STAUFF SWG-WI06 Operating Manual

©Walter Stauffenberg GmbH & Co. KG

Local Solutions For Individual Customers Worldwide

SWG-WI06

Operating Manual

©Walter Stauffenberg GmbH & Co. KG

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-WI06 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 Accessories �� 12

5 Technical Data �� 13

6 Intended Use �� 14

6.1 Usage 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

Drawn-Arc Stud Welding ...................................................................................... 19

10 Preparing Workplace and Welding Process �� 23

10.1 Preparing Surfaces ............................................................................................... 24

10.2 Checking the Stud Welding Gun .......................................................................... 25

11 Connection �� 26

11.1 Connecting the Welding Gun to the Stud Welding Unit ........................................ 27

11.2 Connecting the Ground Cable .............................................................................. 28

11.3 Connecting the Stud Welding Unit to the Mains Supply ....................................... 29

5

Table of Contents

©Walter Stauffenberg GmbH & Co. KG

12 Welding �� 30

12.1 Switching on the Stud Welding Unit ..................................................................... 30

12.2 Determining the Welding Time and the Welding Current ...................................... 31

12.3 Setting the Welding Parameters ........................................................................... 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 Bending Test .................................................................................... 40

13.3 Optimisation of Welding Parameters .................................................................... 42

13.4 Blowing Effect and Remedies ............................................................................... 43

14 Troubleshooting �� 44

15 Shutting Down �� 46

16 Maintenance and Care �� 47

16.1 Cleaning ............................................................................................................... 47

16.2 Inspection and Tests ............................................................................................. 48

17 Storage �� 49

18 Disposal �� 49

EC Declaration of Conformity �� 50

Service & Support �� 51

Index �� 52

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

compliance 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

electrodes 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 unit contains the following parts:

No. of pieces

Part Type

1 Stud welding unit SWG-WI06

1

5

1

Ground cable

Stud welding gun

Distance tube DIT

Stud retainer

Toolkit

Documentation

Packaging

SWG-GC

SWG-WG

DIT-SR6 SWG-WG30

SWG-SR6

 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

5 Technical Data

©Walter Stauffenberg GmbH & Co. KG

5 Technical Data

Stud welding unit SWG-WI06 for the ARC stud welding

according to current standards

Welding range STAUFF internal thread welding stud M6

Welding material Mild steel, stainless 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

Primary plug 16 A 2-pin grounded safety plug (plug type

F CEE 7/4)

Connected load 3 kVA

Cooling type F (temperature controlled cooling fan)

IP Code IP 44 (also permits operation outdoors)

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

Dimension L x B x H 474 x 337 x 351 mm / 18.7 x 13.3 x 13.8 in

(with handle)

Weight 18 kg / 40 lbs

14

6 Intended Use

©Walter Stauffenberg GmbH & Co. KG

6 Intended Use

Our stud welding units are designed and built exclusively for industrial use. Nonindustrial use is expressly forbidden due to the lack of know-how about the welding technology employed and the applicable standards.

The stud welding unit is intended exclusively for stud welding of standardised welding elements. Any other use will result in the desired strength of the welded joint being reduced.

This stud welding unit can only be used with the STAUFF stud welding gun SWG-WG.

The intended use also implies observance of the stud welding gun operating manual and compliance with the intervals and conditions for inspection 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 welding unit must be suitable for welding the welding elements in use.

Welding elements manufactured with the cold formed process have a ange and an ignition tip. During welding, the ange prevents the arc getting to the cylindric part of

the welding element and increases simultaneously the welding area.

 Please refer to the operating manual of your stud welding gun for

detailed information on which welding elements may be used.

6.1 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

7 Warranty

©Walter Stauffenberg GmbH & Co. KG

7 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.

7.1 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 6.1.

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

8 Components of the Stud Welding Unit

©Walter Stauffenberg GmbH & Co. KG

8 Components of the Stud Welding Unit

8.1 Main Assemblies

Mains input

Welding output

1 - PFC mains input 4 - Medium frequency transformer

2 - Electrolytic capacitors 5 - Rectier

3 - IGBT switch 6 - Control unit

The mains voltage is rectied by the master switch and the EMV lter in the PFC unit (1).

The rectied voltage is smoothed 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 medium frequency transformer (4) with

diodes (5) and rectied. The smoothed current is led to the weld bushes.

