STAUFF SWG-WG Operating Manual

Local Solutions For Individual Customers Worldwide

Operating Manual

SWG-WG

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 sales@stauff.com Web www.stauff.com

SWG-WG 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 Technical Data �� 13

5 Intended Use �� 14

5.1 Usage with STAUFF Clamps ................................................................................ 14

6 Warranty �� 15

6.1 Disclaimer ............................................................................................................. 15

7 Design and Function �� 16

8 Welding Process �� 17

9 Preparing the Stud Welding Gun �� 18

9.1 Mounting the Tripod .............................................................................................. 19

9.2 Setting the Welding Parameters ........................................................................... 20

Adjusting Lift ....................................................................................................................... 22

Adjusting Spring Force ....................................................................................................... 23

10 Welding �� 24

11 Troubleshooting �� 25

12 Maintenance and Care �� 27

12.1 Cleaning ............................................................................................................... 27

12.2 Inspection and Tests ............................................................................................. 28

5

Table of Contents

©Walter Stauffenberg GmbH & Co. KG

13 Storage �� 29

14 Disposal �� 29

Declaration of Incorporation of partly completed Machinery �� 30

Service & Support �� 31

Index �� 32

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 particulates.

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 compli-

ance 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 electro-

des 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 gun contains the following parts:

No. of pieces

Part Type

1 Stud welding gun

cable length 5 m

SWG-WG

1 Operating manual SWG-WG

1 Toolkit

optional

distance tube DIT Ø 25mm

distance tube DIT Ø 30mm

stud retainer

spacer size 1,1a,-8

 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

4 Technical Data

©Walter Stauffenberg GmbH & Co. KG

4 Technical Data

Stud welding gun type SWG-WG

for ARC stud welding according to current standards

Welding range M3 - M12, Ø 2 - 12 mm / 0.1 - 0.5 in

Stud length 10 - 400 mm / 0.4 - 15.7 in

(depending on tripod) STAUFF stud 14mm / 0.6 in

Stud material Mild steel, other on request

Stud type Any type or shape (special chucks if required)

Length compensation 3 mm / 0.1 in automatic

Lift Adjustment range 3 mm / 0.1 in, lockable

Spring force Adjustable, arresting

Welding cable 5 m / 197 in

IP-Code IP 20 (protect against humidity)

Workplace noise level Up to 90 dB (A) may occur during welding

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

Dimension L x W x H 200 x 65 x 140 mm / 7.9 x 2.6 x 5.5 in

(without cable, without DIT)

Weight 0,8 kg / 1.8 lbs (without cable)

14

5 Intended Use

©Walter Stauffenberg GmbH & Co. KG

5 Intended Use

The stud welding gun has been designed exclusively for use with standardised stud welding elements. The use of any other elements will result in the desired strength of the welded joint being diminished.

The stud welding gun must only be connected to STAUFF stud welding units.

 Always check with the operating manual of your stud welding unit whether this

stud welding gun may be used.

Observation of the operating manual of the stud welding unit being used is also part of the intended use.

5.1 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

6 Warranty

©Walter Stauffenberg GmbH & Co. KG

6 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.

6.1 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 5.1.

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

7 Design and Function

©Walter Stauffenberg GmbH & Co. KG

7 Design and Function

7

8

1

2

3

4

6

5

9

The stud welding gun SWG-WG is equipped with an integrated length adjustment for automatic compensation of length tolerance for the welding elements.

The body of the stud welding gun consists of a sturdy two-part plastic housing (2).

The control cable and the welding cable (3) are connected through the welding gun handle to the welding gun.

Positioned at the front of the stud welding gun are the welding piston and the

retaining nut (6) used to x the manual chuck.

At the front of the stud welding gun, the distance tube (DIT) (5) is installed. Here the DIT is mounted.

At the rear, there is the mechanism for lift adjustment (8), rotating graduated ring (7) and for spring force adjustment (1).

At the front of the welding gun handle, the welding gun trigger (4) is installed. It is used to trigger the welding process.

