Table of Contents
Troubleshooting
Summary of Contents for IWT LYNX4 Modular
- Page 1 Operating Instructions LYNX Modular & Quickshot Revised 2023 Serial Number _______________ IWT Stud Welding 2650 Egg Harbor Road Lindenwold, NJ 08021 (856) 435-8004 phone www.iwtmarketplace.com Revision 1.05...
- 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 Stud Welding). 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 Product Information ....................6 1.4 Serial plate ........................7 1.5 Documentation ......................7 1.5.1 Operating instructions ..................7 1.5.2 In case of malfunction ..................8 1.6 Contacts and service address .................. - Page 4 5.6.1 Ground connections ....................23 5.6.2 Connect stud welding gun ..................23 5.6.3 Power supply connection ..................23 5.7 Gun set up ........................23 5.8 Operation ........................25 5.9 Welding parameters ....................25 5.10 Polarity……………………………………………………………………………………….26 6 Quality control ......................26 6.1 Standard work test ......................
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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 service. The system incorporates the latest in engineering advances, for completely reliable capacitor discharge stud welding of mild steel, stainless steel, aluminum, copper, and lead-free brass fasteners. -
Page 6: Application
The visible side of the work piece is spared, to a large extent, from pressure marks or deformations, so that, even thin sheet metals down to 0.060” thick retain their decorative appearance. If you need consultation or assistance in solving technical problems, please contact either IWT or one of our field engineers. Product Information... -
Page 7: Serial Plate
Serial Plate The serial plate is located on the rear side of the stud welder. It contains information regarding the manufacturer’s name, address, country of origin, product specifications, method of welding, date manufactured, and serial number. Documentation The following operating instructions are supplied with the LYNX Stud Welding System: •... -
Page 8: In Case Of Malfunction
Contact & Service Address If you have any questions regarding the operation of the stud welding system, spare parts or if you require service, please contact your distributor, or IWT directly at the following address: IWT Stud Welding Attention: Technical Support/Repairs... -
Page 9: Description Of The Stud Welder
Description of Stud Welder Capacitor Discharge Technology The LYNX Stud Welding System with tip ignition operates according to the principle of capacitor discharge welding as defined in the American Welding Society Welding Handbook. This system uses the abrupt discharge of a capacitor bank to generate and electric arc. Stud lifts off and drops Stud immerses into the Stud tip or gun foot... -
Page 10: Dimensions
Straight polarity is when the work surface is positive, and the gun is negative. Whenever the work is clean, straight polarity is used. Reverse polarity, or when the work surface is negative, is used for welding brass or whenever impurities are present. See Section 5.10 for more information on polarity. -
Page 11: Technical Data
Material Lead-Free Brass Welding Method Capacitor Discharge Tip Ignition IWT-G1 Gap, IWT-C1 or IWT-C2 Contact, IWT- Standard Gun Ci Insulation, IWT-S1, S2, M1 for tight access Current Source Capacitor Bank Charging Capacity Modular @ 81,000µF (Quickshot @ 54,000µF) Charging Voltage 50-195v, adjustable 1 –... -
Page 12: Block Diagram
Block Diagram... -
Page 13: Safety Instructions
Safety Instructions This operating manual contains basic instructions that must be complied with during installation and/or operation. It is necessary that the operator and/or welding supervisor reads these operating instructions prior to setup and welding. Not only the general "safety instructions" listed under this main item, but also the special safety instructions e.g., for high temperatures, voltages, etc. -
Page 14: Staff Qualification And Training
Staff Qualification & Training The staff responsible for operation, maintenance, inspection, and assembly must have the respective qualification for carrying out these duties. Field of responsibility, competence and the supervision of staff must be regulated by the user. If your personnel do not have the necessary knowledge they must be trained and instructed. -
Page 15: Before Starting The System
Before Starting to Weld • Check the state of all cables. • Immediately replace defective cables and cable connections with genuine IWT parts. • Ensure that the air louvers are not covered. Heat accumulation may damage the stud welder. •... -
Page 16: Safety Precautions At Installation Site
Safety Precautions at Installation Site • When placing the stud welder on tables or similar workshop furniture, ensure that the stud welding system stands firmly and that the table can bear its weight. • Make sure the power supply and stud welder are properly grounded when in use. •... -
Page 17: Safety Instructions For Maintenance, Inspection And Assembly Works
3.11 Unauthorized Retrofit and Spare Parts This system should never be retrofitted or modified. Only genuine IWT spare parts and accessories authorized by the manufacturer guarantee safety. The use of other parts will result in the cancellation of warranty. -
Page 18: Installation Of The Stud Welder
Gun cable (section 5.1.1, item 5) • Check the welding cable and connections of the stud welder for damage such as arcing, mechanical wear etc. and have damaged parts replaced by IWT or an authorized distributor. • Roll up the cables without buckling them. -
Page 19: Exterior Components
Exterior Components 5.1.1 Front View Item Description Voltage Control Knob Voltage Display Voltage Chart Ground Connectors Gun Weld Cable Connector Gun Control Cable Connector 5.1.2 Rear View Item Description Power Socket/Switch Serial Plate Cooling Louvers Revision 1.05... -
Page 20: Operating Elements
Operating Elements ON/OFF Switch (Item 8) The power switch is located at the back of the unit and serves to switch the welder on and off. Voltage Control Knob (Item 1) The voltage control knob is located on the front of the stud welder. This knob functions to increase or decrease the capacitors’... -
Page 21: Display Elements
IWT-G1 gap gun, the “stud on work” LED will be activated, then when the trigger is pulled the “foot on work” LED will be activated. When welding with an IWT-C1 or C2 contact gun, only the “stud on work” LED will be activated. -
Page 22: Fuse Elements
Fuse Elements The LYNX Stud Welding System is protected by the following fuses: Mains fuse: 2 x 15A 250V Slow Blow (IWT PN: 1-EP500150) Charging fuse: 10A 250V Slow Blow (IWT PN: 1-EP500166) Control fuse: 1A 250V (IWT PN: 1-EP500145) -
Page 23: Preparing To Weld
Preparing to Weld Connect the stud welding gun and the ground cables to the stud welder as indicated in Section 5.3. 5.6.1 Ground Connections • Connect the ground cables into the indicated ground sockets. • Turn the connectors clockwise until they stop. •... - Page 24 Figure 1 Figure 2 Figure 3...
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Page 25: Operation
*When using IWT-Ci Insulation gun, please refer to the insulation supplement on page 34. In the above chart, “GUN” indicates the spring pressure setting on the IWT-G1 gap gun. “-“ indicates decreased spring pressure on the gun spindle. “+” indicates increased spring pressure on the gun spindle which results in greater velocity when the weld is made. -
Page 26: Polarity
LEAVE THE OTHER GROUND SOCKET VACANT. Plug one ground cable into the gun weld cable socket. Alternatively, contact IWT for a “Y” connector so that two ground cables can be used in this configuration, allowing the current to flow from the ground to the gun. -
Page 27: Simplified Work Test
Clean the unit with dry compressed air only. Replacement of Components Defective components may only be replaced by trained IWT personnel. Perfect function of your stud welder can only be guaranteed when original IWT parts are used. Fuses... -
Page 28: Electronic Waste Directive (Weee)
MORTAL DANGER Always replace fuses with the correct replacement value. Do not use oversized fuses that may damage the unit. Always disconnect the stud welder from the mains power supply when replacing fuses or servicing the stud welder. Electronic Waste (WEEE), Directive 2002/96/EC Please help minimize the effects we have on the environment by not disposing of electronic waste (e-waste) with household trash. -
Page 29: Trouble Shooting
If the problem cannot be corrected by adjustments on the welder, you should check the gun. Ensure the gun is set up for the correct material, stud size, engagement of stud in chuck and freely moving. If you are still having difficulty, contact an authorized IWT service center. Revision 1.05... -
Page 30: Fault Light Indications
Some fault codes will reset within a few seconds, while others will require the operator to power down the machine. If a particular fault code continues, please contact an authorized IWT service center for information on servicing your system. -
Page 31: Causes Of Poor/Erratic Welds
1/8” (for steel) of the fastener sticks beyond the foot piece. 12. Incorrect spring pressure Solution: Set spring pressure to “-“ (negative) for steel and to “+” (positive) for aluminum. 13. Poor stud quality Solution: Use only IWT’s, clean fasteners to ensure quality. Revision 1.05... -
Page 32: 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 33: Warranty
(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 34: Lynx Insulation Supplement
Attach the IWT-Ci Insulation Gun to the locking terminals indicated on the front panel of the unit. Install the ground cable in either of the indicated ground terminals. Ensure that all connections are tight. Attach the clamp end of the ground cable to your work piece.
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