The IGBT switch (3) is controlled in the control unit (6). The control unit also coordinates the mechanical process (withdrawing of the welding elements) with the electronic control system (triggering the pre current, triggering the main current,

welding time process). The welding time and welding current are fully adjustable.

The type plate is located on the backside of the stud welding unit.

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8 Components of the Stud Welding Unit

©Walter Stauffenberg GmbH & Co. KG

Type plate

The type plate contains the following information:

– Manufacturer

– Type

– Order No./Serial No.

– Primary voltage

– Fuse

– Power consumption

– Cooling class

– IP code

– Date

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8 Components of the Stud Welding Unit

©Walter Stauffenberg GmbH & Co. KG

8.2 Operation Panel and Display

1 2

3 4 5 6

1

2

3

4

5

6

- Welding current

- Welding time

- Ready indicator

- Contact

- Trigger

- Temperature

In the lower part of the operation 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

element and the workpiece.

Yellow Lights up when the welding gun button is triggered.

Yellow The stud welding unit is locked

– if the stud welding unit is overheated. After a short cooling

period, the work can be continued.

8.3 Mains Switch

1

The switch for mains mode is located on the rear of the stud welding unit.

1 - Mains switch

19

9 Welding Process

©Walter Stauffenberg GmbH & Co. KG

9 Welding Process

Stud welding with a drawn arc process is divided into drawn-arc stud welding with ceramic ferrule and drawn-arc stud welding with shielding gas. This stud welding unit must be used exclusively for stud welding with drawn arc. A ceramic ferrule or shielding gas is not required.

The face of a stud-shaped welding element and the opposite surface of the workpiece are molten by an arc. Stud welding is suitable for the welding of joining elements across the entire cross-section, mainly using pin-shaped metallic welding elements with metallic workpieces.

The various processes of arc stud welding are distinguished by:

– The method of weld pool protection (shielding gas - SG, ceramic ferrule -

CF or no protection - NP)

– The length of welding time (standard ARC or short-cycle drawn-arc

stud welding - SC)

– The energy source (welding rectier supplied by mains, inverter,

capacitor battery).

Drawn-Arc Stud Welding

The STAUFF stud welding unit operates by process of ‘arc stud welding with drawnarc ignition’ according to the current standards. The standards assign this method of joining pin-shaped elements with plane workpieces to the so called ‘Arc Pressure Welding’ (code BH).

Joining is carried out in plastic or liqueed condition of the welding zone. The process can be carried out mechanically or automatically, depending on the used welding guns/welding heads.

Generally, the positive pole of the stud welding unit is connected to the workpiece. The welding element is manually or automatically inserted into the chuck of the welding gun or of the welding head. Then it is placed onto the workpiece - possibly equipped with a ceramic ferrule (does not apply for STAUFF welding studs). (See gure, position 1) When the button of the welding gun is triggered, the automated welding process starts, which works as follows:

20

9 Welding Process

©Walter Stauffenberg GmbH & Co. KG

– At the beginning of the welding process, the welding element (stud) in the

welding gun is lifted clear off the workpiece by a lifting device (solenoid).

An initial switched current triggers a pilot arc of a low current power (see gure,

position 2). Then the main arc ignites between the face area of the welding element and the workpiece.

– The main arc burns at the set current during the welding time preselected at the

stud welding unit. The selected welding energy must match the requirements of the selected welding element. The energy of the arc melts the face of the welding element and the workpiece (see gure, position 3).

– At the end of the preset welding time, the stud is mechanically moved to the

workpiece. 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 zone solidies and cools down. The welding element is now welded to

the workpiece over its entire cross-section of the welding element (see gure,

position 4). As soon as the weld metal is cooled down, the welding gun can be carefully withdrawn from the welding element. When using shielding gas, the shielding gas ow is switched off with the withdrawal of the welding gun. If a ceramic ferrule is used, it can be removed by light hammer blows.

The welding range of drawn-arc stud welding is about 3 to 25 mm diameter when using mild steel/stainless steel. Welding elements with rectangular cross-section should not exceed a ratio length : width of about 5 : 1. All technical information and adjustment values are based on the use of welding elements which correspond with current standards.