The stud welding gun is supplied without a stud retainer (SR) (9).

The serial number is stamped on the welding gun handle.

Type plate

The type plate contains the following information:

– Manufacturer

– Type

17

8 Welding Process

©Walter Stauffenberg GmbH & Co. KG

9 Welding Process

This stud welding gun may only be used for drawn arc stud welding.

 Please refer to the original operating manual of the connected stud welding unit

for the welding procedure.

18

9 Preparing the Stud Welding Gun

©Walter Stauffenberg GmbH & Co. KG

9 Preparing the Stud Welding Gun

Prepare the stud welding gun by

– mounting the chuck

– mounting the DIT

– adjusting lift and spring force

– adjusting the penetration depth (protrusion).

 Do not connect the stud welding gun to the stud welding unit until it has

been prepared.

In this way you can avoid any unintentional starting of the welding process.

19

9 Preparing the Stud Welding Gun

©Walter Stauffenberg GmbH & Co. KG

9.1 Mounting the chuck (SR) / Setting the Insertion Depth (Protrusion)

chuck

 Use the Allen key to remove the three screws of the

positioning tube and remove the tube

 Remove the hexagon nut with the socket spanner and

remove the stud holder

 Place a stud into new stud holder

 Insert the stud holder loosely into the front opening

 Loosely place the positioning tube

 Adjust distance X by inserting the stud holder

 Carefully remove the positioning tube

 Tighten the hexagon nut with the socket spanner

(Ensure not to change the position of the stud holder!)

 Place the positioning tube and tighten the three screws lightly

5

x

A

6

9

5

Allocation of adapter to xing type of clamp bodies

Size STANDARD

1 AGS-1

1a AGS-1A

2 AGS-2 3 AGS-3 4 AGS-4 5 AGS-5 6 AGS-6 7 AGS-7 8 AGS-8

* Use of the AGS only in connection with DIT-SR6-SWG-WG25R

20

9 Preparing the Stud Welding Gun

©Walter Stauffenberg GmbH & Co. KG

9.2 Setting the Welding Parameters

The insertion depth, lift and spring force are, among others, dependent on the workpiece and welding elements used and their diameters.

The specications in the following table are guidelines.

 Select the applicable parameters for insertion depth, lift and spring force for

your workpiece.

Welding elements Material:

4.8 (suitable for welding) / A2-50

4)

Diameter of welding elements

SWG-WG

metric imperial (US)

Stud-

diameter

in mm

eff. diameter

in mm

Stud-

diameter in inches

eff. diameter

in inches

Stud welding gun parameter

1)

Insertion

depth

Lift

Spring

force

Material of workpiece: Mild steel (suitable for welding) / alloyed steel (suitable for welding)

4)

Ø d

1

Ø d

2

Ø d

1

Ø d

2

RD (MR)

2)

M6 4.7 1/4“ 0.187 2.0 1.0 6

RD (MR)

2)

M8 6.2 5/16“ 0.275 2.0 1.0 6

RD (MR)

2)

M10 7.9 3/8“ 0.312 2.5 1.2 6

RD (MR)

2)

M12 9.5 1/2“ 0.435 3.0 1.4 6

Ø d

1

Ø d

2

Ø d

1

Ø d

2

PD/DD (MD)

2)

M6 5.35 1/4“ 0.21 2.0 1.0 6

PD/DD (MD)

2)

M8 7.19 5/16“ 0.28 2.5 1.2 6

PD/DD (MD)

2)

M10 9.03 3/8“ 0.35 3.0 1.4 6

PD/DD (MD)

2)

M12 10.86 1/2“ 0.43 3.0 1.4 6

Ø d

1

Ø d

1

UD / Pins

2)

3 (ISO) #4 / 12 gage 1.5 1.0 6

UD / Pins

2)

4 (ISO) #8 1.5 1.0 6

UD / Pins

2)

5 (ISO) #10 / 3/16“ 2.0 1.0 6

UD / Pins

2)

6 1/4“ 2.0 1.0 6

UD / Pins

2)

8 5/16“ 2.5 1.2 6

UD / Pins

2)

10 7/16“ 3.0 1.4 6

UD / Pins

2)

12 1/2“ 3.0 1.6 6

Ø d

1

Ø d

2

Ø d

1

Ø d

2

IS M6 8 1/4“ 5/16“ 1.5 1.6 5

1)

to be checked by test weldings

2)

Information and recommendations on this can be found in DIN EN ISO 14555.

4)

When welding on galvanized workpieces we recommend increasing the lift.

Ød2

Ød1

21

9 Preparing the Stud Welding Gun

©Walter Stauffenberg GmbH & Co. KG

Welding elements Material:

4.8 (suitable for welding) / A2-50

4)

Diameter of welding elements

SWG-WG

metrisch imperial (US)

Stud-

diameter

in mm

eff. diameter

in mm

Stud-

diameter in inches

eff. diameter

in inches

Stud welding gun parameter

4)

Insertion

depth

Lift

Spring

force

Material of workpiece: Mild steel (suitable for welding) / alloyed steel (suitable for welding)

4)

Ø d

1

Ø d

2

Ø d

1

Ø d

2

ID

2)

M6 10 1/4“ 0.393 3.0 1.4 6

ID

2)

M8 12 5/16“ 0.472 3.0 1.6 6

Ø d

1

Ø d

2

Ø d

1

Ø d

2

PS (US, IS)

3)

M3 4 1/8“ #8 2.0 1.2 6

PS (US, IS)

3)

M4 5 5/32“ #10 / 3/16“ 2.0 1.4 6

PS (US, IS)

3)

M5 6 3/16“ 1/4“ 2.0 1.4 6

PS (US, IS)

3)

M6 7 1/4“ 0.21“ 2.5 1.6 6

PS (US, IS)

3)

M8 9 5/16“ 0.28“ 3.0 2.0 6

PS (US, IS)

3)

M10 11 3/8“ 0.35“ 3.0 2.4 6

1)

to be checked by test weldings

2)

Information and recommendations on this can be found in DIN EN ISO 14555.

3)

Information and recommendations on this can be found in DVS 0902.

4)

When welding on galvanized workpieces we recommend increasing the lift.

The maximum adjustment values which can be set for the insertion depth (3.5 mm) as well as the lift (3 mm) should not be exceeded.

The specied values apply for welding in welding position PA.

22

9 Preparing the Stud Welding Gun

©Walter Stauffenberg GmbH & Co. KG

Adjusting Lift

The adjustment piece for lift must not be turned by more than 360°.

1 - End ring

2 - Marking

3 - Adjustment piece lift

4 - Adjustment piece spring force

 Place the stud welding gun perpendicularly onto the workpiece.

 Pull the adjustment piece for lift (3) to the rear out of the locking position.

 With the stud welding gun in contact with the workpiece, turn the adjustment

piece for lift in clockwise direction until the welding piston allows no further movement in axial direction.

 Now turn the end ring (1) of the stud welding gun until the „0“ position is aligned

with the marking (2) on the adjustment piece for lift.

 Now turn the adjustment piece for lift in counter-clockwise direction to the

selected lift (see table under point 9.2).

The lift can be adjusted in steps of 0.2 mm. (The empty space between 0 and

0.2 mm serves to mechanically balance out the lifting ring construction.)

 Now push the adjustment piece for lift forward again into the locking position.

 You can reduce the lift by turning the adjustment piece for lift clockwise.

 You can increase the lift by turning the adjustment piece for lift

counter-clockwise.

23

9 Preparing the Stud Welding Gun

©Walter Stauffenberg GmbH & Co. KG

Adjusting Spring Force

The adjustment piece for spring force must not be turned by more than 360°.

 Turn the adjustment piece for spring force only until you feel a noticeable

resistance.

 Never turn the adjustment piece further with force,

as otherwise mechanical parts of the stud welding gun may be damaged.

