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.

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©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

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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

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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

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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.

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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.

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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.

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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.

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2 Symbols and Terms Used

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

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2 Symbols and Terms Used

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

STAUFF SWG-WG Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual