ABI - Instructions for Tack I & Tack II

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Instructions for Tack I & Tack II

Back to Tacking Machine Page

Section ASetup Procedures and Requirements

Electrical requirements: please check the welder identification label to insure you have the proper voltagerequirements for your power supply. Tack II welders are configured for either 100/120 volt or 208/240 volt singlephase operation, 50/60 hertz/cycle. If by chance you have ordered or received the wrong voltage requirement foryour area, do not plug the welder into your outlet. Contact the factory or your representative in order to receivethe proper welder with the correct voltage requirement. Once you have checked for the proper voltage, pleaseinspect to insure your power outlet is earth grounded. The Tack II welders will not function properly without thethree prong earth ground power supply in your factory. It is further recommended that no other machines whichhave electrical current surges or heavy electrical line demands be plugged into the same power line source as yourTack II welder. Such other machines may cause the welder to fluctuate and/or may cause the welder to bedamaged electronically.

1.

Position your welder: at the rear of your work bench. Leave enough room at the front of the bench to place yourcontact pad or work station. Insure that the welder and work station area are set upon a wooden or plastic worksurface. Do not use a metal top bench without plastic or wood on the weld area.

2.

Plug the welder into your properly grounded electrical outlet with the proper voltage supply. Turn the powerswitch on. The indicator light should come on within a few seconds or the voltage meter will indicate a voltreading for models i and ii. If there is no indication of power on, unplug the welder from your outlet and removethe welder box cover. Please turn to the troubleshooting section of this manual for instructions.

3.

When the power is on: and the voltage adjust knob is functioning on the front control panel, connect the twoelectrode tools you have chosen to the black and/or red connectors on the front control panel. You have optionalelectrode tools to choose from on the price list or you may make your own. Standard tools available are thecontact pad work station, weld pliers, weld tweezers, touch weld pencil, as well as fusion weld collets of varioustypes. Plug the foot switch pedal into rear of the welder box to complete the welder setup for the Tack II

4.

Section BGeneral Operating Controls

Power switch: located on the front panel, switch the power on and wait for the charge indicator lamp to come onor voltage to register on the voltmeter. Discharge the welder to zero by making firm contact between your positiveand negative electrode tools and depressing the foot switch.

1.

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 youwill not weld. If you select too much voltage you may burn the pieces you are trying to weld. Practice with scrapmetal before trying to weld quality pieces.

2.


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Energy selection switch: is standard on all our tack welders except the small Tack I. The energy equals (amps) atthe weld surface. Please note the welder should be turned off when selecting a different energy range. This willprevent the burning of the selector switch contacts.

3.

Foot switch: all our tack welders are foot switch operated. The Tack II and I Models have the ability to be welddischarged by holding the foot pedal down and striking the two electrodes (work pieces) together. This mode ofoperation is used for tacking together two work pieces. But primarily it is used for fusion welding to create aninstant 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 againstshock or insure you do not touch medal portions of the electrodes.

4.

Indicator charge light: on the Tack I & II, you have the charge indicator light which tells you when the welder isready charged for use. The higher the voltage selection the longer it takes the charge light to recover and comeback on after each weld discharge.

5.

Warranty

Upon receiving your tack welder, please inspect the crate thoroughly for any visual damage. It is yourresponsibility to notify the carrier and/or insurance agent for the carrier if there is any damage whatsoever to thecrate, box or its contents.

All parts and/or components are warranted for a period of one year from the purchase date, fob the factory. Thisdoes 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 propermaintenance 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 mayarise from the general use of the equipment.

This warranty is in lieu of all other warranties expressed or implied, including without limitation warranties orguarantees 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 rubbergloves at all times to prevent electrical shocks to welder operators. These shocks can be caused when an operatoris touching the electrode metal surfaces rather than the insulated portion of the electrodes and/or is not properlygrounded at the contact work surfaces.

Section CWeld Setup and Test

Power switch on, indicator light comes on. Welder charged and ready after a few seconds.1.

Select energy switch by starting at lower settings and increasing to more energy as required. Note: Tack I has noenergy selection switch.

2.

Select the voltage on low at first and increase higher as required to weld pieces.3.


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Test welding with steel pieces such as paper clips will allow you to get the feel of the welder without destroyinggood pieces. Use also scrap gold, silver and brass etc. For test welding to learn the welder’s capabilities.

4.

Hold pieces to be welded firmly against the contacts in order to make good electrical contact and more consistentquality welds.

5.

When pieces are in the proper position, depress the foot pedal to create a weld discharge. In some cases, you maychoose to depress the foot switch first and then bring your work pieces together.

6.

Caution: we firmly recommend the wearing of rubber gloves at all times to prevent electrical shocks to welderoperators. 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 havea metal to metal weld application which needs our technical expertise or you may have a weld application whichis not possible. If you encounter this problem, please send us test pieces for evaluation

Section DTrouble Shooting Guide

Caution: always unplug the welder before servicing.

Problem Cause/Solution

Power failure

Check your power outlet first by using some otherpiece of equipment to insure you have power at thereceptacle. You may have blown a fuse or tripped acircuit breaker switch.

1.

B. Check the power cord and three prong plug.Insure that you have earth ground.

2.

C. If the indicator light is not on check either theinternal fuse or the external circuit breaker.

3.

D. If you have no indicator light on, check to see ifyou have voltage regulation at the voltage controlknob.

4.

E. Unplug the welder and check inside the welderenclosure visually for loose connections or burnedcomponents which could be causing the failure.

5.

F. If the problem still exists, contact the servicecenter.

6.

Welded light on but will not cycleCheck the foot switch for continuity.1.


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Unplug the welder and remove the cover. Check forloose wiring connections and damaged componentsinside.

2.

Check to insure you have voltage charge and properswitch settings per instructions and test.

3.

Check the connections on the weld tools and contactpad.

4.

Call service center is problem persists5.

Welder on but won’t discharge

Check to insure proper electrical contact with weldtools, connections and weld surface.

1.

Raise the voltage adjustment knob progressivelyhigher while attempting to discharge the welder.

2.

Unplug the welder and check all electricalconnections visually: inspect for signs of damageinside. (see schematic).

3.

Call the service center for assistance.4.

Welder will not weld properly

Raise voltage progressively higher as you test weldeach setting for more power.

1.

Switch the energy select switch to a higher level onthe Tack II, but insure the power on/off switch is inthe “off” position whenever you switch energylevels.

2.

If at the highest energy level and voltage settings theparts still will not weld, please contact the factoryfor technical assistance.

3.

Welder does not indicate DC voltage

Check the voltmeter with a dc test meter andmeasure to see if there’s

1.

Voltage going to the meter. If you do measurevoltage, the meter is defective.

2.

Unplug the welder and check internal wireconnections and associated components for damage.

3.

Contact the service center for assistance.4.


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DC voltage on but will not regulate

Note: all functions seem proper and welder discharges butwill not weld your pieces.

Unplug the welder and change the internal PC board1.

Contact the service center for technical assistance2.

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 oilis a must in tack welding of any kind. Clean the weld surface. Insure all electrodes, weld pliers, tweezers, colletsand contacts remain clean to insure good contact electrically.

1.

Contact pad, weld pliers, tweezers or contacts: The weld contact surfaces must be kept clean in order to insuregood electrical conductivity. If your work piece is being scratched or it is sticking to the electrode contactsurfaces, you may find it necessary to use the carbon contact pad option or install carbon contacts or silver tipyour pliers or tweezers to insure conductivity and thereby eliminating arcing and/or burning of your pieces

2.

Tacking work pieces together: The Tack I and Tack II were primarily designed to tack or touch weld piecestogether to prevent their movement during the soldering operation. This tack welding process will eliminate theneed of fixtures, clips, wire or jigs. Once they are attached they will not move during the soldering operation. Theprocess of fusion welding with the properly nibbed findings and the appropriate optional fusion collets and fusionweld 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.

3.

Quality welding/tacking: To weld consistently and weld good quality pieces takes practice. learning to use theproper tools and electrodes also takes time. We suggest that you practice with scrap pieces of metal using variousenergy and voltage levels. Practice will make perfect.

4.

Test weld: Test weld by holding the positive connections electrode tool firmly against the negative electrode tooland depress the foot pedal. The welder should discharge and recharge when you release the foot pedal andseparate the electrode tools. Now, using scrap metal pieces, you should begin to learn the welder parameter. Trydifferent voltage settings with similar and dissimilar metals. Silver or brass will require higher energy settingsthan gold or steel. Practice makes perfect. If you cannot weld a specific application you have, contact the factoryfor assistance or send test pieces for evaluation.

5.

Test weld using the pre-contact live mode: Set the energy on low and lower the voltage on the meter. Using twowork pieces, one negative and on positive (held firmly for good contact). Step on the foot pedal first, then bringthe two work pieces together. This will create a spark as you bring the two work pieces together and make thetack weld.

6.

Use distilled water: Use distilled water on each weld surface at the point of weld to eliminate the carbonblackening of your work surfaces. This is very good to repair pieces.

7.

Electrical Trouble Shooting Tack II


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Symptom Cause & Solution

No Power

Insure that the welder is being supplied with thecorrect input voltage as well as an earth ground.

1.

Reset circuit breaker located on back panel.2.

Power switch.3.

If no solution is found at this time, refer to authorizedservice personnel.

Power, but no voltage on panel meter

Transformer in welder (DP241-8-120).1.

Recharge resistor mounted on bottom plate(HS50-3R).

2.

Hexfet located on PCB (IRF640).3.

Inductor coil located on PCB towards the middleof board

4.

Note: try to weld a sample, even with no voltageindicated on meter. If a weld discharge occurs, the meteris probably defective.

Unit has power, meter has voltage, but no dischargeoccurs

Footswitch.1.

Loose screw leads on discharge capacitor.2.

Unsecured or loose heavy gauge wires, either blackor red, located inside welder.

3.

Loose wires or connectors going to external tools.4.

Inconsistent welding

Loose heavy gauge wires located inside welder.1.

Loose screw leads on either discharge capacitor.2.

Defective charge capacitor.3.

Poor grounding of part(s) being welded.4.

Inconsistency of parts being welded.5.


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No voltage regulationVoltage control potentiometer.1.

Hexfet mounted on chassis plate (IRF640).2.

Electrical Trouble Shooting Tack I

Symptom Cause & Solution

No Power

Insure that the welder is being supplied with thecorrect input voltage as well as an earth ground.

1.

Reset circuit breaker located on back panel.2.

Power switch.3.

If no solution is found at this time, refer to authorizedservice personnel.

Power, but no voltage on panel meter

Transformer in welder (ST5-24).1.

Recharge resistor mounted on bottom plate(Raychem RDE-185A).

2.

Hexfet located on PCB (Q2-D42C12).3.

Inductor coil located on PCB towards the middleof board

4.

Note: try to weld a sample, even with no voltageindicated on meter. If a weld discharge occurs, the meteris probably defective.

Unit has power, meter has voltage, but no dischargeoccurs

Footswitch.1.

Loose screw leads on discharge capacitor.2.

Unsecured or loose heavy gauge wires, either blackor red, located inside welder.

3.

Loose wires or connectors going to external tools.4.


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Inconsistent welding

Loose heavy gauge wires located inside welder.1.

Loose screw leads on either discharge capacitor.2.

Defective charge capacitor.3.

Poor grounding of part(s) being welded.4.

Inconsistency of parts being welded.5.

No voltage regulationVoltage control potentiometer.1.

Hexfet mounted on chassis plate (IRF640).2.

Tack I & Tack II Options


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Tack Welder Options in Use

Offset Nose Fusion PencilFusion welding pin joint. Non-stick carbon overlay also

being used.

Offset Nose Fusion PencilFusion welding tie tack/earring post to an enameled fron

piece using weld pencil as ground

Offset Nose Fusion PencilFusion Welding Bail Ring

Offset Nose Fusion Penci Tack IIThermocouple leads welded to connector

Brass Jaw PliersFusion welding ear clip to finding. Can also be used for

position tack welding prior to final soldering/brazing

Brass Jaw PliersPosition tack welding bar pin prior to final

soldering/brazing


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Tack I Schematics


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Tack II Schematics


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© 2013. Shor International Corporation & The I. Shor Company. All rights reserved.


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ABI - Instructions for Tack I & Tack II