dabotek BS108 User manual

VERSION : 2C
DABOTEK ApS
OPERATING MANUAL FOR
BS1XX and BS2XX RANGE -
COMPACT CAPACITOR DISCHARGE
STUDWELDING EQUIPMENT
MODELS BS108, BS110, BS112 &
BS208, BS210, BS212

INDEX
PAGE CONTENT
1 GENERAL INFORMATION
3 INTRODUCTION
4 EQUIPMENT SCHEDULE
5 EXTERIOR FEATURES
7 SAFETY
10 SETTING UP AND WELDING
16 WELD SETTINGS
27 LOCATION METHODS
28 WELD ASSESSMENT TESTING
29 CONTACT PISTOL EXPLOSION AND PARTS LIST
31 MARK V LIFT GAP PISTOL EXPLOSION AND PARTS LIST
30 CONTROLLER EXPLOSION AND PARTS LIST
33 CIRCUIT SCHEMATICS INC. CHANGING THE INPUT VOLTAGE
36 AVAILABLE ACCESSORIES
43 EC DECLARATION OF CONFORMITY

GENERAL INFORMATION
MANUFACTURERS DETAILS
DABOTEK APS.
BIRKEDAM 10 A 12
6000 KOLDING
DENMARK
TELEPHONE : [phone]
FACSIMILE : [phone]
e-mail : [email protected]m
PURPOSE AND CONTENT OF THIS MANUAL
This manual has been written for :
 The operator of the welding machine.
 The personnel of the final customer responsible for the
installation and operation of the machine.
This manual contains information on :
 Installation and connection
 Operation.
 Technical data.
 Spare parts.
 Accessories.
1

GENERAL INFORMATION
FURTHER INFORMATION
Should you require additional technical information, please contact
us directly (details on page 1) or our local agent distributor (details
of agents etc. can be obtained from us).
This manual contains important information which is a pre-requisite
for safe operation of the equipment. The operating personnel must
be able to consult this manual. In the interests of safety, make this
manual available to your personnel in good time.
If the equipment is sold passed on, please hand over this manual
to the new owner. Please immediately inform us of the name and
address of the new owner, in case we need to contact him regard-
ing the safety of the device.
Please read this manual carefully before installation of
the machine.
Please especially observe the safety instructions.
2

INTRODUCTION
INTRODUCTION
The complete range of DABOTEK ApS Capacitor Discharge units
are compact, portable Stud Welding equipment's. The units are spe-
cifically designed to enable a small diameter range of ferrous and
non-ferrous weld studs to be welded to light gauge, self-finish or
pre-coated materials, in most cases with little or no reverse marking.
The equipment consists of a control unit, a welding pistol and
the necessary interconnecting cables and accessories (see page 4 for
the equipment schedule).
THE PROCESS
Capacitor Discharge stud welding is a form of welding in which
the energy required for the welding process is derived from a bank
of charged capacitors. This stored energy is discharged across the
gap between the two surfaces to be welded as they are propelled
towards each other. The arc produced heats the two surfaces, melt-
ing a thin film of metal on each surface and the propelling force
closes the gap between the two faces, thus forming a weld.
In contact welding the stud to be welded is forced by spring
pressure on to the plate. At this point the arc gap between the two
components is maintained by a small pip on the welding face of the
stud. On initiation of the high current pulse from the capacitors, this
pip vaporises and an arc is drawn between the work piece and the
stud. The heat from this arc melts the base of the stud and the area
of the work piece directly beneath the stud, whilst the spring pres-
sure from the pistol accelerates the towards the work piece. Within
3 to 4 milliseconds the stud hits the work piece and the arc is extin-
guished. The kinetic energy contained in the moving stud and the
remaining spring pressure, forge the molten parts together to form
3

