MG-2500

STUD WELDING MACHINE

MANUAL
INSTRUCTION

(PLEASE READ CAREFULLY BEFORE OPERATION)

Safety Depends on You

WSM arc welding equipments are designed and built with safety in mind. However, your overall safety canbe increased
by proper installation.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

Purchase Date:

Serial Number:

Machine Type:

Purchase Place:
Special Attention (Very Important):

● AVOID FALLING DOWN WHEN THE WELDING MACHINE IS PLACED ON THE INCLINED PLANE.
● IT CAN NOT BE USED FOR UNFREEZING PIPELINES.
● THE SHIELD RANK OF THIS SERIES OF WELDING MACHINE IS IP21S, AND IT IS NOT SUTABLE FOR WORKING IN THE
RAIN.

Cautions Arc and arc rays may harm health

Arc welding can be hazardous. All performing welding workers ought to have health qualification that provided by
authority organization. Protect yourself and others from possible serious injury or death. Keep children away.
Pacemaker wearers should consult with their doctor before operating. Be sure that all installation, operation,
maintenance and repair procedures are performed only by qualified individuals.

1 Electric shock can kill: The electrode and work (or ground) circuits are electrically “hot” when the
welder is on. Do not touch these “hot” parts with your bare skin or wet clothing, Wear dry,
hole-free gloves to insulate hands. Users need to follow the below items to avoid electric shocks:
n Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to
cover your full area of physical contact with work and ground. Otherwise, use automatic or semiautomatic
welding machines, DC welding machines as possible as you can.
n In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or
semiautomatic welding torch are also electrically “hot”.
n Always be sure the work cable makes a good electrical connection with the metal being welded. The connection
should be as close as possible to the area being welded.
n Ground the work or metal to be welded to a good electrical(earth) ground.
n Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating
condition. Replace damaged insulation.
n Never dip the electrode in water for cooling.
n Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders, because
voltage between the two can be the total of the open circuit voltage of both welders.
n When working above floor level, please do wear safety belt to avoid falling or losing balance on electric shock.
2 Arc rays can burn: Use a shield with the proper filter and cover plates to protect your eyes

from sparks and the rays of the arc when welding or observing open arc welding. Head shield
and filter lens should conform to nation standards.
n Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers
from the arc rays.
n Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc
nor expose themselves to the arc rays or to hot spatter or metal.
3 Fumes and Gases can be dangerous: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. While working in limited room, use enough
ventilation and/or exhaust to keep fumes and gases away from the breathing zone, or use the
respirator.
n Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation,
especially in confined areas to insure breathing air is safe.
n Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and
other irritating products.
n Read and understand the manufacturer’s instructions for this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and follow your employer’s safety practices. Make sure they are
asepsis and innocuity.
4 Spatter: Welding or cutting spatter can cause fire or explosion.
n Remove fire hazards from the welding area. If this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
n Where compressed gases are to be used in the field, special precautions should be used to prevent explosion.
n When not welding, make certain that no electriferous part is touching the work piece or the work stage.
Accidental contact can create a fire hazard.
n Do not weld containers or lines, which are not proved to be innocuity.
n Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such
procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even
though they have been “cleaned”.
n Spatter might cause burn. Wear leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your
hair to prevent from burning by spatter. Wear the ear shield when performing sideways or face up welding.
Always wear safety glasses with side shields when being in a welding area.
n The welding cables should be as close to the welding area as possible, and the short, the better. Avoid welding
cables going through the building framework, lifting chains, AC or DC cables of other welding machines and
appliances. The welding current is strong enough to damage them while having short circuit with them.
5 Cylinder may explode if damaged.
n Make sure that the gas in the storage cylinder is qualified for welding, and the decompression
flow meter, the adapter and the pipe are all in good condition.
n Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
n Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
n Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
n Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
n Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected
for use.
6 Power: (For electrically powered welding and cutting equipment) Turn off input power before
installation, maintenance and repair to avoid accidents.
n Huanyuan welding equipment is Ι class safeguard equipment; please install the equipment in
accordance with the manufacturer’s recommendations by specific persons.
n Ground the equipment perfectly in accordance with the manufacturer’s recommendations.
7 Power:(For engine driven welding and cutting equipment)
n Work in ventilated place or outdoors.
 n Do not add fuel near to fire or during engine starting or welding. When not working, add fuel
after engine is cooling down; otherwise, the evaporation of hot fuel would result in dangers. Do
not splash fuel out of the fuel tank, and do not start the engine until complete evaporation of
the outside fuel.
n Make sure that all the safeguard equipments, machine cover and devices are all in a good
condition. Be sure that arms, clothes and all the tools do not touch all the moving and rotating
components including V belt, gear and fan etc.
n Sometimes some parts of the equipment have to be dismantled during maintenance, but you still have to keep
the strongest safety awareness.
n Do not put your hand close to fans and do not move the brake handle while operating.
n Please remove the connection between the engine and the welding equipment to avoid sudden starting during
maintenances.
n When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt by the hot
vapor.
8 Electromagnetic: Welding current going though any area can generate electromagnetic, as well
as the welding equipment itself.
n Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should consult
one’s doctor first.
n The effect of electromagnetic to one’s health is not confirmed, and it might have some negative effect to one’s
health.
n Welders may use following method to reduce the hazardous of electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding cable is by
your left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.
9 Lifting equipment: carton or wooden boxes package the welding machines supplied by
WSM. There is no lifting equipment in its wrapper. Users can move it to the prospective
area by a fork-lift truck, then open the box.
n If there are rings, the machine can be transited by rings. While WSM Welding Machine
Manufacture reminds users, there is potential risk to damage the welding machine. So it is better
to push the welding machine by its rollers unless special situations.
n Be sure that the appurtenances are all removed off when lifting.
n When lifting, make sure that there is no person below the welding machine, and remind people
passing by at any moment.
Do not move the hoist too fast.
10 Noise: WSM Welding Machine Manufacture reminds users: Noise beyond the limit (over80
db) can cause injury to vision, heart and audition depending on oneself. Please consult local
medical institution. Use the equipment after doctor’s permission would help to keep
healthy.
 CONTENT

1. Product introduction and usage ................................................................................................................................... 0

1、 Product instruction ......................................................................................................................................................... 0

2、 Usage .............................................................................................................................................................................. 0

2. Features ...................................................................................................................................................................... 0
1、 Features of common arc stud welding machine ............................................................................................................. 0

2、 Unique features of WSM arc stud welding machine ...................................................................................................... 0

3. Main technical parameters ........................................................................................................................................... 1

4. Operation preparation .................................................................................................................................................. 2
1、 Safety cautions ................................................................................................................................................................ 2

2、 Installation and operation conditions .............................................................................................................................. 2

3、 Structure and panel instruction ....................................................................................................................................... 2

4、 Welding torch structure and adjust instruction............................................................................................................... 4

5. Welding on different conditions.................................................................................................................................... 8

1、 Vertical position welding (Weld position)：.................................................................................................................... 8

2、 Overhead position welding： .......................................................................................................................................... 8

3、 Welding with Lengthen welding cable： ......................................................................................................................... 9

4、 Short stud welding ........................................................................................................................................................... 9

5、 Use sample plate to confirm the stud position precision ................................................................................................ 9

6、 Thin plate welding ........................................................................................................................................................... 9

7、 Welding on corner, edge and other position ................................................................................................................... 9

8、 Penetration welding ........................................................................................................................................................ 9

6. Welding parameter selection and quality control........................................................................................................ 10

1、 Welding parameter selection (please see Table 1) ........................................................................................................ 10

2、 Quality control ............................................................................................................................................................... 10

3、 Welding quality inspection ............................................................................................................................................ 10

7. General maintenance.................................................................................................................................................. 11
1、Welding power source maintenance .............................................................................................................................. 11

2、Welding Torch Troubleshooting and Maintenance ........................................................................................................ 11

3, Welding torch maintenance ........................................................................................................................................ 12

8. Main components list ................................................................................................................................................. 12
9. Packing List ................................................................................................................................................................. 17
10. Attached Drawings ................................................................................................................................................... 18
1. Usage

With the development of industrialization, shear studs are more widely used in different industries. However, the welding

quality of studs is bad if we use general welding methods because of slow welding speed, heavy spatter and heavy labor

intensity, etc. Our company explored a new series of RSN arc stud welding machine according to advanced technique in the

world, which is high efficiency welding equipment suitable for welding carbon steel, stainless steel, copper, aluminum and

their alloy, etc. This equipment has the features of short welding time, high production efficiency, good adaptability, little

welding deformation, material saving and so on. It is widely used in manufacturing of steel structure, bridges, vehicles,

shipping and boiler, etc

2. Features

MG series arc stud welding machines come with welding torch and welding cable. It has below features:

1、 Features of common arc stud welding machine:

(1) It is suitable for welding carbon steel, stainless steel, copper, aluminum and dissimilar metal materials, etc;

(2) Short welding time (0.1~2 seconds) and high efficiency (it can weld 16~25 studs per minute);

(3) Good verticality, little welding deformation, high qualification rate and there is no welding marks at the back ofwork-

piece;

(4) Easy operation of through welding, strong intensity of welding spot, tapping is not needed and the globosity of plate can

be well kept;

(5) The working condition is improved to protect welder better because of the application of ceramic ring, and the labour

intensity is decreased too;

(6) Less pollution of smoke, arc rays and noise;

(7) Easy to operate.

