STUD WELDER

RSR-2500

INSTRUCTION MANUAL

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READ THIS INSTRUCTION MANUAL BEFORE USE AND
KEEP FOR FUTURE REFERANCE. PROPER USE WILL
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Content

1. Summarize(1)
2. Electrical schematic diagram(1)
3. Attention . (1)
4. Use method...(2)
5. Maintenance (2)
6. Main technical parameters.(3)

. Summarize
RSR series energy storage type stud welding machine is the use of capacitor charging, by
the heat resistance produced by parent metal and the stud instantaneous release of large
current to finish welding. This series welding machine introduction of foreign advanced
inverter technology, selects the import high quality components, high reliability, good
welding performance.
Charging time is short (1S ) , high productivity ( 20 / Min);
Small size, light weight, mobile convenience;
Welding position is firm, high strength;
Instantaneous finish welding, small heat affected zoneparent metal deformation small;
The operation simple, without professional training;
Can avoid from drilling, tapping, riveting, etc procedure;
Wide application range, used in construction, boiler, refrigeration, shipbuilding,
automobile, home appliances, hardware products and other industries

. Main technical parameters

model
Parameter

RSR-1600

RSR-2500

input voltageV
frequencyHz
rated energy storageJ
stud diametermm
welding plate thicknessmm
capacitance (uf
productivity ( times/min
charging voltageV
overall dimensions (mm
weightkg

AC 220
50
1600
36
0.21.0
90000
20
50~180
460280460
23

AC110
50
2500
38
0.21.5
120000
20
50~170
460280460
26

. Attention
1. Environmental requirement
aThe altitude does not exceed 1000m
bEnvironment temperature-1040
cAir relative humidity:
40
50%
20
90%
dThe dust ,acid, corrosive gases in the air around no more than normal levels, except
that the result of the welding process;
eUse place should be no violent vibration and bump;
2. The grid quality requirement
aPower supply voltage wave form should be the actual sine waves;
bPower grid & voltage fluctuations 10%
3

cPower grid & voltage frequency fluctuations 1%

3. Operation requirement
aIn order to ensure the security of the operator, welder must be safety grounding
bStud and parent metal surface should be clean;
cWhen welding, should impact the installed stud welding torch on the parent metal
and then start switch;
dIt is strictly prohibited to put the welding torch without stud on the welding
workpieces;
eIt is forbidden to do welding near inflammables and explosives ;
fWhen welding, because the capacitor release the large current instantly, so it is
forbidden to human body touch the positive (ground wire) and the negative (the welding
torch head metal)

. Use method
1. The connection:
A. Access AC 220 v / 50 hz power according to the requirement and safety grounding.
B. Connect the welding torch joint to the welding torch "torch" terminal; Connect the
grounding wire joint to the grounding terminal; Connect the welding gun control line to
the welder control terminal.
2. Voltage adjustment: adjust the welding machine "voltage regulation" potentiometer on
the front panel.
3. When welding, welding torch clamp should be consistent to welding stud.
4. Turn on the external power, open the power switch, digital indicator light on the front
panel welding machine light.
5. According to welding stud diameter adjusting voltage.
6. Press the torch with the stud on the parent metal then can start the welding torch and
do the welding.
7. The welding quality mainly depends on the selected voltage size, before the formal
welding, generally should do the test welding, welding torch and material surface should
be kept vertical, treat stress of welding torch to the material surface has a certain
influence on welding quality.

Maintenance
Maintenance must cut off power supply, choose the "charge/discharge" selector switch on
the front panel to "discharge", wait for 2 minutes
1.Should remove the internal welding dust regularly
2.Should regularly check the cable of the welding machine for damage, if there is a loose
connection
3.The welding torch clamp belong to wearing parts, should change regularly
4.Common failures and troubleshooting methods
Fault phenomenon
Elimination methods
"power" light is not on
power supply problem, connect the power cord again
welding not firm
1.the voltage is too low
2.welding torch not perpendicular to the surface, pressure
3

big splash

voltage is not down

voltage adjustment is not
up

was not enough

3.the welding torch fixture not clamping screw
1.Surface is not clean
2.Poor contact
3.High voltage regulation
PCB2 brokenreplace
1.the potentiometer bad, change it
2.PCB broken, change it
3.the capacitance bad, change it
4.R1 or T1 broken

.Electrical schematic diagram