MIDWEST FASTENERS sureshot Owner's Manual

450 Richard Street • Miamisburg, OH 45342

www.midwestfasteners.com • Fax: [phone]

[phone]

Hand Held – Capacitor Discharge

Welding System

Owner’s Manual

4/09

CONTENTS

SECTION 1: Safety Precautions 3

SECTION 2: Specifications 8

SECTION 3: Set Up 9

SECTION 4: Normal Operation 11

SECTION 5: System Maintenance 14

SECTION 6: Troubleshooting 15

SECTION 7: Schematic Diagram 17

SECTION 8: Parts Lists 18

BE SURE THIS INFORMATION REACHES THE OPERATOR. EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER.

THESE INSTRUCTIONS ARE FOR EXPERIENCED OPERATORS. If you are not fully

C A U T I O N

familiar with the principles of operation and safe practices for arc welding equipment, we urge
you to read AWS SP - “Safe Practices” available from the American Welding Society.

DO NOT permit untrained persons to install, operate, or maintain this equipment. DO NOT
attempt to install or operate this equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for further
information. Be sure to read the Safety Precautions before installing or operating this equipment.

W A R R A N T Y

WARRANTY: All parts used in the assembly of your MIDWEST FASTENERS SureShot Stud Welding System are fully guaranteed for three (3) years from
factory shipment date.

Under this warranty, MIDWEST FASTENERS reserves the right to repair or replace, at its option, defects in material or workmanship which occur
during the warranty period. Notice of any claim for warranty repair must be furnished to MIDWEST FASTENERS within ten (10) days after the defect is
discovered. MIDWEST FASTENERS does not assume liability for shipping, or liability for any labor or material related to use of this system, unless such
costs are expressly authorized in writing by MIDWEST FASTENERS.

MIDWEST FASTENERS, INC. does not warrant defects in welders, parts or accessories resulting from abuse, improper installation or use, or for reasons
beyond its control.

This warranty is valid only when welding pins and/or studs purchased from or approved by MIDWEST FASTENERS.

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2009 MIDWEST FASTENERS, INC. — SureShot Welding System

SAFETY PRECAUTIONS

US ERS R ESP ON SIB IL ITY

This equipment will perform in conformity with the description contained in this manual and accompanying labels and/or
inserts when installed, maintained and repaired in accordance with the instructions provided. This equipment must be checked
periodically. Defective equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated
should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that
a telephone or written request for service advice be made to the Authorized Distributor from whom purchased.

This equipment or any of it’s parts should not be altered without the prior written approval of the manufacturer. The user
of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance,
damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manu
facturer.

This symbol appearing throughout this manual means

AT TEN TI ON! BE AL ER T!

Your safety is involved.

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The following definitions apply to DANGER, WARNING, CAUTION
found throughout this manual.

Used to call attention to immediate

DANGER

WARNING

CAUTION

WARNING: These safety precautions are for your protection.
They summarize precautionary information from the references
listed in the Additional Safety Information section. Before
performing any installation or operating procedures, be sure to
read and follow the safety precautions listed as well as all other
manuals, material safety data sheets, labels, etc. Failure to

observe safety precautions can result in injury or death.

hazards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.

Used to call attention to potential hazards
which could result in personal injury or lost
of life.

Used to call attention to hazards which
could result in minor personal injury.

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2009 MIDWEST FASTENERS, INC. — SureShot Welding System

ARC RAYS CAN BURN EYES AND SKIN -

The arc, like the sun, emits ultraviolet and infrared (visible and in­visible) and other radiation and can injure skin and eyes. Sparks
and hot metal can fly off the weld. Training in the proper use of
the processes and equipment is essential to prevent accidents.
Therefore:

1) Always wear safety glasses with side shields in any work area, even if wearing a
welding helmet, face shields and goggles are also required.

2) Always use a face shield fitted with the correct shade of filter to protect your
face and eyes when welding or watching (See ANSI Z49.1 and Z87.1 listed in
Safety Standards). Cover sparks and rays of the arc when operating or observ
ing operations.