1 - End ring

2 - Marking

3 - Adjustment piece lift

4 - Adjustment piece spring force

 Turn the adjustment piece for spring force (4) up to the stop in „min“ direction.

The position „0“ should be aligned with the marking (2) on the adjustment piece for lift (3).

 Now turn the adjustment piece for spring force to the selected value (see table

under point 9.2).

You thus determine the insertion rate.

The scale on the adjustment piece for spring force does not correspond to any particular dimensions.

 You can reduce the insertion rate of the welding piston by turning the adjustment

piece for spring force clockwise.

 You can increase the insertion rate of the welding piston by turning the

adjustment piece for spring force counter-clockwise.

24

10 Welding

©Walter Stauffenberg GmbH & Co. KG

10 Welding

 Work according to the original operating manual of the STAUFF

stud welding unit.

Danger if used other than for the intended purpose

 Use the stud welding gun only for ARC stud welding and only in

combination with stud welding units from manufacturer:

Walter Stauffenberg GmbH & Co. KG Im Ehrenfeld 4 58791 Werdohl GERMANY

 Always check with the operating manual of your stud welding unit whether

this stud welding gun may be used.

25

11 Troubleshooting

©Walter Stauffenberg GmbH & Co. KG

12 Troubleshooting

Danger from insufciently qualied operating personnel

 Carry out only the work described here on your stud welding unit or stud

welding gun.

 Repairs may only be carried out by appropriately qualied personnel.

 Inform your dealer or your maintenance department.

Fault Possible cause Fault localisation Fault remedy Performance

Welding elements not

rmly attached

Wrong welding parameters selected

Check adjusted parameters on stud welding unit

Change adjusted parameters

Trained personnel

Check spring force of stud welding gun

Change adjusted parameters

Trained personnel

Check lift of stud welding gun

Change adjusted parameters

Trained personnel

Insertion speed of welding element too low

Check welding piston and linear bearing for ease of movement *)

Clean or replace *) Qualied specialists

Burning marks at the welding element

Chuck defective Check chuck for possible

defects

Replace chuck Trained personnel

Lamellas of chuck are not pretensioned

Check lamellas of chuck Try to bend lamellas

if possible, otherwise replace chuck

Trained personnel

O-rings existing? Check o-rings for possible defects

Replace o-rings Trained personnel

Stud welding gun does not weld

Control cable defective (no trigger signal available on stud welding unit)

Check control cable for

electrical ow at control

cable sleeve (Pin 3 and 4) with pressed welding gun trigger *)

In case of no signal: Replace control cable *)

Qualied specialists

Micro switch defective (with present contact signal on stud welding unit)

Check micro switch

for electrical ow with

pressed welding gun trigger *)

In case of no ow: Replace micro switch *)

Qualied specialists

Welding current cable defective (no contact signal on stud welding unit)

Check, whether welding current cable is connected to stud welding unit in a technically correct way

Connect welding current cable

Trained personnel

Check welding current

cable for electrical ow *)

In case of no ow :

Replace welding current cable and/or connecting cable *)

Qualied specialists

26

11 Troubleshooting

Fault Possible cause Fault localisation Fault remedy Performance

Stud welding gun does not weld

Ground connection defective (no contact signal on stud welding unit)

Check, whether ground cable is connected to workpiece in a technically correct way

Connect ground cable Trained personnel

Check ground cable for

electrical ow *)

In case of no ow:

Replace ground cable *)

Qualied specialists

Stud welding unit defective

Follow the instructions of the connected stud welding unit

Repair required Factory service or

authorised agencies

Stud welding gun does not lift, in spite of

,

and

Short circuit of magnetic circuit of the stud welding gun

Meassure resistance value at control cable

connector (18 Ω to 22 Ω)

between Pin 1 and

Pin 2 *)

Replace control cable connector, control cable and solenoid *)

Qualied specialists

Solenoid defective Meassure solenoid (18 Ω

to 22 Ω) *)

Replace solenoid *) Qualied specialists

No

display

Magnetic circuit interrupted

Meassure resistance value at control cable

connector (18 Ω to 22 Ω)

between Pin 1 and

Pin 2 *)

Replace solenoid or control cable *)

Qualied specialists

Work marked with *) may only be carried out by qualied electricians!

