Stauff Swg-wi06 User manual

©Walter Stauffenberg GmbH & Co. KG

Local Solutions For Individual Customers Worldwide

SWG-WI06

Operating Manual

©Walter Stauffenberg GmbH & Co. KG

2

After-sales service for Germany:

Walter Stauffenberg GmbH & Co. KG

Im Ehrenfeld 4

58791 Werdohl

GERMANY

Phone +49 (0) 23 92 / 916 - 0

Fax +49 (0) 23 92 / 25 05

E-Mail [email protected]

Web www.stauff.com

SWG-WI06 Operating Manual Issue 2016-06

Translation of the Original Operating Manual

Please keep the manual in a safe place for future reference.

Transmission and duplication of this document, dissemination and notication

of the contents are not permitted unless expressly approved.

All rights, errors and technical amendments reserved.

3

©Walter Stauffenberg GmbH & Co. KG

Dear Customer,

Many thanks for buying a stud welding machine from STAUFF.

We at STAUFF wish you success at all times when working with this

stud welding machine.

The high level of quality of our products is guaranteed by ongoing further

development in the design, equipment and accessories. This may result in

differences between the present operating manual and your product.

No claims can therefore be derived from the data, illustrations and descriptions.

We have compiled the data and information in this reference work with the greatest

care, and have made every effort to ensure that the information contained in this

manual was correct and up-to-date at the time of delivery. We can nevertheless

give no guarantee for an absolutely error-free document.

Should you discover any errors or unclear points when reading this

operating manual, please do not hesitate to contact us.

We would also be grateful for any feedback should you have any suggestions

or complaints to make about our product.

Walter Stauffenberg GmbH & Co. KG

Im Ehrenfeld 4

58791 Werdohl

GERMANY

4

Table of Contents

©Walter Stauffenberg GmbH & Co. KG

Table of Contents

1 Important Safety Precautions �� 6

2 Symbols and Terms Used �� 9

3 Scope of Supply �� 12

4 Accessories �� 12

5 Technical Data �� 13

6 Intended Use �� 14

6.1 Usage with STAUFF Clamps ................................................................................ 14

7 Warranty �� 15

7.1 Disclaimer ............................................................................................................. 15

8 Components of the Stud Welding Unit �� 16

8.1 Main Assemblies ................................................................................................... 16

8.2 Operation Panel and Display ................................................................................ 18

8.3 Mains Switch ........................................................................................................ 18

9 Welding Process �� 19

Drawn-Arc Stud Welding ...................................................................................... 19

10 Preparing Workplace and Welding Process �� 23

10.1 Preparing Surfaces ............................................................................................... 24

10.2 Checking the Stud Welding Gun .......................................................................... 25

11 Connection �� 26

11.1 Connecting the Welding Gun to the Stud Welding Unit ........................................ 27

11.2 Connecting the Ground Cable .............................................................................. 28

11.3 Connecting the Stud Welding Unit to the Mains Supply ....................................... 29

5

Table of Contents

©Walter Stauffenberg GmbH & Co. KG

12 Welding �� 30

12.1 Switching on the Stud Welding Unit ..................................................................... 30

12.2 Determining the Welding Time and the Welding Current ...................................... 31

12.3 Setting the Welding Parameters ........................................................................... 34

Adjusting the Welding Time ................................................................................................ 34

Adjusting the Welding Current ........................................................................................... 34

12.4 Performing the Welding Process .......................................................................... 35

13 Checking the Quality of the Weld �� 39

13.1 Carrying out Visual Inspection .............................................................................. 39

13.2 Carrying out Bending Test .................................................................................... 40

13.3 Optimisation of Welding Parameters .................................................................... 42

13.4 Blowing Effect and Remedies ............................................................................... 43

14 Troubleshooting �� 44

15 Shutting Down �� 46

16 Maintenance and Care �� 47

16.1 Cleaning ............................................................................................................... 47

16.2 Inspection and Tests ............................................................................................. 48

17 Storage �� 49

18 Disposal �� 49

EC Declaration of Conformity �� 50

Service & Support �� 51

Index �� 52

6

1 Important Safety Precautions

©Walter Stauffenberg GmbH & Co. KG

1 Important Safety Precautions

The target group for this manual are qualied personnel who in view of their

technical training, know-how and experience and knowledge of applicable

regulations are able to assess the work assigned to them and recognise potential

hazards.

Danger from incorrect use

Use the stud welding machine only for the purpose described in this

manual.

Otherwise you may endanger yourself or damage the stud welding machine.

You endanger yourself and others if you operate the stud welding machine

incorrectly or fail to observe the safety precautions and warnings. This can

lead to serious injury or extensive material damage.

