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Operating Manual SWG-WI06

Contact

Walter Stauffenberg GmbH & Co. KG

Im Ehrenfeld 4

 

Ÿ

 

58791 Werdohl 

Ÿ

 

Germany

 

Phone: +49 23 92 916 0

Fax.:  +49 23 92 916 150

E-mail: [email protected]

www.stauff.com

Summary of Contents for SWG-WI06

Page 1: ...r Stauffenberg GmbH Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer Local Solutions For Individual Customers Worldwide SWG WI06 SWG WI06 Operating M...

Page 2: ...3 92 916 0 Fax 49 0 23 92 25 05 E Mail sales stauff com 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 f...

Page 3: ...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 effo...

Page 4: ...e 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 Draw...

Page 5: ...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...

Page 6: ...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 materi...

Page 7: ...fields 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 Ne...

Page 8: ...y 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...

Page 9: ...r 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 y...

Page 10: ...approval of the manufacturer 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 i...

Page 11: ...oltage 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 we...

Page 12: ...e following parts No of pieces Part Type 1 Stud welding unit SWG WI06 1 1 1 5 1 1 1 Ground cable Stud welding gun Distance tube DIT Stud retainer Toolkit Documentation Packaging SWG GC SWG WG DIT SR6...

Page 13: ...tainless 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...

Page 14: ...ection 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 weldi...

Page 15: ...all 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...

Page 16: ...othed 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 mediu...

Page 17: ...Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer Type plate The type plate contains the following information Manufacturer Type Order No Serial No P...

Page 18: ...ion 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...

Page 19: ...gth of welding time standard ARC or short cycle drawn arc stud welding SC The energy source welding rectifier supplied by mains inverter capacitor battery Drawn Arc Stud Welding The STAUFF stud weldin...

Page 20: ...orkpiece 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 zon...

Page 21: ...as SG No protection NP No protection NP Material welding element 4 8 suitable for welding A2 50 Aluminium up to 12 mm 0 47 4 8 suitable for welding A2 50 Aluminium up to 12 mm 0 47 4 8 suitable for we...

Page 22: ...a formation of metal vapor in the arc chamber stabilizes and concentrates the arc thus decreasing the arc blow effect forms the melt under pressure to a weld collar and supports the weld pool on a ver...

Page 23: ...dent prevention regulations This will help to avoid health damage due to fumes and airborne particulates Danger from fire and explosion Remove all inflammable materials and liquids from your working a...

Page 24: ...ng unit Always place the stud welding unit on a stable level and clean surface Check the condition of all cables and cable connections Have defective cables or their connections immediately repaired o...

Page 25: ...to see whether it may be used with this stud welding unit This stud welding unit can only be used with the STAUFF stud welding gun SWG WG Check the chuck of your stud welding gun for proper fit and e...

Page 26: ...oint 10 Preparing Workplace and Welding Process Electric shock hazard Leave the stud welding unit switched off during connection of the connecting leads In this way you can avoid any unintentional sta...

Page 27: ...he corresponding socket of the stud welding unit Press in the plug and turn it firmly clockwise to the right Connect the control cable Plug the control cable in the connector of the stud welding unit...

Page 28: ...y loosely made connections will result in damage to the plug connectors Therefore always check that the plug connector is firmly inserted This prevents a poor contact and hence overheating of the plug...

Page 29: ...the plug socket to which you intended to connect the stud welding unit is correctly earthed Connect the stud welding unit only to a mains supply with the same mains voltage as that indicated on the t...

Page 30: ...welding unit if you have a heart pacemaker In this case never remain in the vicinity of the stud welding unit during welding Never operate the stud welding unit if persons with heart pacemakers are in...

Page 31: ...at the stud welding unit depends i a on the stud welding gun used the material of the welding element the diameter of the welding element the material of the workpiece Determine welding time and weld...

Page 32: ...ud diameter in inches eff diameter in inches Material of workpiece Mild steel suitable for welding d1 d2 d1 d2 RD MR 2 M6 4 7 1 4 0 187 380 100 RD MR 2 M8 6 2 5 16 0 275 500 130 RD MR 2 M10 7 9 3 8 0...

