Thomas NOMARK 65/99 User manual

NOMARK 65/99
Zone Industrielle, 3 ème Rue
B. 6040 JUMET
Tél. : [phone]
Fax : [phone]
www.thomas-welding.com
Manuel NOMARK_65_99_Anglais_01.doc

FOREWORD
Your new THOMAS stud welder is carefully constructed of the finest components and material
available. Used properly, this equipment will give you years of efficient profitable service.
This manual has been specifically prepared for use in familiarizing personnel with the design,
installation, operation, maintenance and trouble-shooting of this equipment. Careful consideration
should be given to all the information presented to assure the proper performance of this
equipment.
A careful study of this manual will enable you to understand how the welders operate to insure
proper performance under all conditions.
GUARANTEE
The electrical and mechanical components of your THOMAS stud welder are thoroughly
performance inspected prior to assembly in the welder. The assembled welder is completely
performance checked. The welder is delivered to you in functional electro-mechanical condition. All
parts used in the assembly of the welder and its accessories are fully warranted for a period of one
(1) year from the date of delivery.
Under this warranty, the manufacturer reserves the right to repair or replace in its plant in JUMET
(BELGIUM), at its option, defective parts which fail during the warrantee period. Notice of any claim
for warranty repair or replacement must be furnished to the manufacturer by the purchaser within
five (5) days after the defect is first discovered. The manufacturer does not assume any liability for
paying shipping costs or for any labor or material furnished where such costs are not expressly
authorized in writing.
We do not warrant THOMAS stud welders, parts, or accessories against failures resulting from
misuse, abuse, improper installation, maladjustment or use not in accordance to the operating
instructions furnished by the manufacturer. The warranty is valid only when studs are purchased
from sources approved by the manufacturer.
Installation servicing or troubleshooting must only be done by qualified personnel trained to
work on this type of equipment.
The equipment must always be accompanied by the instructions of
operation, instructions, safety, inspection and maintenance, applicable
information relating to the devices and security instructions required at the
place of uses of the machine. The security instructions concerning welding
in general must also be well known and applied.
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TABLE OF CONTENTS
Page
1 Introduction 4
1.1
General information
- For your safety
- Field of application of the stud welding system
- Features of the stud welding system
5
5
5
6
1.2 Components of the stud welding system 8
1.3 Functional principle of the stud welding system 7
1.4 Stud welding gun C0 8
1.5 Stud welding gun C1 10
1.6 Meaning and description of symbols 12
1.7 Other descriptions 14
1.8 Welding elements (studs) 14
1.9 Material combinations 15
1.10 Centring device (For future applications) -
1.14 Angle bracket 16
1.15 Bending device 16
1.16 Chucks (standard) 16
1.17 Chucks (for insulation pins) 17
1.18 Chuck extension 17
1.20 Welding on centre punches or scribed lines 17
2 Work safety and rights 18
2.1 Safety symbols 19
2.2 Safety information 20
2.3 Proper use 26
2.4 Guarantee and liability 28
2.5 Copyright 29
2.6 EC Declaration of conformity 30
3 Delivery ... Installation 31
3.1 Extent of delivery 32
3.2 Receiving inspection 32
3.3 Storage 32
3.4 Transport 32
3.5 Place of use 33
3.6 Erection 33
3.7 Power connection 33
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3
Page
4 Operation 34
4.1
Connections of the power unit
Connecting the earth cable
Connecting the welding gun
36
36
37
4.2 Chuck preparation 38
4.3 Adjusting the C0 and C1 guns 40
4.4 Adjusting the CHP (For future applications) -
4.5 Tips for good welding results 42
4.6 Work procedure during welding 43
4.7
Testing the weld
Visual inspection
Impact bending test
45
45
46
5 Maintenance 47
5.1 Troubleshooting 48
5.2 Care and cleaning 52
5.3 Maintenance intervals 53
5.4 Fuse elements 54
5.5 Technical specifications NOMARK 65 / 99 55
5.6 Explosion view of NOMARK 65 / 99 56
5.7 Block circuit diagram 58
5.8 Technical specifications C0 Gun 59
5.9 Explosion view 60
5.10 Welding accessories 63
5.11 Technical specifications C1 Gun 65
5.12 Explosion view 66
5.13 Welding accessories 68
5.14 Iso Kit for C1 71
5.15 Blank page for notes 73

1 Introduction
1.1 General information
1.2 Components of the stud welding system
1.3 Functional principle of the stud welding system
1.4 Stud welding gun C0
1.6 Meaning and description of symbols
1.7 Other descriptions
1.8 Welding elements (studs)
1.9 Material combinations
1.10 Centring device
1.11 Welding template
1.12 Positioning tube
1.13 Sound insulting tube
1.14 Angle bracket
1.15 Bending device
1.16 Chucks(standard)
1.17 Chucks(ISO)
1.18 Chuck extension
1.19 Intermediate ring
4
1.20 Welding on centre punches or scribed lines

1.1 General information
These operating instructions apply to the power unit type NOMARK 65/99
with welding gun C0 and/or CHP and are intended for
the operating, repair and service personnel.
Familiarise yourself with the contents of these operating instructions
before starting the power unit. You will then achieve better
welding results and work safely.
In the event of difficulties or confusion please consult the after sales
service of TWS Tech, who will be pleased to help you.
The figures, specifications and data given in these operating instructions
correspond to the state of development as on 13 March 2001.
TWS reserves the right to make technical changes serving to
improve the power unit.
1.1.1 For your safety
Knowledge of the contents of these operating instructions is essential
to ensure safe and trouble free operation of the stud welding system.
See chapter 2 for information on proper and safe handling of welding
guns.
Circumstances and requirements change from case to case.
Therefore also always comply with your national and EN (European)
standards regarding safety.
Set-up personnel
Set-up personnel need knowledge and experience in welding to
• assess the workplace,
• set up the equipment
• select the right welding element.
Knowledge in the handling of stud welding systems is also required.
This knowledge is taught either by TWS or trained set-up personnel.
Operator
Welding work may only be performed by persons over 18 years of
age. Knowledge of welding is presupposed (see also section 1.1.3).
Employer
The personnel must be instructed according to the regulations of
BG § 1 regularly, at least once a year.
Untrained or unauthorised personnel may not use the power unit.
1.1.2 Field of application of the stud welding system
The power unit is designed for welding of welding elements (e.g.
welding studs) by the arc pressure welding method. The device
only works in combination with a suitable welding gun.
The power unit can be used to weld, for example, welding studs
according to EN 13918 – Studs for arc welding – on to weldable
workpiece surfaces. Many other forms of welding element can
5
also be welded. Contact THOMAS in this regard if necessary.

1.1.3 Features of the stud welding system
• Easy operation
The power unit is easy to use and – except in the case of work
subject to official supervision – no special welding qualification is
necessary. The partial mechanisation of the welding process
means high-quality welding results can be achieved after a short
familiarisation period.

• Safety
We have designed the device according to EU and national Belgian
regulations so that you can work as safely as possible. Work
under increased electrical hazard is permitted. The device fulfils
the requirements of Protection Class I, IP 21 and comes with the
"CE" symbol.
• Long life
The transformers, rectifiers and electronics are especially robust
and together with the modern sheet steel housing guarantee long
life of the power unit.
1.2 Components of the stud welding system
The stud welding system consists of the
power unit (type NOMARK 65/ 99), welding gun ,(C0), Ground cable and chuck
NOMARK 65 / 99 C0 welding gun Double ground clamp
Fig. 1 - 1 Power unit and stud welding gun
1) Power unit NOMARK 65 + C0 ( welding gun for contact welding)
2) Power unit NOMARK 99 + C0 ( welding gun for contact welding)
Both welding units can weld normal welding studs. They are equipped with studs manually.
Volt
4
5
6
3

1.3 Functional principle of the stud welding system
Stud welding systems are used to weld metal welding studs (e.g.
threaded studs) on to weldable metal workpiece surfaces.
The power unit NOMARK 65/99 is a mobile welding unit developed by
THOMAS that sets new standards in stud welding technology with
its compact construction.
It works by the principle of capacitor discharge.
Together with a manually equipped welding gun of the type C0 (contact
welding gun) , it can weld normal welding studs with ignition tips.
The welding energy required is delivered by the power unit, which
charges a capacitor battery via a regulator circuit. The welding
current is then activated by a power SCR. The electric circuit is
closed by the welding gun, stud, workpiece and earth cable.
Fig. 1 - 2 Functional principle of the electric control system
7

1.4 Stud welding gun C0
Field of application
The C0 is a contact welding gun for welding studs with ignition
tips. The welding elements should preferably be of
steel and stainless steel. Brass or Aluminium studs can also be processed
with limitations.
Owing to the somewhat longer welding time (compared to gap
welding) and deeper penetration, the C0 is especially suitable for lightly galvanised steel
.
Fig. 1 - 3 Contact welding gun C0
See chapter 5.6 for technical specifications and chapter 5.8 for individual part
drawings and replacement part numbers.
Method
A welding element is first pushed into the Chuck of the welding
gun. The ignition tip of the element is then placed down vertically
at the required point on the workpiece and the gun pressed down
until all positioning feet touch the workpiece (this pushes the
plunger against the pressure spring).
The welding current is then switched on and the welding process
started by pressing the start button. The ignition tip evaporates
and generates an arc, which melts the face of the stud and the
8
workpiece.