3) Use protective non-flammable screens or barriers to protect others from flash
and glare. Warn bystanders not to watch the arc and not to expose themselves
to the rays of the electric-arc or hot metal.

3) Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers,
high topped shoes, and a welding helmet or cap for hair protection, to protect
against arc rays and hot sparks or hot metal. A flameproof apron may also be
desirable as protection against radiated heat and sparks.

4) Hot sparks or metal can lodge in rolled up sleeves, trousers cuffs or pockets.
Sleeves and collars should be kept buttoned, and open pockets eliminated from
the front of clothing.

6) Use goggles over safety glasses when chipping slag or grinding. Chipped slag
may be hot and can fly far. Bystanders should also wear goggles over safety
glasses.

BUILD UP OF GAS CAN INJURE OR KILL -

1) Shut off shielding gas supply when not in use.

2) Always ventilate confined spaces or use approved air-
supplied respirator.

ELE C TRI C AL S H OCK -

Contact with live electrical parts and ground can cause severe
injury or death. The electrode (the weld stud and chuck) and
work circuit (ground) are electrically live whenever the output
is on. The input power circuit and the machine internal circuits
are also live whenever power is on. Improperly installed or
improperly grounded equipment is a hazard. Therefore:

1) Disconnect input power before installing or servicing this equipment. Lock
out/tagout input power according to OSHA 29 CFR 1910.147 (see Safety
Standards).

2) Do not touch live electrical parts. Do not touch the electrode (stud) if you

­are in contact with the work, ground, or another electrode from a different
machine.

3) Be sure the power source frame (chassis) is connected to the ground system of
the input power.

4) When making input connections, attach proper grounding conductors first and
then double-check connections.

5) Always verify the supply ground - check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.

6) Refer to ANSI/ASC Standard Z49.1 (listed on page 6) for specific grounding
recommendations. Do not mistake the work lead for a ground cable.

7) Clamp work cable with good metal-to-metal contact (spring and/or magnetic
clamps are not recommended) to work piece as near the weld as practical.

8) DO NOT use welding current in damp areas, if movement is confined, or if
there is danger of falling.

9) Properly install and ground this equipment according to this Owner’s Manual
and national, state and local codes.

10) Connect the work cable to the work piece. A poor or missing connection can
expose you or others to a fatal shock.

11) Keep everything dry, including clothing, work area, cables, torch/electrode
holder and power source.

12) Wear dry, hole-free insulated gloves & body protection before turning on
power.

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ELE C TRI C AN D MA G N ETI C FI E LDS -

Electric and Magnetic Fields may be dangerous. Electric current
flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and cutting current creates EMF
around welding cables and welding machines.
Therefore:

1) Welders having pacemakers should consult their physician before welding. EMF
may interfere with some pacemakers.

2) Exposure to EMF may have other health effects which are unknown.

3) Welders should use the following procedures to minimize exposure to EMF:
A) Route the electrode and work cables together. Secure them with tape

when possible.
B) Never coil the torch or work cable around your body.
C) Do not place your body between the torch and work cables. Route cables

on the same side of your body.
D) Connect the work cable to the work piece as close as possible to the area

being welded.
E) Keep welding power source and cables as far away from your body as

possible.

FLYING METAL CAN INJURE EYES -

Welding, chipping, wire brushing and grinding can cause
sparks and flying metal. As welds cool, they can throw off slag.
Therefore:

1) Wear approved safety glasses with side shields even under
your welding helmet.

13) Insulate yourself from work and ground using dry insulating mats or covers big
enough to prevent any physical contact with the work or ground.

14) Don’t stand directly on metal or the earth while working in tight quarters or a
damp area; stand on dry boards or an insulating platform and wear rubber­soled shoes.

15) Turn off all equipment when not in use.

16) Use well-maintained equipment. Frequently inspect input power cord and out
put weld cables for damage or bare wiring. Replace worn or damaged cables

immediately; bare wiring can kill. Repair or replace damaged parts at once.

Maintain this unit according to the manual.

17) Do not use worn, damaged, undersized or poorly spliced cables.

18) Do not drape cables over your body.

19) If earth grounding of the work piece is required, use a separate cable.

