Thomas NOMARK 65/99 Operating Manual

NOMARK 65/99

Zone Industrielle, 3

ème

Rue

B. 6040 JUMET

Tél. : +32 (0)71.91.97.60

Fax : +32 (0)71.91.96.71

www.thomas-welding.com

Manuel NOMARK_65_99_Anglais_01.doc

FOREWORD

Your new THOMAS stud welder is carefully constructed of the finest components and material available. Used properly, this equipment will give you years of efficient profitable service.

This manual has been specifically prepared for use in familiarizing personnel with the design, installation, operation, maintenance and trouble-shooting of this equipment. Careful consideration should be given to all the information presented to assure the proper performance of this equipment.

A careful study of this manual will enable you to understand how the welders operate to insure proper performance under all conditions.

GUARANTEE

The electrical and mechanical components of your THOMAS stud welder are thoroughly performance inspected prior to assembly in the welder. The assembled welder is completely performance checked. The welder is delivered to you in functional electro-mechanical condition. All parts used in the assembly of the welder and its accessories are fully warranted for a period of one (1) year from the date of delivery.

Under this warranty, the manufacturer reserves the right to repair or replace in its plant in JUMET (BELGIUM), at its option, defective parts which fail during the warrantee period. Notice of any claim for warranty repair or replacement must be furnished to the manufacturer by the purchaser within five (5) days after the defect is first discovered. The manufacturer does not assume any liability for paying shipping costs or for any labor or material furnished where such costs are not expressly authorized in writing.

We do not warrant THOMAS stud welders, parts, or accessories against failures resulting from misuse, abuse, improper installation, maladjustment or use not in accordance to the operating instructions furnished by the manufacturer. The warranty is valid only when studs are purchased from sources approved by the manufacturer.

Installation servicing or troubleshooting must only be done by qualified personnel trained to work on this type of equipment.

The equipment must always be accompanied by the instructions of

operation, instructions, safety, inspection and maintenance, applicable

information relating to the devices and security instructions required at the

place of uses of the machine. The security instructions concerning welding

in general must also be well known and applied.

TABLE OF CONTENTS

Page

1 Introduction

1.1

General information

- For your safety

- Field of application of the stud welding system

- Features of the stud welding system

5 5 5 6

1.2 Components of the stud welding system

1.3 Functional principle of the stud welding system

1.4 Stud welding gun C0

1.5 Stud welding gun C1 10

1.6 Meaning and description of symbols 12

1.7 Other descriptions 14

1.8 Welding elements (studs) 14

1.9 Material combinations 15

1.10 Centring device (For future applications) -

1.14 Angle bracket 16

1.15 Bending device 16

1.16 Chucks (standard) 16

1.17 Chucks (for insulation pins) 17

1.18 Chuck extension 17

1.20 Welding on centre punches or scribed lines 17

2 Work safety and rights 18

2.1 Safety symbols 19

2.2 Safety information 20

2.3 Proper use 26

2.4 Guarantee and liability 28

2.5 Copyright 29

2.6 EC Declaration of conformity 30

3 Delivery ... Installation 31

3.1 Extent of delivery 32

3.2 Receiving inspection 32

3.3 Storage 32

3.4 Transport 32

3.5 Place of use 33

3.6 Erection 33

3.7 Power connection 33

Page

4 Operation 34

4.1

Connections of the power unit Connecting the earth cable Connecting the welding gun

36 36 37

4.2 Chuck preparation 38

4.3 Adjusting the C0 and C1 guns 40

4.4 Adjusting the CHP (For future applications) -

4.5 Tips for good welding results 42

4.6 Work procedure during welding 43

4.7

Testing the weld Visual inspection Impact bending test

45 45 46

5 Maintenance 47

5.1 Troubleshooting 48

5.2 Care and cleaning 52

5.3 Maintenance intervals 53

5.4 Fuse elements 54

5.5 Technical specifications NOMARK 65 / 99 55

5.6 Explosion view of NOMARK 65 / 99 56

5.7 Block circuit diagram 58

5.8

Technical specifications C0 Gun

5.9 Explosion view 60

5.10 Welding accessories 63

5.11

Technical specifications C1 Gun

5.12 Explosion view 66

5.13 Welding accessories 68

5.14 Iso Kit for C1 71

5.15 Blank page for notes 73

1 Introduction

1.1 General information

1.2 Components of the stud welding system

1.3 Functional principle of the stud welding system

1.4 Stud welding gun C0

1.6 Meaning and description of symbols

1.7 Other descriptions

1.8 Welding elements (studs)

1.9 Material combinations

1.10 Centring device

1.11 Welding template

1.12 Positioning tube

1.13 Sound insulting tube

1.14 Angle bracket

1.15 Bending device

1.16 Chucks(standard)

1.17 Chucks(ISO)

1.18 Chuck extension

1.19 Intermediate ring

1.20 Welding on centre punches or scribed lines

1.1 General information

These operating instructions apply to the power unit type NOMARK 65/99 with welding gun C0 and/or CHP and are intended for the operating, repair and service personnel. Familiarise yourself with the contents of these operating instructions before starting the power unit. You will then achieve better welding results and work safely. In the event of difficulties or confusion please consult the after sales service of TWS Tech, who will be pleased to help you. The figures, specifications and data given in these operating instructions correspond to the state of development as on 13 March 2001. TWS reserves the right to make technical changes serving to improve the power unit.

1.1.1 For your safety

Knowledge of the contents of these operating instructions is essential to ensure safe and trouble free operation of the stud welding system. See chapter 2 for information on proper and safe handling of welding guns. Circumstances and requirements change from case to case. Therefore also always comply with your national and EN (European) standards regarding safety.

Set-up personnel

Set-up personnel need knowledge and experience in welding to

• assess the workplace,

• set up the equipment

• select the right welding element.

Knowledge in the handling of stud welding systems is also required. This knowledge is taught either by TWS or trained set-up personnel.

Operator

Welding work may only be performed by persons over 18 years of age. Knowledge of welding is presupposed (see also section 1.1.3).

Employer

The personnel must be instructed according to the regulations of BG § 1 regularly, at least once a year. Untrained or unauthorised personnel may not use the power unit.

1.1.2 Field of application of the stud welding system

The power unit is designed for welding of welding elements (e.g. welding studs) by the arc pressure welding method. The device only works in combination with a suitable welding gun. The power unit can be used to weld, for example, welding studs according to EN 13918 – Studs for arc welding – on to weldable workpiece surfaces. Many other forms of welding element can

also be welded. Contact THOMAS in this regard if necessary.

1.1.3 Features of the stud welding system

• Easy operation

The power unit is easy to use and – except in the case of work subject to official supervision – no special welding qualification is necessary. The partial mechanisation of the welding process means high-quality welding results can be achieved after a short familiarisation period. 

• Safety

We have designed the device according to EU and national Belgian regulations so that you can work as safely as possible. Work under increased electrical hazard is permitted. The device fulfils the requirements of Protection Class I, IP 21 and comes with the "CE" symbol.

• Long life

The transformers, rectifiers and electronics are especially robust and together with the modern sheet steel housing guarantee long life of the power unit.

1.2 Components of the stud welding system

The stud welding system consists of the power unit (type NOMARK 65/ 99), welding gun ,(C0), Ground cable and chuck

NOMARK 65 / 99 C0 welding gun Double ground clamp

Fig. 1 - 1 Power unit and stud welding gun

1) Power unit NOMARK 65 + C0 ( welding gun for contact welding)

2) Power unit NOMARK 99 + C0 ( welding gun for contact welding) Both welding units can weld normal welding studs. They are equipped with studs manually.

Volt 4 5

1.3 Functional principle of the stud welding system

Stud welding systems are used to weld metal welding studs (e.g. threaded studs) on to weldable metal workpiece surfaces. The power unit NOMARK 65/99 is a mobile welding unit developed by THOMAS that sets new standards in stud welding technology with its compact construction. It works by the principle of capacitor discharge. Together with a manually equipped welding gun of the type C0 (contact welding gun) , it can weld normal welding studs with ignition tips. The welding energy required is delivered by the power unit, which charges a capacitor battery via a regulator circuit. The welding current is then activated by a power SCR. The electric circuit is closed by the welding gun, stud, workpiece and earth cable.

Fig. 1 - 2 Functional principle of the electric control system

1.4 Stud welding gun C0

Field of application

The C0 is a contact welding gun for welding studs with ignition tips. The welding elements should preferably be of steel and stainless steel. Brass or Aluminium studs can also be processed with limitations. Owing to the somewhat longer welding time (compared to gap welding) and deeper penetration, the C0 is especially suitable for lightly galvanised steel

Fig. 1 - 3 Contact welding gun C0

See chapter 5.6 for technical specifications and chapter 5.8 for individual part

drawings and replacement part numbers.

Method

A welding element is first pushed into the Chuck of the welding gun. The ignition tip of the element is then placed down vertically at the required point on the workpiece and the gun pressed down until all positioning feet touch the workpiece (this pushes the plunger against the pressure spring). The welding current is then switched on and the welding process started by pressing the start button. The ignition tip evaporates and generates an arc, which melts the face of the stud and the

workpiece.

The pre-stressed pressure spring then forces the welding element into the weld pool and the arc is extinguished. The capacitors are discharged completely. The weld pool solidifies. This welding process lasts about 1.5 to 3.0 ms. The welding gun can be pulled off the welding element vertically directly afterwards and fitted with a new one.

Fig. 1 - 4 Contact stud welding sequence

Note:

A threaded stud was chosen as welding element in the figure above. Other welding studs equipped with ignition tip are shown in chapter 1.8

1.5 Stud welding gun C1

Field of application

The C1 is a contact welding gun for welding studs with ignition tips. The welding elements should preferably be of steel and stainless steel. Brass or Aluminium studs can also be processed with limitations. Owing to the somewhat longer welding time (compared to gap welding) and deeper penetration, the C1 is especially suitable for lightly galvanised steel

Fig. 1 - 5 Contact welding gun C1

See chapter 5.6 for technical specifications and chapter 5.8 for individual part drawings and replacement part numbers.

Method

A welding element is first pushed into the Chuck of the welding gun. The ignition tip of the element is then placed down vertically

at the required point on the workpiece and the gun pressed down

until all positioning feet touch the workpiece (this pushes the plunger against the pressure spring). The welding current is then switched on and the welding process started by pressing the start button. The ignition tip evaporates and generates an arc, which melts the face of the stud and the workpiece. The pre-stressed pressure spring then forces the welding element into the weld pool and the arc is extinguished. The capacitors are discharged completely. The weld pool solidifies. This welding process lasts about 1.5 to 3.0 ms. The welding gun can be pulled off the welding element vertically directly afterwards and fitted with a new one.

Fig. 1 - 6 Contact stud welding sequence

Note:

A threaded stud was chosen as welding element in the figure above.

Other welding studs equipped with ignition tip are shown in chapter 1.8

1.6 Meaning and description of symbols

Start check:

• The following must light up when the power unit has been switched on: the main switch, the display (shows the setting for charging voltage)

Note:

• The LED for connection of a gun with hoisting magnet has no function when the gun C0 is being used.

• Hold the gun with stud against the workpiece: the contact LED must light up (when earth cable – on both sides – and welding cable connected).

• Hold the gun in the air and press the start button: the start LED must light up.

• Otherwise no further LEDs should light up.

Troubleshooting

See Troubleshooting chapter 5.1 Troubleshooting.

1.7 Other descriptions

Ignition tip The power unit NOMARK 65/99 and connected stud welding gun work by

the tip ignition welding method. In order to ignite an arc and therefore to generate a weld pool, every stud must have an ignition tip.

Fan To avoid unnecessary soiling, the fan is only switched on when a high temperature is reached.

Inert gas Inert gas is seldom used in tip ignition welding because the short welding time gives little time for oxidation.

1.8 Welding elements (studs)

Depending on how the welding gun is equipped, threaded studs, internal thread bushes and pins (in accordance with DIN 32 501) of various sizes and materials can be welded if they have an ignition tip.

Fig. 1 - 9 Examples of different types of welding elements

The following conditions must be observed:

• The diameter of the welding element must be <= 10.

• Length of welding studs : from 6 to 40 mm with standard components.

For studs longer than 40 mm, an intermediate ring must be used.

• Length of welding pins : from 6 to 100 mm with standard components.

• A suitable chuck must be selected for every welding element.

Note:

Please contact THOMAS regarding different Chuck shapes and sizes. See chapter 5.10 for standard chucks

1.9 Material combinations

The weldability of workpiece and welding element materials is defined as follows: 1 = weldable 2 = limited weldability 0 = not weldable/ not tested * = limited weldability with contact welding gun

Contact and gap welding

Tab: 1 - 10 Suitability of material combinations for tip ignition welding

Note:

Your THOMAS specialist advisor will be glad to advise you in the case of material combinations not listed in this table.

1.14 Angle bracket

With the angle bracket you can approach a right-angled surface to up to 8 mm with the gun and weld studs (order no. see chapter 5.10).

1.15 Bending device

The bending device is used in impact bending tests (see chapter 4.7). It is manufactured according to DIN 0905 Part 2. The five inserts must be ordered individually (order nos. see chapter

5.10).

1.16 Chucks (standard)

These chucks are used for threaded studs and un- threaded studs (order nos. see chapter 5.10).

1.17 Chucks (for insulation pins)

These chucks are used for insulating nails and pins (order nos. see chapter 5.10).

1.18 Chuck extension

The Chuck extension is only used when using a centring device (see chapter 1.10; order nos. see chapter 5.10).

1.20 Welding on centre punches

Welding elements with ignition tip can be positioned for pattern welding exactly on centre punches or scribed lines. Since the welding process is started by the ignition tip, marking must be performed carefully.

The arc cannot ignite on a centre punch struck too deeply. Should it nevertheless ignite, then the strength of the weld is questionable.

Therefore make sure that the depth of the centre punch does not exceed 0.3 mm.

Note: You can rule out this uncertainty by using a so-called automatic punch (order no. see chapter 5.10).