bsk + BTV DAI-1300 Operating and maintenance instructions

print 06/2015_Rev.2 page 1 von 4
Bolzenschweißtechnik bsk + BTV GmbH_Daimlerstraße 25 _ 74252 Massenbachhausen _ www.stud-welding.de
Tel [phone] / 810970 _ Fax [phone] _ Email inf[email protected]
DAI-1300
Quick-Installation manual
Hotline
Mo to Fr 08:00 o´clock AM to 04:00 o´clock PM phone: [phone]
[e-mail]
For technical questions, especially about the device / gun please have ready in advance:
Type of machine and serial number ______________________________________________________
Error description _________________________________________________________________________________
Please observe the detailed operating instructions for equipment and guns! There are
knowledge of stud welding equipment and their components necessary. Stud welding work may
be performed only by persons who have reached the age of 18. Observe all the necessary safety
instructions.
Front panel: backside with gas-connector:
Setting-up operation Inverter
- Switch position power-switch to „0“
- 32A CEE - plug into the appropriate receptacle connect (Fuse: screwgate 25 AT / attention: no
curcuit-braker breaker);
- Control-cable, ground-cable and welding-gun cable connecting to inverter and secure against
twisting;
- fix the two locking pliers of the ground cable ideally evenly diagonally attach far from the
weld on the workpiece to reduce magnetic blow.
In case of protection-gas application:
Connect gas on the rear side with a suitable hose to the pressure reducer a protective gas
bottle and adjust the flow rate of gas to 4-6 l / min (recommended for steel and stainless steel
mixed gas 82% Ar / 18% CO2). Caution: Gas bottle against falling over!
Set up welding-gun(s)
Note: Inverter switch on (switch to "I") and switch to
"Lift test" (function "test" in set-menu "DAI-1300") or
disconnect ground cable from the Inverter!
Welding-gun DA-10M / GAP-M
-select chuck (stud-holder) according the used welding-
element;
-adjust stud-holder (see figure left);
-insert stud-holder in welding-gun;
-tighten and fixed with socket-wrench SW17.
Rotary switch
Graphik-Display
Socket welding current cable
Pressure-air connectors for automatic welding-gun
(optional, only with automatic welding-gun)
Gas-connector für welding-gun
7-pin socket control cable
connector
Socket ground-cable
Power switch
overlap
4 – 5mm
print 06/2015_Rev.2 page 2 von 4
Bolzenschweißtechnik bsk + BTV GmbH_Daimlerstraße 25 _ 74252 Massenbachhausen _ www.stud-welding.de
Tel [phone] / 810970 _ Fax [phone] _ Email inf[email protected]
DAI-1300
Quick-Installation manual
Welding-guns DA-12M / DA-19M / DA-22M / DA-25M
-select chuck (stud-holder) according the used welding-
element;
-Screw the chuck on the double nipple
-Tighten the chuck with open-end wrench SW17
(Attention: counter with a spanner on the double
nipple!)
-Place the corresponding tripod (gas or ceramic tripod)
on the gun and fix it
Ceramic tripod (does not apply to DA-10M / GAP-M)
-Insert suitable ceramic ring holder in base plate and secure
using a 2.5 mm socket wrench
-Insert stud into the stud holder as far as it will go
-Insert appropriate cermanic ring into ceramic ring holder
while slightly turning it
-Adjust excess length (overlap, see table page 4) of stud or
stroke distance according to figure and table by adjusting
the tripod correspondingly and then tightening the locking
screw.
-Align the base plate using the socket scews so that the stud
and the ceramic ring is centered and the stud does not
touch the ceramic ring when lifted. Otherwise it might inhibit
the insertion
-Check the excess length and the free movement of the
motion system by manually pushing the stud in against the
spring in the gun. Or you can use the built-in lift test function
by actuating the gun in the air.
Lift-adjustment (does not apply to DA-10M and DA-12M):
-DA-19M…DA-25M: therefore cap unscrew and with the
setting scale (see brass-scale from 2mm…6mm at the gun)
adjust the correct lift of the welded stud (it depends in
graphics page 4).
-GAP-M: First adjustment of zero-lift with the setting screw
at the top of the gun, than adjustment of correct lift
regarding table page 4.
Guns are now ready to use!
Setting-up operation Inverter
After switching on (mains switch to "I") and self-test of the
inverter, the actual values of welding current, welding
time and arcing voltage be on the top line of the display in
the main menu appears in the line below the corresponding
desired values by default. The values for welding current
and welding time can be infinitely adjusted by pressing the
rotary control on the respective field.
Schweißstrom: 0A…1000A
Schweißzeit: 0ms…1500ms
Overlap

