Instruction manual

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Sparkie® II Mini Fusion Welder

Millennium Edition #503-191

Please read all of the instructions before attempting to operate

Please Note: For your personal safety and for the proper and efficient operation of SPARKIE welders,TRIAD recommends

that you read the instructions before operating the machine. Your familiarity with the machine and its operation will per-

mit the continued safe use of SPARKIE in your workplace and will allow for the efficient production of high quality work.

What is new in the Millineum Edition?

In a word it is simpler to operate. Less buttons and dials gives this new version a clean

unclutered look. Charging times have been reduced for faster production rates.The new

foot pedal charging control frees both hands for accuracy and speed. Extra power for

those big findings now just plugs in.

What is SPARKIE?

SPARKIE is a mini fusion welder. Fusion welding has been a mainstay in the jewelry

industry for many years. Fusion provides a fast, clean bond between similar and dis-

similar metals when using fusion findings. Low temperature (pot metal) and lead

bearing alloys are not compatible with fusion welding.

SPARKIE is a capacitive discharge welder. A large capacitor is used to store an electri-

cal charge, like a battery. That charge is released through a fusion finding as it touch-

es the surface of the receiving metal. A small explosion occurs which blows all of the

oxides and gasses away from the weld. For the next millionth of a sec-

ond a vacuum exists, allowing similar and dissimilar metals to bond in

the residual heat.

What are fusion findings?

When you look closely at the

bottom of a fusion finding

you will see a small (appx.

.01 in. dia.) nib in the center

of a flat plate. It is forged

of the same metal as the finding, it is not a solder or flux. This nib is what explodes

when the capacitor discharges. The geometry of this contact area is the key to fusion welding.

Fusion findings have been standardized in the industry. They are available from your SPARKIE distributor and other sources.

What about quality control?

The simplicity and speed of fusion welding can be misleading. Proper alignment of the machine and preparation of the

pieces to be welded is very important and cannot be over emphasized. Test welds should be performed with the actual

pieces and findings to be used. Occasional tests should be performed on the finished product.

In the final analysis the precision of the operator is the key to success. The hand held operations must be performed with

care and a realization that the quality of the finished product is in the balance during this final few seconds.

Fusion post

Nib

Summary of content (13 pages)