The shown ceramic ferrule does not apply for STAUFF welding studs

21

9 Welding Process

©Walter Stauffenberg GmbH & Co. KG

Variants of drawn-arc stud welding

Item Drawn arc stud

welding with ceramic ferrule

Drawn arc stud welding with shielding gas

Short-cycle drawn arc stud welding with shielding gas

Capacitor discharge drawn arc stud welding

Diameter welding element d metric in mm (imperial)

3 - 25 (#4 or 12 gage to 1“)

3 - 12 (16) (#4 or 12 gage to 1/2“ (5/8“)

3 - 12 (#4 or 12 gage to 1/2“)

2 - 8 (14 gage to 5/16“

Max. current I in A 3 000 2 500 1 500 5 000

Welding time t in ms 50 - 2 000 50 - 2 000 5 - 100 3 - 10

Energy source Welding rectier

Welding transformer Inverter

Welding rectier Welding transformer Inverter

Welding rectier Inverter

Capacitor

Weld pool protection Ceramic ferrule CF Shielding gas SG Shielding gas SG

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 Brass (with shielding gas)

4.8 (suitable for welding) A2-50 Aluminium, brass, copper

Workpiece surface Metallic bright

(rolling skin, rust lm)

Metallic bright

(rolling skin, rust lm)

Metallic bright, galvanised, light oiled

Min. thickness of workpiece

1/4 d min. 1 mm (0.04“)

1/8 d min. 1 mm (0.04“)

1/8 d min. 0.6 mm (0.02“)

1/10 d min. 0.6 mm (0.02“)

Adjustable parameters

Welding current I in A = 80 x d (up to 16 mm/0.63“)

Welding current I in A = 100 x d (up to 12 mm/0.47“)

Charging voltage

Welding time t in ms = 20 x d (up to 12 mm/0.47“)

Welding time Ignition point / lift

Lift (arc length)

Spring pressure (plunging speed)

Plunging depth Plunging depth Plunging depth Plunging depth

22

9 Welding Process

©Walter Stauffenberg GmbH & Co. KG

Drawn-Arc Stud Welding with Ceramic Ferrule

Drawn-arc stud welding with ceramic ferrule is used with welding elements of 3 to 25 mm diameter (preferably above 12 mm diameter) and with welding times of 50 to 2 000 ms. It is generally suitable for all welding positions. When stud welding with ceramic ferrule, the welding position is PA (vertical). The major part of all applications applies to this procedure.

The ceramic ferrule (CF):

– prevents atmosphere from getting to the weld pool by 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

vertical wall and overhead

– protects the welder from arc radiation and welding spatters

Normally, the ceramic ferrule is used for only one weld and is removed after

solidication of the weld pool.

Standard welding elements and ceramic ferrules are described in several standards. When using concrete anchors or shear connectors the front area can be plane constructed with a small pressed-in aluminium ball.

Studs with cone-shaped front area and aluminium ball are preferably used with ceramic ferrule.

NOTE!

Ceramic ferrules, shielding gas or aluminium balls are not nessesary for the use of STAUFF internal thread welding studs M6.

23

10 Preparing Workplace and Welding Process

©Walter Stauffenberg GmbH & Co. KG

10 Preparing Workplace and Welding Process

Danger from fumes and airborne particulates

 Switch on the welding fume extractor at the workplace.

 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 re and explosion

 Remove all inammable materials and liquids from your working area.

 Ensure that there are no explosive materials in your working area.

 Ensure that an approved re extinguisher is available at the workplace.

Danger from tripping and falling

 Lay cables and connecting leads in such a way that they are protected

against damage and

 that you or third parties cannot trip over them or fall.

Warning of weld spatter

 Ensure that there is no equipment or apparatus in the working area that

could be damaged by weld spatter.

 Remove if necessary.

24

10 Preparing Workplace and Welding Process

©Walter Stauffenberg GmbH & Co. KG

Warning of electromagnetic elds

 Ensure that there is no equipment or apparatus in the working area that

could be damaged by magnetic elds.

 Remove if necessary.

Danger!

 Ensure that there is a free circulation of air through the housing of the

stud welding 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 or

replaced by a qualied electrician.

10.1 Preparing Surfaces

 Remove

– Paint, oil and other impurities,

– Rust,

– Non-conductive coatings (of surface-coated materials)

from the welding surface and the contact points of the ground clamps.

This ensures a high strength of the welded joints.

 Weld the welding element only to a at surface.

 Ask your application consultant at STAUFF about welded joints on tubes and rife

plates (see page 2).

25

10 Preparing Workplace and Welding Process

©Walter Stauffenberg GmbH & Co. KG

10.2 Checking the Stud Welding Gun

 Always check the operating manual of your stud welding gun 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 t and ensure it is tightened.

 Check the bellows of your stud welding gun for damage.

 Check if spring force and lift are set according to the welding parameter table in

the operating manual of the stud welding gun.

 Refer here to the operating manual of your stud welding gun.

26

11 Connection

©Walter Stauffenberg GmbH & Co. KG

11 Connection

 First prepare your workplace.

 Read and observe here point 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 starting of the welding process.

 Secure the cables.

Strong magnetic elds are generated during the welding process that can

lead to whipping of the cables. This can cause the cables to come out of the plug sockets.

27

11 Connection

©Walter Stauffenberg GmbH & Co. KG

11.1 Connecting the Welding Gun to the Stud Welding Unit

Connect the welding current cable

 Only now plug the welding current cable into the

corresponding socket of the stud welding unit.

 Press in the plug and turn it rmly clockwise (to the right).

Connect the control cable

 Plug the control cable in the connector of the stud welding

unit.

 Twist the retaining nut of the control cable connector

clockwise.

Only loosely made connections will result in damage to the plug connectors.

 Therefore always check that the plug connector is rmly inserted.

This prevents a poor contact and hence overheating of the plug connectors.

28

11 Connection

©Walter Stauffenberg GmbH & Co. KG

11.2 Connecting the Ground Cable

Connect the ground cable

 Plug the ground cable into the corresponding socket of the

stud welding unit.

 Press in the plug and turn it rmly clockwise (to the right).

Only loosely made connections will result in damage to the plug connectors.

 Therefore always check that the plug connector is rmly inserted.

This prevents a poor contact and hence overheating of the plug connectors.

Connect the ground clamps

 Remove rust, paint and dirt from the points on the

workpiece to which you wish to connect the ground clamps.

 Attach the ground clamps to the workpiece as tightly as

possible.

 Pay attention to a good contact and symmetrical

connection.

The welding point should be in the middle between the two ground clamps.

29

11 Connection

©Walter Stauffenberg GmbH & Co. KG

11.3 Connecting the Stud Welding Unit to the Mains Supply

Electric shock hazard

 Have an electrician check whether 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 type plate.

 Compare the current consumption indicated on the type plate with the

fuse of your mains power supply.

 Check that the stud welding unit is switched off.

 Insert the plug into the plug socket only immediate before the welding

process begins (point 12)

30

12 Welding

©Walter Stauffenberg GmbH & Co. KG

12 Welding

 First connect up the stud welding unit.

 Read and observe here point 11 „Connection“.

Danger for wearers of heart pacemakers

 Never operate the stud 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 the vicinity.

Strong electromagnetic elds are produced in the vicinity of the stud welding unit during welding. These elds may impair the function of the heart pacemakers.

12.1 Switching on the Stud Welding Unit

1

1 - Mains switch

 Only now switch on the stud welding unit

at the mains switch (1).

31

12 Welding

©Walter Stauffenberg GmbH & Co. KG

12.2 Determining the Welding Time and the Welding Current

Determination of welding time and welding current 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 welding current to be set at the stud welding unit using

the following tables.

The gures in these table are indicative values and must be checked by

means of a test welding on the original material with the same properties as the original workpiece.

32

12 Welding

©Walter Stauffenberg GmbH & Co. KG

Determining the Welding Time and the Welding Current for Welding Gun SWG-WGfor drawn-arc stud welding with ceramic ferrule

Welding elements Material:

4.8 (suitable 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. diameter

in inches

Material of workpiece: Mild steel (suitable for welding)

Ø d

1

Ø d

2

Ø d

1

Ø d

2

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“ 0.312 640 160

Ø d

1

Ø d

2

Ø d

1

Ø d

2

PD/DD (MD)

2)

M6 5.35 1/4“ 0.21 432 108

PD/DD (MD)

2)

M8 7.19 5/16“ 0.28 576 144

Ø d

1

Ø d

1

UD / pins

2)

3 #4 /12 gage 240 60

UD / pins

2)

4 #8 320 80

UD / pins

2)

5 #10 7 3/16“ 400 100

UD / pins

2)

6 1/4“ 480 120

UD / pins

2)

8 5/16“ 640 160

1)

to be checked by test weldings

2)

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

NOTE!

