Table of Contents
Troubleshooting
Related Manuals for INTERNATIONAL WELDING TECHNOLOGIES Lynx4 Quickshot
Summary of Contents for INTERNATIONAL WELDING TECHNOLOGIES Lynx4 Quickshot
- Page 1 Operating Instructions Serial Number _______________ International Welding Technologies, Inc. 2650 Egg Harbor Road Lindenwold, NJ 08021 (856) 435-8004 phone (856) 435-4004 www.internationalwelding.com Revision 2...
- Page 2 It is prohibited to transmit or reprint this document, as well as to utilize or disclose its contents, unless this has been expressly granted by International Welding Technologies, Inc. (herein also referred to as IWT). Non-compliance with this regulation is liable to compensation. All rights reserved, particularly in the case of a patent grant or GM registration.
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Page 3: Table Of Contents
Contents 1. General ........................5 1.1 Introduction to stud welding ..................5 1.2 Application ........................6 1.3 Information on the product ..................6 1.4 Serial Plate ......................... 7 1.5 Information on documentation ..................7 1.5.1 Information on operating instructions ..............7 1.5.2 Conduct in the case of malfunctions .............. - Page 4 5.5 Fuse elements ......................25 5.6 Preparation for initiation ....................26 5.6.1 Ground connection ..................... 26 5.6.2 Connect stud welding pistol ................26 5.6.3 Mains supply connection ..................26 5.7 Gun Setup ......................... 27 5.8 Operation ........................29 5.9 Welding parameters ....................29 5.10 Reverse polarity ......................
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Page 5: General
General Introduction to stud welding Your new stud welding equipment is carefully constructed of the finest components and materials available. Used properly, this equipment will give you years of efficient service. The system incorporates the latest in engineering advances, for completely reliable end welding of mild steel, stainless steel, aluminum, copper and lead free brass fasteners. -
Page 6: Application
WARNING Keep sufficient distance from electronic devices. When stud welding, highly intensive electromagnetic fields are created which may permanently damage these devises (e.g. television sets). • Observe the safety instructions in Section 3. • Call a doctor in case of an accident. Application The IWT stud welder LYNX Quickshot Stud Welding System allows you... -
Page 7: Serial Plate
Serial Plate The serial plate is located on the rear side of the stud welder. It contains information regarding the manufacturers name, address, country of origin, product designation, method of welding, date of manufactured, production number and main connection values. Information on documentation The following operating instructions are supplied with the LYNX4 stud welder:... -
Page 8: Conduct In The Case Of Malfunctions
1.5.2 Conduct in the case of malfunctions If malfunctions occur, first try to detect and eliminate the causes according to the list in Section 8 “Troubleshooting”. In all other cases, contact our service department. If you require service, please make sure that you supply the following information: •... -
Page 9: Description Of The Stud Welder
Description of stud welder Capacitor discharge technology The LYNX Quickshot Stud Welding System with tip ignition operates according to the principle of capacitor discharge as defined in the American Welding Society Welding Handbook and in DVS Leaflet 0903 (German Welding Society). This system uses the abrupt discharge of a capacitor bank to generate an electric arc. -
Page 10: Stud Welder Set-Up
To make a good weld occur, two things are needed: heat and pressure. A weld must have sufficient heat to melt the weld zone, and enough pressure to provide good fusion. In the LYNX Quickshot Stud Welding System, heat is easily regulated by the voltage on the capacitor bank. -
Page 11: Dimensions
Dimensions The LYNX Quickshot Stud Welding System is a powerful but lightweight system that is easily carried into the work place. The base unit weighs 20 lbs. The dimensions are: 12” Wide x 12” Long x 5” High 12” 5” 12”... -
Page 12: Technical Data
Technical Data Description LYNX Quickshot Stud Welding System Welding range #4/12ga through 1/4” Steel, Stainless Steel, Aluminum, Copper, Material Lead Free Brass Welding Method Capacitor Discharge Tip Ignition IWT-G1 gap, IWT-C1 contact or IWT-Ci Standard Pistol(s) insulation gun Current Source Capacitor Bank Charging Capacity 54,000 micro Farad... -
Page 13: Block Diagram
Block Diagram Revision 2... -
Page 14: Safety Instructions
3 Safety instructions These operating instructions contain basic instructions that have to be complied with during installation and/or operation. It is therefore absolutely necessary that the operator and responsible specialist staff read these operating instructions prior to assembly and initiation. They must always be available at the installation site. -
Page 15: Staff Qualification And Training
In addition to these symbols, the words “DANGER TO HEALTH” or “MORTAL DANGER” refer to the degree of a possible danger. Safety instructions the non-observance of which may endanger the machine and its functions are marked with the terms "CAUTION" or "WARNING". General instructions are marked with the hand symbol. -
Page 16: Safety Instructions For The Operator/User
3.5 Safety instructions for the operator/user When stud welding, danger may result from • electric current • optical radiation • harmful substances (smoke) • acoustic shock • spraying sparks You are therefore obliged to restrict the dangers to an inevitable degree and to point these dangers out to the operator and other persons involved. -
Page 17: Before Starting To Weld
• Wear gauntlet gloves made of leather. • Never wear rings, watches or electrically conductive jewelry. • Wear protective goggles to protect your eyes from welding spatters and flashes of light that are generated during the process. • Wear ear protection. Capacitor discharge generates a loud bang. •... -
Page 18: Working With The Stud Welder
DANGER TO HEALTH When welding, fumes and suspended matters may be generated. Beware of fumes detrimental to health, particularly when using surface-treated materials. If possible, only weld in rooms that are higher than 10 ft. As per VBG 15, special regulations are applicable for narrow rooms. -
Page 19: Safety Instructions For Maintenance, Inspection And Assembly Works
3.10 Safety instructions for maintenance, inspection and assembly works Only carry out maintenance The user must ensure that all maintenance, inspection and assembly works when stud welder has work is carried out by authorized and qualified technical personnel. been switched off and unplugged—follow Generally, only work on the system when it has been switched off and lockout/tagout procedures. -
Page 20: Inadmissible Operating Methods
3.12 Inadmissible operating methods Working safety of the stud welding system supplied can only be Limit values guaranteed when the stud welder is used in accordance with its purpose. The limit values indicated in the chapter "Technical data" must never be exceeded. -
Page 21: Installation Of Stud Welder
4 Installation of stud welder • Only install the stud welder on an even surface. The four anti-vibration pads located on the bottom of the stud welder guarantee its anti-skid position and serve as vibration dampers. • Although the stud welder is resistant to environmental influences, it should be protected against dampness and dust. -
Page 22: Initiation
Initiation Exterior components 5.1.1 Front View Item Description Voltage Control Knob Voltage Display Informational Display Ground Connectors Gun Weld Cable Connector Gun Control Cable Connector Voltage Reference Chart 5.1.2 Rear View Item Description Power Socket/Switch Serial Plate Cooling Louvers... -
Page 23: Operating Elements
Operating elements • Mains switch (Section 5.1.2., Item 8) The mains switch is located at the rear of the stud welding unit and serves to switch the stud welder on and off. • Voltage control knob (Section 5.1.1., Item 1) The voltage control knob is located on the front of the stud welder. -
Page 24: Display Elements
ground cable to the work piece. When possible, weld between the ground cables to minimize the affects of “arc blow” on weld quality. • Weld cable connector (Section 5.1.1., Item 5) The welding pistol weld cable connector attaches to the front of the unit in the gun connector socket. -
Page 25: Fuse Elements
indicator is used in contact welding mode. • “Foot on work surface” light The GREEN “foot on work surface” indicator is used to indicate a complete electrical path for gun foot piece to the welding system. When this light is activated, the unit is ready to weld a fastener in gap mode. -
Page 26: Preparation For Initiation
Preparation for initiation Connect the stud welding pistol and the ground cables to the stud welder as indicated in Section 5.3. 5.6.1 Ground connection • Connect the ground cables into the indicated ground sockets. • Turn the connectors clockwise until they stop. •... -
Page 27: Gun Setup
Gun Setup Figure 5.1 on the next page depicts the optimal set-up for the fastener in the chuck. To set the stud in the chuck, loosen the backstop screw until the fastener extends approximately inch from the front of the chuck. Tighten the back-stop locking nut to preserve this setting. - Page 28 Fig 5.1 Fig 5.2 Fig 5.3...