print 06/2015_Rev.2 page 3 von 4
Bolzenschweißtechnik bsk + BTV GmbH_Daimlerstraße 25 _ 74252 Massenbachhausen _ www.stud-welding.de
Tel [phone] / 810970 _ Fax [phone] _ Email inf[email protected]
DAI-1300
Quick-Installation manual
With correct operation of the inverter and correctly
connecting of connectiong-cable and the ground-cable
adjacent symbols in the illustrated color light up (from left to
right):
Solenoid (black), temperature indicator (green), standby
message (black) and library symbol (yellow).
Using of the fixed library for current, time and / or gas
Select a permanently stored and related to the stud
diameter parameters [set out by in the "Library (fixed)"] by
scrolling the encoder to a stud type ("RD", "PS", pin or
"SD"), mark in the table, pressing on the rotary encoder
and switch to "START" or "Back" returns to the main menu.
The welding parameters are taken to the main menu.
The inverter is now ready to use.
Welding-current I(A) manual setting
2.
Welding-time t(ms) manual setting
I(A) einstellen
Protection-Gas: pre – and post-time gas manuel setting
The inverter is now also ready to weld. Note that it can be welded only if you are in the main
menu of the inverter!

1. Rotate encoder to the position "welding current" in the
main menu;
2. Press on the rotary encoder (the field changes to the
color "Magenta");
3. Set the value for welding current by turning the rotary
encoder;
4. Pressing the encoder, the field returns to the color "blue"
and the set value is taken over.
1.
Rotate
encoder
to the position
"
welding current"
in the
main menu;
2. Press on the rotary encoder (the field changes to the
color "Magenta");
3. Set the value for welding time by turning the rotary
encoder;
4. Pressing the encoder, the field returns to the color "blue"
and the set value is taken over.
1.
In the submenu "
gas
"
the
inert gas
Select function
by
scrolling, pressing and turning (to the right) to the symbol
"gas bottle" using the rotary control (bottle symbol with
black activation);
2. Set the same principle pre-flow and post-flow;
3. "START" or "Back" again switch to the main menu: The
activation of the gas module is indicated by the black
bottle symbol in the bottom status bar of the main-display.
print 06/2015_Rev.2 page 4 von 4
Bolzenschweißtechnik bsk + BTV GmbH_Daimlerstraße 25 _ 74252 Massenbachhausen _ www.stud-welding.de
Tel [phone] / 810970 _ Fax [phone] _ Email inf[email protected]
DAI-1300
Quick-Installation manual
Setting graphics and tables / evaluation of welding results
For example: M8 (approximately):
Ca. 600A, 320 ms, 1,3 mm lift, 3 mm depth of immersion
Evaluation of welding results:
G
ra
p
hic für stud
-
typ
e R
D (
reduced studs
)
:
About
-
settings
of
welding current, lift and depth of immersion as a function of
the bolt diameter:
Gra
phic for stud
-
type „SD“
(shear
-
connectors)
:
About
-
settings of welding current, lift and depth of immersion as a
function of the bolt diameter:
Stud-type PS
M 3
PS
M 4
PS
M 5
PS
M 6
PS
M8
PS
M10
Stahl
unalloyed
1 1 1,3 1,5 2 2
Cr
-
Ni
-
Steel
1
1
1,3
1,5
2
2
Heat
resistance
Steels
1 1 1,3 1,5 2 2
T
able lift
-
se
ttings
f. gun GAP
-
M
for
stud-type „PS“ (short -cycle):
All measurements in Millimeter
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=
Lift
Adjustment
(mm)
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=
jÉ~ëìêÉ=çÑ=éÉåÉíê~íáçå
=
Lift
Adjustment
(mm)
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