Nelson ALPHA 850 Operating Manual
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Nelson ALPHA 850 Operating Manual

Stud welding unit
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Operating manual
Stud welding unit
ALPHA 850
for drawn arc and short-term drawn arc processes
Edition:
Revision:
Document number
2021-07
Rev. A / 07.2021 / EN
EN

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  • Page 1 Operating manual Stud welding unit ALPHA 850 for drawn arc and short-term drawn arc processes Edition: 2021-07 Revision: Rev. A / 07.2021 / EN Document number...
  • Page 2 ALPHA 850 Operating manual Model / Device: Stud welding unit Original- Manufacturer TUCKER GmbH A Division of STANLEY Engineered Fastening Max-Eyth-Straße 1 D-35394 Gießen, Germany Tel.: +49 641 405 0 Fax: +49 641 405-383 E-mail: sef.europe@sbdinc.com Internet: www.tucker.eu www.stanleyengineeredfastening.com/brands/tucker Imprint...

  • Page 3: Table Of Contents

    Delivery and transport ................. 19 Scope of delivery ................ 19 Packaging and dispatch ............. 19 Incoming inspection ..............19 Interim storage ................19 Transport ..................19 Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 4 Visual inspection “drawn arc process” ............44 7.5.2 Visual inspection “short cycle drawn arc process” ........45 Maintenance ..................46 Care and cleaning ............... 46 Maintenance intervals..............47 Repairs ....................48 Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 5 Table of Contents Notes on repair ................48 Troubleshooting ................49 Appendix....................55 10.1 Disposal of welding devices ............55 10.2 Abbreviations ................58 10.3 Bibliography ................59 Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 6: Introduction

    Page 1 Introduction General remarks This operating manual is about the ALPHA 850 welding device and is intended for operating and service personnel. The ALPHA 850 welding device can only be operated safely and reliably with knowledge of the contents of this operating manual.

  • Page 7: Device Description

    850 A. The AC grid power supply is transformed through a transformer and then rectified. The entire weld cycle is coordinated by the ALPHA 850’s control unit and can be monitored with the LED display elements.

  • Page 8: Weld Process

    Introduction Page 3 Weld process The ALPHA 850 welding device can be used to weld ordinary commercial studs both in the short cycle drawn arc process (BH 10) as well as under the drawn arc process (abbreviated BH 100). The drawn arc process is for full-surface welding of studs of specific geometric dimensions on metal workpieces that have a wall thickness of at least 1/4 of the stud diameter.

  • Page 9: Process

    The weld time in the short cycle drawn arc process is about 10 ms – 100 ms. The weld time in the drawn arc process is about 100 ms – 1000 ms. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 10: Weld Elements

    The following conditions must be observed. • A matching ceramic ring (CF) is necessary for every stud diameter. • For different ceramic rings, corresponding ceramic ring holders are needed . Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 11: Material Combinations

    For material combinations that are not listed in the table, a Tucker expert must be consulted. EN ISO 15614-1, 2: Specification and qualification of welding procedures for metallic materials – Welding procedure test Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 12: Technical Data

    Introduction Page 7 Technical data Device designation/type: ALPHA 850 welding device Version: Europe standard Input voltage: 3 ~ 400 V (± 10%); others on request Grid frequency: 50/60 Hz Power fuse: per phase 35 A (at 400 V) Connected load:...
  • Page 13 1 Power cable for sorter (220 V): Order No. 49-06-25 • Shielding gas-retrofit kit: 1 Retrofit kit (complete): Order No. 66-01-37 10 m shielding gas hose system (ALPHA 850 gun): Order No. 67-07-50 • Catalogue: “Fastening elements” catalogue: Order No. LFH 000 “Gun accessories” catalogue: Order No.
  • Page 14 8 × 0.5 mm Length 5.0 m: Order No. 68-04-82 (others on request) • Connecting cable (extension): ALPHA 850 - Gun NS 40: 1 Cable set complete with welding cable and control cable: Welding cable diameter: 50 mm Control cable diameter: 4 ×...
  • Page 15 Stud bolt (SC - S) 3 mm - 12 mm Internally threaded socket (MI) M4 - M8 / 10 mm - 12 mm ≤ 10 mm Head bolt (KB) Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 16: Declaration Of Conformity

    Germany Product name: Control and power unit for stud arc welding Models: Alpha 850 Serial Number: Year of construction: The manufacturer hereby declares that the products stipulated above comply with all relevant provisions and requirements of the following applicable directives: 2006/42/EU –...

