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KÖCO KST 108 Operating Manual

Stud welding equipment, stud welding gun
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This operating manual has the part-no. 399-0411-000. It is a translation of the original document.
Issue 4/2019 ver. 2.0
Köster & Co. GmbH
•
D-58256 Ennepetal
Internet:
http://www.koeco.
Operating Manual
KÖCO Stud Welding Equipment
KÖCO Stud Welding Gun
ESP 1 ISO
•
Spreeler Weg 32
net
•
E-Mail: koeco@koeco.
KST 108
KST 110
ESP 1 K
ESP 1 S
•
Tel. +49 2333 8306-0
net
page 1 of 42
•
Fax +49 2333 8306-38

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Summary of Contents for KÖCO KST 108

  • Page 1 Operating Manual KÖCO Stud Welding Equipment KST 108 KST 110 KÖCO Stud Welding Gun ESP 1 K ESP 1 S ESP 1 ISO This operating manual has the part-no. 399-0411-000. It is a translation of the original document. Issue 4/2019 ver. 2.0 page 1 of 42 Köster &...

  • Page 2: Operating Manual Köco Stud Welding Equipment Kst 108 Kst 110

    Hersteller: Köster & Co. GmbH Spreeler Weg 32 D-58256 Ennepetal Bezeichnung der Maschine: Bolzenschweißgerät Serien- / Typenbezeichnung: KST 108 & KST 110 Der oben beschriebene Gegenstand der Erklärung erfüllt die einschlägigen Harmonisierungsrechtsvorschriften der Union: 2006/42/EG Maschinenrichtlinie 2014/30/EU Elektromagnetische Verträglichkeit (EMV-Richtlinie) 2011/65/EU Beschränkung der Verwendung bestimmter gefährlicher Stoffe (RoHS-...

  • Page 3: Declaration Of Conformity Ec

    Germany, North Rhine Westphalia Product Type: stud welder Product Model: KST 108 & KST 110 The object of the declaration described above is in conformity with the essential requirements and other relevant requirements of the: Supply of Machinery (Safety) Regulations 2008 (S.I. 2008/1597) Electromagnetic Compatibility Regulations 2016 (S.I.

  • Page 4: Table Of Contents

    Table of contents Operating Manual KÖCO Stud Welding Equipment KST 108 KST 110 KÖCO Stud Welding Gun ESP 1 K ESP 1 S ESP 1 ISO Declaration of Conformity EC Table of contents 1 Introduction Information for the User Safety Instructions 1.1.1Personal Safety...
  • Page 5 Spare Parts List KST 108 and KST 110 Illustration of the ESP 1 K Welding Gun Illustration of the ESP 1 S Welding Gun Illustration of ESP 1 ISO welding gun Spare Parts List for the ESP 1 K Welding Gun...

  • Page 6: Introduction

    Information for the User This manual for your KÖCO KST 108 or KST 110 stud welding system and KÖCO ESP 1 K and ESP 1 S stud welding guns contains all necessary information about the equipment, safety instructions for stud welding opera-tions, and assessment of welds.

  • Page 7: 2Operational Safety Of The Equipment

    • No metallic jewellery (rings, chains, etc.) or watches may be worn during welding. • While welding is in progress, persons wearing heart pace-makers must keep at a safe distance from the appliance and the welding cables, because the strong magnetic fields generated could endanger their lives. •...
  • Page 8 taining oil, grease or solvent or packaging materials, even at several metres’ distance. • In case of doubt, check with the security officer in charge and obtain his release for the welding project be- fore starting work! • Make sure that the operating site has sufficient ventilation! •...

  • Page 9: Stud Welding With Tip Ignition

    Stud Welding with Tip Ignition Stud welding with tip ignition is a process for welding mostly cylindrical metallic parts with diameters from about 0.8 to 10 mm onto metallic workpieces from approximately 0.6 mm thickness. This process requires a capacitor plus a mobile device (welding gun).
  • Page 10 Fig 1: Tip ignition stud welding with voltage and current development curves (gap welding process) Explanation: 1: Stud welding with an air gap, start of the downward movement. 2: Contact between the ignition tip and the workpiece, explosion of the ignition tip and generation of the arc. 3: Generation of the welding pools while the stud continues its downward movement.

  • Page 11: The Power Source

    The standard model is laid out for a 230 V mains input voltage. Technical Data of KST 108 and KST 110 Power Sources Technical data KST 108...

  • Page 12: The Welding Gun

    The Welding Gun In tip ignition stud welding, the task of the welding gun is to hold the stud in its chuck, to conduct the welding current through the stud, and to unite the two welding pools by means of precisely controlled movements. When the welding process is triggered, the ESP 1 S gun first generates the air gap by activating its lifting mag- net.

  • Page 13: Requirements Placed On Materials

    Requirements placed on materials Basically, stud welding with tip ignition is possible with all materials suitable for arc welding. Even different mate- rials, such as carbon steel and stainless steel, can be welded together by this method without any problems, since blending between the two welding pools is only minimal, with hardly any brittle transition zones resulting.

  • Page 14: Working With The Stud Welding Equipment

    Working with the stud welding equipment Requirements before start-up 1. The power connection must be earthed according to regulations. 2. The housing of the power source must not have any electrical contact with the workpiece. Make sure that the insulating supporting legs are in perfect condition! 3.

  • Page 15: Start-Up Of The Esp 10 K Welding Gun

    each turn of the screw. A large gap shortens the welding time, a small gap lengthens the welding time. Now place the gun firmly on the workpiece so that all support legs are resting on the surface. The piston should now be pushed back by app. 1.5 mm (“protrusion”). Start-up of the ESP 10 K Welding Gun 1.

  • Page 16: Start-Up Of The Welding Gun Esp 1 Iso

    Start-up of the welding gun ESP 1 ISO With the ESP 1 ISO welding gun, insulating mats can be fastened to a metallic wall with cup head pins. The pin is pushed through the insulating mat, the mat should be a few millimeters thicker than the length of the pin. Upon initiation of the welding process, the tip of the pin melts and the underlying sheet melts.

  • Page 17: Start-Up Of Kst 108 Or Kst 110 Power Sources

    Start-up of KST 108 or KST 110 Power Sources Ready for Stud contact welding Increase charging voltage Charging voltage shown in volts (example) Reduce charging voltage Gap gun connected Figure 6: Control (with solenoid) panel 1. Make sure that the mains switch is in the „0“ position. Then plug in the mains plug.

  • Page 18: The Welding Process

    A longer welding time (reduction of the spring force, respectively reduction of the gap) can improve the quality of the welding on slightly soiled (oily) surfaces. The following recommended values for charging voltage and spring force, respectively gap, can serve as a guide: Pistol KST 110 KST 108 Pistol KST 110 ESP 1 K ESP 1 S Steel,...

  • Page 19: Weld Tests

    Weld tests Stud welds can be tested by several different methods: 1. Visual inspection A good weld will be surrounded by a closed, even ring of splashes with a diameter exceeding the diameter of the flange by no more than 1.5 mm. There must not be any visible gap between the flange of the stud and the workpiece surface.

  • Page 20: Maintenance Of The Power Source

    2. Bend Test: A good weld must reach a bending angle of 30° without developing cracks in the welding zone. The bend test serves to check the selected settings as well as the suitability of the welding conditions and the combination of materials.

  • Page 21: Maintenance Of The Welding Gun

    which may cause short-circuits and thus damage parts of the machine. Do not aim the jet of air at any PCB’s, but remove the dust from these with a vacuum cleaner. The power source must not be cleaned with water jets (for example high-pressure cleaners). Do not use sol- vents, because these could damage protective coatings and plastic parts.

  • Page 22: Trouble-Shooting

    Trouble-shooting In the event of malfunctions which the power source itself recognises, in the display field an "E" followed by a number will be shown. The following table shows the type of error. Error Signals from the Power Source Error No. Cause Remedy Mains power supply too high or too low...

  • Page 23: Other Malfunctions

    Other Malfunctions In the chart below, a number of malfunctions are described which can be diagnosed and remedied by trained service technicians with relative ease. In case you cannot solve these problems yourself, contact our agent in your neighbourhood or our customer service department. It is important that you give us details of the type and serial number of your appliance, as well as an exact description of the malfunction.

  • Page 24: Illustrations Of Kst Power Sources

    Illustrations of KST Power Sources 15, 16 Fig. 14: Right-side view of KST108 with the cover removed Issue 4/2019 ver. 2.0 page 23 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 •...
  • Page 25 Fig. 15: Left-side view (front) of KST 108 with the cover removed Issue 4/2019 ver. 2.0 page 24 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.
  • Page 26 15, 16 Fig. 16: Left-side view (rear) of KST 108 with the cover removed Issue 4/2019 ver. 2.0 page 25 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.
  • Page 27 15,16 Figure 17: Right-side view (rear) of KST 110 with the cover removed Figure 18: Detail diode KST 110 Issue 4/2019 ver. 2.0 page 26 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 •...
  • Page 28 Figure 19: Left-side view front of KST 110 with the cover removed Issue 4/2019 ver. 2.0 page 27 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.
  • Page 29 15, 16 Figure 20: Left-side view rear of KST 110 with the cover removed Issue 4/2019 ver. 2.0 page 28 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.

  • Page 30: Spare Parts List Kst 108 And Kst 110

    Spare Parts List KST 108 and KST 110 Item Quantity Description Part number housing 320-6500-000 cover 320-6501-000 carrying handle 320-0566-000 appliance leg 320-0012-000 cable gland 325-0027-000 nut for cable gland 325-0028-000 resistor 330-0148-000 operating card 330-5294-000 control card 330-5293-000 front foil...

  • Page 31: Illustration Of The Esp 1 K Welding Gun

    Illustration of the ESP 1 K Welding Gun Fig. 21: Detailed view of the ESP 1 K welding gun (contact welding) Issue 4/2019 ver. 2.0 page 30 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 •...

  • Page 32: Illustration Of The Esp 1 S Welding Gun

    Illustration of the ESP 1 S Welding Gun Fig. 22: Detailed view of the ESP 1 S welding gun (gap welding) Issue 4/2019 ver. 2.0 page 31 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 •...

  • Page 33: Köster & Co. Gmbh D-58256 Ennepetal Spreeler Weg

    Illustration of ESP 1 ISO welding gun Fig. 23: Detailed view of the ESP 1 ISO welding gun (welding of cup head pins) Issue 4/2019 ver. 2.0 page 32 of 42 • • • • Köster & Co. GmbH D-58256 Ennepetal Spreeler Weg 32 Tel.

  • Page 34: Spare Parts List For The Esp 1 K Welding Gun

    Spare Parts List for the ESP 1 K Welding Gun Item Description Part No. Note gun handle set 326-0001-000 Only available as set push button 326-0002-000 leg ring 326-0003-000 support leg 326-0004-000 lock ring 326-0005-000 bellows 326-0006-000 ball lining 326-0007-000 Not available as individual piston unit 326-0020-000...

  • Page 35: Spare Parts List For Esp 1 S Welding Gun

    Spare Parts List for ESP 1 S Welding Gun Item Description Part No. Note gun handle set 326-0001-000 Only available as set push button 326-0002-000 leg ring 326-0003-000 support leg 326-0004-000 lock ring 326-0005-000 bellows 326-0006-000 ball lining 326-0007-000 Not available as individual piston unit 326-0021-000 parts...

  • Page 36: Spare Parts List For Esp 1 Iso

    Spare Parts List for ESP 1 ISO Pos. Description Part No. Note welding gun body 322-0575-000 bottom gun handle 322-0597-000 top gun handle 322-0596-000 bellows 322-0589-000 clamping nut SW 17 322-0582-000 threaded pin M 6 x 8 322-0220-000 piston for cylindrical chuck 322-0577-000 connection chuck 329-0050-000...

  • Page 37: Circuit Diagram

    Circuit Diagram Fig. 23: Circuit diagram KST 108 and KST 110 Issue 4/2019 ver. 2.0 page 36 of 42 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...

  • Page 38: Accessories

    Accessories 14.1 Accessories for ESP 1 S and ESP 1 K welding guns Designation / Application Part No. Illustration 10 mm Ø chuck for threaded studs, D = 3 mm: 351-7003-000 smooth pins, tapped studs D = 4 mm: 351-7004-000 (D = external diameter of the stud) D = 5 mm: 351-7005-000 D = 6 mm: 351-7006-000...

  • Page 39: Special Centring Device

    chuck for 38 mm Ø pin, with copper 351-6162-000 plate part-no. 351-0048-000 Set of spacer bolts 10 mm long (3 pieces) 326-0026-000 Set of spacer bolts 20 mm long (3 pieces) 326-0024-000 14.2 Special centring device For welding with stencils, we offer the positioning tube No. 370-0335-000 or the support tube No. 326-0034-000. With these, a slight eccentricity of the gun’s axis cannot be excluded due to unavoidable tolerances in the gun’s plastic body.
  • Page 40 For setup, proceed as follows. Remove the 3 support legs, the lock ring and the protective bellows. Keep these for later re-use. Fig. 26: Setup, step 1 1. Thread a P5x sealing disc (Pos. 5) over the piston and press it about 2 mm down into the base ring, using a socket spanner (combination tool).
  • Page 41 1. Place the rear end of the gun on a horizontal surface. 2. Put the centring tube adapter (Pos. 1) on the base ring and place the three fastening holes above the three screw-in threads for the support legs. 3. Fasten the centring tube adapter lightly to the base ring with the 3 M4x12 screws (Pos.

  • Page 42: Alternative Gun Support For Studs Exceeding 50 Mm Length (In Particular Insulation Pins)

    14.3 Alternative gun support for studs exceeding 50 mm length (in particular insulation pins) Fig. 30: Gun support for studs exceeding 50 mm length Mounting Foot plate Supporting tube Stud diameter Chuck pos. 1 Leg pos. 5 flange pos. 2 pos.

  • Page 43: Literature

    Literature EN ISO 14555 “Arc Stud Welding of Metallic Materials” EN ISO 13918 “Studs and Ceramic Ferrules for Arc Stud Welding” DVS Technical bulletin 0901 “Stud Welding Processes for Metals – Overview” DVS Technical bulletin 0902 “Drawn Arc Stud Welding” DVS Technical bulletin 0903 “Stud Welding with Tip Ignition”...

This manual is also suitable for:

Kst 110Esp 1 kEsp 1 sEsp 1 iso

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