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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

M4

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

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Summary of Contents for BS108

Page 1: ...VERSION 2C DABOTEK ApS OPERATING MANUAL FOR BS1XX and BS2XX RANGE COMPACT CAPACITOR DISCHARGE STUDWELDING EQUIPMENT MODELS BS108 BS110 BS112 BS208 BS210 BS212...

Page 2: ...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 P...

Page 3: ...mail sales dabotek com 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...

Page 4: ...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 ple...

Page 5: ...elded 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...

Page 6: ...STEM 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...

Page 7: ...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...

Page 8: ...ne must only be operated in an industrial environment This machine is set up to operate on either 115 Volts AC or 230 Volts AC Check the serial plate before plugging into the correct supply Never obst...

Page 9: ...atal 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...

Page 10: ...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 t...

Page 11: ...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 man...

Page 12: ...urning 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...

Page 13: ...ntroller 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 Se...

Page 14: ...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...

Page 15: ...y 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...

Page 16: ...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...

Page 17: ...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 o...

Page 18: ...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...

Page 19: ...0 2 M3 St37 3 CR4 75 8 80 2 S304 75 8 80 2 ZINTEC 100 8 110 2 1 4303 CR4 75 8 80 2 S304 75 8 80 2 ZINTEC 100 8 110 2 AlMg3 HE3 80 10 90 3 M4 St37 3 CR4 85 8 90 2 S304 85 8 90 2 ZINTEC 120 8 130 2 1 43...

Page 20: ...S304 125 8 135 2 ZINTEC 160 8 175 2 1 4303 CR4 135 8 145 2 S304 135 8 145 2 ZINTEC 175 8 180 2 AlMg3 HE3 180 10 135 4 M8 St37 3 CR4 180 8 S304 180 8 ZINTEC 200 8 1 4303 CR4 190 8 S304 190 8 ZINTEC 20...

Page 21: ...8 70 2 M3 St37 3 CR4 45 8 50 2 S304 45 8 50 2 ZINTEC 75 8 85 2 1 4303 CR4 45 8 50 2 S304 45 8 50 2 ZINTEC 90 8 100 2 AlMg3 HE3 50 8 55 3 M4 St37 3 CR4 60 8 65 2 S304 60 8 65 2 ZINTEC 100 8 110 2 1 43...

Page 22: ...8 160 2 1 4303 CR4 110 8 120 2 S304 110 8 120 2 ZINTEC 140 8 160 2 AlMg3 HE3 120 12 140 4 M8 St37 3 CR4 130 8 175 2 S304 130 8 175 2 ZINTEC 180 8 1 4303 CR4 160 8 S304 160 8 ZINTEC 180 8 AlMg3 HE3 15...

Page 23: ...40 8 50 2 M3 St37 3 CR4 25 8 30 2 S304 25 8 30 2 ZINTEC 55 8 65 2 1 4303 CR4 25 8 30 2 S304 25 8 30 2 ZINTEC 70 8 80 2 AlMg3 HE3 30 12 35 3 M4 St37 3 CR4 40 8 45 2 S304 40 8 45 2 ZINTEC 80 8 90 2 1 4...

Page 24: ...80 8 90 2 S304 80 8 90 2 ZINTEC 110 8 130 2 AlMg3 HE3 120 12 120 4 M8 St37 3 CR4 130 8 145 2 S304 130 8 145 2 ZINTEC 150 8 185 3 1 4303 CR4 130 8 175 3 S304 130 8 175 3 ZINTEC 150 8 185 3 AlMg3 HE3 16...

Page 25: ...e production Advice on jig manufacture can be ob tained from your sales representative EXTENDED LEG ASSEMBLY This is used where a requirement for welding very long studs is neces sary The extended leg...

Page 26: ...bar This bending bar available from your supplier see the accessories section of this manual fitted with the correct size of nozzle for the stud to be tested is used to bend over the stud in accordanc...

Page 27: ...COMPONENT EXPLOSION STANDARD CONTACT PISTOL CDK1 TSK310 25...