 Please contact our Service department if none of the measures described

remedies the situation.

 Please use the form „Service & Support“ in the annex to send in the stud

welding gun.

27

12 Maintenance and Care

Electric shock hazard

 Never perform maintenance and service work on your stud welding gun

while it is connected to the stud welding unit

 Prior to this disconnect the stud welding gun from the stud welding unit.

Danger from insufciently qualied operating personnel

 Carry out only the work described here on your stud welding gun.

 Repairs may only be carried out by appropriately qualied personnel.

 Inform your dealer or your maintenance department.

12.1 Cleaning

 Clean the casing of your stud welding gun with a slightly damp washcloth, when

necessary.

 Do not use solvents for cleaning.

These may damage plastic components.

28

12 Maintenance and Care

12.2 Inspection and Tests

 Inspect the chuck before every use.

 Replace the chuck if you discover burning marks on the welding element and/or

on the chuck.

 Work here in accordance with point 9.1 „Mounting the chuck“ in this manual.

 Before every use, inspect the bellows on the front part of the stud welding gun for

proper seating and/or damage.

 Never work with damaged or incorrectly seated bellows.

This will contribute to a long service life of your stud welding gun.

 Inform your dealer or maintenance department if you discover any

damage.

 Before every use, check that the type designations and adjustment aids on the

stud welding gun are still legible.

 Clean the type plates in the event of soiling.

 Replace any type plates that are damaged or no longer legible.

29

13 Storage

 Store the stud welding gun in a safe and dust-free location when not in use.

 Protect the stud welding gun from moisture and metallic contamination.

 Store the stud welding gun only under the following ambient conditions.

Storage temperature:

-5 °C to +50 °C (23 °F to 122 °F)

Relative humidity:

0 % - 50 % at +40 °C (104 °F) 0 % - 90 % at +20 °C (68 °F)

14 Disposal

 Dispose of the stud welding gun only via the manufacturer or a

specialist disposal company.

 Never dispose of the stud welding gun in the domestic refuse.

30

Declaration of Incorporation of partly completed Machinery

to Directive 2006/42/EC, Annex II 1 B

(Original Declaration of Incorporation)

Herewith the manufacturer

Walter Stauffenberg GmbH & Co. KG Im Ehrenfeld 4 58791 Werdohl GERMANY Tel. +49 (0) 23 92 / 916 - 0 Fax +49 (0) 23 92 / 25 05

declares for the following product

Machine information: Stud welding gun Type: SWG-WG Year of manufacture: 2015

that the following essential requirements of the above mentioned Directive – including chan-

ges to the Directive to be applied at the moment of this declaration – were applied and fullled:

Annex I, Article 1, 1.1.2, 1.1.3, 1.1.5, 1.1.6, 1.1.7, 1.2.1, 1.2.2, 1.2.3, 1.2.4.1, 1.2.6,

1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.7, 1.3.8, 1.3.9, 1.4.1, 1.4.2.1, 1.5.1, 1.5.2, 1.5.4, 1.5.5,

1.5.6, 1.5.8, 1.5.10, 1.5.11, 1.5.15, 1.5.16, 1.6.1, 1.6.2, 1.6.3, 1.6.4, 1.7.1.1, 1.7.2,

1.7.3, 1.7.4,

that special technical documentation was compiled in accordance with Part B of Annex VII of the above mentioned regulation and will be transmitted, in response to a reasoned request by

the national authorities as follows:

The above mentioned documents will be transmitted by e-mail as a data le in German language.

that this partly completed machinery must not be put into service until the nal machinery

into which it is to be incorporated has been declared in conformity with the provisions of the Directive, where appropriate.

that this incomplete machine complies with corresponding regulations of the following additi-

onal EU Directives, including any changes to be applied at the moment of this declaration:

„Electromagnetic compatibility“ 2014/30/EU Protection targets of the low voltage regulation were kept to appendix I, no. 1.5.1 of the

machine regulation.

