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STAUFF SWG-WI06 Operating Manual

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Local Solutions For Individual Customers Worldwide
SWG-WI06
SWG-WI06
Operating Manual
©Walter Stauffenberg GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer

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  • Page 1 Local Solutions For Individual Customers Worldwide SWG-WI06 SWG-WI06 Operating Manual ©Walter Stauffenberg GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
  • Page 2 +49 (0) 23 92 / 25 05 E-Mail sales@stauff.com 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 notification of the contents are not permitted unless expressly approved.
  • Page 3 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.

  • Page 4: Table Of Contents

    Scope of Supply ��������������������������������������������������������������������������������������� 12 Accessories ���������������������������������������������������������������������������������������������� 12 Technical Data ������������������������������������������������������������������������������������������ 13 Intended Use �������������������������������������������������������������������������������������������� 14 Usage with STAUFF Clamps ................14 Warranty ��������������������������������������������������������������������������������������������������� 15 Disclaimer ......................15 Components of the Stud Welding Unit �������������������������������������������������� 16 Main Assemblies ....................16 Operation Panel and Display ................
  • Page 5 Table of Contents 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 ................

  • Page 6: Important Safety Precautions

    1 Important Safety Precautions Important Safety Precautions The target group for this manual are qualified 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.
  • Page 7 1 Important Safety Precautions 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.
  • Page 8 1 Important Safety Precautions ‹ Do not weld when wearing working clothes soiled with flammable substances such as oil, grease, petroleum, etc. ‹ Wear your proper protective clothing, such as: – Protective gloves in accordance with the relevant standard, – Non-flammable clothing, –...

  • Page 9: Symbols And Terms Used

    2 Symbols and Terms Used 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.
  • Page 10 2 Symbols and Terms Used 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 fire extinguisher for the working area ready before starting work.
  • Page 11 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 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.

  • Page 12: Scope Of Supply

    3 Scope of Supply Scope of Supply The basic configuration of your stud welding unit contains the following parts: No. of Part Type pieces Stud welding unit SWG-WI06 Ground cable SWG-GC Stud welding gun SWG-WG Distance tube DIT DIT-SR6 SWG-WG30 Stud retainer...

  • Page 13: Technical Data

    5 Technical Data 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...

  • Page 14: Intended Use

    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.

  • Page 15: Warranty

    The same applies likewise to installed units from our sub-suppliers. 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).

  • Page 16: Components Of The Stud Welding Unit

    8 Components of the Stud Welding Unit Components of the Stud Welding Unit Main Assemblies 1 - PFC mains input 4 - Medium frequency transformer 2 - Electrolytic capacitors 5 - Rectifier 3 - IGBT switch 6 - Control unit The mains voltage is rectified by the master switch and the EMV filter in the PFC unit (1).
  • Page 17 8 Components of the Stud Welding Unit 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 ©Walter Stauffenberg GmbH &...

  • Page 18: Operation Panel And Display

    8 Components of the Stud Welding Unit Operation Panel and Display - 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.

  • Page 19: Welding Process

    Drawn-Arc Stud Welding The STAUFF stud welding unit operates by process of ‘arc stud welding with drawn- arc 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’...
  • Page 20 9 Welding Process The shown ceramic ferrule does not apply for STAUFF welding studs – 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).
  • Page 21 9 Welding Process Variants of drawn-arc stud welding Item Drawn arc stud Drawn arc stud wel- Short-cycle drawn Capacitor discharge welding with ceramic ding with shielding arc stud welding with drawn arc stud welding ferrule shielding gas Diameter 3 - 25 3 - 12 (16) 3 - 12 2 - 8...
  • Page 22 NOTE! Ceramic ferrules, shielding gas or aluminium balls are not nessesary for the use of STAUFF internal thread welding studs M6. ©Walter Stauffenberg GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...

