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Spot WelderSpotwSPOT WELDERMODELS TSP-1/TSP-2/TBWOwner’s Manual forTSP1:SN# 21809 and belowTSP2:SN# 30897 and belowTBW:SN# 41001 and belowApprox:July ‘13 and earlierOWNER’SMANUALMACHINERYDIVISION

INTRODUCTIONCONTROL SCREW ADJUSTMENTDuro Dyne Spot Welders have over 50 years of provenreliability in shop environments. The latest models, TSP/TBW, incorporate the established durability with a builtin solid state timer for weld accuracy and consistency.Optional accessories such as water cooled arms and theST-2 Spotwelder Stand mean the TSP/TBW Spot Welderscan be customized for your special needs in producing atop quality product.Located on the underside of the welder handle, towards theback is a small, knurled screw. This screw determines thepoint at which the welder is activated after the welding tipsare brought together against the metal. This switch controlscrew should be adjusted as follows:To avoid unnecessary problems while using your TSP/TBWSpot Welder, please read this instruction manual fully andunderstand its contents completely.IMPORTANT: Always follow manufacturer’s recommendations for proper safety and handling procedures for allmaterials used in conjunction with this machine as outlinedin Manufacturer’s Safety Data Sheet (MSDS) for eachproduct.ELECTRICAL INSTALLATIONMODEL TSP-1 MODEL TSP-2 MODEL TBW -110V - Fuse for 25 amps220V - Fuse for 15 amps220V - Fuse 25 amps2. Loosen jam nut. Adjust switch screw up or down, asthe case may be, so that further pressure on thehandle will activate switch and apply current. Tightenjam nut to lock adjustment.3. This setting is changed only if the thickness of themetal being welded is changed greatly, or to compen-sate for the dressing of the tips.NOTE: In some cases the range of switch adjustmentmay not be sufficient for proper setting. To adjust for newarms, remove the upper arm, place back end in a vise andbend slightly in the direction necessary to allow for properadjustment.ELECTRIC TIMERSConnect the welder to a lightly loaded circuit supply line.For best results: Use a separate line as voltage drops canseverely affect the efficiency of your welder.WIRING CONNECTIONSWelders are normally supplied with a 3 prong polarized plugto insure that the body of the welder is grounded. This isa safety precaution which should be taken on all electricaltools. In the event that you wish to use a plug other thanthe one supplied, the following diagram shows the welderconnections:white1. Place metal between welding tips. Squeeze handle,applying moderate pressure to the welding tips.Current should NOT yet be “ON.”connectto powerblackgreen togroundAll TSP and TBW welders are supplied with solid statetimers. The timer allows complete control of the weldingcycle to assure fast and quality welding on even very lightgauge steel. When properly adjusted the timer will eliminate“burn through.”The timer is adjustable from 1/10th to one (1) second. Toadjust, simply turn the knob on the back of the welder untilthe desired time is set ( counterclockwise to decrease;clockwise to increase).TBW HI-LO SWITCHWhen welding extremely light gauge metal the power of theTBW may be too hot to avoid “burn through.” To “cool down”the TBW, a Hi-Lo switch was installed. When welding lightgauge steel simply “flip” the Hi-Lo switch to Lo and adjust thetimer as usual. Be sure to change the switch to Hi when goingto heavy gauge or difficulty in welding will be experienced.OPERATION OF THE WELDERIt is suggested that before using the Spot Welder on regularwork, the operator should try welding pieces of scrap metalsimilar to the production material in order to determine thelength of time it takes for proper fusion of the metals. Theheavier the thickness of metals to be welded, the longer thetimer must be on to perform a satisfactory weld.INSTALLATION OF ARMSWELDING GALVANIZED METALSThe arms of your welder should be inserted as follows:Since the galvanized coating is a poor conductor of electricity,it does not weld as readily as uncoated metal. The followingsimple procedure is suggested when welding galvanized iron:1. Loosen slightly the 1/4-20 Allen Head Cap Screw onthe side of the “nose piece.” Insert top arm (shorterarm) all the way in, seat firmly and tighten screw.2. Loosen slightly the 1/4-20 Allen Head Cap Screw onthe side of "lower arm mounting" (hole in side of frontbody allows easy access). Insert lower arm deepenough so that tips meet exactly when arms arebrought together. Tighten screw.3. Recheck the alignment and readjust as necessary.1. As soon as current is applied, tilt the work so that thetips can “bite” into the coating. This will start the weld.2. Keep handle depressed until weld cycle is complete. Incases of metal which is rusty or has a heavy scale,cleaning is recommended before welding.In all cases, materials being welded should be clampedtogether so it will not be necessary for the arms to pullthe material together.

CARE OF THE TIPSThe tips supplied are made of a top grade copper andwill last a long time under normal conditions.Since the “power” of the welder is reflected in the diameter and cleanliness of the tips, it is recommendedthat the tips be kept at a diameter of not greater than1/8”. For best results, keep them at 3/32”. Tips shouldbe dressed by using a small mill file regularly. Keep themclean and to correct diameter.GENERAL MAINTENANCEThreaded Cone Tips (MT-3): Type MT-3 tip removal issimple, however, it is necessary to use the followingprocedure in order to break copper oxide scale whichforms in the threads:Place an open end wrench on the tip and hit the far endof the wrench with a sharp blow of a hammer. This breaksthe bond, and the tip can easily be removed and replaced.Taper Fit Tips (MT-1 & MT-2): Tap the part of the armin which the tip is inserted, to loosen the tip. It shouldthen drop out easily.Other than the proper adjustment and care of the tips,there is little maintenance of the welder except to:1. Make sure the line cord is not cut or damaged.2. Make sure the plug wiring is secure and proper.3. Remove the arms periodically to clean any scalewith steel wool.ACCESSSORIESWater Cooled ArmsMost standard arm styles are available with the watercooling feature. These arms are especially useful wherethe heat generated in the arms is objectionable. Watercooled arms allow for most efficient operation and longertip life.Welder StandModel ST-2Part# 9203Allows all Duro DynePortable Spotwelders tobe converted to stationarytype units.The welder is operatedby means of a foot lever. The welder may beinstalled and removedwith ease.SPOT WELDER PARTS 429243TSP/TBW Front BodyTSP Rear BodyTBW Rear BodyTSP/TBW Rear Body CoverTSP CarriageTBW CarriageTSP/TBW Nose PieceTSP/TBW Lower Arm MountingTSP HandleTBW HandleTSP/TBW Switch Mounting BracketTSP/TBW Handle SpringTSP/TBW Actuator SpringTSP Nylon ActuatorTSP/TBW Micro SwitchTSP/TBW Switch Control ScrewTSP Timer 110 VoltTSP/TBW PotentiometerTSP-1 Weld TransformerTBW Weld TransformerTSP Line Cord 110 VoltTSP2/TBW Line Cord 220 VoltTBW Hi/Lo SwitchTSP/TBW Filter ScreenTSP-1 PrimaryTBW PrimaryTSP SecondaryTBW SecondaryTSP/TBW Pivot BoltTSP2/TBW Timer 220 VoltLine Cord RetainerTBW Nylon ActivatorTSP-2 Weld TransformerTSP-2 PrimaryDURO DYNE WARRANTYDuro Dyne Machinery is manufactured by skilled mechanics,utilizing the latest production techniques. Each unit has beenrigorously tested prior to packaging and shipment in order toensure trouble free operation.Your Duro Dyne machine has a 90 day warranty against defects in material. Any component found to be defective willbe repaired or replaced (at manufacturer’s discretion) atno cost, if faulty component is returned freight prepaid tothe nearest Duro Dyne Service Department. Warranty doesnot apply to expendable parts or repairs or service due toimproper maintenance or operation procedures.Duro Dyne products have been engineered to maximize operator safety. Unauthorized modification of this product willvoid the warranty.All warranty claims must be accompanied by serial number,date of purchase and distributor purchased from.For Service or Parts:Welder Service DepartmentDuro Dyne CorporationBay Shore, N.Y. 11706Phone: 631-249-9000Fax: 631-249-8346Give us the details of your problem. The answer is often simple,and in most cases eliminates unnecessary repairs.

9217 LowerArm Mounting9210 Front Body9216 Nose PieceSecondary9236 TSP9237 TBWCarriage9214 TSP9215 TBWPARTS LOCATION9238 Pivot Bolt9218 TSP Handle9219 TBW HandleComplete Transformer9228 TSP-19242 TSP-29229 TBWTBW PrimaryShown (4 wires) 9235 TBW(2 wires) 9234 TSP-1(2 wires) 9243 TSP-29233 Filter Screen9220 Switch Mounting Bracket9211 Rear Body TSP9212 TBW9224 Micro Switch9226 Timer 110 Volts9239 Timer 220 Volts9240 Line Cord Retainer9213 Rear Body Cover9227 Potentiometer9222 Actuator SpringLine Cord9230 TSP-1 110 Volts9231 TSP-2/TBW 220 Volts17385 Pot Knob9232 TBW Switch (Hi-Lo)9223 Nylon Actuator9241-TBW9225 Switch Control Screw9221 Handle Spring

ACCESSORIESTIPSSTANDARD ARMSMT3ITEM# 9018S2S3S1MT1ITEM# 9019A3MT2ITEM# 9020STANDARDA2WATER COOLEDSTANDARDA1WATER COOLEDLength Descrip. Item# Length Descrip. Item# Length Descrip. Item# Length Descrip. W902318”A-3901718”A-3-W9027*NOTE: Dimensions reflect arms in closed position.WIRING DIAGRAMS

MACHINERY DIVISION 2012 Duro Dyne CorporationPrinted in USA 05/2012BI009401 leldeSpotw Remanufactured MachineryFor inquiries contact Duro Dyne Tech Service at 1-800-899-3876