Page 28: ...a Gutekunst 37047655 F4112245 13 Nordlockscheibe D18 37028308 F4112253 14 Schutzkappe HP 308 01 14 4 37046004 F4112180 15 Federring M5 DIN 128 135 F3405052 F3405052 16 Zylinderschraube DIN 84 M5x8 350...

Page 29: ...6 45 Senkschraube DIN 963 M3x6 35000015 F 46 Senkschraube DIN 963 M3x20 35000325 F 47 Federring M3 DIN 128 A3 F3405036 F 48 Mutter M3 DIN 934 M3 35010002 F 49 Aufsatze 50 St tzrohr 4000706 0004 370286...

Page 30: ...COMPONENT EXPLOSION 27 Parts of CDH1 TSG 310 H...

Page 31: ...47671 F 13 Nord lock washer D18 37028308 F4112253 14 Protection cape HP 308 01 14 4 37046004 F4112180 15 Spannh lse 4001478 113 4 37050745 F4112113 16 Lock washer M5 DIN 128 135 F3405052 17 Screw DIN...

Page 32: ...2 37006347 F4019512 Anschluss 44 Gewindeanschluss 4000706 0009 37028332 F4112156 45 Screw DIN 963 M3x6 35000015 F 46 Screw DIN 963 M3x20 35000325 F 47 Loch washer M3 DIN 128 A3 F3405036 F 48 Nut M3 DI...

Page 33: ...Parts of CDH1 TSG 310 H...

Page 34: ...COMPONENT EXPLOSION 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CD M SERIES 2 CONTROLLER M8 M9 M10 MODEL...

Page 35: ...ACITOR M10 7 2 70 105 258 INSULATIVE MOUNT M8 or 3 70 105 258 INSULATIVE MOUNT M9 or 4 70 105 258 INSULATIVE MOUNT M10 8 2 70 105 259 INSULATIVE WASHER M8 or 3 70 105 259 INSULATIVE WASHER M9 or 4 70...

Page 36: ...10 000 INSULATIVE PROTECTION CAPNUT 24 1 70 105 115 TERMINAL BLOCK 25 1 70 102 080 TRIAC 26 1 70 102 100 RECTIFIER 27 1 70 105 114 RELAY 28 1 70 105 113 TRANSFORMER 29 1 70 105 270 SWITCH 30 1 70 105...

Page 37: ...UIT SCHEMATIC CONTACT BS108 BS110 BS112 STANDARD CONTACT MODELS 33 TO CHANGE THE INPUT VOLTAGE BETWEEN 115 AND 230 VOLTS LINK THE TERMINALS IN TERMINAL BLOCK 70 105 115 ITEM 24 AS SHOWN IN THIS SIDE P...

Page 38: ...CIRCUIT SCHEMATIC GAP 34 BS208 BS110 BS212 GAP MODELS TO CHANGE THE INPUT VOLTAGE BETWEEN 115 AND 230 VOLTS LINK THE TERMINALS IN TERMINAL BLOCK 70 105 115 ITEM 24 AS SHOWN IN THIS SIDE PANE...

Page 39: ...CIRCUIT SCHEMATIC CNC 35 BS1XX or BS2XX CNC MODELS TO CHANGE THE INPUT VOLTAGE BE TWEEN 115 AND 230 VOLTS LINK THE TERMINALS IN TER MINAL BLOCK 70 105 115 ITEM 24 AS SHOWN IN THIS SIDE PANE...

Page 40: ...m 8250050 LARGE BRACKET CHUCK NOT ILLUSTRATED PART No 12 mm 8350050 STANDARD CD CHUCK 10 WITH BACKSTOP PART No s M2 5 8250025 M3 8250003 M4 8250004 M5 8250005 M6 8250006 M7 1 8250071 M8 8250008 STANDA...

Page 41: ...ent TYPES PART NUMBERS BS108 CONTACT 600708 BS110 CONTACT 600710 BS112 CONTACT 600712 BS208 GAP 600808 BS210 GAP 600810 BS212 GAP 600812 BS1XX CNC 6007XX BS2XX CNC 6008XX Applicable EC directives and...

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