  • Page 17: Work Safety

    This sign indicates important information about proper handling of the product or special instructions that should receive special attention. Warning: • Everyone who works on the ALPHA 850 is obligated, before starting work, to read and follow the safety instructions in this operating manual! •...

  • Page 18: Safety Instructions

    A prerequisite for safe handling and trouble-free operation of the ALPHA 850 welding device is knowledge of the following safety instructions. Informal safety instructions: • The operating manual must always be stored at the place where the ALPHA 850 is used. • The safety symbols and type plate must be kept legible.
  • Page 19 The system owner is obligated to take suitable corrective measures. Warning: • The ALPHA 850 welding device is suitable according to standard EN 55011 for use in an industrial environment (limit class A). • It is explicitly pointed out that devices in limit class A can cause radio interference in residential and business areas.
  • Page 20 • Only authorized electro-technical personnel are allowed to open the welding device or work inside its housing. • Before the welding device is closed, the earth conductor must be connected to the device housing. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 21 Safety features of the ALPHA 850 welding device The ALPHA 850 welding device bears the “S” symbol and is suitable for “welding in tight spaces and under elevated electrical hazards” (for more details, see DGUV Information 209-010).

  • Page 22: Intended Use

    • The information in this operating manual regarding material combinations and characteristics of studs and base materials must be observed. • The ALPHA 850 welding device’s place of use is limited to the industrial and commercial sector. The ALPHA 850 is not suitable for use in residential and business areas because, depending on the process, there may be electromagnetic disturbances to external electrical and electronic devices.

  • Page 23: Warranty And Liability

    • Unintended use of the ALPHA 850 welding device. • Failure to follow the operating manual of the ALPHA 850 welding device. • Failure to follow the operating manuals of the system components.

  • Page 24: Delivery And Transport

    Interim storage If the ALPHA 850 welding device is not put into operation immediately after delivery, it must be temporarily stored in a secured area. The welding device must be adequately protected against dust and moisture. The storage temperature can be found in the technical data (see Chapter 1.8).

  • Page 25: Location Of Use

    Delivery and transport Page 20 Location of use The ALPHA 850 welding device’s place of use is limited to the industrial and commercial sector. During bad weather, such as rain, snow, etc., welding outdoors or in unprotected rooms is prohibited.

  • Page 26: Connection And Installation

    The power supply cable and connecting parts are functionally arranged on the front plate of the ALPHA 850 welding device. Warning: • Before starting connection work, turn off the ALPHA 850 welding device! The device’s main switch must be in the “O” position.

  • Page 27: Power Cable Connection

    • Only electro-technical personnel are to open the welding device or work within its housing! The power supply values are marked on the ALPHA 850 type plate: Europe standard version: • Grid frequency: 50 Hz – 60 Hz, •...
  • Page 28 When connecting to a 230 V delta circuit [ ] / 400 V star circuit [ ] the phases must be assigned as follows and the following connection terminals must be linked: Primary voltage Link 230 V 400 V Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 29: Welding Cable Connection

    When connecting a welding gun with manual stud loading, the gun’s welding cable must be: - connected directly to the ALPHA 850, - connected through a welding cable extension (option) to the ALPHA 850. Automatic mode (option): • When connecting a gun with automatic stud loading, the welding gun’s...

  • Page 30: Control Cable Connection

    When connecting a welding gun with manual stud loading, the gun’s control cable must be: - connected directly to the ALPHA 850’s 4-pin control cable socket, - connected through a control cable extension (option) to the ALPHA 850. Automatic mode (option): •...

  • Page 31: Earth Cable Connection

    The earth cable’s plug must be connected to the socket marked X21. The connection must be secured by a strong turn rightward. Earth cables and earth clamps are not delivered with the ALPHA 850. Warning: • The earth cable connection cannot be locked! The connection must be tested regularly for tightness! •...
  • Page 32 90°. clamp and additional metal plates. Note: The polarity in the illustration relates to ferromagnetic materials. When welding aluminium, the opposite polarity must be ensured! Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 33: Control And Display Elements

    Operating and display elements Page 28 Control and display elements All control and display elements of the ALPHA 850 welding device are on the upper front plate and marked with graphic symbols. Power switch LED for gun coil circuit Weld current potentiometer...
  • Page 34 = drawn arc process (BH 100) = Short cycle process (BH 10) The setting is done according to the weld process BH 10 or BH 100. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 35: Display Elements

    The LED display elements signal specific functions of the welding process and are useful for troubleshooting the welding system. After connection of the ALPHA 850 welding device (see Chapter 4), the following functions can be understood visually. *) The position numbers in parentheses refer to the position numbers in the illustration on page 28.

  • Page 36: Equipment Fuses

    • Only authorized electro-technical personnel are allowed to open the welding device or work inside its housing. • Before opening the welding device, the ALPHA 850 must be switched off, unplugged and secured against restart! • Before closing the device housing, the earth conductors must be reconnected to all housing parts.
  • Page 37 Fuse elements F1–F3 are on PCB LP 850. The fuse element F4 is on the transformer clamping strip: Warning: • Defective fuses should always be exchanged for identical fuses with identical nominal values! Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 38: Start-Up And Weld Quality Check

    8. Always lay the welding and earth cable without loops. This can largely prevent electromagnetic influences. 9. Check the setting values required for your welding task* on the ALPHA 850 welding device and on the connected gun. 10. During the welding process, the position of the gun and welding process are not to be changed.

  • Page 39: Adjusting The Weld Parameters

    Based on the weld result, the settings to the electrical and mechanical weld parameters must be adjusted to the specific welding task. If defective welds are suspected, the settings on the ALPHA 850 welding device and the welding gun must be optimized.
  • Page 40 Rule of thumb for drawn arc process: • Weld current [A] ≈ 70 × Weld Ø [mm] Weld time [ms] ≈ 40 × Weld Ø [mm] • Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 41 WELD DIAMETER [MM] Electrical weld parameters (short cycle process) 1000 Strom [A] Zeit x 10 [ms) WELD DIAMETER [MM] *) ESF: Weld stud with even front surface Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 42 Strom [A] Zeit x 10 [ms] WELD DIAMETER [MM] *) ESF: Weld stud with even front surface *) KSF: Weld stud with conically tapered front surface Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 43: Commissioning Conditions

    1. Make sure that the welding system’s location of use meets the requirements in Chapters 3.6 and 3.7. 2. Check for correct configuration of the ALPHA 850 with the welding guns, sorters and any shielding gas equipment indicated in Chapter 1.8.

  • Page 44: Functional Test

    1. Set the mechanical weld parameters on the gun. The settings can be found in the NS 40 operating manual. 2. Turn the ALPHA 850 on. If welding is being done under shielding gas (optional), a toggle switch on the back of the device must also be turned on.
  • Page 45 Start-up and weld quality check Page 40 5. Set the electrical weld parameters on the ALPHA 850. The parameter guidelines can be found in the table in Chapter 7.2. 6. Position the gun on the weld point. As soon as the stud contacts the workpiece surface, the “Contact”...
  • Page 46 4. Turn the sorter and welding device on. If welding is being done under shielding gas, a toggle switch on the back of the ALPHA 850 must also be activated. When the welding device is turned on, the “System voltage” LED goes on. The welding gun is supplied with 90 VDC and 24 VDC.
  • Page 47 24. If the weld results are poor, optimize the weld parameters. The test welds must be repeated until the optimal weld quality can be achieved. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 48: Checking Weld Quality

    • Make sure welding work does not continue until the test results are satisfactory. *) Information for visual inspection can be found on the following pages. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 49: Visual Inspection "Drawn Arc Process

    Corrective action: Decrease weld time and weld current, adjust stud stick out and/or damping. EN ISO 15614-1, 2: Specification and qualification of welding procedures for metallic materials – Welding procedure test Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 50: Visual Inspection "Short Cycle Drawn Arc Process

    Corrective action: Eliminate blow effect by applying smoothing compound or correcting the earth clamps. EN ISO 15614-1, 2: Specification and qualification of welding procedures for metallic materials – Welding procedure test Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 51: Maintenance

    The stud welding system requires no special care. The required cleaning tasks for the gun and sorter can be found in the specific devices’ operating manuals. For the ALPHA 850 welding device, the following cleaning tasks are required. Here it should be noted: Warning: •...

  • Page 52: Maintenance Intervals

    Before maintenance starts, the welding device must be switched off, unplugged and secured against restart! • If there are malfunctions, mechanical defects, overheating damage or contact with liquids, the ALPHA 850 must shut down and repairs made! Maintenance interval Warnings...

  • Page 53: Repairs

    Technical personnel in the field of electrical repair, preferably familiar with welding, cutting and related processes (see EN 60974-4) • Repairs to the ALPHA 850 welding device are to be done only as part of maintenance. • The ALPHA 850 can be repaired with ordinary commercial tools. No special tools are needed.

  • Page 54: Troubleshooting

    • After the problem has been repaired, it is absolutely necessary to perform a functional inspection of the welding system! Fault: Power supply • ALPHA 850 shows no reaction Features: • “System voltage" LED doesn’t light up • Fan won’t run...
  • Page 55 Repairs Page 50 Fault: Overload/phase error • ALPHA 850 is switched on Features: • “System voltage" LED lights up • Gun doesn’t work when start triggered • no weld Possible What is to be Test Test result achieved? cause tested or how?
  • Page 56 Repairs Page 51 Fault: Gun function • ALPHA 850 is switched on Features: • “System voltage" LED lights up • Fan runs • The “Fault” multi-function LED doesn’t go on • Gun doesn’t work when start triggered • no weld...
  • Page 57 Repairs Page 52 Fault: Welding • ALPHA 850 is switched on Features: • “System voltage" LED lights up • Fan runs • “Fault” multi-function LED lights up white • Gun works at start trigger (air release) • no weld Possible...
  • Page 58 The arrangement of the internal fuses (F1, F2) and the diagnostic LEDs (H2–H18) on the internal PCBs can be found in the illustration on the next page. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 59 Repairs Page 54 F1 – F3: Fuse elements X1 – X4: Plug connection H2 – H18: Diagnostic LEDs Internal control card (example illustration) Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 60: Appendix

    Underground landfill Disposal as waste requiring special supervision When storing materials, environmental regulations must be complied with. Proof is required of proper disposal according to KrWG* Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 61 Appendix Page 56 In terms of product stewardship, Tucker offers fee-based return and disposal of its device and system components. KrWG; Circular Economy Act Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 62 Tucker offers fee-based return and environmentally sound disposal of its devices and system components. Please contact us! ) B2B device: Business-to-business device, device intended only for commercial use. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 63: 10.2 Abbreviations

    Shielding gas T [°C] Temperature in [degrees Celsius] t [ms], [s] Time in [milliseconds], [seconds] U [V] Voltage in [volts] Verband der Elektrotechnik Elektronik Informationstechnik e. V. Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

  • Page 64: 10.3 Bibliography

    Part 12 – Coupling devices for welding cables EN ISO 13918: Welding – studs and ceramic rings for arc stud welding EN ISO 14555: Welding – Arc stud welding of metallic materials Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...
  • Page 65 EN ISO 15614-2: Specification and qualification of welding procedures for metallic materials – Welding procedure test Part 2: Arc welding of aluminium and its alloys KrWG: Circular Economy Act Stud welding unit operating manual Date: July 2021 ALPHA 850 07.2021 / EN Rev.:...

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