20) Wear a safety harness if working above floor level.

21) Keep all panels and covers securely in place.

22) Insulate work clamp when not connected to work piece to prevent contact
with any metal object.

23) Don’t connect multiple electrodes or work cables to a single weld output
terminal.

SIGNIFICANT DC VOLTAGE exists after removal of the input power on invert

ers. Turn off inverter, disconnect input power, and discharge input capacitors
according to instructions in Maintenance Section before touching any parts.

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2009 MIDWEST FASTENERS, INC. — SureShot Welding System

FUM E S A N D GA S ES -

Welding produces fumes and gases. Breathing these fumes and
gases can be hazardous to your health, particularly in confined
spaces. Do not breathe fumes and gases. Shielding gases can
cause asphyxiation. Therefore:

1) Keep your head out of the fumes. Do not breathe the fumes.

2) If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.

3) If ventilation is poor, use an approved air-supplied respirator.

4) Read the Material Safety Data Sheets (MSDS) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners and degreasers.

5) Work in a confined space only if it is well ventilated, or while wearing an air­supplied respirator. Always have a trained watch-person nearby. Welding fumes
and gases can displace air and lower the oxygen level causing injury or death.
Be sure the breathing air is safe.

6) Don’t weld in locations near degreasing, cleaning or spraying operations. The
heat & rays of an arc can react with vapors to form highly toxic & irritating
gases.

7) Don’t weld on coated metals, such as galvanized, lead or cadmium plated steel,
unless the coating is removed from the weld area, the area is well ventilated,
and if necessary, while wearing an air-supplied respirator. The coatings and any
metals containing these elements can give off toxic fumes if welded.

8) Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium or cadmium unless positive mechanical ventilation
is provided. Do not breathe fumes from these materials.

9) If your develop momentary eye, nose, or throat irritation while operating, this
is an indication that ventilation is not adequate. Stop work and take necessary
steps to improve ventilation in the work areas. Do not continue to operate if
physical discomfort persists.

10) Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.

WELDING CAN CAUSE FI RES AND EXPLO SI ON S -

Welding on closed containers, such as tanks, drums or pipes, can
cause them to blow up. Sparks can fly off from the welding arc.
The flying sparks, hot work piece, and hot equipment can cause
fires and burns. Accidental contact of electrode to metal objects
can cause sparks, explosion, overheating or fire. Check and be
sure the area is safe before doing any welding. Therefore:

1) Protect yourself and others from flying sparks and hot metal.

2) Do not weld where flying sparks can strike flammable material.

3) Remove all combustible materials a minimum of 35 ft. away from the welding
arc or cover the materials with a protective nonflammable covering. Combusti
ble materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints
and coatings, paper, etc.

4) Hot sparks or hot metal can fall through cracks or crevices in floors or wall
openings and cause a hidden smoldering fire or fires on the floor below. Make
certain that such openings are protected from hot sparks and metal.

5) Do not weld, cut, or perform other hot work until the work piece has been
completely cleaned so that there are no substances on the work piece which
might produce flammable or toxic vapors.

6) Be aware that welding on a ceiling, floor, bulkhead or partition can cause fire
on the hidden side.

7) Do not weld on closed containers such as tanks, drums or pipes unless they are
properly prepared according to AWS F4.1.

8) Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and caus
ing electric shock and fire hazards.

9) Do not use welder to thaw frozen pipes.

10) Remove electrode (weld stud) from the stud weld gun when not in use.

11) Remove any combustibles, such as a butane lighter or matches from your
person before doing any welding.

12) Have appropriate fire extinguishing equipment handy for instant use, such as a
garden hose, water pail, sand bucket or portable fire extinguisher. Be sure you
are trained for proper use.

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CYL I NDE R HAN D LIN G -

Shielding gas cylinders contain gas under high pressure. If dam
aged or mishandled a cylinder can explode and violently release
gas. Sudden rupture of cylinder, valve, or relief device can injure
or kill. Since gas cylinders are normally part of the welding pro
cess, be sure to treat them carefully. Therefore:

1) Protect compressed gas cylinders from excessive heat, mechanical shocks,
slag, open flames, sparks and arcs.