  • Page 23: Preparing Workplace And Welding Process

    10 Preparing Workplace and Welding Process 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. ‹...

  • Page 24: Preparing Surfaces

    This ensures a high strength of the welded joints. ‹ Weld the welding element only to a flat surface. ‹ Ask your application consultant at STAUFF about welded joints on tubes and riffle plates (see page 2). ©Walter Stauffenberg GmbH & Co. KG...

  • Page 25: 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 fit and ensure it is tightened.

  • Page 26: Connection

    11 Connection 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. ‹...

  • Page 27: Connecting The Welding Gun To The Stud Welding Unit

    11 Connection 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 firmly clockwise (to the right). Connect the control cable ‹...

  • Page 28: Connecting The Ground Cable

    11 Connection 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 firmly clockwise (to the right). Only loosely made connections will result in damage to the plug connectors.

  • Page 29: Connecting The Stud Welding Unit To The Mains Supply

    11 Connection 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.

  • Page 30: Welding

    12 Welding 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.

  • Page 31: Determining The Welding Time And The Welding Current

    12 Welding 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, –...
  • Page 32 NOTE! Ceramic ferrules, shielding gas or aluminium balls are not nessesary for the use of STAUFF internal thread welding studs M6. ©Walter Stauffenberg GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
  • Page 33 SWG-WG for drawn-arc stud welding without ceramic ferrule Diameter of welding elements Welding Welding Welding elements metric imperial (US) current time Material: SWG-WI06 SWG-WI06 4.8 (suitable for welding) Stud Stud I in A t in ms eff. diameter eff. diameter diameter...

  • Page 34: Setting The Welding Parameters

    12 Welding 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.

  • Page 35: Performing The Welding Process

    12 Welding 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.
  • Page 36 12 Welding Danger of deflagration 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 inflammable or promote combustion, – which may create health-endangering gases, fumes or airborne particulates, –...
  • Page 37 12 Welding 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. ‹...
  • Page 38 12 Welding ‹ 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.

  • Page 39: 13 Checking The Quality Of The Weld

    (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.

  • Page 40: Carrying Out Bending Test

    13 Checking the Quality of the Weld 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.

  • Page 41: Bending Test

    13 Checking the Quality of the Weld ‹ You don’t need to test all studs. It is sufficient 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...

  • Page 42: Optimisation Of Welding Parameters

    13 Checking the Quality of the Weld 13.3 Optimisation of Welding Parameters ‹ As first 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“. ‹...

  • Page 43: Blowing Effect And Remedies

    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 deflection of the light arc. This results in uneven melting of the stud material, in increased poring and undercuts in the welding area.

  • Page 44: Troubleshooting

    14 Troubleshooting Troubleshooting Danger from insufficiently qualified 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 qualified personnel. ‹ Inform your dealer or your maintenance department. Fault Possible cause Fault localisation...
  • Page 45 14 Troubleshooting Work marked with *) may only be carried out by qualified 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.

  • Page 46: Shutting Down

    15 Shutting Down 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.

  • Page 47: Maintenance And Care

    16 Maintenance and Care 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 insufficiently qualified operating personnel ‹ Carry out only the work described here on your stud welding unit. ‹...

  • Page 48: Inspection And Tests

    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.

  • Page 49: Storage

    17 Storage 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:...

  • Page 50: Ec Declaration Of Conformity

    Machine information: Stud welding unit Type: SWG-WI06 in conjunction with STAUFF components that the machinery fulfils 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“...

  • Page 51: Service & Support

    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.

  • Page 52: Index

    Index Index accessories . . . . . . . . . . . . . . . . . . . . . . . 12 hazards for the machine .
  • Page 53 Index stud feeder . . . . . . . . . . . . . . . . . . . . . . . . 11 stud welding gun .
  • Page 56 Operating Manual SWG-WI06 Contact Walter Stauffenberg GmbH & Co. KG Im Ehrenfeld 4 58791 Werdohl Germany Ÿ Ÿ Phone: +49 23 92 916 0 Fax.: +49 23 92 916 150 E-mail: sales@stauff.com www.stauff.com...

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