Page 33: ...itable for welding Diameter of welding elements Welding current 1 SWG WI06 I in A Welding time 1 SWG WI06 t in ms metric imperial US Stud diameter in mm eff diameter in mm Stud diameter in inches eff...

Page 34: ...Welding Time First determine the necessary welding time Read and observe here Point 12 2 Determining the Welding Time and Welding Current Only now set the welding time with the knob Adjusting the Wel...

Page 35: ...nductive parts in their vicinity during the welding process These parts are live Never wear metal jewellery even a wristwatch on your body during the welding process This will help to avoid injuries a...

Page 36: ...uch work may only be carried out by welding specialists Do not carry out such work if you have not been specially trained for it Risk of fire and burns due to glowing weld spatter Wear your personal p...

Page 37: ...Place the welding gun perpendicularly onto the workpiece as soon as the stud welding unit is ready for the welding process Press the welding gun firmly with both hands against the workpiece until the...

Page 38: ...t to mix welding elements from different batches Carry out test welds again after a batch change Even the slightest changes to the geometry in particular to the tip of the welding elements require dif...

Page 39: ...a visual inspection on all welding elements Visual Inspection Condition Possible cause Corrective actions Collar regular bright and complete Lengths after weld within tolerances Correct parameters no...

Page 40: ...ded joint is stressed by bending in a non defined way 1 Welding element 2 Welded joint Place the bending device on the welding element 1 and bend the welding element 1 with the bending device once by...

Page 41: ...on Correct parameters none Fracture within the weld High porosity Weld energy too low Increase current and or welding time Unclean surface Clean the surface Material not suitable for stud welding Sele...

Page 42: ...rameters As first step conduct the tests outlined under points 13 1 and 13 2 As second step optimise the welding parameters according to the table under point 12 2 Determining the Welding Time Optimis...

Page 43: ...e of a workpiece a blowing effect can occur This is an undesirable deflection of the light arc This results in uneven melting of the stud material in increased poring and undercuts in the welding area...

Page 44: ...gun cable Qualified specialists No display Defective connecting line of welding gun Check function of connecting line Replace connecting line Qualified specialists Welding gun trigger button defectiv...

Page 45: ...whole or in part only with the approval of the manufacturer Work marked with may only be carried out by qualified electricians Please contact STAUFF if none of the measures described remedies the situ...

Page 46: ...part only with the approval of the manufacturer 15 Shutting Down Switch off the stud welding unit Pull out the mains plug Disconnect the control cable and welding cables from the stud welding unit Pr...

Page 47: ...el Carry out only the work described here on your stud welding unit Repairs may only be carried out by appropriately qualified personnel Inform your dealer or your maintenance department 16 1 Cleaning...

Page 48: ...ion of the mains cable Inform your dealer or maintenance department if you discover any damage Check whether the readings on the display of the stud welding unit are still legible before starting work...

Page 49: ...Protect the stud welding unit from moisture and metallic contamination Store the stud welding unit only under the following ambient conditions Storage temperature 5 C to 50 C 23 F to 122 F Relative h...

Page 50: ...including changes to the Directives to be applied at the moment of this declaration Low voltage guideline 2014 35 EU EMC guideline 2014 30 EU Directive on the restriction of the use of certain hazardo...

Page 51: ...number enclose document Date of purchase enclose document Purchased at distributor Detailed descriptions of errors Service Support may be done up to the value of EUR without quotation Yes No Could yo...

Page 52: ...isher 7 36 fire extinguisher approved 23 fire hazard 7 form Service Support 45 51 full ear hearing protection 8 fumes harmful to health 7 23 fuse 29 G glossary 11 goggles with visor 8 ground cable 27...

Page 53: ...ng unit 11 25 substances explosive 23 surface of base material 41 surface of welding element 41 switch on the stud welding unit 30 symbols used 9 T test welding 31 troubleshooting 44 type plate 17 29...

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Page 56: ...Operating Manual SWG WI06 Contact Walter Stauffenberg GmbH Co KG Im Ehrenfeld 4 58791 Werdohl Germany Phone 49 23 92 916 0 Fax 49 23 92 916 150 E mail sales stauff com www stauff com...

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