stud welding products STUDPRO Series Manuale utente
OPERATOR’S MANUAL
STUDPRO SERIES
Capacitor Discharge Stud Welder
MODELS:
StudPro 2500XI
StudPro 2500XIP
StudPro 3125XI
StudPro 3750XI
CONTENTS
Descripon Pages
Safety 2
Specicaons and Features 3
Product Components 4-5
Screen Operaon 6-8
Setup and Welding 9-11
CD Stud Gun Exploded View 12
CD Accessories 13-15
Read the safety noces before operang welder
Electrical
•Due to potenal dangerous electrical input and output the
equipment must be disconnected from all incoming power
when servicing. Do not operate the equipment with the outer
cover removed or with the case open.
•Capacitors store electrical energy, completely discharge before performing any maintenance.
•Do not use uids to clean electrical components as these may penetrate the electrical system
and cause shorts.
•Connecon of the unit into service must be in accordance with the setup procedures as de-
tailed in this manual. Operaon of this equipment must be in accordance with all local, region-
al, and naonal safety codes.
Fire
•During welding, small parcles of hot metal can be expelled. Ensure
that no combusble materials are near the welding area.
Personal Safety
•Arc rays can burn eyes and skin. Wear protecve clothing and eye pro-
tecon when welding.
•Loud noises from welding can damage hearing. Wear earplugs or oth-
er protecve gear, if applicable.
•Fumes and gases expelled during welding can be health hazards. Make sure welding is done in
a well-venlated area.
•Hot metal splaer can cause res and burns. Wear protecve clothing, work in an area free of
combusble materials, and have a re exnguisher nearby.
Maintenance
•All cables must be inspected regularly to ensure that no danger exists from damaged insula-
on or unsafe electrical connecons. Take special note of the cables near the stud gun, this is
where maximum wear occurs.
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 mes.
Installaon
•Select a site which is capable of supporng the weight of the equipment.
•Select a site which is clear from heavy foot trac areas to avoid tripping hazards.
•Select a site that prevents cable damage from equipment and vehicles.
•Do not hang connecng cables over sharp edges or place near heat sources.
SAFETY
FIRE HAZARD
FROM SPARKS
2
SPECIFICATIONS AND FEATURES
StudPro XI- Capacitor Discharge Stud Welder Series
The StudPro XI series of capacitor discharge stud welders incorporates the latest solid state
technology into a compact, lightweight, and rugged CD stud welder. This full line of equipment is
capable of welding pins, cup head pins, and CD studs ranging from 14-gauge up to 3/8” full-flanged
stainless steel studs.
Specifications
Features
•Intuive Touchscreen Interface with preset values for fast, accurate, and repeatable weld sengs
•Set-Point Discharge: Unit discharges directly to a new set point without needing to discharge com-
pletely
•Universal Input Voltage: Plug and play, no need to re-tap the machine for 110V or 220V input volt-
ages
•Low input voltage capability enables operaon with long extension cords
•Contact and Trigger indicators for fast troubleshoong of hand tool and weld cable maintenance
issues
•Thermal and Voltage protecon indicators to protect the unit from damage due to overheang or
poor input power
•Rigid internal construcon minimizes the possibility of components coming loose during rough han-
dling or operaon
•Hand tool has been ergonomically designed to reduce operator fague for increased welding e-
ciency
•Hand tool has an adjustable internal spring to apply the correct spring pressure for every welding
applicaon
•Hand tool can be congured for B collets, CI (Collet Inserts), Euro collets, or standard tapered
chucks
SPECS StudPro 2500XI StudPro 2500XIP StudPro 3125XI StudPro 3750XI
SIZE 14” L, 10.5” W, 11.5” H
356mm x 267mm x 292mm
WEIGHT
(Power Supply Only) 18 lbs. (8.1Kg) 18 lbs. (8.1Kg) 20.8 lbs. (9.4Kg) 23.4 lbs. (10.6Kg)
