stud welding products StudPro 2500i User manual

OPERATION MANUAL
MODELS
TWE-250
TWE-321
TWE-375
TRU‐WELDEQUIPMENTCOMPANY
6400N.HONEYTOWNROAD
SMITHVILLE,OHIO44677
(330)669‐2773
Downey, CA
9459 Washburn Rd.
Downey, CA 90242
Phone- 800.252.1919
Fax- 562.862.3022
Hayward, CA
2391 American Ave.
Hayward, CA 94545
Phone- 510.782.7883
Fax- 510.782.7918
Renton, WA
927 Thomas Ave. SW
Renton, WA 98057
Phone- 425.656.9787
Fax- 425.656.9786
Phoenix, AZ
3535 East Wier Ave., Ste. #4
Phoenix, AZ 85040
Phone- 602.305.9350
Fax- 602.305.4890
Toll free customer support: 1.800.252.1919
MODEL
StudPro 2500i

2
22
CONTENTS
SectionDescriptionPages
1Introduction3
2ExternalFeatures4‐5
3Safety6‐8
4SetupandWelding9‐15
5TestingWeldSettings16
6InspectingTheWeld17
7CDStudGunViews18
8CDStudGunExplodedView19
9CDStudGunPartsList20
10CDControllerExplodedView21
11CDControllerPartsList22
1 Introducon 3
2 External Features 4-5
3 Safety 6-8
4 SetupandWelding 9-15
5 TesngWeldSengs 16-19
6 TypesofFractures 20
7 ArcBlowEect 21
8 CDStudGunExplodedView 22
9 InternalComponents 23-25
10 CDAccessoreis 26-30
11 TorqueBendingTest 31-32
12 CDGunSetUp’s 33-34
1 Introducon 3
2 External Features 4-5
3 Safety 6-8
4 SetupandWelding 9-15
5 CupHeadWelding 16-17
6 TesngWeldSengs 18-21
7 TypesofFractures 22
8 ArcBlowEect 23
9 CDStudGunExplodedView 24
10 InternalComponents 25-27
11 CDAccessoreis 28-32
12 TorqueBendingTest 33-34
13 CDGunSetUp’s 35-36

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33
Thecompleterangeofthecapacitordischargeequipmentiscompact,portablestud
weldingequipment.Theunitsarespecificallydesignedtoenableasmalldiameter
rangeofferrousandnonferrousweldstudstobeweldedtolightgaugemetalmateri‐
alswithlittleornoreverse‐sidemarking.

Theequipmentconsistsofacontrolunit,aweldinghandgun,andallnecessaryinter‐
connectingcables.

THEPROCESS
CapacitorDischarge(CD)studweldingisaformofweldinginwhichtheenergyre‐
quiredfortheweldingprocessisderivedfromabankofchargedcapacitors.This
storedenergyisdischargedatthebaseofthespeciallydesignedCDstudanditfuses
thestudtothebasematerial.Thetimeoftheweldisdeterminedinsuchashortdu‐
rationthatnoburnthroughmarkingismadeonthefinishsideofthematerial.

CONTACT
IncontactCDwelding,thestudisplacedunderspringpressureonthematerialtobe
welded.Whenthecapacitorsaredischarged,thespecialtipoftheCDstudmeltsand
thespringpressureforcesthestudtofusewiththebasematerial.

GAP
IngapCDwelding,thestudisplacedontothematerialtobewelded.Asthestudgun
isengaged,thestudliftsfromthebasematerialandthenreturnstothepointofcon‐
tactatthetimeofthedischargeofthecapacitors.Asthecapacitorsdischarge,melt‐
ingthetipoftheweldstud,thepressurecreatedbythemovementofthestudtothe
basematerialbythestudgunfusesthestudtothebasematerial.
INTRODUCTION

4
4
4
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FRONTPANEL
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1.WeldVoltageSelector‐rotatetochangetorequiredvoltage.
2.WeldingVoltageDigitalDisplay‐displaysselectedvoltage.
3.LEDLights‐Charging(capacitorsarebeingchargingtodesiredvoltage),Ready
(unitisreadytoweld),Reset(indicatesanerrorandunitshouldbeturnedoff).
4.WeldingGroundCableConnector(+)
5.StudGunControlConnector
6.WeldingStudGunCableConnector(‐)

EXTERNAL FEATURES
1
4
2
56
3
1
2
3
654
7. GroundCupHead
7

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55
REARPANEL
1.On/OffSwitch
2.FuseHolder(10amp)
3.ACPowerCord
4.ManufacturerModelNumberandSerialNumberPlate


WARNING!
Thisunitoperatesfroma110VAC60Hertz@10ampcircuit.
Donotobstructtheventilationfan,asthismaycauseunittooverheat.
Donotremoveanyportionoftheunithousingwithoutfirstdisconnectingtheunit
fromthepowersupply.


EXTERNAL FEATURES
ON/OFFSwitch
15AmpFuse
PowerSupplyFan
ACCord
ON/OFF Switch
15Amp Fuse
Power Supply Fan
AC Cord

6
6
6

PROTECTYOURSELFANDOTHERS!
Readthesafetynoticesbeforeusingwelder.



ELECTRICAL
Noportionoftheoutercoveroftheweldingcontrollershouldberemovedbyany‐
oneotherthanqualifiedpersonnel.Alwaysdisconnecttheunitfromthemainpower
priortoremovingcover.
• Thisequipmentcontainsatransformerpowersupplysystem,whichisenergized
byACcurrentandtransformstheACtoDCcurrent.Duetopotentialdangerous
electricalinputandoutputtheequipmentmustbedisconnectedfromallincom‐
ingpowerwhenservicing.
• Capacitorsstoreelectricalenergy.Checkforresidualchargebeforeperforming
anymaintenance.
• Donotusefluidstocleanelectricalcomponentsasthesemaypenetratetheelec‐
tricalsystemandcauseshorts.

Connectionoftheunitintoservicemustbeinaccordancewiththesetupprocedures
asdetailedinthismanual.Operationofthisequipmentmustbeinaccordancewith
alllocal,regional,andnationalsafetycodes.

SAFETY

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77

FIRE
Duringwelding,smallparticlesofhotmetalcanbeexpelled.Ensurethatnocombus‐
tiblematerialsareneartheweldingarea.


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
PERSONALSAFETY
Arcrayscanburnyoureyesandskin.Wearprotectiveclothingandeyeprotection
whenwelding.
Loudnoisesfromweldingcandamagehearing.Wearearplugsorotherprotective
gear,ifapplicable.
Fumesandgasesexpelledduringweldingcanbehazardoustoyourhealth.Make
sureweldingisdoneinawell‐ventilatedarea.
Hotmetalsplattercancausefiresandburns.Wearprotectiveclothing,freeofcom‐
bustiblematerials.Haveafireextinguishernearbyandknowhowtouseit.
MAINTENANCE
Allcablesmustbeinspectedregularlytoensurethatnodangerexistsfromwornor
damagedinsulationorunsafeelectricalconnections.Takespecialnotetothecables
nearthestudgun‐thisiswheremaximumwearoccurs.
Worncablesnotonlyproduceinconsistentwelds,butcanoverheatorspark.

SAFETY
FIRE HAZARD
FROM SPARKS

8
8
8

TRAINING
Useofthisequipmentmustbelimitedtoauthorizedpersonnelonly.Theymustbe
adequatelytrained,andhavereadandunderstoodeverythinginthismanual.The
manualmustbeavailabletooperatorsatalltimes.
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

INSTALLATION
Selectasitefortheequipmentwhichiscapableofsupportingtheweightofthe
equipment,whichisclearfromtrafficrouteswherepeoplemaytripovercables,or
theymaybedamagedbyotherequipmentorvehicles.
Donothangconnectingcablesoversharpedgesorhavenearheatsources.
DISPOSAL
Theequipment,initsentiretyorascomponents/partsmaybedisposedofasgeneral
industrialwasteorscrap.Noneofthecomponentsusedinthemanufacturingofthe
CDWeldersaretoxic,carcinogenic,orotherwiseharmfultoyourhealth.

SAFETY
AUTHORIZED
PERSONNEL ONLY

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99
POWERINGUPTHEEQUIPMENT
Setuptheequipmentpowersupply(ControlUnit)andconnecttothemainpower,
makingcertainofthepropervoltagerequirementoftheparticularunit.
CapacitorDischarge(CD)unitsgenerallyrequire110VAC@60Hzincomingpower.
Refertothesafetyrecommendationsbeforepluggingthisunitin.

ON/OFFSwitch

Fuse

PowerCord(110VAC)

CONNECTINGTHEWELDINGLEADS
Connecttheweldinggroundcableintothe(+)terminalmountsocketonthefrontof
theweldingunit.
***NOTE‐thecableendplughasaflatwhichalignswithadotonthepanelmount
socket.Securetheconnectorintothepanelmountsocket,andthenturnitclockwise
untilitlocksintoproperposition.Failuretodosocouldresultindamagetothecon‐
nector.



GroundCableSocket
SET-UP AND WELDING
ON/OFF Switch
Fuse
Power Cord (110 VAC)
For Cup Head to
Ground Cable Socket

10
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10
CONNECTINGTHEWELDINGLEADS
Connecttheweldingstudgunpowercableintothe(‐)terminalpanelmountsocket
(designatedbythegunsymbol)onthefrontoftheweldingunit.
***NOTE‐thecableendplughasaflatwhichalignswithadotonthepanelmount
socket.Securetheconnectorintothepanelmountsocket,andthenturnitclockwise
untilitlocksintoproperposition.Failuretodosocouldresultindamagetothecon‐
nector.



WeldingGunPowerConnector





WeldingGunControlCableConnector

Connecttheweldguncontrolcableintothecenterpanel2‐pinsocket.
**NOTE‐theplughasalargepinandasmallpinthatmatchthesocketontheunit.
Thisistopreventincorrectconnections.Pushtheplugfirmlyintothesocketand
twistclockwisetosecuretheplugintothecorrectposition.
SET-UP AND WELDING
Welding Gun Control Cable Connector
Welding Gun Power Connector

11
1111
CONNECTINGTHEGROUNDCLAMP
Attachtheclampoftheweldinggroundleadtotheworkpiece.Priortosecuringthe
clamp,makecertainthatthecontactareaisfreeofrust,paint,grease,oranyother
impuritiestoensureagoodgroundconnection.








NOTE***Mostapplicationswillrequireonlyonegroundclamp,butcertainapplica‐
tionswillrequireanadditionaldualclamp.
SET-UP AND WELDING
13
CONNECTINGTHEGROUNDCLAMP
Attachtheclampoftheweldinggroundleadtotheworkpiece.Priortosecuringthe
clamp,makecertainthatthecontactareaisfreeofrust,paint,grease,oranyother
impuritiestoensureagoodgroundconnection.










NOTE***Mostapplicationswillrequireonlyonegroundclamp,butcertainapplica‐
tionswillrequireanadditionaldualclamp.

SET-UP AND WELDING

12
12
14
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• EuroColletshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.








Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.






Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
Adapterisrequired.
Adapterisrequired.
Nofootpieceorlegsrequiredwhenweldingcupheadpins.
 Forcupheadpinsusecupheadpincollet
Thechoicebetweenthesesystemsisusuallyamaerofpersonalpreference.
12
14
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• EuroColletshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.








Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.






Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
14
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• EuroColletshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.








Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.






Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
14
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• EuroColletshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.








Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.






Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
MagnecChuck
CupheadPins

13
13
13
SELECTINGTHESPRINGLOAD
Theproperspringpre‐loadsettingonthestudgunwillvarydependingonthese‐
lectedapplication.Generalsrulesofapplicationwouldbe;mildsteelorstainless
steelusuallyinthe1to2range,dependingonthestuddiameterandthethicknessof
thebasematerial.Aluminumandothernonferrousmetalswouldrequiresettings
from3to5dependingonthediameterofthestudandbasematerialthickness.







Thisspringpre‐loadadjustmentismadebyturningthescrewinsertinthebackofthe
studgunwithascrewdriver.Onthebottomofthebackcapofthestudgunisthe
indicatornumbered1thru5,whichwillshowyouthetensionsettingduringthead‐
justment.
SET-UP AND WELDING
AdjustmentScrew
TensionIndicator
15
SELECTINGTHESPRINGLOAD
Theproperspringpre‐loadsettingonthestudgunwillvarydependingonthese‐
lectedapplication.Generalsrulesofapplicationwouldbe;mildsteelorstainless
steelusuallyinthe1to2range,dependingonthestuddiameterandthethicknessof
thebasematerial.Aluminumandothernonferrousmetalswouldrequiresettings
from3to5dependingonthediameterofthestudandbasematerialthickness.








Thisspringpre‐loadadjustmentismadebyturningthebackcapofthestudgun.On
thesideofthestudgunistheindicatornumbered1thru5,whichwillshowyouthe
tensionsettingduringtheadjustment.

SET-UP AND WELDING
AdjustmentCap
TensionIndicator
Locationofadjustment
onbackofthegun.

14
1414
READYFORWELDING
Whenyouhavecompletedallofthepreviousstepstoprepareforwelding,including
connectingthestudgunandgroundcablestotheunit,attachingthegroundcable(s)
totheworkarea,settingupandadjustingthestudgunfortheselectedstuddiame‐
terandmaterial,youcannowpoweronthewelder.









ThecontrollerON/OFFswitchislocatedontherearoftheunitintheupperright
handcorner.Belowthisswitchisthe15ampfuseholderforthesystem.
SET-UP AND WELDING
ON/OFFSWITCH
FUSE
ON/OFF Switch
FUSE

15
1515
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
MODEL 3125 & 3750
(3750)
Voltage Adjustment Knob
1515
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
MODEL 3125 & 3750
(3750)
Voltage Adjustment Knob
MODEL STUDPRO 2500i
1515
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
MODEL 3125 & 3750
(3750)
Voltage Adjustment Knob
CupheadPin 70-100
1515
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
MODEL 3125 & 3750
(3750)
Voltage Adjustment Knob

16
Cup Head Welding
(A) (B) (C)
Connect Male Ground Camlok To Cup Head Ground
Camlok Receptacle On Unit (See Location A)
Connect Male Gun Control To The Female Gun Control
Receptacle On Unit. (See Location B)
Connect Male Gun Camlok To The Female Gun Camlok
Receptacle On Unit. (See Location C)

17
Cup Head Welding
Insert Magnetic Chuck Into The Supplied “B” Adapter
And Tighten The Set Screws. (See Figure Above)
Set Spring Pressure Between #1 And #2 By Turning The
Back Cap. (See Figure Above)
Set The Voltage. Recommended Voltage Setting For
Cup Head Pins Is Between 70 And 100 Volts.

18
16
18
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.












Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS
Cupheadpinwelding–Whenweldingcupheadpinstherewillnotbeafootpiece
toholdthegunperpendicularthismustbedonemanually.Pressdownonthework
piecesothegunshaisatapprox.½”ofit’smaxtravel(springswillbecompressed
properly)anddepressthetrigger.
16
18
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.












Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS
16
18
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.












Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS

19
17
17
INSPECTINGTHEWELD
Visuallyinspecttheweld.Agoodweldwillresultinanall‐aroundweld,withasmall
visibleamountofweldsurroundingtheflangeofthestud.Toomuchsplatterandthe
weldistoohot,lowerthevoltage.Nosplatterandtheweldistoocold,increasethe
voltage.
Ifyougetweldflashtoonesideofthestudasopposedtoanevenamountaround
thebaseoftheflange,thisiscalled“arcblow”,andcanbesolvedbyrepositioning
thegroundclamporusingadualgroundclamp.

Properweldedstudscanbetestedbyeithertorquingorbendingthestud.The
weldedflangeofthestudshouldstayinplaceusingeithermethod,eventhoughthe
threadedportionofthestudbreaks.Ifthebasematerialisverythin,thenafullslug,
thediameteroftheflangewillpullfromthebasemetalforaproperlyweldedstud.




CDStudWeldingSteps

SET-UP AND WELDING
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.










Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS

20
18
18
CD 2301 Order No. BA 92-12-0231A Issue 05.01.10 31
5.8.1
Visual Inspection
A visual inspection must be carried out with each welding element.
Condition Possible cause Corrective actions
Good welded joint
Low spatters around the weld
without outer flaws
The weld pool forms a collar around
the flange of about 1 - 1,5 mm
- Correct parameters - None
Cold weld pool
Gap between flange and workpiece
- Heat input too low
- Plunging speed too low
- No sufficient backing of workpiece
- Increase charging voltage
- Adjust plunging speed correctly
- Provide sufficient backing
Hot weld pool
Many spatters around the weld
- Heat input too high
- Plunging speed too low
- Reduce charging voltage
- Increase plunging speed
One-sided weld pool
One-sided spatter collar
Weld pool came out on one side
- Arc blow effect
- Unsymmetric ground connection
- Welding gun put at an angle
- Take care for symmetrical ground
connection
- Put welding gun vertically to the workpiece
Visual Inspection
5 Stud Welding Procedure
5.8 Checking the Quality of the Weld
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.










Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS