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4

Connection and installation

Page 21

Stud welding unit

operating manual

Date:

July 2021

ALPHA 850

07.2021 / EN

Rev.:

A

4

Connection and installation

The power supply cable and connecting parts are functionally arranged on the front
plate of the ALPHA 850 welding device.

Warning:

•

Before starting connection work, turn off the ALPHA 850 welding

device!
The device’s main switch must be in the “O” position.

1

2

3

4

1

Power cable connection

3

Control cable connection (X7)

2 Welding cable connection (X20)

4 Earth cable connection (X21)

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Summary of Contents for ALPHA 850

Page 1: ...Operating manual Stud welding unit ALPHA 850 for drawn arc and short term drawn arc processes Edition 2021 07 Revision Rev A 07 2021 EN EN Document number ...

Page 2: ...cker Imprint Responsible for the content from STANLEY Engineered Fastening in this medium according to Section 5 of the German Teleservices Act is the manufacturer Tucker GmbH Stanley Tucker and other logos are registered trademarks belonging to Stanley Black Decker Inc Restricted confidentiality No part of this manual may be transmitted reproduced and or copied by any electronic or mechanical mea...

Page 3: ...Process 4 1 5 Weld elements 5 1 6 Ceramic rings 5 1 7 Material combinations 6 1 8 Technical data 7 1 9 Declaration of Conformity 11 2 Work safety 12 2 1 Safety symbols 12 2 2 Safety instructions 13 2 3 Intended use 17 2 4 Warranty and liability 18 2 5 Copyright 18 3 Delivery and transport 19 3 1 Scope of delivery 19 3 2 Packaging and dispatch 19 3 3 Incoming inspection 19 3 4 Interim storage 19 3 ...

Page 4: ...nnection 26 5 Control and display elements 28 5 1 Operating elements 28 5 2 Display elements 30 6 Equipment fuses 31 6 1 Fuse elements 31 7 Start up and weld quality check 33 7 1 Notes about stud welding 33 7 2 Adjusting the weld parameters 34 7 3 Commissioning conditions 38 7 4 Functional test 39 7 5 Checking weld quality 43 7 5 1 Visual inspection drawn arc process 44 7 5 2 Visual inspection sho...

Page 5: ...s Stud welding unit operating manual Date July 2021 ALPHA 850 07 2021 EN Rev A 9 1 Notes on repair 48 9 2 Troubleshooting 49 10 Appendix 55 10 1 Disposal of welding devices 55 10 2 Abbreviations 58 10 3 Bibliography 59 ...

Page 6: ...lp you The illustrations information and data in this operating manual were valid as of July 2021 Tucker reserves the right to make technical changes that contribute to improvement of the ALPHA 850 welding device Also follow our instructions for safely operating the system in chapter 9 2 Troubleshooting of this operating manual This will greatly ease independent solution of problems In addition we...

Page 7: ...rolled thyristor copper bar and delivers constant welding currents up to 850 A The AC grid power supply is transformed through a transformer and then rectified The entire weld cycle is coordinated by the ALPHA 850 s control unit and can be monitored with the LED display elements The welding current needed for stud welding and the weld times must be set on the relevant potentiometers To keep the AL...

Page 8: ...sition the ceramic ring CF forces a constantly uniform shape of the weld bead and protects the user from weld splatters In exceptional cases such as when welding in tub position or reduction of the aluminium preparation weld pool guard can also be ensured by introducing shielding gas SG The shielding gas introduced drives the atmosphere out of the welding zone If welding is to be done with shieldi...

Page 9: ...wn and then the main arc is ignited During the lift movement the arc melts the front surface of the stud and a surface of approximately the same size on the workpiece so that a pool of liquid melt occurs on the surfaces to be welded When the set weld time is over power is cut off to the gun coil so that the stud is accelerated back onto the workpiece Immersion of the stud into the weld pool exting...

Page 10: ...site the welding gun is directed at the stud to be welded The stud type is noted on the gun s type plate The studs to be welded are listed in chapter 1 8 1 6 Ceramic rings Ceramic rings CF are used to centre the arc and for shaping the weld bead uniformly At the same time undesired atmospheric influences are shielded For welds on oblique or vertical walls and for overhead welds the ceramic ring pr...

Page 11: ...roups 3 and 4 EN ISO 15614 1 Group 9 EN ISO 15614 2 Groups 21 and 22 1 Stud S 235 4 8 weld suitable 16 Mo 3 a b b 2 X 10 CrAl 18 X 10 CrAl 24 X 10 CrNiSi 25 4 c c c 1 4301 1 4303 1 4401 1 4451 1 4571 b a 1 b a EN AW AlMg 3 EN AW AlMg 5 b Group 1 Steels with minimum yield stress of ReH 360 N mm2 Group 2 Standardized or thermodynamically treated fine grain structural steels with a minimum yield stre...

Page 12: ... range 100 A 850 A Welding time range Short cycle 10 ms 100 ms Drawn arc 100 ms 1000 ms Fuse elements Supply to PCB control F1 1 A 250 V slow Supply 18 VAC F2 4 A 250 V slow Supply to coil circuit F3 4 A 50 V slow Fan F4 3 15 mA 250 V slow Protection type IP 23 Protection class I Storage temperature 25 C to 55 C Operating temperature 0 C to 40 C Cooling type Fan AF Relative humidity 0 to 50 at 40 ...

Page 13: ...rder No 67 03 04 Weld guns for automatic stud loading 1 Welding gun Type PFL 901 complete with accessories see operating manual PFL 901 Shielding gas device on request Sorter for automatic stud feeder 1 Sorter stud specific Type NSA 606 M NON AUTO manual mode complete with accessories see operating manual NSA 606 B 1 Power cable for sorter 220 V Order No 49 06 25 Shielding gas retrofit kit 1 Retro...

Page 14: ...ers on request ALPHA 850 sorter 1 Cable set complete with welding cable and control cable Welding cable Cable diameter 50 mm2 Length 5 0 m Order No 68 03 63 others on request Control cable 7 pin Cable diameter 8 0 5 mm2 Length 5 0 m Order No 68 04 82 others on request Connecting cable extension ALPHA 850 Gun NS 40 1 Cable set complete with welding cable and control cable Welding cable diameter 50 ...

Page 15: ...d stud SC B M3 M8 4 mm 9 mm Stud bolt SC S 3 mm 9 mm Internally threaded socket SC I M3 M5 7 mm 9 mm Sawtooth stud SC Z M3 M8 4 mm 9 mm DA stud for drawn arc process DA stud type Shaft Ø weld Ø Threaded stud MP MPF M6 M12 5 3 mm 10 8 mm Threaded stud M MD M8 M12 6 mm 12 mm Threaded stud MR M6 M12 4 7 mm 9 5 mm Stud bolt SC S 3 mm 12 mm Internally threaded socket MI M4 M8 10 mm 12 mm Head bolt KB 1...

Page 16: ...MC Directive The conformity assessment was conducted for machines not subject to Appendix IV with internal production controls for manufacturing machines according to Appendix VIII References of the directives as published in the Official Journal of the European Union The following harmonized standards were used DIN EN IEC 60974 1 2018 12 Arc welding equipment Part 1 Welding power sources DIN EN I...

Page 17: ...r severe property damage will occur if the appropriate precautionary measures are not taken Warning This means that death severe bodily injury or severe property damage may occur if the appropriate precautionary measures are not taken Caution This means that minor bodily injury or property damage may occur if the appropriate precautionary measures are not taken This sign indicates important inform...

Page 18: ...of this operating manual Set up and electrical personnel must have had training enabling them to make repairs have authorization to start up electrical circuits and devices according to the safety standards Personnel in training are allowed to work on the welding system only under the supervision of experienced technical personnel Personal safety equipment It is mandatory to wear the following saf...

Page 19: ... Depending on the process stud welding can produce strong electromagnetic fields These can be life threatening for people with heart pacemakers disturb or damage electrical or electronic devices irrecoverably erase magnetic storage media magnetize and damage watches The weld current cables also produce strong electromagnetic fields Make sure that the welding and earthing cables are as free of loop...

Page 20: ... devices in limit class A can cause radio interference in residential and business areas Safety measures during normal operation Use welding systems only in technically perfect condition Any unsafe way of working must be avoided Safety measures after finishing work Turn off the welding device and pull the power plug Secure and mark the welding device against unauthorized use Adhere to the specifie...

Page 21: ...ched such that conductive parts moist walls and moist floors cannot be touched If it is not possible to use insulating materials due to additional hazards falling hazard special spacial conditions etc work must be done at least in dry undamaged work clothing Safety features of the ALPHA 850 welding device The ALPHA 850 welding device bears the S symbol and is suitable for welding in tight spaces a...

Page 22: ...esidential and business areas because depending on the process there may be electromagnetic disturbances to external electrical and electronic devices The ALPHA 850 is to be configured only with the device components indicated in Chapter 1 8 Configuration with device components from other manufacturers or independent design changes to the system are not allowed The welding device is to be operated...

Page 23: ...y attached safety equipment Start up after improperly done repairs Start up after repair done by unqualified personnel Independent design changes to the system Failure to adhere to the specified maintenance intervals The ALPHA 850 welding device is designed only for the range of application indicated in Chapter 2 3 Intended use Before using the welding device outside its contractual range of use T...

Page 24: ...voidable We therefore ask that upon delivery the welding device be inspected for transport damage an for completeness of the parts included in delivery Any transport damage and or missing parts must be reported to the manufacturer or the authorized carrier company immediately 3 4 Interim storage If the ALPHA 850 welding device is not put into operation immediately after delivery it must be tempora...

Page 25: ... or property Danger Beware of death hazard People with heart pacemakers must always stay away from stud welding systems Welding near flammable materials or in fire or explosion prone areas or damp environments is explicitly forbidden Warning External electrical devices may be disrupted or damaged by the electromagnetic fields that occur during welding 3 7 Device set up When setting up the welding ...

Page 26: ...ply cable and connecting parts are functionally arranged on the front plate of the ALPHA 850 welding device Warning Before starting connection work turn off the ALPHA 850 welding device The device s main switch must be in the O position 1 2 3 4 1 Power cable connection 3 Control cable connection X7 2 Welding cable connection X20 4 Earth cable connection X21 ...

Page 27: ...y electro technical personnel Only electro technical personnel are to open the welding device or work within its housing The power supply values are marked on the ALPHA 850 type plate Europe standard version Grid frequency 50 Hz 60 Hz Three phase system voltage 400 V device version 500 V Network protection phase 35 A slow Special version Grid frequency 50 Hz 60 Hz The power connection voltage must...

Page 28: ...pply fuse T 35 A System voltage 500 V Power supply fuse T 35 A Transformer version France Norway System voltage 230 V 400 V Power supply fuse T 63 A T 35 A When connecting to a 230 V delta circuit 400 V star circuit the phases must be assigned as follows and the following connection terminals must be linked Primary voltage L1 L2 L3 Link 230 V 1 2 3 1 4 2 5 3 6 400 V 2 4 6 1 3 3 5 ...

Page 29: ...A 850 Automatic mode option When connecting a gun with automatic stud loading the welding gun s multicoupling must be connected directly to the sorter connected through an optional hose package extension to the sorter The connection between the sorter and welding ALPHA 850 welding device is made with an optional welding device see Chapter 1 8 Welding cable connection The DIX 50 welding cable plug ...

Page 30: ...onnected through a control cable extension option to the ALPHA 850 Automatic mode option When connecting a gun with automatic stud loading the welding gun s multicoupling must be connected directly to the sorter connected through an optional hose package extension to the sorter The connection between the ALPHA 850 s 7 pin control cable socket and the sorter is made using an optional control cable ...

Page 31: ...s the earth cable must be laid without looping to the degree possible 4 5 Workpiece connection The earth cable comes standard with two earth clamps that must be connected to the workpiece When connecting the earth clamps observe the following 1 The earth clamps must be connected directly to the workpiece or workpiece mount welding table welding frame Steel constructions railway tracks pipes etc mu...

Page 32: ...e limited to the most exact possible centring of the stud and stud holder To reduce the effects of magnetic blow effect several corrective measures are available some of which are shown below To favourably influence the arc the earth clamps must be arranged as symmetrically as possible at the welding location Influences on the arc by the welding cable can largely be prevented by turning the weldin...

Page 33: ...aphic symbols 3 7 8 9 1 2 4 5 6 1 Power switch 6 LED for gun coil circuit 2 Weld current potentiometer 7 Malfunction LED 3 Weld time potentiometer 8 Contact LED 4 System voltage LED 9 Operating mode selector switch 5 Start weld cycle LED 5 1 Operating elements Power switch Function Turning the ALPHA 850 on and off Switch position I ON O OFF When the welding device is turned on the system voltage L...

Page 34: ...tentiometer The required weld current is set from the potentiometer Function Selection of weld current range Setting range 100 A 850 A The welding currents can be continuously set based on the requirements of the weld process used short cycle drawn arc Note Guidelines for weld current are shown in Chapter 7 2 Operating mode selector switch The toggle switch is for presetting the weld time for the ...

Page 35: ...olour change red Fault overheat LED green Contact Pos 8 LED lights up when the stud contacts the workpiece The external welding circuit is closed LED goes out when the stud is lifted from the workpiece LED green System voltage Pos 4 LED lights up when the ALPHA 850 is switched on LED goes out when the ALPHA 850 is switched off LED yellow Start weld cycle Pos 5 LED lights up when a start signal is ...

Page 36: ...llowed to open the welding device or work inside its housing Before opening the welding device the ALPHA 850 must be switched off unplugged and secured against restart Before closing the device housing the earth conductors must be reconnected to all housing parts Nominal values for fuse elements Backup Nominal current Nominal voltage Response behaviour F1 1 A 250 V Slow F2 4 A 250 V Slow F3 4 A 25...

Page 37: ... manual Date July 2021 ALPHA 850 07 2021 EN Rev A Fuse elements F1 F3 are on PCB LP 850 F2 F3 F1 The fuse element F4 is on the transformer clamping strip Warning Defective fuses should always be exchanged for identical fuses with identical nominal values ...

Page 38: ...laced free of vibration especially important for large and thin walled workpieces 6 Solvents that contain chlorine absolutely must be removed from the welding zone They are not to be exposed to arc radiation 7 Impairments to weld quality due to arc blow can be prevented with symmetrical attachment of earthing tongs 8 Always lay the welding and earth cable without loops This can largely prevent ele...

Page 39: ...rating manual or the following graphic Guidelines for weld parameters The settings values indicated in the following tables or graphics should be considered only as guidelines to be achieved under optimized welding conditions The optimal weld parameters must always be determined in consideration of factors such as material and surface characteristics of the workpiece sheet metal thickness welding ...

Page 40: ... M6 7 700 25 SC stud 8 0 M8 9 850 40 Rule of thumb for short cycle drawn arc process Weld current A 100 Weld Ø mm Weld time ms 4 Weld Ø mm Parameters for the drawn arc process Stud type according to Tucker Weld Ø mm Welding current I A Welding time t ms IS stud 3 200 150 IS stud 4 280 200 IS stud 5 350 230 KB6 MR M8 S6 6 410 250 MP F M8 7 470 300 MR M10 S8 8 550 300 MP F M10 9 650 300 KB10 MR M12 ...

Page 41: ...d parameters short cycle process Electrical weld parameters short cycle process ESF Weld stud with even front surface 0 0 0 5 1 0 1 5 2 0 2 5 4 5 6 7 8 9 LIFT STUD STICK OUT MM WELD DIAMETER MM Abhub ESF Eintauchmaß ESF 0 100 200 300 400 500 600 700 800 900 1000 4 5 6 7 8 9 CURRENT A TIME X 10 MS WELD DIAMETER MM Strom A Zeit x 10 ms ...

Page 42: ...eters drawn arc process ESF Weld stud with even front surface KSF Weld stud with conically tapered front surface 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 3 4 5 6 7 8 9 10 11 12 LIFT STUD STICK OUT MM WELD DIAMETER MM Abhub KSF Eintauchmaß KSF Abhub ESF Eintauchmaß ESF 0 100 200 300 400 500 600 700 800 900 1000 3 4 5 6 7 8 9 10 11 12 CURRENT A TIME X 10 MS WELD DIAMETER MM Strom A Zeit x 10 ms ...

Page 43: ... the welding location such that people nearby are adequately protected against blinding and electromagnetic fields Chapter 2 4 Check the configured device components for correct connection When connecting a gun with manual stud loading the inspection is limited to the electrical connection of the gun and workpiece When connecting a welding gun with automatic stud loading the pneumatic and any shie...

Page 44: ...elding device with an NSA 606 M NON AUTO manual mode sorter and a PFL 901 gun with automatic stud loading Standard operation 1 Set the mechanical weld parameters on the gun The settings can be found in the NS 40 operating manual 2 Turn the ALPHA 850 on If welding is being done under shielding gas optional a toggle switch on the back of the device must also be turned on When the welding device is t...

Page 45: ...ed is activated for the duration of the pre set pre flow time 10 After the shielding gas pre flow time is over a pilot current flows through the external welding circuit Welding cable Stud Workpiece Earth cable 11 The gun coil activates and lifts the stud from the workpiece surface The Contact LED goes out 12 When the pre flow time is over the main welding current is shut off When the weld time en...

Page 46: ... parameters on the ALPHA 850 The parameter guidelines can be found in the table in Chapter 7 2 6 Turn on the compressed air at the sorter s manual slide valve and check the operating pressure of 5 5 bar 6 0 bar on the manometer 7 When the compressed air is turned on the welding gun s loading pin immediately goes to its home position front end position 8 Give the command to convey studs The conveyo...

Page 47: ...urrent flows through the external welding circuit Welding cable Stud Workpiece Earth cable 17 The gun coil activates and lifts the stud from the workpiece surface The Contact LED goes out 18 After the pre flow time is over the main welding current is shut off When the weld time ends the solenoid actuator is depowered 19 The stud dips into the melt bath the arc goes out and the weld current is swit...

Page 48: ...ocumentation Simplified work inspection To check the device settings and functionality before start of shift three studs must be welded on which the following tests must be made 1 Visual inspection all studs 2 Bend test all studs The test results must be documented and added to the quality documentation Ongoing production monitoring During ongoing production monitoring generally a visual inspectio...

Page 49: ... mechanical parameters 2 Defective weld Constriction on the weld stud too long Corrective action Enlarge stud stick out check lift check centring of the ceramic ring Decrease welding current and or welding time 3 Defective weld Weakly formed uneven weld bead with matt surface Stud too long Corrective action Increase weld time and weld current dry the ceramic rings in the oven if necessary 4 Defect...

Page 50: ...e flaws Corrective action Not necessary No change to the electrical and mechanical parameters 2 Defective weld Diameter not fully welded Corrective action Increase welding current and or welding time possibly change polarity 3 Defective weld Large uneven weld bead Corrective action Reduce weld time 4 Defective weld Pores in the weld bead Corrective action Reduce weld time or increase weld current ...

Page 51: ...ped with dry cloths The type plate and safety instructions must be easily readable The ALPHA 850 s front plate must be cleaned with a grease cutting cleaning agent The LED display elements must be recognizable The electrical connection cables must be cleaned with a dry cloth This makes scorch marks or mechanical defects easy to notice Depending on the conditions of use and the level of soiling cle...

Page 52: ...ual inspection outside the device housing welding cable control cables and hoses Power plug and power cable Display and control elements Connector sockets and connection plugs Components assemblies marked with are only to be replaced by electrical experts Every 3 months Visual inspection inside the device housing cabling printed circuit boards electrical connections and components Visual inspectio...

Page 53: ...ical repair preferably familiar with welding cutting and related processes see EN 60974 4 Repairs to the ALPHA 850 welding device are to be done only as part of maintenance The ALPHA 850 can be repaired with ordinary commercial tools No special tools are needed Troubleshooting can be done with ordinary commercial measuring devices Defective components on printed circuit boards require replacement ...

Page 54: ...efective or loose contact Check fan Check power supply Fan runs No 3 No 3 3 Power supply defective or loose contact Check network protection Check power supply OK No 4 Replace fuse 4 Cable break Measure through the cable OK No 5 Replace the cable 5 Power switch error Power supply clamp error Check the power cable connection at the power plug Check the transformer connection at the power switch Fea...

Page 55: ...onnection voltage White LED ready No 7 3 Device overloaded inadequate cooling Check fan Fan runs No 5 No 4 4 Phase error L1 Fuse F41 defective Blower connection fan Check power supply fuse plug cable Check the fuse 315 mA Check fan connection Check fan Features removed ready No 7 5 Welding sequence too high Let the welding device cool Reduce the welding sequence White LED ready No 6 6 Fan disabled...

Page 56: ...ctive Replace the control cable Replace gun OK ready No 12 6 Coil defective Replace the coil Replace gun OK ready No 12 7 PCB connection defective Check the connection plug of PCB X1 X31 OK No 8 Make the connection 8 Fuse defective Check the equipment fuse F2 and F32 OK ready No 12 9 Start button defective Start weld cycle LED ON OFF when triggered OFF No 10 No 11 10 Start button defective Replace...

Page 57: ...Clean the weld point OK ready No 5 5 Contact detection defective Check the PCB plug X41 OK No 7 No 6 6 Connection X41 open Make the connection OK ready No 7 7 PCB defective Replace the PCB OK ready No 14 8 Pilot current fault Does the arc ignite YES No 9 No 12 9 Arc break or short circuit Lift set incorrectly YES No 10 No 14 10 Lift error Set lift OK ready No 11 11 No phase L2 Check the transforme...

Page 58: ...s Diagnostic LEDs H3 H4 H7 H9 H141 briefly go on when the release button on the welding gun is pressed Place the welding gun on the workpiece Contact LED Pos 8 goes on If no display Connect the earth cable and welding gun correctly Diagnostic LED H81 always goes on upon workpiece contact Display goes out during welding Welding in short circuit no arc occurs set the welding gun up correctly Welding...

Page 59: ...lding unit operating manual Date July 2021 ALPHA 850 07 2021 EN Rev A F1 F3 Fuse elements X1 X4 Plug connection H2 H18 Diagnostic LEDs Internal control card example illustration F1 X4 X1 X2 X3 H9 H14 H7 F3 H5 H18 H3 H2 H4 F2 H8 ...

Page 60: ...c container over collection tank marking UTD SA V Battery dry None Plastic container VER SA Components containing mercury Undamaged Closed plastic container Hg absorber VER of mercury LCDs Undamaged Dense container HM VER Cables wires None No requirements VER Components containing gold None No requirements VER Packaging Separate collection None VER Other materials According to requirements Accordi...

Page 61: ... 56 Stud welding unit operating manual Date July 2021 ALPHA 850 07 2021 EN Rev A In terms of product stewardship Tucker offers fee based return and disposal of its device and system components KrWG Circular Economy Act ...

Page 62: ...2B devices1 and therefore intended only for commercial use Tucker stud welding units and system components must never be disposed of with household waste or at municipal collection points According to European directive 2012 19 EU on used electrical and electronic devices and implementation in national law Tucker offers fee based return and environmentally sound disposal of its devices and system ...

Page 63: ...V EMC Electromagnetic compatibility EN European standard ESF Weld stud with even front surface HPE Bundesverband Holzpackmittel Paletten Exportverpackung e V I A amperage in amperes IEC Norm International standard IP Protection type code ISO International Standards Organization KrWG Circular Economy Act KSF Weld stud with conically tapered front surface LED light emitting diode Mg Magnesium m kg M...

Page 64: ...es Transmittance requirements and recommended use EN 55011 Industrial scientific and medical equipment VDE 0875 11 Radio frequency disturbance characteristics Limits and methods of measurement EN 60529 Degrees of protection provided by enclosures IP code VDE 0470 1 EN 60974 1 Arc welding equipment VDE 0544 1 Part 1 Welding power sources EN 60974 4 Arc welding equipment VDE 0544 4 Part 4 Recurring ...

Page 65: ...tion of welding procedures for metallic materials Welding procedure test Part 1 Arc and gas welding of steels and arc welding of nickel and nickel alloys EN ISO 15614 2 Specification and qualification of welding procedures for metallic materials Welding procedure test Part 2 Arc welding of aluminium and its alloys KrWG Circular Economy Act ...

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