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Summary of Contents for STAUFF SWG-WG
- Page 1 Local Solutions For Individual Customers Worldwide SWG-WG SWG-WG Operating Manual...
- Page 2 +49 (0) 23 92 / 25 05 E-Mail sales@stauff.com www.stauff.com SWG-WG Operating Manual Issue 2016-06 Translation of the Original Operating Manual Please keep the manual in a safe place for future reference. Transmission and duplication of this document, dissemination and 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.
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Page 4: Table Of Contents
Symbols and Terms Used ������������������������������������������������������������������������� 9 Scope of Supply ��������������������������������������������������������������������������������������� 12 Technical Data ������������������������������������������������������������������������������������������ 13 Intended Use �������������������������������������������������������������������������������������������� 14 Usage with STAUFF Clamps ................14 Warranty ��������������������������������������������������������������������������������������������������� 15 Disclaimer ......................15 Design and Function ������������������������������������������������������������������������������� 16 Welding Process �������������������������������������������������������������������������������������� 17 Preparing the Stud Welding Gun �����������������������������������������������������������... - Page 5 Table of Contents Storage ����������������������������������������������������������������������������������������������������� 29 Disposal ���������������������������������������������������������������������������������������������������� 29 Declaration of Incorporation of partly completed Machinery �������������������������� 30 Service & Support ������������������������������������������������������������������������������������������������ 31 Index ���������������������������������������������������������������������������������������������������������������������� 32 ©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 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. Danger from incorrect use ‹... - 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, –...
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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 electro- des when the current is high enough. A whitish light is emitted in the process.
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Page 12: Scope Of Supply
Scope of Supply The basic configuration of your stud welding gun contains the following parts: No. of Part Type pieces Stud welding gun SWG-WG cable length 5 m Operating manual SWG-WG Toolkit optional distance tube DIT Ø 25mm distance tube DIT Ø 30mm... -
Page 13: Technical Data
4 Technical Data Technical Data Stud welding gun type SWG-WG for ARC stud welding according to current standards Welding range M3 - M12, Ø 2 - 12 mm / 0.1 - 0.5 in Stud length 10 - 400 mm / 0.4 - 15.7 in (depending on tripod) STAUFF stud 14mm / 0.6 in... -
Page 14: Intended Use
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. -
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: Design And Function
7 Design and Function Design and Function The stud welding gun SWG-WG is equipped with an integrated length adjustment for automatic compensation of length tolerance for the welding elements. The body of the stud welding gun consists of a sturdy two-part plastic housing (2). -
Page 17: Welding Process
8 Welding Process Welding Process This stud welding gun may only be used for drawn arc stud welding. ‹ Please refer to the original operating manual of the connected stud welding unit for the welding procedure. ©Walter Stauffenberg GmbH & Co. KG All rights reserved –... -
Page 18: Preparing The Stud Welding Gun
9 Preparing the Stud Welding Gun Preparing the Stud Welding Gun Prepare the stud welding gun by – mounting the chuck – mounting the DIT – adjusting lift and spring force – adjusting the penetration depth (protrusion). ‹ Do not connect the stud welding gun to the stud welding unit until it has been prepared. -
Page 19: Mounting The Tripod
9 Preparing the Stud Welding Gun Mounting the chuck (SR) / Setting the Insertion Depth (Protrusion) chuck ‹ Use the Allen key to remove the three screws of the positioning tube and remove the tube ‹ Remove the hexagon nut with the socket spanner and remove the stud holder ‹... -
Page 20: Setting The Welding Parameters
The specifications in the following table are guidelines. ‹ Select the applicable parameters for insertion depth, lift and spring force for your workpiece. Diameter of welding elements SWG-WG metric imperial (US) Welding elements Material: 4.8 (suitable for welding) / A2-50... - Page 21 9 Preparing the Stud Welding Gun Diameter of welding elements SWG-WG metrisch imperial (US) Welding elements Material: 4.8 (suitable for welding) / A2-50 Stud welding gun parameter Stud- Stud- eff. diameter eff. diameter diameter diameter in mm in inches Insertion...
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Page 22: Adjusting Lift
9 Preparing the Stud Welding Gun Adjusting Lift The adjustment piece for lift must not be turned by more than 360°. 1 - End ring 2 - Marking 3 - Adjustment piece lift 4 - Adjustment piece spring force ‹ Place the stud welding gun perpendicularly onto the workpiece. ‹... -
Page 23: Adjusting Spring Force
9 Preparing the Stud Welding Gun Adjusting Spring Force The adjustment piece for spring force must not be turned by more than 360°. ‹ Turn the adjustment piece for spring force only until you feel a noticeable resistance. ‹ Never turn the adjustment piece further with force, as otherwise mechanical parts of the stud welding gun may be damaged. -
Page 24: Welding
10 Welding Welding ‹ Work according to the original operating manual of the STAUFF stud welding unit. Danger if used other than for the intended purpose ‹ Use the stud welding gun only for ARC stud welding and only in combination with stud welding units from manufacturer: Walter Stauffenberg GmbH &... -
Page 25: Troubleshooting
11 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 26: Welding Gun
11 Troubleshooting Fault Possible cause Fault localisation Fault remedy Performance Stud welding gun does Ground connection Check, whether ground Connect ground cable Trained personnel not weld defective (no contact cable is connected to signal on stud welding workpiece in a technically unit) correct way Check ground cable for... -
Page 27: Maintenance And Care
12 Maintenance and Care Maintenance and Care Electric shock hazard ‹ Never perform maintenance and service work on your stud welding gun while it is connected to the stud welding unit ‹ Prior to this disconnect the stud welding gun from the stud welding unit. Danger from insufficiently qualified operating personnel ‹... -
Page 28: Inspection And Tests
12 Maintenance and Care 12.2 Inspection and Tests ‹ Inspect the chuck before every use. ‹ Replace the chuck if you discover burning marks on the welding element and/or on the chuck. ‹ Work here in accordance with point 9.1 „Mounting the chuck“ in this manual. ‹... -
Page 29: Storage
13 Storage Storage ‹ Store the stud welding gun in a safe and dust-free location when not in use. ‹ Protect the stud welding gun from moisture and metallic contamination. ‹ Store the stud welding gun only under the following ambient conditions. Storage temperature: -5 °C to +50 °C (23 °F to 122 °F) Relative humidity:... -
Page 30: Declaration Of Incorporation Of Partly Completed Machinery
Walter Stauffenberg GmbH & Co. KG Address: see manufacturer Werdohl, 21.03.2016 __________________________________ Place of issue, Date Carsten Krenz (General Manager STAUFF) ©Walter Stauffenberg GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 31: 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 32: Index
Index Index accessories . . . . . . . . . . . . . . . . . . . . . . . 12 insertion depth . - Page 33 Index warranty entitlement . . . . . . . . . . . . . . . . 15 welding cable . . . . . . . . . . . . . . . . . . . . . . 16 welding element .
- Page 36 Operating Manual SWG-WG 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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