Instructions for
Tack I & Tack II
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Tacking Machine Page
Section A
Setup Procedures and Requirements
1. Electrical requirements: please check the welder
identification label to insure you have the proper voltage requirements for your
power supply. Tack II welders are configured for either 100/120 volt or 208/240
volt single phase operation, 50/60 hertz/cycle. If by chance you have ordered or
received the wrong voltage requirement for your area, do not plug the welder
into your outlet. Contact the factory or your representative in order to receive
the proper welder with the correct voltage requirement. Once you have checked
for the proper voltage, please inspect to insure your power outlet is earth
grounded. The Tack II welders will not function properly without the three prong
earth ground power supply in your factory. It is further recommended that no
other machines which have electrical current surges or heavy electrical line
demands be plugged into the same power line source as your Tack II welder. Such
other machines may cause the welder to fluctuate and/or may cause the welder to
be damaged electronically.
2. Position your welder: at the rear of your work bench.
Leave enough room at the front of the bench to place your contact pad or work
station. Insure that the welder and work station area are set upon a wooden or
plastic work surface. Do not use a metal top bench without plastic or wood on
the weld area.
3. Plug the welder into your properly grounded
electrical outlet with the proper voltage supply. Turn the power switch on. The
indicator light should come on within a few seconds or the voltage meter will
indicate a volt reading for models i and ii. If there is no indication of power
on, unplug the welder from your outlet and remove the welder box cover. Please
turn to the troubleshooting section of this manual for instructions.
4. When the power is on: and the voltage adjust knob
is functioning on the front control panel, connect the two electrode tools you
have chosen to the black and/or red connectors on the front control panel. You
have optional electrode tools to choose from on the price list or you may make
your own. Standard tools available are the contact pad work station, weld
pliers, weld tweezers, touch weld pencil, as well as fusion weld collets of
various types. Plug the foot switch pedal into rear of the welder box to
complete the welder setup for the Tack II
Section B
General Operating Controls
1. Power switch: located on the front panel, switch
the power on and wait for the charge indicator lamp to come on or voltage to
register on the voltmeter. Discharge the welder to zero by making firm contact
between your positive and negative electrode tools and depressing the foot
switch.
2. Voltage control regulator: (potentiometer) allows
you to select the amount of dc voltage at the weld surface. Selecting the proper
amount of voltage is accomplished through trial and error. If you select too
little voltage you will not weld. If you select too much voltage you may burn
the pieces you are trying to weld. Practice with scrap metal before trying to
weld quality pieces.
3. Energy selection switch: is standard on all our
tack welders except the small Tack I. The energy equals (amps) at the weld
surface. Please note the welder should be turned off when selecting a different
energy range. This will prevent the burning of the selector switch contacts.
4. Foot switch: all our tack welders are foot switch
operated. The Tack II and I Models have the ability to be weld discharged by
holding the foot pedal down and striking the two electrodes (work pieces)
together. This mode of operation is used for tacking together two work pieces.
But primarily it is used for fusion welding to create an instant discharge at
the work surface. Use low power and low voltage settings when using this mode.
Caution: when the foot pedal is depressed, the electrodes are live
electricity. Please wear protective gloves to guard against shock or insure you
do not touch medal portions of the electrodes.
5. Indicator charge light: on the Tack I & II, you
have the charge indicator light which tells you when the welder is ready charged
for use. The higher the voltage selection the longer it takes the charge light
to recover and come back on after each weld discharge.
Warranty
Upon receiving your tack welder, please inspect the crate
thoroughly for any visual damage. It is your responsibility to notify the
carrier and/or insurance agent for the carrier if there is any damage whatsoever
to the crate, box or its contents.
All parts and/or components are warranted for a period of one
year from the purchase date, fob the factory. This does not include consumables.
Shor does not warranty such consumable parts as ceramic tips,
electrodes, contact pads or the like.
Shor does not assume any responsibility for damage in
shipment, damage due to misuse, lack of proper maintenance and/or damage
resulting in the operation of the welder in a manner not described herein.
Shor will no be liable for loss of profits, loss of use
during repair or consequential damage of any kind which may arise from the
general use of the equipment.
This warranty is in lieu of all other warranties expressed or
implied, including without limitation warranties or guarantees of
mechanicablility or fitness of purpose, which all other warranties are hereby
expressly excluded.
Caution: always wear eye protection when using any
welder of any kind. We firmly recommend wearing rubber gloves at all times to
prevent electrical shocks to welder operators. These shocks can be caused when
an operator is touching the electrode metal surfaces rather than the insulated
portion of the electrodes and/or is not properly grounded at the contact work
surfaces.
Section C
Weld Setup and Test
1. Power switch on, indicator light comes on. Welder charged
and ready after a few seconds.
2. Select energy switch by starting at lower settings and
increasing to more energy as required. Note: Tack I has no energy
selection switch.
3. Select the voltage on low at first and increase higher as
required to weld pieces.
4. Test welding with steel pieces such as paper clips will
allow you to get the feel of the welder without destroying good pieces. Use also
scrap gold, silver and brass etc. For test welding to learn the welder's
capabilities.
5. Hold pieces to be welded firmly against the contacts in
order to make good electrical contact and more consistent quality welds.
6. When pieces are in the proper position, depress the foot
pedal to create a weld discharge. In some cases, you may choose to depress the
foot switch first and then bring your work pieces together.
Caution: we firmly recommend the wearing of rubber
gloves at all times to prevent electrical shocks to welder operators. Shocks are
caused when operators touch the metal areas of the electrode tools.
Please note: If all functions of the welder seem to
be in order, but you are experiencing a problem, you may have a metal to metal
weld application which needs our technical expertise or you may have a weld
application which is not possible. If you encounter this problem, please send us
test pieces for evaluation
Section D
Trouble Shooting Guide
Caution: always unplug the welder
before servicing.
| Problem |
Cause/Solution |
Power failure |
A. Check your power outlet first by using some other piece
of equipment to insure you have power at the receptacle. You may have blown
a fuse or tripped a circuit breaker switch. B. Check the power cord and
three prong plug. Insure that you have earth ground.
C. If the indicator light is not on check either the
internal fuse or the external circuit breaker.
D. If you have no indicator light on, check to see if you
have voltage regulation at the voltage control knob.
E. Unplug the welder and check inside the welder
enclosure visually for loose connections or burned components which could be
causing the failure.
F. If the problem still exists, contact the service
center. |
Welded light on but will not
cycle |
A. Check the foot switch for continuity.
B. Unplug the welder and remove the cover. Check for
loose wiring connections and damaged components inside.
C. Check to insure you have voltage charge and proper
switch settings per instructions and test.
D. Check the connections on the weld tools and contact
pad.
E. Call service center is problem persists |
Welder on but won't discharge |
A. Check to insure proper electrical
contact with weld tools, connections and weld surface.
B. Raise the voltage adjustment knob progressively higher
while attempting to discharge the welder.
C. Unplug the welder and check all electrical connections
visually: inspect for signs of damage inside. (see schematic).
D. Call the service center for assistance. |
Welder will not weld properly |
A. Raise voltage progressively higher as
you test weld each setting for more power.
B. Switch the energy select switch to a higher level on
the Tack II, but insure the power on/off switch is in the "off" position
whenever you switch energy levels.
C. If at the highest energy level and voltage settings
the parts still will not weld, please contact the factory for technical
assistance. |
Welder does not indicate DC
voltage |
A. Check the voltmeter with a dc test
meter and measure to see if there's
Voltage going to the meter. If you do measure voltage,
the meter is defective.
B. Unplug the welder and check internal wire connections
and associated components for damage.
C. Contact the service center for assistance. |
DC voltage on but will not
regulate
Note: all functions seem proper
and welder discharges but will not weld your pieces. |
A. Unplug the welder and change the internal PC board B.
Contact the service center for technical assistance |
Section E
General Operation and Maintenance Tack I & II
1. Weld flash, carbon, slag and surface oxides: Keeping
all weld surfaces clean of surface oxide and dirt or oil is a must in tack
welding of any kind. Clean the weld surface. Insure all electrodes, weld pliers,
tweezers, collets and contacts remain clean to insure good contact electrically.
2. Contact pad, weld pliers, tweezers or contacts: The
weld contact surfaces must be kept clean in order to insure good electrical
conductivity. If your work piece is being scratched or it is sticking to the
electrode contact surfaces, you may find it necessary to use the carbon contact
pad option or install carbon contacts or silver tip your pliers or tweezers to
insure conductivity and thereby eliminating arcing and/or burning of your pieces.
3. Tacking work pieces together:
The Tack I and Tack II were primarily designed to tack or touch weld pieces
together to prevent their movement during the soldering operation. This tack
welding process will eliminate the need of fixtures, clips, wire or jigs. Once
they are attached they will not move during the soldering operation. The process
of fusion welding with the properly nibbed findings and the appropriate optional
fusion collets and fusion weld pencil will allow you to permanently finish weld
such findings as threaded studs, tie tac nails, earring posts, joints, catches,
pin backs, wire couplings or cuff link actions.
4. Quality welding/tacking: To weld consistently and
weld good quality pieces takes practice. learning to use the proper tools and
electrodes also takes time. We suggest that you practice with scrap pieces of
metal using various energy and voltage levels. Practice will make perfect.
5. Test weld: Test weld by holding the positive
connections electrode tool firmly against the negative electrode tool and
depress the foot pedal. The welder should discharge and recharge when you
release the foot pedal and separate the electrode tools. Now, using scrap metal
pieces, you should begin to learn the welder parameter. Try different voltage
settings with similar and dissimilar metals. Silver or brass will require higher
energy settings than gold or steel. Practice makes perfect. If you cannot weld a
specific application you have, contact the factory for assistance or send test
pieces for evaluation.
6. Test weld using the pre-contact live mode: Set the
energy on low and lower the voltage on the meter. Using two work pieces, one
negative and on positive (held firmly for good contact). Step on the foot pedal
first, then bring the two work pieces together. This will create a spark as you
bring the two work pieces together and make the tack weld.
7. Use distilled water: Use distilled water on each
weld surface at the point of weld to eliminate the carbon blackening of your
work surfaces. This is very good to repair pieces.
Electrical Trouble Shooting Tack II |
Symptom |
Cause & Solution |
| No Power |
- Insure that the welder is being supplied with the correct input
voltage as well as an earth ground.
- Reset circuit breaker located on back panel.
- Power switch.
If no solution is found at this time, refer to authorized
service personnel. |
Power, but no voltage on panel meter |
1.
Transformer in welder (DP241-8-120).
2. Recharge resistor mounted on bottom plate (HS50-3R).
3. Hexfet located on PCB (IRF640).
4. Inductor coil located on PCB towards the middle of
board
Note: try to weld a sample, even with no
voltage indicated on meter. If a weld discharge occurs, the meter is
probably defective. |
Unit has
power, meter has voltage, but no discharge occurs |
1.
Footswitch.
2. Loose screw leads on discharge capacitor.
3. Unsecured or loose heavy gauge wires, either black or
red, located inside welder.
4. Loose wires or connectors going to external tools. |
Inconsistent welding |
1. Loose
heavy gauge wires located inside welder.
2. Loose screw leads on either discharge capacitor.
3. Defective charge capacitor.
4. Poor grounding of part(s) being welded.
5. Inconsistency of parts being welded. |
No voltage
regulation |
1. Voltage
control potentiometer.
2. Hexfet mounted on chassis plate (IRF640). |
Electrical Trouble Shooting Tack I |
Symptom |
Cause & Solution |
| No Power |
- Insure that the welder is being supplied with the correct input
voltage as well as an earth ground.
- Reset circuit breaker located on back panel.
- Power switch.
If no solution is found at this time, refer to authorized
service personnel. |
Power, but no voltage on panel meter |
1.
Transformer in welder (ST5-24).
2. Recharge resistor mounted on bottom plate (Raychem
RDE-185A).
3. Hexfet located on PCB (Q2-D42C12).
4. Inductor coil located on PCB towards the middle of
board
Note: try to weld a sample, even with no
voltage indicated on meter. If a weld discharge occurs, the meter is
probably defective. |
Unit has
power, meter has voltage, but no discharge occurs |
1.
Footswitch.
2. Loose screw leads on discharge capacitor.
3. Unsecured or loose heavy gauge wires, either black or
red, located inside welder.
4. Loose wires or connectors going to external tools. |
Inconsistent welding |
1. Loose
heavy gauge wires located inside welder.
2. Loose screw leads on either discharge capacitor.
3. Defective charge capacitor.
4. Poor grounding of part(s) being welded.
5. Inconsistency of parts being welded. |
No voltage
regulation |
1. Voltage
control potentiometer.
2. Hexfet mounted on chassis plate (IRF640). |
Tack I & Tack II Options |
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Tack Welder Options in Use |
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Tack I Schematics |
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Tack II Schematics |
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