The pre-stressed pressure spring then forces the welding element
into the weld pool and the arc is extinguished. The capacitors are
discharged completely. The weld pool solidifies.
This welding process lasts about 1.5 to 3.0 ms.
The welding gun can be pulled off the welding element vertically
directly afterwards and fitted with a new one.
.
Fig. 1 - 4 Contact stud welding sequence
Note:
A threaded stud was chosen as welding element in the figure above.
Other welding studs equipped with ignition tip are shown in chapter 1.8
9

1.5 Stud welding gun C1
Field of application
The C1 is a contact welding gun for welding studs with ignition
tips. The welding elements should preferably be of
steel and stainless steel. Brass or Aluminium studs can also be processed
with limitations.
Owing to the somewhat longer welding time (compared to gap
welding) and deeper penetration, the C1 is especially suitable for lightly galvanised steel
.
Fig. 1 - 5 Contact welding gun C1
See chapter 5.6 for technical specifications and chapter 5.8 for individual part
drawings and replacement part numbers.
Method
A welding element is first pushed into the Chuck of the welding
gun. The ignition tip of the element is then placed down vertically
10
at the required point on the workpiece and the gun pressed down

until all positioning feet touch the workpiece (this pushes the
plunger against the pressure spring).
The welding current is then switched on and the welding process
started by pressing the start button. The ignition tip evaporates
and generates an arc, which melts the face of the stud and the
workpiece.
The pre-stressed pressure spring then forces the welding element
into the weld pool and the arc is extinguished. The capacitors are
discharged completely. The weld pool solidifies.
This welding process lasts about 1.5 to 3.0 ms.
The welding gun can be pulled off the welding element vertically
directly afterwards and fitted with a new one.
.
Fig. 1 - 6 Contact stud welding sequence
Note:
A threaded stud was chosen as welding element in the figure above.
11
Other welding studs equipped with ignition tip are shown in chapter 1.8

1.6 Meaning and description of symbols
12

Start check:
• The following must light up when the power unit has been
switched on:
the main switch, the display (shows the setting for charging voltage)
Note:
• The LED for connection of a gun with hoisting magnet has no
function when the gun C0 is being used.
• Hold the gun with stud against the workpiece: the contact LED
must light up (when earth cable – on both sides – and welding cable connected).
• Hold the gun in the air and press the start button: the start LED
must light up.
• Otherwise no further LEDs should light up.
Troubleshooting
See Troubleshooting chapter 5.1 Troubleshooting.
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1.7 Other descriptions
Ignition tip The power unit NOMARK 65/99 and connected stud welding gun work by
the tip ignition welding method.
In order to ignite an arc and therefore to generate a weld pool,
every stud must have an ignition tip.
Fan To avoid unnecessary soiling, the fan is only switched on when a
high temperature is reached.
Inert gas Inert gas is seldom used in tip ignition welding because the short
welding time gives little time for oxidation.
1.8 Welding elements (studs)
Depending on how the welding gun is equipped, threaded studs,
internal thread bushes and pins (in accordance with DIN 32 501)
of various sizes and materials can be welded if they have an ignition tip.
Fig. 1 - 9 Examples of different types of welding elements
The following conditions must be observed:
• The diameter of the welding element must be <= 10.
• Length of welding studs : from 6 to 40 mm with standard components.
For studs longer than 40 mm, an intermediate ring must be used.
• Length of welding pins : from 6 to 100 mm with standard components.
• A suitable chuck must be selected for every welding element.
Note:
14
Please contact THOMAS regarding different Chuck shapes and sizes.
See chapter 5.10 for standard chucks

1.9 Material combinations
The weldability of workpiece and welding element materials is de-
fined as follows:
1 = weldable 2 = limited weldability 0 = not weldable/ not tested
* = limited weldability with contact welding gun
Contact and gap welding
Tab: 1 - 10 Suitability of material combinations for tip ignition welding
Note:
Your THOMAS specialist advisor will be glad to advise you in
the case of material combinations not listed in this table.
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16
1.14 Angle bracket
With the angle bracket you can approach a right-angled
surface to up to 8 mm with the gun and weld studs (order
no. see chapter 5.10).
1.15 Bending device
The bending device is used in impact bending tests (see
chapter 4.7).
It is manufactured according to DIN 0905 Part 2. The five
inserts must be ordered individually (order nos. see chapter
5.10).
1.16 Chucks (standard)
These chucks are used for threaded studs and un-
threaded studs (order nos. see chapter 5.10).

1.17 Chucks (for insulation pins)
These chucks are used for insulating nails and pins
(order nos. see chapter 5.10).
1.18 Chuck extension
The Chuck extension is only used when using a centring
device
(see chapter 1.10; order nos. see chapter 5.10).
1.20 Welding on centre punches
Welding elements with ignition tip can be positioned for
pattern welding exactly on centre punches or scribed lines.
Since the welding process is started by the ignition tip,
marking must be performed carefully.
The arc cannot ignite on a centre punch struck too deeply.
Should it nevertheless ignite, then the strength of the weld
is questionable.
Therefore make sure that the depth of the centre punch
does not exceed 0.3 mm.
Note: You can rule out this uncertainty by using a so-called
automatic
punch (order no. see chapter 5.10).
17

2 Work safety and rights
2.1 Safety symbols
2.2 Safety information
2.3 Proper use
2.4 Guarantee and liability
2.5 Copyright
2.6 EC Declaration of conformity
18

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