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Inverter Arc Stud Welder - IT 90 AT

The IT 90 AT is a high-current inverter arc stud welder delivering up to 2,000 A for large-diameter stud welding. It supports ARC and Short Cycle welding, studs from M3 to M24, and automated configurations with optional four-gun/head connections.

Inverter Arc Stud Welder - IT 90 AT

GENERAL INFORMATION

Application

  • Especially suitable for thicker sheets of about 2 mm or higher

Equipment

  • Inverter (2000 A) with options for 4 outputs, process monitoring and shielding gas
  • Welding with ceramic ferrule

Technology

  • 2,000 A output for heavy-duty stud welding
  • M3–M24 range for large studs
  • 30 kHz frequency for dynamic control
  • Up to 4 heads for automation
  • Process monitoring for weld consistency
  • Parameter library for fast setup
  • Automatic lift test for gun verification
  • RS-232 interface for data transfer
Mild steel
Stainless steel
Aluminium
M3 to M24 - #4 to 1"
FEATURES
  • Microcontroller – for precise process times, optimal functional reliability and maximum operating convenience
  • Function monitoring – automatic function test following power-up; monitoring of all internal system functions
  • Lift test – for gap welding guns and stud welding heads
  • Library function – automatic specification of welding current and welding time through selection of stud diameter according to welding range (with and without shielded gas); fine adjustment via arrow keys
  • Process monitoring – recording and analysis of factors affecting the welding process; after each weld, the reference and actual values are compared; display of the welding energy input; switchable automatic welding stop if limits are exceeded
  • RS232 interface – for data output; data and time of day are stored; welding parameters of each weld are logged
  • 4 gun connections (optional)
Advantages
Structure
  • Extremely easy to operate
  • Compact / Mobile – highly mobile thanks to compact dimensions and low weight (50% weight savings in relation to conventional stud welding units)
  • Robust – metal housing withstands rough treatment in shop and on site
Safety
  • With integrated mains filter (protection against voltage peaks)
  • Optimal for construction sites with large mains voltage fluctuations – use even with critical voltage supply (-10% +10%)
  • EMC test
  • High-voltage test with log
  • Retriggering lock-out – prevents welding on a welding element that has already been set
  • Thermal monitoring of transformer – automatic shutdown in case of overheating
  • Temperature-regulated ventilator – reduces noise and dust in the stud welding unit (greater system reliability)
  • Control unit galvanically separated from welding lines – high degree of functional safety
  • Optimal protection against external interferences
  • IP Code: IP 21
Welding
  • Display – infinitely adjustable power setting; easy monitoring of all functions via LED displays; easy operation via membrane keyboard and digital display; setting of welding parameters, programs, shielding gas, automation and process monitoring possible; digital display of current, welding and gas-preflow time (optional; pneumatic feed time for automation); separate settings for welding current and welding time
  • Powerful – built-in power reserves
  • Trouble-free changing of welding voltage polarity possible by reconnecting welding current and ground cables
  • Outstanding welding quality – very high arc stability even at weak welding currents
  • High process flexibility – high clock frequency (30 kHz) of stud welding unit allows highly dynamic regulation of welding process
Technical Data
Welding Process ARC, SC
Welding material Mild steel, stainless steel, aluminum
Technology Inverter
Equipment Welding with ceramic ferrule
Welding with shielding gas
Process control
Automation
4 gun/head connections - (optional)
Display Digital
Welding range M3 to M24, dia. 2 to 22 mm /
#4 to 1", dia. 14 ga to 7/8"
Welding rate Dia. 22 / 7/8" = 6 studs/min
Welding current 2,000 A (max.)
Current adjustment range 300 to 2,000 A (stepless)
Welding time 5 to 1500 ms (stepless)
Primary power 400 V*, 3 phase, 50/60 Hz, 63 AT (slow blow)
* alternative primary power available - see - Order Number below
Primary plug 63 A (with 400 V mains)
Connected load 100 KVA (with 400 V mains)
Cooling type F (temperature controlled cooling fan)
IP code IP 21
Dimensions - LxWxH (without handle) 650 x 560 x 1290 mm /
25.6" x 22" x 50.8"
Weight 145 kg / 319.67 lbs (1 gun conn.)
165 kg / 363.76 lbs (4 gun conn.)
Suitable guns See below
Order number 93-60-12096 (400 V - 1 gun connection)
93-60-42096 (400 V - 4 gun connection)
93-66-12096 (480/460 V - 1 gun connection)
93-66-42096 (480/460 V - 4 gun connection)
93-40-019 (Ground cable, 2 pcs., 5 m, 70 mm 2, 1 vice grip 10")

Where the IT 90 AT Fits

Application Why the IT 90 AT Fits
Heavy Equipment High-current welding for large structural studs.
Structural Steel Supports large-diameter studs for heavy steel assemblies.
Construction Equipment Suitable for frames, chassis, and structural components.
Shipbuilding High-current ARC welding for demanding steel applications.
Rail & Transportation Automated stud attachment on large metal assemblies.
Industrial Machinery Supports repetitive stud welding on heavy components.
Large Sheet Fabrication Suitable for thicker steel sections and large studs.
Automated Production Lines Up to 4 welding heads support multi-position production.
Pressure & Energy Equipment High-current capacity for demanding industrial components.
General Heavy Fabrication M3–M24 range covers diverse stud sizes and applications.

FAQs

The IT 90 AT supports studs from M3 to M24 / #4 to 1 inch, with the listed welding diameter extending to 22 mm / 7/8 inch. Actual capability depends on stud type, material, and welding configuration.

A 2,000 A output provides the high welding current required for larger-diameter studs and demanding arc welding applications. The IT 90 AT is therefore suited to heavy fabrication where lower-current stud welders may not provide sufficient capacity.

Yes. The IT 90 AT is available with an optional four-gun/head connection, allowing multiple welding heads to be integrated into automated or production-oriented configurations.

Process monitoring records factors affecting each weld and compares reference values with actual values. The system can display welding energy and automatically stop welding when programmed process limits are exceeded.

Its library function can automatically specify welding current and time based on the selected stud diameter. Operators can then fine-tune the parameters using the machine controls.

The IT 90 AT uses a 30 kHz switching frequency for highly dynamic regulation of the welding process. This supports precise control of welding behavior, particularly across changing current and time requirements.

Yes. The IT 90 AT includes an automation configuration and can be equipped with automatic welding heads, including the KAH 412 and KAH 412 LA, or automatic feeding configurations using the PAH-1 and VBZ-3.

Stud Welding Guns

PAH-1 (Tripod)
M3 to M8
  • Studs length (from 0.31 to 1.18") - other lengths only by request
  • Universal design for flat surfaces
  • Hand gun for fully automatic stud feed (with VBZ-3) or hand feed
  • Recommended for large-scale production
PAH-1 (centering device dia. 30 mm)
M3 to M8
  • Studs length (from 0.31 to 1.18 inches) - other lengths only by request
  • Used for welding with templates
  • Hand gun for fully automatic stud feed (with VBZ-3) or hand feed
  • Recommended for large-scale production
KAH 412 - Automatic Stud Welding Head
M3 to M8 (dia. 10 to 12.7 mm)
  • Studs length (from 0.31 to 1.18") - other lengths only by request
  • Setting the lift and plunge via digital display (selection mm/inch)
  • No length compensation
KAH 412 LA - Automatic Stud Welding Head
M3 to M8 (dia. 10 to 12.7 mm)
  • Studs length (from 0.31 to 1.18") - other lengths only by request
  • Setting the lift via adjustment screw (increments 0.1 mm)
  • Length compensation of length variances in studs height and variances of the workpiece