PAGE 1
Sparkie® II Mini Fusion Welder Millennium Edition #503-191 What is new in the Millineum Edition? In a word it is simpler to operate. Less buttons and dials gives this new version a clean unclutered look. Charging times have been reduced for faster production rates. The new foot pedal charging control frees both hands for accuracy and speed. Extra power for those big findings now just plugs in. What is SPARKIE? SPARKIE is a mini fusion welder.
PAGE 2
TRIAD Inc. PO Box 92 Chartley, MA 02712 508/222-7126 • 800/646-4218 DISCLAIMER WARRANTY TRIAD, INC and/or its representatives shall not be held liable for any injury, incidental or consequential damages or loss of profit. No liability is assumed for damages due to accident, abuse, tampering with the instrument, lack of reasonable care, loss of parts, or subjecting the instrument to short circuits or input values of a magnitude in excess of those specified.
PAGE 3
SPARKIE II working diagram #1Cylinder ENGAGE knob #2 Collet adjusting rod #3 Cylinder RELEASE knob #4 Collet holder #5 Collet allen screw #6Collet (interchangeable) #7 Jig (interchangeable) #8 Jig holder (interchangeable) & thumb screw #9 ON/OFF switch #8A Fixture base & adjusting allen screw #10 Voltmeter #11 Power ON indicator light #12 Foot Pedal Charger Please Note: On the back banana plugs are provided for installation of a Power Pack.
PAGE 4
General information The following items where packed with your SPARKIE II: 1) Video instruction manual (VHS). 2) Collets for ear posts(.030L, installed) and tie tacs(.045L). 4) Jigs SF-6(ear post, installed) and SF-7(tie tac). 3) Allen wrench. 4) Two extra 'O' rings and ball bearings. 7) Safety glasses. 8) Sample kit and test report. Please save your shipping carton. Practice Prior to plugging SPARKIE II into a power source, a dry run should be made to learn what to expect.
PAGE 5
8 Gently pull on the cylinder RELEASE knob (#3). Bang! The cylinder should have dropped to the down position, sparks should have flown and the weld is complete. 9 Remove the welded piece and reset the cylinder into the up, locked position. 10 Examine the weld closely for a true perpendicular (right angle) position. An uneven splash around the weld may also indicate a misalignment. Poor alignment may make the weld fail. Test the weld by bending the post back and forth.
PAGE 6
the thumb screw for leverage. Do not overtighten and break the bolt! Residue can also build up on the bottom of the collet. 1 Loosen the front allen screw on the collet holder. (Not the one with the wire attached.) Pull the collet down and out. 2 The small black stain that appears around the weld is just carbon. It will wipe off with mild soap and water. 3 The jigs that came with SPARKIE II are of an all purpose design.
PAGE 7
edge of the base hit first. The post will probably peel off. 12 Remember, SPARKIE will continue to charge as long as you hold down the foot pedal! It will discharge slowly if allowed to sit and quickly if turned off. Can SPARKIE shock you? The answer is unquestionably, yes! But, where and when and how bad is it? The components of SPARKIE represent two sides of a short circuit. POSITIVE and NEGATIVE. Almost all of SPARKIE is NEGATIVE.
PAGE 8
Guide to Joints and Catches Operation As with other findings, joints and catches used with SPARKIE II must be designed specifically for fusion welding. Examine the bottom of the findings for the small nib necessary for fusion. Findings must also be compatible with SPARKIE's specific collet mechanisms. Using improperly designed findings may cause damage to the machine, collets or your product.
PAGE 9
Guide to Cuff Links Operation As with other findings, cuff links used with SPARKlE® II must be designed specifically for fusion welding. Examine the bottom of the findings for the small nib necessary for fusion. Findings must also be compatible with SPARKlE's specific collet mechanisms. Using improperly designed findings may cause damage to the machine, collets or your product. WARNING! Electrical shock hazard! Always check the volt meter before loading a finding.
PAGE 10
Guide to Ear Clips Operation As with other findings, ear clips used with SPARKIE® II must be designed specifically for fusion welding. Examine the bottom of the findings for the small nib necessary for fusion. Ear clips must also be compatible with SPARKlE's specific collet mechanisms. Using improperly designed findings may cause damage to the machine, collets or your product. WARNING! Electrical shock hazard! Always check the volt meter before loading a finding.
PAGE 11
Gulde to Stick Plns OperatIon As with other findings, stick pins used with SPARKlE® II must be designed specifically for fusion welding. Examine the bottom of the finding for the small nib necessary for fusion. Stick pins must also be compatible with SPARKlE's specific collet mechanisms. Using improperly designed findings may cause damage to the machine collets or your product. WARNING! Electrical shock hazard! Always check the volt meter before loading a finding.
PAGE 12
Guide to Using the Production Table As with other accessories, the Production table is specifically designed for use with SPARKIE II. All findings must be designed for fusion welding. Examine the bottom of the findings for the small nib necessary for fusion. Findings must also be compatible with SPARKlE's specific collet mechanisms. Using improperly designed findings may cause damage to the machine, collets or your product. InstallatIon The Production Table replaces the Jig holder.
PAGE 13
Set up OperatIon Replace the disk onto the table and load a piece into the new mold. Load the finding that you will use with this piece into the collet. Release the cylinder and slowly lower it, adjusting its position with the collet Adjusting Rod (see page 5 of the instructions) until it hangs just above the piece to be welded. The disk position can now be adjusted so that the weld is properly located. At this time check that the hold down seats squarely on the piece and holds it firmly down.