Danger for unauthorised operating personnel

Work with the stud welding machine only when

– You are appropriately trained, instructed and authorised to do so, and

– You have read and completely understood this operating manual.

Never work with the stud welding machine when you are under the

inuence of

– Alcohol,

– Drugs or

– Medication.

Danger from unauthorised modications

Never modify the stud welding machine or parts thereof without obtaining

a clearance certicate from the manufacturer.

You will otherwise endanger yourself. This can lead to serious injury or

extensive material damage.

7

1 Important Safety Precautions

©Walter Stauffenberg GmbH & Co. KG

Danger for wearers of heart pacemakers

Never operate the stud welding machine if you have a heart

pacemaker.

In this case, never remain in the vicinity of the stud welding machine

during welding.

Never operate the stud welding machine if persons with heart

pacemakers are in the vicinity.

Strong electromagnetic elds are produced in the vicinity of the stud

welding machine during welding. These elds may impair the function

of the heart pacemakers.

Danger from fumes and airborne particulates

Switch on the welding fume extractor at the place of work.

Ensure that the room is well ventilated.

Never weld in rooms with a ceiling height of less than 3 m.

Observe furthermore your working instructions and the accident

prevention regulations.

This will help to avoid health damage due to fumes and airborne parti-

culates.

Danger from glowing metal spatter (re hazard)

Glowing hot weld spatter and liquid splashes, ashes of light and a

loud bang > 90 dB (A) must be anticipated during stud welding.

Inform colleagues working in the immediate vicinity accordingly

before starting work.

Ensure that an approved re extinguisher is available at the

workplace.

8

1 Important Safety Precautions

©Walter Stauffenberg GmbH & Co. KG

Do not weld when wearing working clothes soiled with ammable

substances such as oil, grease, petroleum, etc.

Wear your proper protective clothing, such as:

– Protective gloves in accordance with the relevant standard,

– Non-ammable clothing,

– A protective apron over your clothing,

– Full-ear hearing protection in accordance with the relevant

standard,

– A safety helmet when welding above your head,

– Safety shoes,

– Safety goggles with sight glass of protection level 2 in

compliance with the applicable standards and do not look

directly into the light arc.

Remove all ammable materials and liquids from the vicinity of the

work area before starting welding.

Weld at a safe distance from ammable materials or liquids.

Select a safety distance large enough to ensure that no danger can

arise from weld spatter.

Protection of the stud welding unit

Protect the stud welding machine against the ingress of foreign

matter and liquids caused by cutting or grinding work in the vicinity

of your work area.

This will help to prolong the service life of your stud welding machine.

9

2 Symbols and Terms Used

©Walter Stauffenberg GmbH & Co. KG

2 Symbols and Terms Used

The symbols used in this operating manual have the following meanings:

Danger

Warns you of hazards that can lead to injury of persons or to

considerable material damage.

Caution

Problems with the operating procedures can occur if this information is

not observed.

No access for people with active implanted cardiac devices

Danger

Warns you of electrical hazards

Danger

Warns you of electromagnetic elds that can be generated during welding

These symbols prompt you to wear personal protective clothing when

working with the stud welding unit.

This symbol prompts you to wear ear protection.A loud bang > 90 dB (A)

can occur during the welding process.

10

2 Symbols and Terms Used

©Walter Stauffenberg GmbH & Co. KG

Tip

Cross-reference to useful information on the use of the stud welding

machine

Cross-references in this operating manual are marked with this

symbol or are printed in italics

Fire hazard

Have a suitable re extinguisher for the working area ready before starting

work.

Work instruction

– List

11

2 Symbols and Terms Used

©Walter Stauffenberg GmbH & Co. KG

Glossary

Automatic welding head: Device for welding of welding elements

Capacitor: Component for storage of electrical energy.

Light arc: Independent gas discharge between two

electrodes when the current is high enough.

A whitish light is emitted in the process. The light

arc allows very high temperatures to be generated.

Rectier: Electrical component that converts alternating

voltage into direct voltage

Stud feeder: Device for automatic feeding of welding elements

Stud welding gun: Device for welding of welding elements

Stud welding machine: Stud welding unit including stud welding gun

Stud welding unit: Device for provision of the electrical energy for

stud welding

Thyristor: Electronic component for contact-free switching of

high currents; switching takes place via the control

input

Welding element: Component such as stud or pin that is welded to

the workpiece

Welding parameters: Mechanical and electrical settings at the stud

welding gun and at the stud welding unit

(e.g. spring force, charging voltage)

Workpiece: Components such as sheet metal or tubes to

which the welding elements are to be fastened

12

3 Scope of Supply

©Walter Stauffenberg GmbH & Co. KG

3 Scope of Supply

The basic conguration of your stud welding unit contains the following parts:

No. of

pieces

Part Type

1 Stud welding unit SWG-WI06

1

5

1

Ground cable

Stud welding gun

Distance tube DIT

Stud retainer

Toolkit

Documentation

Packaging

SWG-GC

SWG-WG

DIT-SR6 SWG-WG30

SWG-SR6

Inspect the shipment for visible damage and completeness immediately

on receipt.

Report any transport damage or missing components immediately to the

delivering shipping agent or the dealer (address, see page 2).

13

5 Technical Data

©Walter Stauffenberg GmbH & Co. KG

5 Technical Data

Stud welding unit SWG-WI06 for the ARC stud welding

according to current standards

Welding range STAUFF internal thread welding stud M6

Welding material Mild steel, stainless steel, aluminium

Welding rate M6 = 10 studs/min

Welding current 650 A

Current adjustment range 100 to 650 A

Welding time 5 to 200 ms (stepless)

Primary power 100 V to 240 V, 1 phase, 50/60 Hz, 16 AT

Primary plug 16 A 2-pin grounded safety plug (plug type

F CEE 7/4)

Connected load 3 kVA

Cooling type F (temperature controlled cooling fan)

IP Code IP 44 (also permits operation outdoors)

Ambient temperature limits ±0 °C to +40 °C / ±32 °F to +104 °F

Dimension L x B x H 474 x 337 x 351 mm / 18.7 x 13.3 x 13.8 in

(with handle)

Weight 18 kg / 40 lbs

14

6 Intended Use

©Walter Stauffenberg GmbH & Co. KG

6 Intended Use

Our stud welding units are designed and built exclusively for industrial use.

Nonindustrial use is expressly forbidden due to the lack of know-how about

the welding technology employed and the applicable standards.

The stud welding unit is intended exclusively for stud welding of standardised

welding elements. Any other use will result in the desired strength of the welded

joint being reduced.

This stud welding unit can only be used with the STAUFF stud welding gun

SWG-WG.

The intended use also implies observance of the stud welding gun operating manual

and compliance with the intervals and conditions for inspection and maintenance of

the stud welding unit and the components employed.

Always check the operating manual of your stud welding gun whether it may be

used with this stud welding unit.

The stud welding unit must be suitable for welding the welding elements in use.

Welding elements manufactured with the cold formed process have a ange and an

ignition tip. During welding, the ange prevents the arc getting to the cylindric part of

the welding element and increases simultaneously the welding area.

Please refer to the operating manual of your stud welding gun for

detailed information on which welding elements may be used.

6.1 Usage with STAUFF Clamps

For obtaining the maximum power rating of the weld joint, in usage with STAUFF

Clamps, is a maximum height of the welded element of 13.0 mm observed.

In addition, the maximum torque rating of 6 Nm must be adhered in the

application.

Specic series can limit the torque additionally.

In case of doubt, please contact STAUFF.

15

7 Warranty

©Walter Stauffenberg GmbH & Co. KG

7 Warranty

Please refer to the latest "General Terms and Conditions" for the scope of the

warranty.

The warranty does not cover faults caused by e.g.

– Normal wear,

– Improper handling,

– Failure to observe the operating manual,

– Failure to observe the safety precautions,

– Use for other than the intended purpose, or

– Transport damage.

Warranty entitlement shall no longer be valid if modications, changes or service

and repair work is carried out by unauthorised persons or without the knowledge

of the manufacturer. Invalidation of warranty entitlement shall also render the

declaration of conformity invalid. The CE marking shall be declared invalid by the

manufacturer.

We expressly point out that only spare parts and accessories or components

approved by us may be used. The same applies likewise to installed units from

our sub-suppliers.

7.1 Disclaimer

STAUFF provides SWG, devices and accessories with its production range for the

use of attaching STAUFF Clamps according to DIN3015-1.

The STAUFF production range SWG, devices and accessories uses short-term stud

welding with drawn-arc (procedure 784).

The executing welding personnel bears the responsibility for strength and quality of

welding joints.

Please note especially chapter 6.1.

Welding personnel and coordination as well as further framework conditions must

meet the requirements according to ISO 14555.

Beside the common examination agreement between the welding joint creator and

the purchaser of the product there are the simplied or the recommended production

control tests according to ISO 14555 to be executed.

16

8 Components of the Stud Welding Unit

8.1 Main Assemblies

Mains input

Welding output

1 - PFC mains input 4 - Medium frequency transformer

2 - Electrolytic capacitors 5 - Rectier

3 - IGBT switch 6 - Control unit

The mains voltage is rectied by the master switch and the EMV lter in the PFC

unit (1).

The rectied voltage is smoothed by the electrolytic capacitors (2) and led to the

IGBT switches (3). These switches turn the direct voltage into a high-frequency

alternating voltage of 30 kHz.

The energy is transferred via the medium frequency transformer (4) with

diodes (5) and rectied. The smoothed current is led to the weld bushes.

The IGBT switch (3) is controlled in the control unit (6). The control unit also

coordinates the mechanical process (withdrawing of the welding elements) with

the electronic control system (triggering the pre current, triggering the main current,

welding time process). The welding time and welding current are fully adjustable.

The type plate is located on the backside of the stud welding unit.

17

8 Components of the Stud Welding Unit

Type plate

The type plate contains the following information:

– Manufacturer

– Type

– Order No./Serial No.

– Primary voltage

– Fuse

– Power consumption

– Cooling class

– IP code

– Date

18

8 Components of the Stud Welding Unit

8.2 Operation Panel and Display

1 2

3456

1

2

3

4

5

6

- Welding current

- Welding time

- Ready indicator

- Contact

- Trigger

- Temperature

In the lower part of the operation panel are light-emitting diodes (LED) with the

following meanings:

Yellow Lights up when the stud welding unit is ready for welding.

Yellow Lights up when electrical contact exists between the welding

element and the workpiece.

Yellow Lights up when the welding gun button is triggered.

Yellow The stud welding unit is locked

– if the stud welding unit is overheated. After a short cooling

period, the work can be continued.

8.3 Mains Switch

1

The switch for mains mode is located on the

rear of the stud welding unit.

1 - Mains switch

19

9 Welding Process

Stud welding with a drawn arc process is divided into drawn-arc stud welding with

ceramic ferrule and drawn-arc stud welding with shielding gas. This stud welding

unit must be used exclusively for stud welding with drawn arc. A ceramic ferrule or

shielding gas is not required.

The face of a stud-shaped welding element and the opposite surface of the

workpiece are molten by an arc. Stud welding is suitable for the welding of joining

elements across the entire cross-section, mainly using pin-shaped metallic welding

elements with metallic workpieces.

The various processes of arc stud welding are distinguished by:

– The method of weld pool protection (shielding gas - SG, ceramic ferrule -

CF or no protection - NP)

– The length of welding time (standard ARC or short-cycle drawn-arc

stud welding - SC)

– The energy source (welding rectier supplied by mains, inverter,

capacitor battery).

Drawn-Arc Stud Welding

The STAUFF stud welding unit operates by process of ‘arc stud welding with drawn-

arc ignition’ according to the current standards. The standards assign this method

of joining pin-shaped elements with plane workpieces to the so called ‘Arc Pressure

Welding’ (code BH).

Joining is carried out in plastic or liqueed condition of the welding zone. The pro-

cess can be carried out mechanically or automatically, depending on the used wel-

ding guns/welding heads.

Generally, the positive pole of the stud welding unit is connected to the workpiece.

The welding element is manually or automatically inserted into the chuck of the

welding gun or of the welding head. Then it is placed onto the workpiece - possibly

equipped with a ceramic ferrule (does not apply for STAUFF welding studs). (See

gure, position 1) When the button of the welding gun is triggered, the automated

welding process starts, which works as follows:

20

9 Welding Process

– At the beginning of the welding process, the welding element (stud) in the

welding gun is lifted clear off the workpiece by a lifting device (solenoid).

An initial switched current triggers a pilot arc of a low current power (see gure,

position 2). Then the main arc ignites between the face area of the welding

element and the workpiece.

– The main arc burns at the set current during the welding time preselected at the

stud welding unit. The selected welding energy must match the requirements of

the selected welding element. The energy of the arc melts the face of the welding

element and the workpiece (see gure, position 3).

– At the end of the preset welding time, the stud is mechanically moved to the

workpiece. On plunging into the weld pool, the two weld zones join and solidify.

The contact of stud and workpiece extinguishes the arc in a short-circuit and the

main current is switched off.

– The weld zone solidies and cools down. The welding element is now welded to

the workpiece over its entire cross-section of the welding element (see gure,

position 4). As soon as the weld metal is cooled down, the welding gun can be

carefully withdrawn from the welding element. When using shielding gas, the

shielding gas ow is switched off with the withdrawal of the welding gun.

If a ceramic ferrule is used, it can be removed by light hammer blows.

The welding range of drawn-arc stud welding is about 3 to 25 mm diameter when

using mild steel/stainless steel. Welding elements with rectangular cross-section

should not exceed a ratio length : width of about 5 : 1. All technical information and

adjustment values are based on the use of welding elements which correspond with

current standards.

The shown

ceramic

ferrule does

not apply

for STAUFF

welding

studs

STAUFF SWG-WI06 User manual

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