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Page 29: Operation
Operation Switch on the mains switch. The unit will power all LED’s and run a quick diagnostic check. The amber LED will then illuminate indicating line voltage (110VAC or 220VAC). The digital LED on the front panel will indicate the charge voltage. Once the charge voltage is reached, the “ready”... -
Page 30: Reverse Polarity
5.10 Reverse Polarity Sometimes is may be beneficial to use reverse polarity during stud welding. Reverse polarity is often recommended when welding to brass material or through galvanized materials. Normally, straight polarity is used in stud welding. In straight polarity the work surface is the positive electrode and the stud is negative. -
Page 31: Quality Control
Quality Control 6.1 General The 0905 DVS Guideline, part 2, of April 1979 is applicable with regard to quality assurance of stud weld joints. The tests described in this section are written in simplified terms, following above regulation. They refer to work tests that are carried out and supervised by the user prior to and during welding. -
Page 32: Simplified Work Test
6.4.1 Standard work test Generally, standard work tests have to be carried out and supervised by the user before welding at a structure and after a certain number of welds has been made. The number of welds after which a standard work test is required is agreed upon with the customer. -
Page 33: Maintenance
Maintenance Stud welder The stud welder is constructed in such a way that only a minimum of maintenance is required. The interior of the stud welder should, however, be cleaned at regular intervals depending on the environmental conditions at the location of use. Clean the unit with compressed air only. -
Page 34: Electronic Waste
Electronic Waste (WEEE), Directive 2002/96/EC Please help minimize the effects we have on the environment by not disposing electronic waste (e-waster) with household trash. Please follow your local instructions for disposal and/or recycling of electronic equipment and batteries. -
Page 35: Trouble Shooting
Trouble Shooting Trouble shooting the LYNX There are a few basic rules to follow when trouble shooting any C.D. welding system. They are as follows: • When approaching a welder the studs "aren’t sticking," stand back and look at the entire situation. More often than not the problem will be something simple, such as wrong polarity, bad grounding, coiled cables, etc. - Page 36 Fault Light Indications The LYNX Quickshot Stud Welding System is powered by an intelligent microcontroller which can notify the operator if a problem occurs during the welding, with a fault code. Most fault codes will reset themselves within a few seconds, while others will require the operator to power down the machine.
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Page 37: Causes Of Poor Or Erratic Welds
Causes of poor or erratic welds 1. Loose collet. The collet does not grip the stud tightly. Solution: Change collet 2. Not enough engagement of the stud in the collet. Solution: Remove the collet from the gun, loosen the back-stop so that approximately 1/8”... -
Page 38: Trouble Shooting Poor Welds
Trouble shooting poor welds 1. Weld too hot • Decrease voltage • Set protrusion as indicated in Section 5.7 • Increase spring pressure 2. Weld too cold • Increase voltage • Set protrusion as indicated in Section 5.7 • Decrease spring pressure 3. -
Page 39: Warranty
WARRANTY IWT’s mechanical components are warranted against manufacturer’s defects in material and workmanship for a period of one (1) year from the time of shipment from IWT’s facility. IWT’s electrical components are similarly warranted for a period of one (1) year from the time of shipment from IWT’s facility. IWT’s sole obligation under this warranty is limited to repairing the product or, at its option, replacing the product without additional charge, provided the item is properly returned to IWT for repair as described below. - Page 41 LYNX OPERATION MANUAL SUPPLEMENT - WELDING INSULATION PIN The LYNX Quickshot Stud Welding System is the state of the art welding systems capable of welding pins, threaded fasteners and insulation fasteners. Depending on your application, your system may have been shipped with IWT’s Gap (IWT-G1), Contact (IWT-C1), or Insulation Gun (IWT-Ci).
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Page 42: Parts List
LYNX Quickshot & Modular Parts List Appendix B... - Page 43 FRONT/LEFT VIEW OF LYNX4 Description Part Number Front Panel /Overlay 9-IW004094U/9-LYNX4 OVERLAY Control Knob 9-K51-C151-01 Case Top 9-IW005093U Dinse Connectors Panel Mount (3 req.) 9-EP500020A Amphenol Connector 9-361-1081-ND Screw Cover for 8-32 x 3/8 (10 req.) 9-91620A200 Case Bottom 9-IW004092U Handle 9-186F-193A-5051...
- Page 44 REAR/RIGHT VIEW OF LYNX4 Description Part Number Power Switch (Fuse Holder) 9-Q307-ND Serial Plate SERIAL # PLATE Fan Guard 9-EP500071 Case Rear 9-IW004095U Case Bottom 9-IW004092U...
- Page 45 LEFT VIEW OF LYNX4 Description Part Number Internal Weld Cable (Positive) 9-EP500021 Transformer Hold Down Hardware 9-EP500023 Main Power Switch 9-Q307-ND LYNX4 Capacitor (2 or 3 depending on unit) 9-EP5000167 Handle 9-186F-193A-5051 Main Board Support Plate 9-IW004098 Internal Weld Cable (Negative) 9-EP500022 Dinse Connector –...
- Page 46 RIGHT VIEW OF LYNX4 Description Part Number Main Charging Printed Circuit Board 9-LYNX4-CTRL Main Display Printed Circuit Board 9-LYNX4-DISP Ground Lug (4 req.- 1 per panel) 1-CDA009021 Grounding Buss Bar Assembly 9-IW004105-ASMBLY Ribbon Cable 9-04F5528/1649007 Transformer 9-EP500166 Main SCR 9-T690N04TOF Capacitor Bank Buss Bar Assembly 9-IW004104U Resistor Bank (assembly of 5 resistors)
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