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  9. dabotek BS108 User manual

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 : +45 7550 5666
FACSIMILE : +45 7550 4795
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
SAFETY
. INSTALLATION
Ensure that the site chosen for the equipment is able to support the
weight of the equipment and that it will not fall or cause a danger
in the course of its normal operation. Do not hang connecting ca-
bles over sharp edges and do not install connecting cables near
heat sources or via traffic routes where people may trip over them
or they may be damaged by the passage of vehicles (forklifts etc.).
7. INTERFERENCE
During welding operations, intense magnetic and electrical fields are
unavoidably produced which may interfere with other sensitive Elec-
tronic equipment.
All DABOTEK ApS. Studwelding equipment is designed, manufac-
tured and tested to conform the current appropriate European
standards and directives regarding electromagnetic emissions and
immunity and as such is safe to use in any normal environment
8. DISPOSAL
The equipment either wholly or any of its component parts may be
disposed of as part of general industrial waste or passed to a scrap
merchant. Non of the components used in the manufacture are tox-
ic, carcinogenic or harmful to health.
9
SETTING UP & WELDING
SETTING UP & WELDING
Set up the control unit at the place of work, en-
suring that the mains switch is in the OFF posi-
tion. Ensure that this is done in line with the
notes and safety recommendations on pages 7
through 9 of this manual.
Plug the controller into the correct mains AC
supply. The controller is rated for either 230V or
115V, check the rating plate and ensure that the
controller is plugged into the correct supply be-
fore turning the power on.
Connect the welding earth cables to the
controller socket marked +-
Note that the cable end plug has a peg
which mates with a key slot in the panel
mounted socket.
IMPORTANT ! Secure the connectors with a
clockwise turn until they lock. Failure to do this
will result in damage to the connectors during
welding.
Attach the welding earth clamps to the work
piece at approximately 180° to each other. This
will help to prevent "Arc blow" when weld-
ing takes place. Prior to fitting the clamps,
ensure that the contact area of the work
piece is free from rust, paint, grease etc.
As this will result in a poor welding con-
nection and poor results.
10
SETTING UP & WELDING
SETTING UP & WELDING
Connect the welding pistol cable to the control-
ler socket marked -.
Note that the cable end plug has a peg
which mates with a key slot in the panel
mounted socket.
IMPORTANT ! Secure the connector
with a clockwise turn until it locks. Failure to
do this will result in damage to the connector
during welding.
Connect the welding pistol control cable
to the controller. Note that the cable end
plug and panel mounting socket are
keyed to prevent incorrect fitting. Push
the plug firmly home and twist the lock-
ing ring clockwise to secure the plug in
position.
Select the required weld stud on the basis of
diameter, length and material. See our separate
catalogue entitled "Capacitor Discharge
Stock list" which is available on request
from your local sales representative.
Select the required CD chuck for the cho-
sen weld stud and set the stud protrusion
to the dimension shown in the accompa-
nying diagram by adjusting the backstop
screw as shown.
11
1 mm
SETTING UP & WELDING
SETTING UP & WELDING
After setting the chuck, insert it into the
pistol chuck holder and push firmly home
until it comes to a rest.
Tighten the chuck locking nut with the
box spanner provided. A gentle pressure
is all that is required. Over tightening
may result in damage to your pistol.
SETTING THE PISTOL
STANDARD CONTACT PISTOL—CDK1
Set the pistol spring preload to the appro-
priate setting for the welding task to be per-
formed. (See the tables on pages 16 - 22).
STANDARD LIFT GAP PISTOL—CDH1
Set the pistol lift to the appropriate setting for
the welding to be performed (See the tables on
pages 16 - 22.
(This works only for BS2XX series.)
This is achieved by placing the pistol in the
welding position thereby pushing the tip of
the weld stud back level with the end of
the tripod legs nosecone.
Whilst the pistol is being held firmly in this
position twist the rear end cap of the pistol
clockwise until the motion becomes stiff.
12
SETTING UP & WELDING
SETTING UP & WELDING
SETTING THE PISTOL (CDH1)
LIFT GAP PISTOL (CONTINUED)
It is at this point that further twisting of the
end cap begins to lift the tripod legs
nosecone away from the plate.
The pistol is now in the zero lift position
and twisting the rear end cap anti-
clockwise by one "click" at a time will increase
the lift by 0.25 mm increments (see the tables
on pages 16 - 22 for suggested settings).
Switch the controller ON.
Select the required welding
voltage by turning the se-
lector knob. The voltage is
adjustable between 35
and 200 volts in 1 volt
steps.
13
SETTING UP & WELDING
SETTING UP & WELDING
Place the pistol perpendicular to the work piece
with the stud touching down at the desired loca-
tion to be welded. Press down on the pistol until
the legs come firmly into contact with the work
piece. Press the trigger.
The welding
process is as
follows :-
Always lift the welding pistol vertically from the
welded stud. Failure to do this may cause the
tines of the chuck to splay outwards, which will
result in the chuck and stud arcing together dur-
ing subsequent welds.
Visually inspect the weld. A good weld will result
in an all round weld with a small visible witness
of spatter surrounding the flange of the stud.
14
INITIAL PRES-
SURE
LIFT & RELEASE
STRIKE ARC
FUSION & IM-
MERSION
COMPLETED
WELD
LIFT GAP PROCESS,
TIME TAKEN (s)
0.000 0.0005 0.001 0.0015 0.002
CONTACT PROCESS,
TIME TAKEN (s)
0.000  0.001 0.002 0.003
SETTING UP & WELDING
SETTING UP & WELDING
A cold stud weld is noticeable by undercutting of the
flange and lack of minimal formation of spatter. A
cold weld is usually caused by too little energy and
or too high spring pressure.
A hot stud weld is noticeable by excessive spatter for-
mation and partial melting of the flange. A hot weld
is usually by too much energy and or too little
spring pressure.
A one sided stud weld (arc blow) is usually caused by
incorrect earthing of the work piece. This may be cor-
rected by placing the welding earths opposite each
other across the area where the weld is to occur.
Finished studs may be subjected to a bending test to ascer-
tain the strength of the weld. This may be achieved by
placing a bending bar assembly, fitted with the correct noz-
zle, over the stud and bending the stud through 30° and
then back to the vertical. This test follows the specification
of DVS 0905 part 2.
A simpler test may be achieved by bending the stud over
30° using a hide mallet.
15
WELD SETTINGS
The following pages (17 to 22) detail the suggested settings for the
following models:
BSXX8, BSX10 & BSX12 both Contact & Lift Gap
The setting charts were established with the performance of repeti-
tive weld tests using the standard equipment's specified above, studs
manufactured to the BS EN ISO 13918 standard, in the following ma-
terials :
Mild Steel, Grade St37-3
Stainless Steel, Grade 1.4303
Aluminium Alloy, Grade AlMg3
and sheet materials of the following types :
1.6 mm Thick, Mild Steel, Grade CR4
1.6 mm Thick, Stainless Steel, Type S304
1 mm Thick, ZINTEC Coated Mild Steel, Grade CR4
1.6 mm Thick, Aluminium Alloy, Grade HE3, Half Hard
The settings are given only as a general guide and it is recommend-
ed that sample welds be carried out on your own material, as quality
of materials and site conditions may vary from user to user.
16
WELD SETTINGS BS108 & BS208
BS108 M8 CONTACT BS208 M8 GAP
17
STUD
DIAMETER
STUD
MATERIAL
SHEET
MATERIAL
VOLTAGE
SETTING
SPRING
SETTING
VOLTAGE
SETTING
LIFT
SETTING
M2.5
St37
-
3
CR4
60
8½
65
2½
S304
60
8½
65
2½
ZINTEC
80
8½
90
2
M3
St37
-
3
CR4
75
8½
80
2½
S304
75
8½
80
2½
ZINTEC
100
8½
110
2
1.4303
CR4
75
8½
80
2½
S304
75
8½
80
2½
ZINTEC
100
8½
110
2
AlMg3
HE3
80
10½
90
3
M
St37
-
3
CR4
85
8½
90
2½
S304
85
8½
90
2½
ZINTEC
120
8½
130
2
1.4303
CR4
90
8½
95
2½
S304
90
8½
95
2½
ZINTEC
120
8½
130
2
AlMg3
HE3
90
10½
100
3
M5
St37
-
3
CR4
105
8½
110
2½
S304
105
8½
110
2½
ZINTEC
135
8½
145
2
1.4303
CR4
110
8½
115
2½
S304
110
8½
115
2½
ZINTEC
135
8½
145
2
AlMg3
HE3
105
10½
110
3
WELD SETTINGS BS108 & BS208
BS108 CONTACT BS208 GAP
18
STUD
DIAMETER
STUD
MATERIAL
SHEET
MATERIAL
VOLTAGE
SETTING
SPRING
SETTING
VOLTAGE
SETTING
LIFT
SETTING
M6
St37
-
3
CR4
125
8½
135
2½
S304
125
8½
135
2½
ZINTEC
160
8½
175
2
1.4303
CR4
135
8½
145
2½
S304
135
8½
145
2½
ZINTEC
175
8½
180
2
AlMg3
HE3
180
10
135
4
M8
St37
-
3
CR4
180
8½
S304
180
8½
ZINTEC
200
8½
1.4303
CR4
190
8½
S304
190
8½
ZINTEC
200
8½
AlMg3
HE3
195
4
M10
St37
-
3
CR4
S304
ZINTEC
EARTH TAG
St37
-
3
CR4
90
8½
85
2½
S304
95
8½
95
2½
ZINTEC
AlMg3
HE3
80
9½
80
3
LARGE
BRACKET
St37
-
3
CR4
110
8½
130
2½
S304
130
8½
135
2½
ZINTEC

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