CAPACITANCE/ENERGY 76,000µF/1520Ws 76,000µF/1520Ws 114,000µF/2280Ws 152,000µF/3040Ws
WELD RANGE 14Ga - 1/4” Stainless 14Ga - 1/4” Stainless
(including cup head pins) 14Ga - 5/16” Stainless 14Ga - 3/8” Stainless
DUTY CYCLE 18 studs per minute
(1/4” sengs)
18 studs per minute
(1/4” sengs)
14 studs per minute
(5/16” sengs)
10 studs per minute
(3/8” sengs)
PRIMARY POWER
(Universal Input) 85-250 VAC, 6.0-2.0A, 50/60Hz
CHARGE VOLTAGE 35-200 VDC
3
* Specicaons are subject to change without prior nocaon
Front View Back View
Components
1. Touch Screen Interface
2. Weld Ground Connector
3. Cup Pin Weld Ground Connector (Model 250CP only, on all other TW-i models this connector is a
secondary Weld Ground Connector)
4. Stud Gun Control Cable Connector
5. Stud Gun Weld Cable Connector
6. ON/OFF Switch
7. 10A Fuse
8. Manufacturer Model Number and Serial Number Plate
9. Power Cord Socket
PRODUCT COMPONENTS
1
4
25
7
3
6
9
8
4
Internal View
Components
1. Venlaon Fan
2. ON/OFF Switch
3. 10A Fuse
4. AC Inline Filter/Power Cord Socket
5. Capacitor Bank
6. Freewheeling Diodes
7. SCR/Clamp
8. Discharge Resistor
9. Control Board
PRODUCT COMPONENTS
4
3
1
2
5
9
876
5
SCREEN OPERATION
Trigger Indicator
Stud Presets
Metric Stud Mode
Contact Indicator
Stud Preset Screen
Voltage Preset Screen
Charge Indicator
Welding Voltage
Stud Counter
Voltage
Adjustment
Adjustment
Voltage
Presets
Mode Selecon
Voltage
Mode Selecon
6
SCREEN OPERATION
Stud Counter Screen
Reseng the Stud Counter
Stud Counter Reset
•While on the stud counter screen, press the RESET tab located at the boom of the screen.
•The screen will then prompt the user for a conrmaon to clear the stud counter.
•To cancel the reseng of the stud counter, simply press NO on the screen.
•To conrm the reseng of the stud counter, simply press YES on the screen.
Stud Count
7
Screen Status Indicators
SCREEN OPERATION
Status Indicator
8
Status
Indicator Descripon Soluon
OVERTEMP Unit Has Exceeded
Temperature Threshold
Unit needs to cool down before more welds can be
made. Please allow the unit to cool down and clear
the overtemp warning.
UNDER
VOLTAGE
Insucient Input
Power
Unit has detected insucient supply power. Connect
the unit to a more stable power supply.
DC LIMIT ON Duty Cycle Limiter
Acvated
Protects capacitor from overheang by liming the
user to a maximum average duty cycle. This protec-
on only acvates when the set point of the welder
is above 85V. Below 85V there is no limitaon to the
duty cycle of the unit.
ERR: CHRG TIME Max Charge Time
Exceeded
Unit has taken too long to charge and there may be an
issue with the capacitor. With unit powered down en-
sure that all connectors and connecons are ght.
ERR: OUTPUT Capacitor Short
Detecon
Capacitor is not charging properly and the outputs
may be shorted. Check the unit for damage as well as
Connecng the Welding Leads
1. Connect the stud gun weld cable into the gun terminal socket on the front of the welding unit. 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 properly make these connections could result in damage to the connectors.
2. Connect the weld gun control cable into the center socket connector. The control cable plug has a
large pin and a small pin that match the socket on the unit. Push the plug firmly into the socket
and twist clockwise to secure the plug into the correct position.
3. Connect the ground clamp into the ground terminal socket on the front of the unit, this connec-
tion is identical to step 1.
Connecng the Ground Clamp
1. Prior to securing the clamp, make certain that
the contact area is free of rust, paint, grease, or
any other impuries to ensure a good ground
connecon.
2. Aach the clamp of the welding ground lead to
the work piece.
3. Most applicaons will require only one ground
clamp, but certain applicaons will require an
addional dual clamp.
SETUP AND WELDING
9
Stud Gun Weld
Cable Connecon
Ground Cable Connecon
Stud Gun Control
Cable Connecon
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