dabotek DT410 User manual

D A B O T E K
D A B O T E K T r a d i n g A p S
B i r k e d a m 1 0 C
D K - 6 0 0 0 K o l d i n g ;
T E L + 4 5 7 5 5 0 5 6 6 6
F A X + 4 5 7 5 5 0 4 7 9 5
I N S T R U K T I O N ' s M A N U A L
F O R D T 4 1 0

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We will be there for you if you need us
We do not only take trouble over our customers until the date of sale but we also offer
extensive service by means of easily comprehensible operating instructions for examp-
le. We have conceived the operating instructions so that you can glance at them and
then easily work with the equipment.
In case there should be anything you do not understand or you should have difficulties
you cannot solve by means of these instructions just call us. We are always ready to
listen to your ideas, criticism and suggestions for improvement because we are there
for you.
You can get in touch with your DABOTEK -Team on
(Denmark ) [phone]
Mo-Fr 8.00-1600
Hotline (in Denmark)
In an emergency you can inform us round the clock. Then we will contact you as soon
as possible. If you call us, please give:
1. your company
2. your name
3. telephone number (where we can reach you)
4. possible cause of fault or
brief description of fault
Hotline-number: (Denmark) [phone]

Table of contents
Introductory information.....................................................4
Target group of these operating instructions.....................4
Special qualifications and regulations...............................5
Meaning of symbols..........................................................6
Field of use of the stud welding equipment ......................7
Features of the stud welding equipment...........................7
Safety information ...............................................................8
Installation and connection ..............................................12
Checking scope of delivery.............................................12
Choosing place of installation.........................................13
Transport.........................................................................13
Connection......................................................................14
Setting-up equipment and welding gun...........................15
Connecting earth cables to work piece...........................15
Setting-up welding gun...................................................15
Adjusting equipment .......................................................20
Welding...............................................................................21
Tips for stud welding.........................................................22
Studs, chucks and ceramic ferrules................................22
Adjustments....................................................................22
Avoiding magnetic blowing action...................................24
Vertical weldings.............................................................25
Checking weld joints.......................................................26
Cleaning and attendance ..................................................28
Maintenance.......................................................................29
Blowing out equipment interior .......................................29
Checking plugs and cables.............................................30
Eliminating faults...............................................................31
Technical data ....................................................................32
Guarantee...........................................................................33
Where to put the old equipment.......................................34
Certificate of EC-conformity.............................................35
Index....................................................................................36
Your equipment in overview .............................................39
After-sales service.............................................................40
Tip:
Ifyouunfoldthelast
page you will find an
overview of the
equipment.
3

Introductory information
Target group of these
operating instructions
Safety information
Before putting the equipment into operation acquaint yourself
with the contents of these operating instructions. Thus you will
achieve the best welding results and you will work safely.
These instructions are intended for operators and supervisors
of the stud welding equipment.
For the operator
Knowledgeandexperienceinthefieldofweldingarenecessary
to:
•judge the place of work
•set-up the equipment
•choose the weld stud
In addition knowledge of the handling of stud welding equip-
ment is required. This kowledge is either given by the manu-
facturer or by a trained operator.
For the operating staff
Onlypeopleover18areallowedtoweld.Knowledgeinthisline
of work is required.
For the employer
Thestaffhavetobeinstructedregularlybutatleastonceayear
according totheregulationsofthesafety-laws ofyourcountry.
Untrained or unauthorized staff are not allowed to use the stud
welding equipment.
Introductory information
4

Special qualifications and
regulations Normally there is no particular examination necessary. For the
sector of planning controls according to DIN 18 800 or Euro-
code4(afieldlaiddownbylaw)therearespecialrequirements
for the executing factory.
Examination For stud welding in the sector of planning controls there is an
examination necessary according to DIN 8563, part 10 –
securing the quality of welding works – or DIN EN ISO 14 555.
According to DIN EN ISO 14 555 – securing the quality of
welding works, stud welding of metal materials– the operating
staff have to be examined according to EN 1418 .
The welding supervision is responsible for the production and
the security of the quality.
Quality assurance In order to secure the quality DIN EN 729 – general welding
technical requirements – is applied.
Introductory information
5

Meaning of
symbols Toshape the text clearly we haveuseddifferent symbols. They
are explained as follows:
•A dot is used with enumerations.
— A dash announces works you have to carry out.
→Cross-references to other passages in the text are provi-
ded with an arrow.
The little welder has three different functions depending on
what he is holding in his hand.
The stud marks tips and hints regarding the operation.
The spanner announces tips regarding adjustments.
The warning triangle refers to important safety precautions.
Introductory information
6

Introductory information
Field of use of the
stud welding equipment
Features of the
stud welding equipment
The stud welding equipment is designed for the welding of studs
using the arc pressure welding process. The equipment only
works when a welding gun is fitted.
With the welding gun welding elements can be welded on to
suitable parent metals according to EN 13 918 – studs for arc
welding. For further use consult your country representative or
DABOTEK Denmark.
 Ease of operation
The stud welding equipment is easy to operate and demands
no special exam for welders – except for the sector of planning
controls. By means of the partial mechanization of the welding
process high-quality weldings can be achieved after a short
training period.
. Safety
In order to work as safely as possible with the equipment
we have constructed it according to the regulations of the
EU and the national German regulations. Working under
increased electric danger is permitted. The equipment
meets the demands of the protection category I, I P23 and
has the “S” as well as the “CE”-sign.
 Long life
The transformers, rectifiers and electronics are especially
robust and guarantee - together with the modern sheet steel
case - a long life of the equipment.
7

Safety information In this chapter you will find general advice on safety
precautions. In addition the single chapters of these ope-
ratinginstructionsrefertosafetyprecautionswhicharenot
described here.
Please observe the following pieces of advice for interest
of your own safety, your colleagues’ safety and to ensure
the safety of the equipment.
When welding with power a number of dangers can result
from undisciplined conduct. Therefore you should work
especially carefully and not under pressure. Accidents
cannot be undone.
Studweldingrequirestheusualsafetyprecautionsapplied
toarcwelding.Thesafetyprecautionsaredescribedinthe
German UVV 26.0 – welding, cutting and related
processes.
For the employer
Inform those people working with the equipment regularly
aboutthesesafety precautionsandinaccordancewiththe
legal regulations.
For the operating staff
Operators have got experience with the stud welding
equipment and are able to realize and to avert dangers of
electric welding.
Theoperatingstaffmayonlyworkwiththeequipmentafter
release and instruction by an authorized trainer.
People working with the equipment must be over 18.
No unauthorized persons!
Make sure that unauthorized, untrained staff or especially
children do not use the equipment.
Do not work unobserved
Weld only within sight of other persons who can help you
in an emergency.
Safety information
8

Working surroundings Mains connection
The mains connection socket has to bechecked by a qualified
employee in the field of electrical equipment. This is also true
for, e.g. mobile connections on construction sites.
The mains voltage and the safeguarding have to meet the
values of the technical data.
Danger of fire and explosion
Sparks can unintentionally cause fires. Therefore remove all
inflammable things from the working area or take appropriate
protective measures.
There is increased danger in flammable areas as well as in or
at containers filled with dangerous substances. In such areas
youareonlypermittedtoweldafterreceiptoftheofficialrelease
by the works manager.
Restricted areas
In cramped rooms with conductive walls welding current sour-
ces are not permitted to be installed.
Ventilation or suction
At fixed welding places or when welding objects that are
leaded, galvanized, cadmium-plated or painted with leaded
coloursandincrampedroomsappropriateventilationisneces-
sary. Health damaging smoke and gas can develop.
Magnetic fields Pacemakers or implants
Duetothe designhigh magneticfieldsdevelopforashorttime.
Persons with magnetically influenceable pacemakers or metal
implants may not approach the equipment. If necessary signs
have to be put up.
Staying away from electric equipments
A sufficient safe gap must be kept between electric and elec-
tronic equipments that can be disrupted or destroyed by ma-
gnetic fields.
Magnetic stores
All magnetic stores near the equipment or the cables can be
destroyed, such as floppy discs, magnetic tapes or magnetic
cards (telephone- and cheque cards).
Safety information
9