2、 Unique features of WSM arc stud welding machine:

The power source consists of contactor, IGBT module, fast recovery diode and digital control circuit, which specify as:

(1) Digital control: welding process is accurately controlled by electronic dialing, which ensure the reliability.
(2) Automatic compensation for the grid fluctuation, stable welding current and good repeatability;The welding time is

controlled by electronic dialing (0.00~9.99S): the welding heat can be accurately and reliablycontrolled, the repeatability

precision is high;

(3) The welding current is step-less adjusted and digital displayed, which ensures the same welding conditions, accordingly

guarantee the high welding quality;

(4) Manual/auto selection function, suitable for multi layer penetration welding;

(5) MMA/Stud welding selection function, can work as both stud welding and stick welding;

(6) Automatic welding time preset function, the longest time limitation is 9.99S after press the welding torch switch to

avoid damaged caused by operation.

3. Main technical parameters

Model
MG-1600i MG-2500i MG-3150i
Specification

Input power 3～440V ±10% /60Hz

Rated input current 112A 162.5A 220A

Rated input power 69kW 94kW 126kW

Rated input capacity 73.5kVA 107 kVA 145kVA

Rated welding voltage 32VDC 32VDC 32VDC

Efficiency 74.3% 80% 82%

Power Factor 0.94 0.88 0.94

Rated Overload Voltage 160A~1600A 250A~2500A 315A~3150A

Stud diameter(mm) Φ6~Φ19 Φ6~Φ25 Φ6~Φ30

Welding time (s) 0.01~9.99

Stud length(mm) ≤400

50kg 96kg 98kg
Net weight
F
Insulation Class

Protection Degree IP21S

680×335×625 905×390×800 905×390×800

Dimension (L×W×H)

Reference values of stud welding technical parameters:

4. Operation preparation

1、 Safety cautions

(1) The lifting of welding machine: if the lifting of machine frequent, you should use special lifting equipment. Since the

thrust face is on the bottom of machine, so forklift is the right choice;

(2) The machine should be grounded well: to prevent electric shock, please connect the ground bolts of power source

well;

(3) Safety guards should be worn according to related labour protection regulations to prevent ultraviolet rays and arc

rays from injuring eyes and skin;

(4) Never breath in harmful welding gas: the gas which produced in welding process is harmful to health, so ventilating

devices should be set according to related labour protection regulations;

(5) Welding machines and operation place should be away from combustibles;

(6) Prevent foreign matters and sharp objects from dropping in the machine;

(7) Prevent machine from dropping and crash.

2、 Installation and operation conditions

Ø The fluctuation of distribution voltage should ≤ +_10%, three phase unbalance rate should < 5%, frequency fluctuation

should ≤ +_1%;

Ø The power source line, switch and fuse that used on distributor should be conform to the below table:

Specification MG-1600i MG-2500i MG-3150i

Switch capacity (A) 150 200 250
Fuse capacity (A) 125 200 200
Sectional area of copper power line(mm2) 10 16 16
Sectional area of copper cored line(mm2) 10 16 16

3、 Structure and panel instruction

a. Adjust the welding current: rotate it in clockwise to increase the preshow current, rotate in anticlockwise to reduce the

preshow current; this function works only if the machine is on power;

b. Adjust the welding time: rotate it in clockwise to increase the welding time, rotate in anticlockwise to reduce the

welding time; this function works only if the machine is on power;

c. Current displaying: to display the welding current and preshow current;

d. Time displaying: to display the automatic welding time, the range in 0.01～9.99 second;

e. Welding process: to switch the welding process between stick welding and Stud welding;

f. Operating mode: to switch the welding mode between manual and automatic;
 Welding Status
current Adj indicator

Current Display
Welding

Time display
Operation Mode

Welding time
Function selection
adj.

Negative

(Welding torch)

Positive

(Work-piece
Control

(Welding

g. Function switching: to switch between torch checking and welding;

h. The indicator light of preshow welding current: it displays the preshow current when it lights;

i. The indicator light of welding current: it displays the real welding current when it lights;

j. Power indicator light: it lights when power on;

k. Overheating indicator light: it indicates that the welding power source is overheating, need to stop to cool;

l. Abnormal indicator of network voltage: it indicates the abnormal condition such as default phase on the network voltage

or under-voltage, need to stop the machine and check the power voltage;

m. Stick welding indicator light: when work as stick welding, it lights;

n. Stud welding indicator light: when the welding process is on stud welding, it lights;

o. Manual indicator light: when the welding process is on manual stud welding, it lights;

p. Automatic indicator light: when the welding process is on automatic stud welding, it lights;

q. Torch checking indicator light: when check the torch, it lights;

r. Welding indicator light: it lights when welding;

s. Controlling(Welding torch): 6 cored outputting terminal of welding torch controlling wire, foot 1 and 2 is torch switch, foot 3

and 4 is torch coil, foot 5 and 6 is empty;

 t. Positive pole (Work-piece): to connect with the welding cable outputting terminal of work-piece;

u. Negative pole (Welding torch): to connect with the welding cable outputting terminal of welding torch;

Power

Power

Groundin
g

v. Power switch: a switch for the 3 phase power;

w. Power input connecting box: To connect three phase input power cable;

x. Grounding terminal: Ground the power source well;

Note: when the stick welding indicator lights, the other indicators such as time displaying, automatic displaying, torch

checking displaying and welding displaying do not light; When manual indicator lights, the time indicator does not light.

4、Welding torch structure and adjust instruction

(1) Welding torch model instruction

Model NS 20HD

Product serial number

Heavy Duty Gun

Name: NS20HD drawn arc stud welding gun

a: Usage and operation range

To work with MG series stud arc welding machine. High working efficiency, easy operation, reliable and stable.

b: Technical parameters:

Welding stud diameter ..................................... Φ10-Φ25mm

Total travel distance of pressing and lifting ............. 25mm

Welding cable ........................................................ 120mm²

Torch weight ..................7 kg

(2) CONFIGURATION OF GUNS FOR WELDING STEEL BOLT
Installation of accessories
1. Insert the chuck for 1" or smaller bolts into the chuck adapter. While holding the gun by the chuck adapter, tap the
chuck with a hammer until it is seated and held firmly in the taper of the chuck adapter . (Figure 1). Mandrels for bolts
larger than 1" thread diameter over the ½-20 hex shaft adapter.
Note: A different chuck is required for each bolt diameter.
2. Insert the Ferrule Grip into the foot and secure with the provided set screws (Figure 1).
3. Insert the bolt into the chuck and the ferrule into the ferrule grip or ferrule holder.
4. Loosen the screws securing the foot to the Leg piece and adjust the foot so that the bolt is centered in the splint. This
is important as inadequate welds will result if there is bonding or friction between the bolt and the socket. Tighten the
oppressors and check the centering again.

1. Adjust the leg and foot assembly so that the bolt extends ⅛” to ¼” beyond the end of the ferrule (Figure 1).
2. When adjusting the Plunge, tighten the leg screws so that the foot assembly cannot move.
Note: It is necessary to adjust pitch when changing bolt lengths.

(3) FREE TRAVEL ADJUSTMENT

With the free stroke adjustment sleeve screw in fully, (clockwise) there will be 1/16” of free stroke. To increase free
travel, move back (counterclockwise) the free travel adjustment handle. Each full turn provides 0.071” of additional free
travel (Figure 2).

Figure 2: Location of the free-moving sleeve

Note: A 1/2” open-end wrench is the appropriate tool to adjust the idle stroke.
 For bolts with a weld base ½” diameter or smaller: 1/8 turn

For bolts with a base of 5/8” to ¾” diameter welding: ½ - ¾ turns

Larger diameter bolts can tolerate a greater increase in free travel.

These recommendations are for normal stud welding applications. For special applications, such as Weld-Thru Decking,
obtain appropriate application sheet.

(4) LIFT AND PLUNGE ADJUSTMENT

Lift Adjustment

Gun lifting can be checked without welding a stud. The recommended procedure for lifting control is under a simulated
welding condition as described below for: MG-1600i, MG-2500i and MG-3150i

Figure 3: Rear view of the gun

1. Load stud and ferrule into gun with proper dip setting for welding.
2. Set the welding time to approximately ½ second. If the control unit is equipped with a weld monitor module, set the 3-
position switch to the "Lift Check" position.
3. Place the gun in normal welding position on a piece of wood or other insulated type surface.
4. Press the fire button, as for welding.
5. Measure the inward movement of the shaft extension. This is the actual elevation under the welding condition.

Note: Firing the gun into the air away from the work surface will cause the gun to rise. The lift in open air will be greater
than when the gun is in the actual or simulated welding condition.

Caution: Erratic lifting may be caused by low voltage; Therefore, it is suggested that a minimum of 65 volts open circuit
voltage be used when checking lifting or operation of stud welding equipment.

To change Lift:
Remove the rear cap from the gun, loosen the locking screw and adjust the core position as necessary (See Figure 3).

To increase lift, screw out (counterclockwise) the adjustable core.

To decrease Lift, screw (clockwise) the adjustable core.

After proper elevation is obtained, lock adjustable core in position by tightening the locking screw. Replace the rear
cover of the gun. Adjust to obtain proper welding time

Recommended elevation settings for steel studs for welding:

½” diameter weld pins/studs or less……………………………………….. 1/16”
⅝” and ¾” studs diameter…………………………3/32”
⅞” diameter studs and over………………………7/64” to 1/8”
5、Operation process

(1) Connect the welding torch cable (Negative pole), control cable (Control), grounding cable (Positive pole) with machine

accordingly, and connect the other terminal of grounding cable with work-piece.

(2) Adjust the welding torch according to relevant require.

(3) Prepare all power supply, and connect power leads. Turn on the power switch, now the emergency stop switch on panel

should be “pressed”(Power off). Rotate the emergency stop switch on clockwise, the indicators on. When the “stick welding”

indicator on, the motor fan start working; when the “stud welding” indicator on, the motor fan not working unless press the welding

torch knob.

A、Automatic welding
(4) Press and adjust the knobs on machine panel of welding process and operation mode, make sure set on: “stud welding”,
“automatic” and “torch checking”. Check and make sure the stud and ceramic ring is concentric. Make sure the stud plunge length
accord with welding technology requirement.
(5) Based on shear stud material, diameter and welding position, choose the suitable welding current and welding time
according to welding technology requirement. (Refer to Table 1)
(6) Hold the torch with one hand , and the other hand supporting torch body, aim the stud end to the welding position, press
down the torch body, make the ceramic ring and stud welded end flatting with work-piece surface, to ensure stud is perpendicular
to the work-piece surface , press the button on the torch (No need press that all the time), at the mean time, the welding machine
will automatically check the arc striking current, and there will be blue continuous arc between stud head and work-piece surface,
with some “zizi” voice, until preset welding time, which means the torch checking is normal, both the welding machine and welding
torch can work well.
(7) Press the function swift button on machine panel to “welding”, aim the stud end to the welding position, press down the
torch body, make the ceramic ring and stud welded end flatting with work-piece surface, to ensure stud is perpendicular to the
work-piece surface , press the button on the torch. Then the machine will automatically finish the stud lifting → arc strike→ turn

on welding current → turn off welding current→ stud insert into the weld crater → form a weld joint. (Note: After pressing the
welding torch button, while in the automatic welding process, do not shake the welding torch body, so as not to affect the quality
of welding). Clear ceramic ring in joint portion, visual inspect weld joints. Thus, a stud welding process ends.
B、Manual
(8) Press and adjust the knobs on machine panel of welding process and operation mode, make sure set on: “stud welding”,
“manual” and “torch checking”. Check and make sure the stud and ceramic ring is concentric. Make sure the stud plunge length
accord with welding technology requirement.
(9) Based on shear stud material, diameter and welding position, choose the suitable welding current and welding time
according to welding technology requirement. (Refer to Table 1)
(10) Hold the torch with one hand , and the other hand supporting torch body, aim the stud end to the welding position, press
down the torch body, make the ceramic ring and stud welded end flatting with work-piece surface, to ensure stud is perpendicular
to the work-piece surface , press the button on the torch all the time (For safety consideration, the open circuit voltage will be cut
automatically after pressing torch knob 10 seconds), in the mean time, the welding cable should be manually lift to lift the stud,
and there will be blue continuous arc between stud head and work-piece surface, with some “zizi” voice, then loosen the torch
knob and arc distinguish, which means the torch checking is normal, both the welding machine and welding torch can work well.
(11) Press the function swift button on machine panel to “welding”, aim the stud end to the welding position, press down
the torch body, make the ceramic ring and stud welded end flatting with work-piece surface, to ensure stud is perpendicular to the
work-piece surface, press the button on the torch all the time, manually lift the welding cable to lift the stud. Then the machine
will finish the: stud lifting → arc strike→ turn on welding current. Loosen the welding torch knob at right time Only if loosen the
torch knob, welding current can be cut), then put down the stud Note: try the best to loosen torch knob and put downstud at a
same time), insert the stud into welding crater to form a weld joint. Clear ceramic ring in joint portion, visual inspect weld joints.
Thus, a stud welding process ends.
 (12) Check the welding quality, if not get a good welding quality, adjust welding parameters again. If get a good welding
quality, then keep working on next studs (Note: please don’t torch the torch knob when install a new stud.
(13) Press the emergency stop knob to turn off the machine, and cut the power.
(14) Put the welding machine & welding accessories in a clean environment with -25℃ ～ +40℃temperature and ≤90% relative
humidity.

5. Welding on different conditions

Generally, stud welding is the welding at flat position; however, there are other welding conditions. To obtain high quality

welding quality at different conditions, we hereby list some other examples to reference.

1、 Vertical position welding (Weld position)：

At this position, melted metal will flow down to the bottom of stud and form asymmetrical weld because of the gravity. The

bigger stud diameter size is, the more obvious the asymmetry will be. Below are the suggestions for this condition:

(1) To the stud diameter that ≥16mm，the welding at vertical position is not suggested;

(2) If the stud diameter that ≥16mm is required, please increase the welding current and reduce the welding time;

Pay high attention to plumb the stud on work-piece and keep the chuck clean.

2、 Overhead position welding：

While overhead welding, sparks and spatter from the welding arc may cause burn accident. To avoid accidents, please wear

oil free protective garments such as leather gloves, heavy shirt, cuff-less trousers, high shoes and caps. Always wear safety glasses

with shields at welding area. Adjust a proper welding current and welding time at flat welding position before operation. While

operating, keep a constant welding time and increase the welding current to obtain high quality weld.

3、 Welding with Lengthen welding cable：

When working on wide ground and the welding cable must be lengthened, you can adopt bigger size cable or run cables in

parallel, otherwise the welding quality will be badly influenced, because longer the cable is, the larger the resistance will be.

4、 Short stud welding

Since the ceramic ring and chuck of welding torch has particular depth, and the stud should be sticked out, so if the stud is

too short, the welding quality cannot be good, even fail. So a special "necking stud" is suggested to use.

5、 Use sample plate to confirm the stud position precision

When weld studs which requires high precision position, we suggest you make a sample plate which has similar shape with

work-piece, and a pressing plate is required to fix the sample plate. Make holes on sample plate accordingly in suitable position,

the diameter of these holes should be a little bit bigger than ceramic ring. Keep some space between sample plate and work-piece,

to blow off the gases caused by welding.

6、 Thin plate welding

The thin plate is that when the thickness of work-piece exceed 3mm, the scale of the stud diameter and work-piece thickness

equal or exceed 4:1 (for example, if use Φ16 stud, the work-piece thickness is less than 3mm, that is called ‘thin plate’); in addition,

when work-piece thickness is between 1.5 to 3mm, the scale equal or exceed 3:1(for example, if using Φ6 stud, the thickness is

≤2mm, that is called ‘thin plate’). Generally, the sheet steel don`t have enough intensity to support the stud and it will be damaged

by loading stud.
 However, in some condition, the stud welding of thin plate is needed, to get ideal welding quality, some methods are

suggested below:

(1) Underlay the sheet with a flat copper, which will not only support the work-piece but also transfer away the heat that

from welding pool;

(2) Change welding polarity, that is connect the welding torch to the positive pole and the work-piece to the negative pole,

thus more heat act on the stud to avoid burning the sheet steel plate(work-piece). Specially note: this method can be only used on

the thin plate welding!

7、 Welding on corner, edge and other position

When welding on this position, there usually will be weld asymmetry on the stud foot, molten steel is ‘blew’ to one side, this

is called ‘arc blow’ or ‘magnetic blow’. Many factors cause this phenomenon, and there is no methods which can solve this

absolutely. However, we can reduce bad influence by following the below(only for reference):

(1) Connect the work cable to the rear of the stud welding position that on the work-piece;

(2) Respectively connect two root work cables to the both sides of work-piece.

(3) If welding on the edge of work-piece, use a steel plate cling the edge to increase the area of magnetic effect.

8、 Penetration welding

Penetration welding is a special stud welding method: insert a low carbon steel sheet between stud and work-piece (the

thickness of steel sheet must be less than 3mm), and then weld the stud, plate and work-piece together (see figure 7). The

penetration welding is especially suitable for welding profiled steel plate and it is widely used in tier steel structure building. But

the profiled steel plate have a protective zinking layer, which will influence the welding quality badly.(see appendix penetration

welding parameter reference value). Here are the suggestions as follows:

(1) Before welding, clean the oil, dirt and paint on the welding position. If the welding quality is still not ideal, clean the

zinking layer.

(2) Drill holes on the welding position according to actual condition to ensure the welding quality.

Reference parameter value of penetration welding

Stud dia(mm) Current(I) Time(S) Plunge length(mm) Lifting distance(mm)

Φ16 1500 1.0 7～8 3.0

Φ19 1800 1.2 7～9 3.0

6. Welding parameter selection and quality control

1、 Welding parameter selection (please see Table 1)2

、 Quality control

(1)Choose qualified stud and ceramic ring. The material of stud and ceramic ring will influence the welding quality a lot.
(2) Keep the welding position of work-piece clear, clean out oil, dirt, paint and oxidation.

(3) Adjust the welding torch exactly, such as the stud stick out length and lifting distance, etc;

(4) Select the proper welding parameter and standard according to different diameter stud.

(5) Adopt direct current straight polarity (DCSP) while welding steel i.e. the welding torch is connected to the negative pole

and the work-piece is connected to the positive pole. While welding aluminum, adopt direct current reverse polarity (DCRP)

i.e. the welding torch is connected to the positive pole and the work-piece is connected to the negative pole.

(6) Ground the work-piece well.

(7) The size and length of the welding cable and work cable accord with the requirement of the equipment.
 (8) Hold the welding torch steadily and plumb the stud with the work-piece.

(9) Keep the equipment clean.

(10) Welding test before formally welding is requested to make sure the suitable welding parameter. When the stud and

ceramic ring is changed, or the welding torch is regulated, we should test again;

(11) Wait a moment to move welding torch after welding is over.

3、 Welding quality inspection

(1) Visual inspection

Stud welding quality can be visually inspected from appearance of the weld. If the weld has any defects, the welding

parameters should be adjusted.

(3) Intensity test

Jointing intensity should be tested when test machine, choose the welding parameter to ensure the designed jointing

intensity.

a、Bend test

(As Figure 4)Bend the stud 15° away from its spindle with a bending wrench, and bend it back to 0° again, if

there is no crack on the joint, it means good welding.

 b、Torque test

Torque testing equipment is showed as below table. Fasten the tested plate, cover a sleeve (its inner-dia is bigger than stud

dia), a washer and a nut, and turn the nut with a torque spanner, good weld should be no crack when reached the value as

below.
Stud dia（mm） Φ6 Φ8 Φ10 Φ12 Φ16 Φ20 Φ22

Torque value (kg-m) 0.7 1.2 2.1 4.4 11 21 29

7. General maintenance

1、Welding power source maintenance:

User should maintain the machine one time per half-year at least according to using and storing condition. The methods and

steps as below:

(1) Turn off the power supply；

(2) Open the shell of machine；

(3) Clean away dust and dirt inside with dry high-pressure air or hairbrush；

(4) Check all fastener, screw down the loose fastener；

(5) Check the fan, infuse some lubrication oil to spindle of rotation；

(6) Finally, put on the shell and turn on the power to check the equipment works normally or not.

Special notice: maintenance can only be operated by authorized electrician under guidance of professional persons; Welding

machine should not be carried or moved by dragging cables; Don’t touch any electric components inside the welding machine; Any

electric components damages please contact with supplier for supports.

2、Welding Torch Troubleshooting and Maintenance

Welding torch general failures and treatment method

Faults Fault Cause Inspection Method Maintenance

1、 CHECK is there input voltage on the

1、 No power supply; welding torch (DC16V±10%); Ø Make sure the stable

2、 The welding torch 2、 Press the welding torch switch, and input voltage;

switch circuit control check the 1,2 pin on the socket of Ø Connect the switch

switch is bad or torch controlling cable, the circuit circuit again or

damaged ; must be connected; after loosening change a new switch;

Unable to lift the switch, it must be non-circuit; Ø Connect the
3、 Electromagnet circuit
the welding 3、 Check the 3,4 pin on the socket of electromagnet circuit
is disconnected ;
torch torch controlling cable, the circuit again;
4、 Electromagnet is
damaged; must be connected. The normal Ø Change a new

5、 Adjust too much size resistance value should be 16Ω±10%; Electromagnet;

on adjusting central 4、 Open the rear cover, take the central Ø Adjust the display size

spindle; spindle out to check the according to the

electromagnet coil, make sure there is operation manual;
no deformation on it;
 5、 Open the rear cover to check the
displayed value on adjusting central
spindle, adjust the size according to
Table 1 and diagram 5.
1、 Check the returning spring and make
1、 The returning spring is
Bad welding sure it is not burned or broken; 1、 Change the spring;
damaged;
torch 2、 Take down the damping bumper and 2、 Change the damping
2、 the damping bumper
returning press the rubber head on it, it must be bumper;
is damaged;
pressed stably and easily.
1、 To fasten the nut on
1、 The damping bumper 1、 Check if it is loosen; damping bumper;
is loosen; 2、 Adjust the damping bumper; 2、 4.2-C;The adjusting
Too much
2、 The damp is too small; 3、 Take down the damping bumper and method please refer
spatter
3、 The damping bumper press it, check if it can be returned to 4.2-C;
is broken; normally; 3、 Change the damping
bumper.

3, Welding torch maintenance

The welding gun is an electromechanical combinative precision groupware of the machine. Under the general condition, do

not disassemble it completely. Don’t disassemble it except the professional personnel. Because some parts can’t be

disassembled, or the original precision even the parts may be broken. The welding gun maintaining steps as follows:

(1) Open the rear cover, fasten ring and damping gas room, clean away the dust and dirt. If it is too dry, daub a little silicon-oil;

(2) Disassemble the chuck, foot and front cover carefully, clean away the dust and sundries to ensure good conductive ability;

(3) Assembly the spring well after cleaning the front part, do not torch with the main shaft the torch;

(4) Check the insulation situation between chuck and support feet regularly.

Note: if it’s not insulated between chuck and support feet, then there will be risk to burn the welding torch.

8. Main components list

MG-1600i
No. Item Model Note

1 Linear inductance

2 Capacitor 2200μF-400VDC+85℃

3 PCB PT31

4 Diode MMF200ZB040DK1

5 Linear inductance

6 PCB PR03

7 Main transformer

8 Hall sensor TKC1000BR

9 Filter reactor

10 PCB PT02

11 Capacitor HYC3006

12 Saturation inductance

13 Capacitor HYC4002

14 PCB PT05

15 Capacitor HYC4013

16 IGBT FF300R12KT4

17 Bridge rectifier MDS150-16

18 Fan 200FZY2-D
 19 Air breaker DZ158-12513P

20 Three phase inductance

21 Control transformer TR01

22 PCB PT03

23 PCB PR02

24 PCB PR01

MG-2500i
No. Item Model Note

1 Capacitor 2200μF-400VDC+85℃

2 Capacitor HYC4013

3 IGBT FF300R12KT4

4 Capacitor HYC4002

5 Filter reactor

6 Hall sensor TKC1000BR

7 PCB PT02

8 Capacitor HYC3006

9 Main transformer

10 Saturation inductance

11 Temperature relay KSD305A shut 75℃

12 Fan 200FZY2-D

13 Linear inductance

14 PCB PT31

15 Diode MMF200ZB040DK1

16 Air breaker DZ158-125/3P

17 Control transformer TR01

18 Three phase inductance

19 PCB PR03

20 PCB PT05

21 PCB PT03

22 PCB PR02

23 PCB PR01
MG-3150i

No. Item Model Note

1 Capacitor 2200μF-400VDC+85℃

2 Capacitor HYC4013

3 IGBT FF300R12KT4

4 Capacitor HYC4002

5 Filter reactor

6 Hall sensor TKC1000BR

7 PCB PT02

8 Capacitor HYC3006

9 Main transformer

10 Saturation inductance

11 Temperature relay KSD305A 常闭 75℃

12 Fan 200FZY2-D

13 Linear inductance

14 PCB PT31

15 Diode MMF200ZB040DK1
 16 Air breaker DZ158-125/3P

17 Control transformer TR01

18 Three phase inductance

19 PCB PR03

20 PCB PT05

21 PCB PT03

22 PCB PR02

23 PCB PR01

9. Packing List

l MG SERIES Welding Power Source 1

l NS20HD Welding Gun 1

l Control Cable 1

l Welding Cable 1

l Chuck 5

l Support Plate 5

l Fuse 2

l Operation Manual 1
10. Attached Drawings

Figure 5: The schematic diagram of welding power source

Figure 7: The welding process

1. Put stud on the welding position

2. Press down the welding torch to the
surface of the work-piece.

3. Press the trigger, lifting the stud and strike arc 4. The stud and work-piece was melted by
welding current.

5. The stud plunge into the molten pool. 6. Remove the gun and break the ceramic ring
Figure 3、multi-layer penetration welding

1. Adjust the torch for welding, press down the torch and make ceramic ring and stud on a surface .
2. Press the trigger, lift stud--arc striking--turn on welding current--turn off the welding current--plunge stud
into molten metal--complete a penetration welding cycle.

Figure 8: Bend testing

The final explanation rights reserved to WSM Company!

If there are any changes in the manual instruction, forgive not to inform separately!

WELD STUDS MEXICO

Address: Av. José Vasconcelos Ote 150-A, Del Valle, San Pedro Garza García, Nuevo Léon

Postcode: 66220

Telephone:+528183555100

E-mail: [email protected]

www.weldstuds.mx