2) Keep cylinders away from any welding or other electrical circuits.

3) Never drape a welding gun over a gas cylinder.

4) Never allow a welding electrode (weld stud) to touch any cylinder.

1) Use the proper gas for the process and use the proper pressure reducing
regulator, hoses and fittings designed to operate from the specific compressed
gas cylinder. Do not use adaptors. Maintain hoses and fittings and other
associated parts in good condition.

2) Always secure cylinders in an upright position by chain or strap to suitable
hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may become part of an
electrical circuit.

3) When not in use, keep cylinder valves closed. Have valve protection cap
in place if regulator is not connected. Secure and move cylinders by using
suitable hand trucks. Avoid rough handling of cylinders.

4) Locate cylinders away from heat, sparks, and flames. Never strike an arc or
weld on a cylinder; it will explode.

6) Turn face away from valve outlet when opening cylinder valve.

5) For additional information, refer to CGA Standard P-1, “Precautions for
Safe Handling of Compressed Gases in Cylinders”, which is available from
Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA

22202.

13) Do not use equipment beyond its ratings. For example, overloaded welding

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cable can overheat and create a fire hazard.

14) After completing operations, inspect the work area to make certain there are
no hot sparks or hot metal which could cause a later fire. Use fire watchers
when necessary.

15) For additional information, refer to NFPA Standard 51B, “Fire Prevention
in Use of Cutting and Welding Processes,” available from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

NOISE CAN DAMAGE HEARING -

Noise from some processes or equipment can damage hearing.
Therefore:

1) Wear approved ear protection if noise level is high.

FIRE OR EXPLOSION HAZARD -

1) Do not install or place unit on, over, or near combustible
surfaces.

2) Do not install unit near flammables.

3) Do not overload electrical wiring - be sure power supply
system is properly sized, rated and protected to handle the

unit.

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2009 MIDWEST FASTENERS, INC. — SureShot Welding System

FALLING UNITS CAN CAUSE INJURY -

MOVING PARTS CAN CAUSE INJURY -

1) Use lifting eye to lift unit only, NOT running gear, gas
cylinders or any other accessories.

2) Use equipment of adequate capacity to lift and support unit.

3) If using lift forks to move unit, be sure forks are long enough
to extend beyond opposite side of the unit.

OVERUSE CAN CAUSE OVERHEATING -

1) Allow cooling period; follow rated duty cycle.

2) Reduce current or reduce duty cycle before starting to weld
again.

3) Do not block or filter airflow to unit

STATIC (ESD) CAN DAMAGE PC BOARDS -

1) Put on grounded wrist strap BEFORE handling boards or
parts.

2) Use proper static-proof bags and boxes to store, move or
ship PC boards.

WELDING WIRE CAN CAUSE INJURY -

1) Do not press weld gun trigger until instructed to do so.

2) Do not point weld gun toward any part of the body, other
people or any metal when threading welding wire.

1) Keep hands, hair, loose clothing and tools away from moving
parts such as fans.

2) Keep all doors, panels, covers and guards closed and
securely in place.

3) Always disconnect electrical power prior to service to

prevent the fan from starting unexpectedly.

H.F. RADIATION CAN CAUSE INTERFERENCE -

1) High-Frequency (H.F.) can interfere with radio navigation,
safety services, computers and communications equipment.

2) Have only qualified persons familiar with electronic
equipment perform this installation.

3) The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the

installation.

4) If notified by the FCC about interference, stop using the equipment at once.

5) Have the installation regularly checked and maintained.

6) Keep high-frequency source doors and panels tightly shut and use grounding
and shielding to minimize the possibility of interference.

ARC WELDING CAN CAUSE INTERFERENCE -

1) Electromagnetic energy can interfere with sensitive electronic
equipment such as computers and computer-driven
equipment such as robots.

2) Be sure all equipment in the welding area is electro-
magnetically compatible.

3) To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

4) Locate welding operation 100 meters from any sensitive electronic equipment.

MOVING PARTS CAN CAUSE INJURY -

1) Keep hands, hair, loose clothing and tools away from moving
parts.