EQUIPMENT SCHEDULE
EQUIPMENT
No. OFF DESCRIPTION PART No.
1 SYSTEM BS108 CONTACT SDTBS108-CDK1
COMPLETE WITH CONTACT PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM BS110 CONTACT SDTBS110-CDK1
COMPLETE WITH CONTACT PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM BS112 CONTACT SDTBS110-CDK1
COMPLETE WITH CONTACT PISTOL
& EARTH CABLE ASSEMBLY
ACCESSORIES (SUPPLIED WITH EQUIPMENT)
No. OFF DESCRIPTION
PART No.
1 CHUCK KEY 79-101-111
1 CD CONTACT PISTOL 99-100-020
or CD LIFT GAP PISTOL 99-100-023
2 EARTH CABLE ASSEMBLY 99-100-125
ACCESSORIES (NOT SUPPLIED WITH EQUIPMENT)
See pages 36 to 42 of this manual for a selection of accessories
available from either your local stockist or the manufacturer.
4

EXTERNAL FEATURES
FRONT PANEL
1 Welding voltage selector knob
2 Welding voltage digital display.
3 Charging (Yellow) - Indicates that the unit is in the process of
charging the capacitors to the pre-selected voltage.
4 Ready (Green) - Indicates that the capacitor bank is charged to
the pre-selected value and is ready to weld.
5 Reset (Red) - Indicates that the unit safety circuit has tripped.
To reset the unit, switch off the mains switch, wait between 5
and 30 seconds then switch back on.
6 Welding Earth panel connections
7 Welding pistol control socket.
8 Welding pistol panel connection
5

EXTERNAL FEATURES
REAR PANEL
SERIAL RATING PLATE
ON OFF SWITCH
COOLING FAN
MAINS FUSE
MAINS INPUT LEAD
IMPORTANT NOTES !
Due to the power requirements and Electromagnetic emis-
sions produced during normal use, this machine must only
be operated in an industrial environment.
This machine is set up to operate on either 115 Volts C, or
230 Volts C. Check the serial plate before plugging into
the correct supply.
Never obstruct the ventral or rear panel ventilation holes as
this may cause the unit to overheat during operation.
Never remove any portion of the unit housing without first
isolating the unit from the mains electrical supply.
6

SAFETY
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notices.
1. ELECTRICAL
No portion of the outer cover of the welding controller should be
removed by anyone other than suitably qualified personnel and nev-
er whilst mains power is connected. ALWAYS disconnect the mains
plug from the socket.
RISK TO LIFE !!!
BE AWARE ! This equipment contains a sealed power supply mod-
ule which operates on high frequency inverter principles. Due to the
potentially fatal voltages in this module we do not recommend tam-
pering with the module. It can be safely removed and replaced via
our factory exchange system.
BE AWARE ! Capacitors store electrical energy. Check for residual
charge before carrying out any internal maintenance.
DO NOT ! Use any fluids to clean electrical components as these
may penetrate into the electrical system
Installation must be according to the setting up procedure detailed
on page 10 of this manual and must be in line with national, region-
al and local safety codes.
2. FIRE
During welding small particles of very hot metal are expelled. En-
sure that no combustible materials can be ignited by these.
7

SAFETY
3. PERSONNEL SAFETY
Arc rays can burn your eyes and skin and noise can damage your
hearing.
Operators and personnel working in close proximity must wear suit-
able eye, ear and body protection.
Fumes and gases can seriously harm your health. Use the equipment
only in a suitably ventilated area. If ventilation is inadequate, then
appropriate fume extraction equipment must be used.
Hot metal spatter can cause fire and burns. Appropriate clothing
must be worn.
Clothing made from, or soiled with, combustible materials must NOT
be worn. Have a fire extinguisher nearby and know how to use it.
Magnetic fields from high currents can affect heart pacemakers or
other
electronically controlled medical devices. It is imperative that all per-
sonnel likely to come into the vicinity of any welding plant are
warned of the possible RISK TO LIFE before entering the area.
4. MAINTENANCE
All cables must be inspected regularly to ensure that no danger ex-
ists from worn or damaged insulation or from unsound electrical
connections. Special note should be made of the cables close to the
pistol, where maximum wear occurs.
As well as producing inconsistent welds, worn cables can overheat
or spark, giving rise to the risk of fire.
5. TRAINING
Use of the equipment must limited to authorised personnel only
who must be suitably trained and must have read and understood
this manual. This manual must be made available to all operators at
8