Ceramic ferrules, shielding gas or aluminium balls are not nessesary for the use of STAUFF internal thread welding studs M6.

33

12 Welding

©Walter Stauffenberg GmbH & Co. KG

Determining the Welding Time and the Welding Current for Welding Gun SWG-WG for drawn-arc stud welding without ceramic ferrule

Welding elements Material:

4.8 (suitable 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. diameter

in inches

Material of workpiece: Mild steel (suitable for welding)

Ø d

1

Ø d

2

Ø d

1

Ø d

2

PS (US, IS)

3)

M3 4 1/8“ #8 400 10

PS (US, IS)

3)

M4 5 5/32“ #10 / 3/16“ 600 15

IS M6 8 1/4“ 5/16“ 650 90

1)

to be checked by test weldings

3)

Information and recommendations on this can be found in DVS 0902 (serial number 784).

Ød2

Ød1

34

12 Welding

©Walter Stauffenberg GmbH & Co. KG

12.3 Setting the Welding Parameters

Adjusting the 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 Welding Current

 First determine the necessary welding current.

 Read and observe here Point 12.2 „Determining the Welding Time and

Welding Current“.

 Only now set the welding current ( ) with the knob.

35

12 Welding

©Walter Stauffenberg GmbH & Co. KG

12.4 Performing the Welding Process

 First set the necessary welding parameters.

 Read and observe here point 12.3 „Setting the Welding Parameters“.

Electric shock and light arc hazard

 Never touch the welding elements, chuck, retaining nut or electrically

conductive 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 and damage due to electric power or

electromagnetic elds.

Electric shock and light arc hazard

 Stand on an insulated mat if you have to weld under the following

conditions:

– In conned spaces with electrically conductive walls

– Under cramped conditions between or against electrically conductive

parts

– Where there is limited mobility on electrically conductive parts

– In damp, wet or hot rooms.

36

12 Welding

©Walter Stauffenberg GmbH & Co. KG

Danger of deagration of explosive gases and substances

 Never weld in rooms with an explosion hazard.

 Never weld on vessels containing or that have contained substances

– which are inammable or promote combustion,

– which may create health-endangering gases, fumes or airborne

particulates,

– or which could cause explosions.

Such 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 re and burns due to glowing weld spatter

 Wear your personal protective equipment and

 your safety goggles with sight glass of protection class 2.

 Wear a protective helmet when welding over head.

 Remove all inammable materials and liquids from the vicinity of the place

of work before starting welding.

 Ensure that an approved re extinguisher is available at the place of work.

 Observe furthermore your working instructions and the accident

prevention regulations.

Glowing hot weld and liquid spatter occur during welding.

37

12 Welding

©Walter Stauffenberg GmbH & Co. KG

Danger due to noise

 Wear your ear protection during welding.

 Observe furthermore your working instructions and the accident

prevention regulations.

 Inform colleagues working in the immediate vicinity accordingly before

starting work.

A > 90 dB (A) bang can occur during the welding process.

 Ensure that the welding gun has been prepared in accordance with the

corresponding operating manual.

 Check whether a welding element has been inserted into the welding gun.

 Insert a welding element, if necessary.

 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 rmly with both hands against the workpiece until the

welding gun attachment (spacer) is resting uniformly on the workpiece.

 Hold the welding gun rmly, steady and straight.

 Ensure that you do not touch any metal parts of the welding gun.

 Only now should you press the button of the welding gun.

The welding process is started.

 Always pull the welding gun perpendicularly away from the welding

element after the welding process.

If you pull the welding gun away at an angle, you will strain the chuck and shorten its service life.

Risk of burns

The gun head becomes very hot during the welding process. The same applies to the welded element and the workpiece.

 Wear your proper protective clothing.

38

12 Welding

©Walter Stauffenberg GmbH & Co. KG

 Use only welding elements of one batch.

 Pay strict attention not 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 different settings for the welding process.

 Now check the quality of the welded joint before inserting a new welding

element and repeating the welding process.

 Work in accordance with the following point 13.

39

13 Checking the Quality of the Weld

©Walter Stauffenberg GmbH & Co. KG

13 Checking the Quality of the Weld

You can check the quality of the weld by means of a visual inspection and a bending test.

