharge-
power
3. Finish welding

5
Set-Up Slide Hammer
1)
2)

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3. Cable Connections
1) For stud welding/spot welding-torch with earth cable
4. Operation:
The machine is different from traditional spot welder as it uses patent capacitor discharge power source
design. The peak output current is over three times of traditional welder but the welding current is reduced
to several milliseconds so it can greatly reduce welding heat on the body panel which reduces distortion,
dis-coloration and oxidation; however, if the output circuit has poor contact, it may burn black the work
piece or arc. Given this “burst” of high power, the stud head and earth tips require positive contact to the
surface to “set” the stud correctly. Please note the following suggestion:
1) Remove all paint and contamination from weld area using 80-grit or higher for finish before welding.
2) Earth tips on torch head must make full contact. Use two earth contacts, when aluminum stud welding.
3) Clean the stud head and earth tip(s) with a wire brush just prior to welding.
4) When using puller slide hammer, be sure to tighten all parts and apply weld-tip with pressure on panel.
5) Apply even pressure to the stud, tab or weld-tip onto the panel to insure full contact prior to welding. Any
“gaps” or loose connections may create an arc that will diminish the power to the weld point.
WARNING: ARCs or SPARKs are a sign of poor connections and will result in poor welds.
EARTH CABLE （ONE CABLE）
STUD WELDING TORCH CABLE
CONTROL CABLE
WORK PIECE
Stud torch with earth cable
GRD

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5. Control Panel
A—There are two modes to select
Auto mode: The torch and earth cable Fire-On-Contact
with the panel. Designed only for slide hammer use!
Manual mode: The torch trigger controls machine output.
Note: If Auto or Manual LED is flickering, machine is
recharging and cannot output power.
If Auto and Manual LEDs are flickering together, machine
is in over-heat protection and cannot output power.
Machine will auto-reset and LED’s will light constantly.
B/B1—Power Adjustment
The higher the lamp level indication, the higher the output power. This will automatically be set by
Function Select (below) but may be adjusted (+) or (-) according to operator preference.
C\D—Function Select and save
Select by welding modes and the system will automatically
set the power level (Factory setting) and indicate on display.
Change Factory Preset: Press C & D at the same time
(indicator will flicker for three times) to confirm SAVED.
Factory Reset: Select mode and press B & B1 at the
same time (indicator will flicker for three times) to restore.
E—Stud Contact
LED will illuminate when stud & earth contact panel and
compress torch head spring. No light, no trigger function.
G—Earth Cable
Install earth cable plug & twist to securely lock.
H—Control Cable
Install control cable plug and tighten ring
I—Torch Power Cable
Install torch power cable plug & twist to securely lock.
J—Power Switch
Main power ON/OFF switch.
K—Input Power Cord
Connect to LINE circuit at rated input voltage
P—Main Fuse
Factory installed 15-amp fuse for electrical safety.
J
P
K
L
Φ4~6 aluminum stud
Tab shooter
Quick puller slide hammer
Stud
A
G H I
CD
BB1
E

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6. Stud Welding Torch Operation
Stud collet or tab tip holder or slide hammer shaft installed into chuck and tighten.
Earth tip extensions, with tips, into earth collar. Two tips for aluminum. One tip for steel
Set pressure with adjustment wheel.
Pull trigger to weld stud or tab to panel.
Remove torch from stud or tab to pull dent
6-2-1 Set-Up Stud Collet
1. Chuck wrench will loosen collet body.
2. Insert aluminum stud & turn screw until stud
head extends 2mm from face of collet body.
3. Tighten lock nuts on extension screw.
4. Insert collet body flush with earth tip heads
6-2-2 Adjust the pressure and extend distance
1. Install collet body flush with earth pins so stud extends 2.0mm beyond earth pins.
2. Turn spring adjustment knob to set weld pressure. Stud weld heat increases as the
torch pressure is reduced.
3. Factory spring setting should be adequate for standard operation.
Extend 2mm
Diagram 4
Spring adjustment
Pressure spring
Chuck key
wrench
Handle
Stud collet
Output cable
control cable plug
from torch
red plug to welding torch
black plug to earth
Tab Holder
Trigger
Earth wire
End Tips
Earth tip shaft
s
Earth Tip Collar
Pressure adjustment
Body

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7. Operating Process for Stud Welding
WARNING: Where safety glasses, gloves and appropriate clothing before use!
7-1 Preparation for Operation
(1) Keep the work piece free of dirt, oil, paint and rust. Use 80-Grit or smoothed to finish surface.
(2) If the base metal is thin, it may deflect under pressure so add a backing plate when stud welding.
(3) Select suitable stud type (Al/Mg or Al/Si) and diameter for the required repair.
(4) Make sure the diameter of the collet is correct and the length of the stud stick-out is correct.
(5) Make sure all the cables are securely connected and torch contact points are in contact with work piece.
(6) Plug into line power and turn power switch to ON position.
7-2 Operating Stud Welding System
(1) Insert the correct type of pulling stud screw into stud collet body.
Note: Make sure the stud screw inserted with 2mm stick-out and adjustment screw is tight.
(2) Keep earth support feet in contact the base metal. The torch presses on base metal.
(3) Press torch trigger: Discharge→Stud welding complete.
(4) Lift torch STRAIGHT off surface being careful not to deflect stud or tab.
Test stud weld to confirm pull strength before repeating the process along the dent.
8. Stud Pull Screw Styles
TYPE: mild steel, stainless steel, aluminum, titanium (Ti), brass or copper
TYPES: FLANGE STUD TAPPED
DIMENSIONS: outside thread-------- thread diameter * total length
internal thread --------screw diameter * total length - thread diameter
total length
total length
total length
thread
diameter
screw
diameter
Over time with insertion of many studs, the collet body jaws will
expand and cause the stud to be loose in the collet. Use pliers to
clamp collet jaws closed for good contact. This can greatly extend
life of the stud collet body.