Persons who are based in the European community and who are authorised to compile the

technical documentation:

Name: Walter Stauffenberg GmbH & Co. KG Address: see manufacturer

Werdohl, 21.03.2016 __________________________________ Place of issue, Date Carsten Krenz (General Manager STAUFF)

31

Service & Support

Please enclose a copy of the completed form with the repair number provided by STAUFF when sending the repair item to us! Repairs without a repair number cannot be processed. For processing of warranty claims, please enclose a copy of the delivery note/invoice with the serial number.

Repair number

(given by STAUFF)

Company:

Name / Surname:

Street:

City, State and ZIP/Postcode:

Country:

Phone & Fax:

E-mail address:

Stud welding unit / stud welding gun type of model:

Serial 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 you nd any damage / burn marks

on the cables:

Yes No

on chucks:

Yes No

Are all plug and screw connections tightly fastened *:

Yes No

Are there any burn marks on plug or screw connections:

Yes No

Is there any other visual damage (e.g. cracks, dents):

Yes No

Have you checked the fuses:

Yes No

Default on the display of the stud welding unit:

SC

Which LED´s are illuminated (please mark with a cross)?

Please e-mail or fax this form to sales@stauff.com or fax: +49 (0) 23 92 / 25 05. Or use our online form at: www.stauff.com/service-swg In case a repair is necessary a repair number will be given!

* See also operating manual chapter „Connection“

32

Index

A

accessories ....................... 12

adjustment piece lift ................. 23

airborne particulates ................. 7

automatic welding head .............. 11

B

bang. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

basic conguration. . . . . . . . . . . . . . . . . . 12

C

capacitor ......................... 11

chuck, mounting ................... 19

cleaning .......................... 28

clothing, non-ammable .............. 8

control cable ...................... 16

D

danger from incorrect use ............. 6

Declaration of Incorporation .......... 30

disposal .......................... 29

E

ear protection. . . . . . . . . . . . . . . . . . . . . . . 9

electrical hazards. . . . . . . . . . . . . . . . . . . . 9

electromagnetic elds ................ 9

F

face plate ......................... 16

re extinguisher ..................... 7

re hazard ......................... 7

form „Service & Support“ .......... 26, 31

full-ear hearing protection ............. 8

fumes, harmful to health .............. 7

G

glossary .......................... 11

goggles with visor ................... 8

graduated ring ..................... 16

H

hazards for the machine .............. 9

hazards for the operator .............. 9

heart pacemaker .................. 7, 9

helmet ............................ 8

I

insertion depth ..................... 21

intended use ...................... 14

L

lift ............................ 21

lift adjustment .................. 16, 22

light arc .......................... 11

M

maintenance and care ............... 27

O

operating manual ................... 12

P

protective apron ..................... 8

protective equipment ................. 8

protective equipment, personal ......... 9

protective gloves .................... 8

R

rectier ........................... 11

retaining nut ....................... 16

S

safety goggles ...................... 9

safety goggles with sight glass ......... 8

safety precautions ................... 6

scope of supply .................... 12

serial number ...................... 16

setting the insertion depth ............ 19

spring force ....................... 20

spring force adjustment ........... 16, 23

storage. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

storage temperature ................ 29

stud feeder. . . . . . . . . . . . . . . . . . . . . . . . 11

stud welding gun ................... 11

stud welding machine ............... 11

stud welding unit ................... 11

symbols used. . . . . . . . . . . . . . . . . . . . . . . 9

T

troubleshooting .................... 25

type plate ......................... 16

33

Index

W

warranty entitlement ................ 15

welding cable ...................... 16

welding element. . . . . . . . . . . . . . . . . 11, 14

welding gun, design ................. 16

welding gun trigger ................. 16

welding parameters .............. 11, 20

workpiece ........................ 11

Operating Manual SWG-WG

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

STAUFF SWG-WG Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual