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Table of Contents
Related Manuals for INTERNATIONAL WELDING TECHNOLOGIES LYNX
Summary of Contents for INTERNATIONAL WELDING TECHNOLOGIES LYNX
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Page 1: Operating Instructions
Operating Instructions LYNX Modular Stud Welding System Serial Number _______________ NTERNATIONAL ELDING ECHNOLOGIES, INC. 276 Pinedge Drive West Berlin, NJ 08091-9218 Tel: (856) 753-8126 Fax:(856) 753-8439 www.internationalwelding.com technicalsupport@internationalwelding.com Revision 1... - 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...............8 1.6 Contacts and service address..................8 2 Description of the stud welder ................9 2.1 Capacitor discharge technology..................9... - Page 4 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 ......................30 5.11 Modular circuitry......................30 6 Quality control ......................31 6.1 General ........................31 6.2 Demands on the company..................31 6.3 Proof of qualification ....................31 6.4 Type and scope test ....................31 6.4.1 Standard work test ....................31...
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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
• Call a doctor in case of an accident. Application The IWT stud welder LYNX Modular Stud Welding System allows you to weld pins and threaded studs sizes #4 through 5/16” as well as various fastening elements made of steel, stainless steel, aluminum, copper and lead free brass. -
Page 7: Serial Plate
Information on documentation The following operating instructions are supplied with the LYNX3 stud welder: • Operating instructions for the LYNX Modular Stud Welding System • 123 Quick Setup Guide to Gap Welding 1.5.1... -
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
A weld must have sufficient heat to melt the weld zone, and enough pressure to provide good fusion. In the LYNX Modular Stud Welding System, heat is easily regulated by the voltage on the capacitor bank. The length of weld cable used also affects the heat. -
Page 10: Stud Welder Set-Up
(see Section 5.9 for a discussion of polarity). Stud welder set-up The standard pistol to be connected to the LYNX Modular Stud Welding System is the IWT-G1 gap gun or IWT-C1 contact gun. See additional information on the weld guns in Section 5. -
Page 11: Dimensions
Dimensions The LYNX Modular 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”... -
Page 12: Technical Data
Technical Data Description LYNX Modular Stud Welding System Welding range #4/12ga through 5/16” Steel, Stainless Steel, Aluminum, Copper, Material Lead Free Brass Welding Method Capacitor Discharge Tip Ignition Standard Pistol IWT-G1 gap or IWT-C1 contact Current Source Capacitor Bank Charging Capacity... -
Page 13: Block Diagram
Block Diagram Revision 1... -
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
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. 3.2 Staff qualification and training The staff responsible for operation, maintenance, inspection and assembly must have the respective qualification for carrying out these works. -
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. • Wear neither rings, watches nor 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: Unauthorized Retrofit And Spare Parts Production
comply with the procedure for stopping the stud welding system described in the operating instructions (chapter 3.13). Immediately after having completed your work, re-install and activate all safety and protective devices. 3.11 Unauthorized retrofit and spare parts production The system may only be retrofitted and modified after consultation with the manufacturer. -
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
Ensure sufficient ventilation of the working room when operating the system. The housing of stud welder LYNX corresponds to safety class IP 21. Please observe that this system of protection is not suitable for being operated or transported in the rain. -
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 1-856-753-8126... -
Page 23: Operating Elements
• Ground cable connector (Section 5.1.1., Item 4) There are two ground cable connectors on the front to the LYNX Modular Stud Welding System. Insert each cable connector into the ground socket and twist in a clockwise direction to tighten. Ensure these connectors are tight. -
Page 24: Display Elements
The stud welder is configured at the manufacturer to use a 12 Amp, 120V 50/60 Hz supply. Display elements The LYNX Modular Stud Welding System is equipped with seven indicator displays: •... -
Page 25: Fuse Elements
This LED indicates the base unit is working as designed. Fuse elements The LYNX Modular Stud Welding System is protected by the following fuses: Mains fuse: 2 x 10A 125 V slow blow... -
Page 26: Preparation For Initiation
5.6.3 Mains supply connection Connect the power cable supplied with the LYNX Modular Stud Welding System into the rear of the unit. Connect the three prong plug into a grounded shock proof supply. Do not use an extension cord with this unit. -
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 1-856-753-8126...
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Page 29: Operation
Upon successful recharge, the “ready” light will turn on. Welding parameters The table on the front of the LYNX Modular Stud Welding System provides standard values for welding different size fasteners. charge voltage is selected based on the diameter of the fastener. These estimated voltages listed below are for “flanged”... -
Page 30: Reverse Polarity
To initiate reverse polarity welding with the LYNX Modular Stud Welding System unplug all weld cables from the unit. Then, plug the gun weld cable into one of the ground sockets. -
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
The standard work test is restricted to the stud diameter, base material and type of equipment used. It comprises the following tests: • Visual inspection (all samples) • Tensile test (at least 3 samples) • Bend test (at least 3 samples) In case of doubt, the test scope should be extended in compliance with DVS Guideline 0905, part 2, section 5.1.1. -
Page 33: Maintenance
Defective components may only be replaced by trained IWT servicemen. Perfect function of your stud welder can only be guaranteed when original IWT spare parts are used. Fuses The stud welder LYNX Modular Stud Welding System is protected by the following fuses: Mains fuse:... -
Page 34: 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 that "isn't working," stand back a moment 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 35: 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 36: 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.
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