Model 100 with scissor type operation Model 200 with plunger type operation
Mini-Weld Miniature Portable Welders for Projection & Resistance Welding
Light-weight welding guns are ideal hand-sized units for light duty projection and resistance welding. Applications Mini-Weld guns and accessories are recommended for production line use in light industries such as small appliance, instrument, and electronics. They are also extremely useful in machine shop and maintenance operations.	Features / Benefits Series 2000 microprocessor-based controller stores programmable, pre-selected weld Schedules. Schedules are programmed and recalled through a removable, hand-held terminal that prevents unauthorized changes. Unique, paten pending, approaches to voltage compensation and phase shift heat control assure the highest degree of precision and consistency

Mini-Weld portable, light-weight welding guns are ideal hand-sized units for light-duty projection and resistance welding.

Two welding guns are available:
Model 100 with scissor-type operation.
Model 200 with plunger-type operation.

Mini-Weld guns and accessories are manufactured for Welding & Automation, Inc. by Omnitech Industries, Inc. A full range of Welding & Automation, Inc. power supplies are available for these units.

Features/Benefits

Precise and Consistent Welds

Series 2000 microprocessor-based controller stores programmable, pre-selected weld Schedules. Schedules are programmed and recalled through a removable, hand-held terminal that prevents unauthorized changes. Unique, patent-pending, approaches to voltage compensation and phase shift heat control assure the highest degree of precision and consistency.

Easy Operation

Compact, light-weight Mini-Weld guns are maneuverable and easy to operate.

Durable, Trouble Free

Designed and precision built for rugged, long-lasting operation, Mini-Weld guns have provided years of trouble-free operation on appliance assembly lines.

Low Maintenance

Mini-Weld guns require a minimum of maintenance. They are designed to make it easy to redress or replace electrodes.

Applications

Mini-Weld guns and accessories are recommended for production line use in light industries such as small appliance, instrument and electronics. They are also extremely useful in machine shop and maintenance operations.

Specifications

WELDING GUNS

MODEL 100

Scissor Type Operation.
Electrode Pressure: Approx. 30 lbs. And 60 PSI.
Electrode Travel: 1/4".
Throat Depth: 1 5/8".
Capacity: Max 10 KVA A.C. or 50 watts/sec D.C. power supply.
Size: 8 1/4" long x 1 3/4" deep x 7/8" wide.
Weight: 16 oz.

MODEL 200

Plunger Type Operation.
Electrode Pressure: Approx. 48 lbs. At 80 PSI.
Electrode Travel: 3/8".

Standard Throat Depth: 5/8".

Optional Throat Depth: 2 1/2".
Capacity Max. 10 KVA A.C. or 500 watt/sec. D.C. power supply
Size: 9 3/16" long x 2 5/8" deep x 1" wide.
Weight: 25 oz.
Note: With optional 2 1/2" throat depth, weight is increased to 32 oz. and length to 10 1/2".

TRANSFORMER

Standard
1 to 10 KVA with 12 tap selector switch, 208V, 220V, or 480V
60 Hz, single phase primary with 12V secondary.
50 amp circuit breaker (main).
10' No. 10/3 input line.
Receptacles for control and initiation lines.

CONTROLLER

Series 2000 Microprocessor-based, Programmable Weld Controller:

Stores pre-selected weld schedules. Automatically controls Percent Heat, Squeeze Time, Weld Time, Hold Time.

Heat Time Range: 1/2 cycle to 100 cycles

Stores multiple pre-selected weld schedules.

Automatically controls Squeeze Time Percent Heat, Weld Time, Hold Time.

Squeeze-hold time: 3 to 75 cycles.
Weld time: 1/2 to 30 cycles.

Schedules programmed and recalled through hand-held terminal.

Automatic line-Voltage compensation 1/2-cycle of weld, starting with the first 1/2-cycle.

Unique phase shift control provides true under-the-curve adjustment for consistent welds.

Battery back-up to protect memory

RS232 port provides input/output interface

Polarity selection and 1/2-cycle control.

Semi-automatic and automatic mode selector.

Heat/no heat selector switch. Used for set-up and dry cycling.

Back-to-back SCR firing circuits.

Face-mounted keyboard may be substituted for hand-held terminal.

Up slope/down slope option. For applications requiring gentle heat-up prior to full weld energy or controlled cool down.

Preheat/post-heat (quench and temper) option. Selectable in straight line steps. Preheat useful for brazing flux activation; post heat as an annealing function.

Options

Weld Monitor
Weld monitors have been available for many years. Unfortunately, most of these devices are either current, or milli-volt second monitors, neither of which satisfy the basic requirement. To properly evaluate a weld, we must establish a correlation with what is happening electronically, and the mechanical test results. To do this we must have weld monitoring instrumentation capable of providing the necessary information. To properly monitor a weld, the equipment must measure current and area under the curve on each half cycle in A.C. applications, and measure current and area under the curve for each weld in D.C. applications. Further, it must be capable of calculating the product of these and reporting in half cycle increments, for A.C. applications. This product is called the weld energy, which is expressed in watt-seconds or joules.

H=I²RT
H is the heat energy developed in each weld.
I is the current in amperes.
R is the resistance in ohms.
T is the time in milliseconds, or microseconds.

Finally, the weld monitor must be capable of accepting both upper and lower control limits with alarms to alert, or shut down the process.

Only Welding & Automation, Inc. offers such a device. The optional weld monitor is an intregal part of the Series 2000 Weld Control, and measures energy in real time, unlike remote add on monitors. It is fully programmable for upper and lower process control limits. The weld monitor audits every half cycle of the weld, capturing the readings for current (in amperes) and milli-volt seconds (area under the curve). The product of these is expressed in joules of energy for each half cycle. The weld monitor protects against process shifts caused by dirty or worn electrodes, dirty or inconsistent product, equipment malfunctions, and countless other variables. The weld monitor stores the readings in memory for downloading to SPC packages for process capability analysis, or to printers for charting and evaluation.

WEIGHT AND SIZE

Transformer/Control Unit.
Weight - 125 lbs.
Size - 16 1/4" wide x 13 1/2" deep x 12 1/2" high.

CABLES

Standard

Two Cables, 3' long No. 6 AWG.
Options

Up to 6' in length.

ACCESSORIES

TOOL COLUMN

Rotatable column can be mounted on left side of power supply. Column is 37" high with 15" overarm and 2 1/2 lb. Balance.

WELD PROJECTION FORMING TOOL

This tool can be used to form standard weld projections on light guage metals. It is small and easy to use on the bench or in a small arbor press. Extremely useful for development work, short run production repair and maintenance work. Available in a variety of projection sizes for sheet metal up to 16 guage.
Size: 5/8" x 2 1/4" x 3 1/2" high. Weight 14 oz.