2) Keep away from pinch points such as drive rolls.

EQU I PME N T M A INT E N ANC E -

Faulty or improperly maintained equipment can cause injury or
death. Therefore:

1) Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not perform
any electrical work unless you are qualified to do the work.

2) Before performing any work inside a power source, disconnect the power
source from the incoming electrical power using the disconnect switch at the
fuse box before working on the equipment.

3) Maintain cables, grounding wire, connections, power cord, and power supply
in safe working order. Do not operate any equipment in faulty condition.

4) Do not abuse any equipment or accessories. Keep equipment away from:

- heat sources such as furnaces

- wet conditions such as water puddles and inclement weather

- oil or grease

- corrosive atmospheres.

5) Keep all safety devices and cabinet covers in position and in good repair.

6) Use equipment only for its intended purpose. Do not modify it in any manner.

5) Be sure this welding machine is installed and grounded according to this
manual.

6) If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the
work area.

HOT PARTS CAN CAUSE SEVERE BURNS -

1) Do not touch hot parts with bare hands.

2) Allow cooling period before working on welding tool (gun
or torch).

EMF Information

Considerations about welding and the effects of low frequency Electric and Magnetic
Fields (EMF):
Welding current, as it flows through welding cables, will cause electromagnetic
fields. There has been and still is some concern about such fields. However, after
examining more than 500 studies spanning 17 years of research, a special blue
ribbon committee of the National Research Council concluded that: “The body of
evidence, in the committee’s judgement, has not demonstrated that exposure to
power-frequency electric and magnetic fields is a human-health hazard.” However,
studies are still going forth and evidence continues to be examined. Until the final
conclusions of the research are reached, you may wish to minimize your exposure
to electromagnetic fields when welding or cutting.

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2009 MIDWEST FASTENERS, INC. — SureShot Welding System

California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of Califor­nia to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

For Gasoline Engines:
Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other re
productive harm.

For Diesel Engines:
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth
defects, and other reproductive harm.

AD DIT IO NAL S AFE TY IN FO RM A TI ON -

For more information on safe practices for electric arc welding refer to the following publications:

American Welding Society
550 N.W. LeJuene Road, Miami, FL 33126, (phone [phone], website: www. aws.org)

1) ANSI/ASC Z49.1 - Safety in Welding, Cutting and Allied Processes

2) AWS CH5 - Recommended Practices for Stud Welding

3) AWS D1.1 - Structural Welding

2) AWS C5.1 - Recommended Practices for Plasma Arc Welding

3) AWS C5.6 - Recommended Practices for Gas Metal Arc Welding

4) AWS SP - Safe Practices - Reprint, Welding Handbook

5) ANSI/AWS F4.1, Recommended Safe Practices for Welding and Cutting of Containers and Piping

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National Fire Protection Association
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone [phone], website: www.nfpa.org and sparky.org)

1) NFPA Standard 70 - National Electrical Code

2) NFPA Standard 51B - Standard for Fire Prevention During Welding, Cutting and Other Hot Work

Compressed Gas Association
1735 Jefferson Davis Highway, Suite 1004; Arlington, VA 22202-4102 (phone [phone], website: www.cganet.com)

1) CGA Pamphlet P-1 - Safe Handling of Compressed Gas Cylinders

Canadian Standards Association
Standards Sales, 178 Rexdale Blvd, Rexdale, Ontario, Canada M9W 1R3 (phone [phone] in Toronto 416-747-4044, website: www.csa-international.org)

1) CSA Standard W117.2 - Code for Safety in Welding and Cutting

American National Standards Institute
11 West 42nd Street, New York, NY 10036-8002 (phone [phone], website: www.ansi.org)

1) ANSI Standard Z87.1 - Practice for Occupational and Educational Eye and Face Protection

U.S. Government Printing Office
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (phone [phone], website: www.osha.gov)

1) Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, & Part 1926, Subpart J - Occupational Safety and Health Standards for General Industry

With any power source, it may or may not contain a battery which may contain hazardous materials. Please follow
local battery disposal procedures when changing batteries or disposing of the power supply.

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2009 MIDWEST FASTENERS, INC. — SureShot Welding System