The number and type or method of the tests to be performed and the acceptance criteria are dened in respective standards (see inter alia: ISO 14555) for quality demands.

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.

13.1 Carrying out Visual Inspection

 Carry out 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 none

Contraction of weld collar Welding element too long

Plunging depth or lift too low Increase plunging depth,

check lift and centering of the ceramic ring

Weld power too high Reduce current and/or time

Ceramic ring not centered correctly

Check centering

Plunge rate too high Adjust plunge and/or gun

dumper

Weakly developed, uneven weld collar with mat surface Welding element too long

Weld power too low Increase current and/or time

Ceramic ferrule is moist Dry out ferrules in oven

Lift too low Increase lift

Collar off centre

Undercut

Effect of arc blow See arc blow effect

Ceramic ferrule incorrectly centred

Check centring

Weld collar low, shiny surface with many spatters Welding element too short

Weld energy too high Decrease current and/or time

Plunging speed too high Adjust plunging depth and/or

damping factor

40

13 Checking the Quality of the Weld

©Walter Stauffenberg GmbH & Co. KG

13.2 Carrying out Bending Test

Bending devices with inserts for different diameters of the welding elements are available in specialist shops.

The bending test serves as an easy work sample and as a check for the selected

welding parameters. The welded joint is stressed by bending in a non-dened 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 60° in any direction.

The bending test is passed if a crack or a fracture of the welded zone does not occur.

 Further tests should be conducted if the connection fails in the weld

area.

 In this case, bend the welding element exactly in the opposite direction by

60° towards the failing seam.

For a non-destructive strength test of the welding elements is a torque bending test device in accordance with DIN EN ISO 14555.

41

13 Checking the Quality of the Weld

 You don’t need to test all studs.

It is sufcient to carry out stud tests on several production samples that are

picked at random.

Bending Test

Type of fracture Possible cause Corrective actions

Tearing of parent material Correct parameters none

Fracture above collar after sufcient

deformation

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

Select suitable material

Fracture of weld Bright appearance

Welding time too low. Increase welding time

If the strength of the joint is inadequate, then:

 check the setting of the stud welding unit.

 check whether the surface of welding element and base material are clean and

electrically conductive.

They must be free from scale, oil, paint, oxide layers.

 Grind off hardened workpiece surfaces (e.g. roll hardening).

 Check the piston of the welding gun for ease of movement.

42

13 Checking the Quality of the Weld

13.3 Optimisation of Welding Parameters

 As rst 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“.

 Optimise the welding parameters of the stud welding unit.

 Check the settings of the welding gun.

 If necessary re-adjust the lift and spring pressure.

 Refer here to the operating manual of your welding gun.

43

13 Check Quality of the Welded Joint

13.4 Blowing Effect and Remedies

With asymmetric ground connections, different material distributions or when welding at the edge of a workpiece a "blowing effect" can occur. This is an undesirable deection of the light arc. This results in uneven melting of the stud material, in increased poring and undercuts in the welding area.

The blowing effect is proportional to the current amperage and can be inuenced

by symmetrical connection of the ground terminals, by connecting compensating grounds or (on welding guns with external welding cable) by turning the

welding gun about its vertical axis.

Blowing effect

Cause Remedy

44

14 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

No

display

No ground connection Check ground connection

on workpiece

Tighten ground connection properly

Trained personnel

Welding gun not connected

Check welding gun connection

Connect welding gun properly

Trained personnel

Transition resistance (between stud and workpiece) too high

Check material surface Clean or grind material

surface

Trained personnel

Ground cable broken Check ground cable*) Replace ground cable*) Qualied

specialists

Welding gun cable broken

Check welding gun cable*) Replace welding gun

cable*)

Qualied specialists

No

display

Defective connecting line of welding gun

Check function of connecting line*)

Replace connecting line*)

Qualied specialists

Welding gun trigger button defective

Check control cable for elec-

trical ow with triggered start

button*)

Replace welding gun trigger button*)

Qualied specialists

Control cable broken Check control cable for elec-

trical ow*)

Replace control cable*) Qualied

specialists

Continuously Yellow

Welding sequence too

fast

Stud welding unit resets automatically

Let switched on stud welding unit cool down

Trained personnel

Gun does not lift, in spite of

and

No lift adjusted Check settings of welding

gun

Modify set parameters Trained personnel

Short circuit of solenoid circuit of the stud welding gun

Check 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 Check solenoid (18 Ω to

22 Ω)*)

Replace solenoid*) Qualied

specialists

Lifting impossible Solenoid circuit inter-

rupted

Check 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

45

14 Troubleshooting

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

 Please contact STAUFF if none of the measures described remedies the

situation.

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

welding unit.

46

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.

 Protect the stud welding unit and its components against the ingress of liquids

and foreign matter.

47

16 Maintenance and Care

Electric shock hazard

 Always switch off the stud welding unit before starting maintenance and

care work.

 Pull out the mains plug.

Danger from insufciently qualied operating personnel

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

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

 Inform your dealer or your maintenance department.

16.1 Cleaning

 Clean the surface of the stud welding unit with a slightly damp cloth, when

necessary.

 Add a little household detergent to the cleaning water.

 Do not use solvents for cleaning.

These can damage the surface of your stud welding unit.

The inside of the stud welding unit must be cleaned at least every

three months.

 Inform your dealer or your maintenance department.

48

16 Maintenance and Care

16.2 Inspection and Tests

 Inspect the condition 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.

 Clean display and control panel in the event of soiling.

 Replace any removed or damaged signs:

Before opening machine disconnect mains

Observe the operating manual

Warning of electric shock hazard

49

17 Storage

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

 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 humidity:

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

18 Disposal

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

specialist disposal company.

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

50

EC Declaration of Conformity

in Accordance with Directive 2006/42/EC, Annex II 1 A

(Original EC Declaration of Conformity)

Herewith the manufacturer

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

declares for the following product

Machine information: Stud welding unit Type: SWG-WI06

in conjunction with STAUFF components

that the machinery fulls all the relevant provisions to this Directive, including changes to the Directive to be applied at the moment of this declaration.

The product is conform with following further EU Directives, 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 hazardous substances in electrical and electronic equipment“ 2011/65/EU

Following harmonised standards (or parts thereof) were applied: DIN EN 60974-1 Arc welding equipment - Part 1:

Welding power sources DIN EN 60974-10 Arc welding equipment - Part 10:

Product standard for arc welding equipment DIN EN 60204-1 Safety of machinery - Electrical equipment of machines;

Part 1: General requirements

The following national standards and other specications (or parts thereof) were applied:

VDE 0544-1

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)

51

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“

52

Index

A

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

airborne particulates .............. 7, 23

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

B

bang. . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 37

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

batch ............................ 38

bending device with inserts ........... 40

bending test ....................... 40

blowing effect ...................... 43

C

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

checking the quality ................. 39

cleaning .......................... 47

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

components of the stud welding unit .... 16

control cable ...................... 27

D

damage to the plug connectors ........ 27

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

determination of welding current ....... 31

determination of welding time ......... 31

disposal .......................... 49

drawn-arc stud welding, variants ....... 21

E

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

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

electromagnetic elds ............. 9, 30

F

re extinguisher .................. 7, 36

re extinguisher, approved ........... 23

re 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

ground clamps ..................... 28

H

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

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

heart pacemaker ............... 7, 9, 30

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

I

intended use ................ 14, 23, 25

L

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

liquids, inammable ................. 23

M

main assemblies ................... 16

mains power supply ................. 29

mains switch ...................... 18

mains voltage ..................... 29

maintenance and care ............... 47

maintenance and care, regular ........ 47

materials, inammable. . . . . . . . . . . . . . . 23

O

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

operation panel and display. . . . . . . . . . . 18

P

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

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

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

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

R

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

risk of burns ....................... 36

risk of falling. . . . . . . . . . . . . . . . . . . . . . . 23

risk of re ......................... 36

risk of tripping ..................... 23

S

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

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

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

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

shutting down ..................... 46

spacer ........................... 37

storage. . . . . . . . . . . . . . . . . . . . . . . . . . . 49

storage temperature ................ 49

53

Index

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

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

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

stud welding 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

V

vessels, welding work on ............. 36

visual inspection ................... 39

W

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

welding current cable. . . . . . . . . . . . . . . . 27

welding element. . . . . . . . . . . . . . . . . . . . 11

welding gun attachment. . . . . . . . . . . . . . 37

welding parameters .............. 11, 25

welding process .................... 19

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

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

STAUFF SWG-WI06 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual