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KÖCO ELOTOP 510 Operating Manual

Stud welding equipment, stud welding guns
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Operating Manual
KÖCO-Compact Stud Welding Equipment
ELOTOP 510
KÖCO Stud Welding Guns
CLASSIC
SK 14 from no. 10000
SK 14-ISO from no. 17200
SK 14 short
SK 15
K 22
This operating manual has the part-no. 399-0541-000. It is a translation of the original document.
Issue 02/2023 ver. 1.3
Page 1 of 51
Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38
Internet: http://www.koeco.net • E-Mail: koeco@koeco.net

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  • Page 1: Operating Manual Köco-Compact Stud Welding Equipment Elotop 510

    Operating Manual KÖCO-Compact Stud Welding Equipment ELOTOP 510 KÖCO Stud Welding Guns CLASSIC SK 14 from no. 10000 SK 14-ISO from no. 17200 SK 14 short SK 15 K 22 This operating manual has the part-no. 399-0541-000. It is a translation of the original document.

  • Page 2: Ukca-Declaration Of Conformity

    58256 Ennepetal Germany, North Rhine Westphalia Product Type: stud welder Product Model: ELOTOP 510 Serial Number: 18100475 - 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 3: Original-Eg-Konformitätserklärung

    Die alleinige Verantwortung für die Ausstellung dieser Konformitätserklärung trägt der Hersteller: Köster & Co. GmbH Spreeler Weg 32 D-58256 Ennepetal Bezeichnung der Maschine: Bolzenschweißgerät Serien- / Typenbezeichnung: Reihe ELOTOP 510 Seriennummer: 18100475 - Der oben beschriebene Gegenstand der Erklärung erfüllt die einschlägigen Harmonisierungsrechtsvorschriften der Union: 2006/42/EG Maschinenrichtlinie 2014/30/EU Elektromagnetische Verträglichkeit (EMV-Richtlinie)

  • Page 4: Table Of Contents

    Table of Contents Operating Manual KÖCO-Compact Stud Welding Equipment ELOTOP 510 KÖCO Stud Welding Guns CLASSIC SK 14 from no. 10000 SK 14-ISO from no. 17200 SK 14 short SK 15 K 22 UKCA-Declaration of Conformity Original-EG-Konformitätserklärung Table of Contents...
  • Page 5 Pictures of the Power Sources ELOTOP Spare Parts for Welding Power Source ELOTOP 510(-ISO) Pictures of Stud Welding Guns CLASSIC Spare Parts for Stud Welding Guns CLASSIC Spare parts list gun SK 14, SK 14-ISO, SK 14 short and SK 15...

  • Page 6: Introduction

    Safety Instructions The KÖCO stud welding equipment ELOTOP 510 and the stud welding gun system CLASSIC is designed for use in drawn-arc stud welding only. It must not be used for any other purpose. In particular, welding under water is strictly prohibited, nor is it permissible under any circumstances to use the appliance for thawing up frozen water pipes.

  • Page 7: Operational Safety Of The Equipment

    ▪ During the welding process, persons wearing heart pace-makers must be kept at a safe distance from the appliance and the welding cables, because the strong magnetic fields could endanger their lives. ▪ In addition to the above, all normal accident prevention regulations must be observed. 1.2.2 Operational Safety of the Equipment ▪...
  • Page 8 ▪ Do not carry out welding on hollow objects which contain, or have contained, inflammable liquids or gases, or which are under pressure, or inside which a dangerous level of pressure can be generated by welding heat! ▪ The heat generated by welding may lead to the release of gases or vapours which are dangerous to health or even explosive.

  • Page 9: Drawn Arc Stud Welding

    Drawn Arc Stud Welding Drawn-arc stud welding is used for the welding of metallic parts, generally of cylindrical shape, onto metallic workpieces. For this purpose, a DC power source and a mobile device, the welding gun, are required. Depending on the type of welding-pool protection and welding time range used, the appropriate process may be stud welding with a ceramic ferrule, stud welding with with shielding gas, or short-cycle stud welding, either with or without shielding gas.

  • Page 10: Technical Data On Elotop Power Source 510

    Technical Data on ELOTOP Power Source 510 Technical data ELOTOP 510 3 – 8 (M 10r) Stud welding with ceramic ferrule, weldable stud range Ø (mm) 3 – 6 (with shielding gas 3 to 8) Short-cycle stud welding, weldable stud range Ø (mm) Stud welding with shielding gas, weldable stud range Ø...

  • Page 11: The Power Source

    The Power Source The power source consists of a 3-phase transformer, a rectifier, a thyristor module and an electronic control. All ELOTOP power source models can be supplied with alternative nominal voltages. Operation at undervoltage will lead to reduced welding current. Depending on circumstances, it may be necessary to shorten the extension cables, to ensure satisfactory welding quality.

  • Page 12: Technical Data On Köco Stud Welding Guns

    Technical Data on KÖCO Stud Welding Guns Technical Data SK 14 (short) SK 14-ISO SK 15 K 22 Stud welding with ceramic ferrule 4 - 12 4 - 12 4 - 12 4 - 14 Weldable stud range Ø (mm) Short cycle stud welding 3 - 12 3 - 12...

  • Page 13: Setting Guidelines For Stud Welding

    Setting Guidelines for stud welding The settings given in chart 3 have been tested for welds on clean metallic surfaces and standard type studs in downhand position (PA). Under different conditions (other welding position, or oily, scaly or primer-coated sur- faces) the optimal settings must be determined by test welds.

  • Page 14: Material Requirements

    Material requirements General remarks In principle, all materials suitable for fusion welding are also suitable for drawn arc stud welding. However, for some sensitive varieties of steel there is a certain risk that they may harden and become brittle by the quick heating and cooling processes involved.

  • Page 15: Working With The Stud Welding Equipment

    Working with the stud welding equipment Requirements before starting-up 1. Ensure adequate power supply, according to instructions under section 2.2. 2. The power connection must be earthed according to regulations. 3. The housing of the welding power source must not have any electrical contact with the workpiece. Make sure that the insulating supporting legs are in perfect condition! 4.
  • Page 16 8. Only when welding with a ceramic ferrule: Place a suitable ceramic ferrule into its grip. Check the center- ing of the footpiece by manually pulling back the piston of the gun and then slowly releasing it again. The stud should then move forward without pushing the ceramic ferrule out of its guide. If the ceramic ferrule is pushed out, loosen the footpiece and improve its centering.
  • Page 17 (length of the drawn arc) must therefore be calculated as follows: Lift = value displayed + 1 mm – protrusion The lift can only be adjusted in 0.5 mm steps. Do not try to set any intermediate values! Follow the instructions according to chart 3 when setting the lift. Figure 5: Setting of the lift (SK 14, SK 14 short and SK 15) Issue 02/2023 ver.

  • Page 18: Starting-Up Of The Power Source

    Starting-up of the Power Source 1. Insert the mains plug into the socket and lock it into position using the lock ring (if available). 2. Connect the ground cable to the ground socket of the welding power source and the workpiece. The con- nection points on the workpiece must be bright metal.
  • Page 19 Figure 6: Assessment of visual examination Explanantion: Nominal length of stud A: Good weld B: Energy too high C: Energy too low A frequent fault is a so-called plunging impediment. It occurs whenever the plunging movement of the stud is cut short and the stud comes to a halt above the welding pool (see chart 5, figure 4).

  • Page 20: Maintenance Of The Welding Power Source

    Chart 5: Assessment of stud welds Appearance Remarks Good weld with ceramic ferrule Good weld with shielding gas Lopsided melting because of arc-blow effect. This can be reme- died by adjusting the earth clamps, by providing compensating masses at the rim, or by turning the gun (if the welding cable is on the outside).

  • Page 21: Maintenance Of The Welding Gun

    workpiece. Therefore make sure that the insulating legs are in perfect condition if the ground has any conducting connection with the workpiece. Maintenance of the Welding Gun The welding gun is an electrical tool which must be kept perfectly insulated. In case of any damage to its body or cables, welding must be discontinued at once.

  • Page 22: Shutting-Down

    3.11 Shutting-Down After termination of welding the power switch must first be turned off. In case of interruption for any length of time, the appliance should also be disconnected from the mains (i.e. by pulling out the plug). Never use the mains plug in lieu of a switch, i.e.

  • Page 23: Remedies For Malfunctions

    Remedies for Malfunctions Error signals at the Power Source The following errors are indicated at the front panel of the power source: “E01”: Excessive current or short circuit in the control cable 4.1.1 “E02”: Over heating: The yellow LED below the green LED lights up. Keep the power source 4.1.2 switched on (fan operating) to minimize cooling time.
  • Page 24 Malfunction Cause Remedy Faulty welding result Surface of the workpiece oily, Clean the surface of the workpiece in the welding area in spite of correctly greasy, rusty, zinc-coated or and at the ground connection points. The best results set welding parame- painted, etc.

  • Page 25: Pictures Of The Power Sources Elotop

    Pictures of the Power Sources ELOTOP Figure 8: Front view ELOTOP 510 Issue 02/2023 ver. 1.3 Page 25 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38...
  • Page 26 Figure 9: Rear view of ELOTOP 510 Issue 02/2023 ver. 1.3 Page 26 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net...
  • Page 27 Figure 10: View from above Issue 02/2023 ver. 1.3 Page 27 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net...

  • Page 28: Spare Parts For Welding Power Source Elotop 510(-Iso)

    Spare Parts for Welding Power Source ELOTOP 510(-ISO) Part No. Pos. Designation 230 V 400 V 460 V 320-0800-000 320-0800-000 320-0800-000 Frame 320-0050-000 320-0050-000 320-0050-000 Handle Hood 320-0801-000 320-0801-000 320-0801-000 320-0263-000 320-0263-000 320-0263-000 Plastic leg 399-0040-000 399-0040-000 399-0040-000 Front foil...

  • Page 29: Pictures Of Stud Welding Guns Classic

    7 Pictures of Stud Welding Guns CLASSIC Figure 11: Exploded view of gun SK 14 Issue 02/2023 ver. 1.3 Page 29 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net •...
  • Page 30 Figure 12: Exploded view of gun SK 14-ISO Issue 02/2023 ver. 1.3 Page 30 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net...
  • Page 31 Figure 13: Exploded view of gun SK 14 short Issue 02/2023 ver. 1.3 Page 31 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net...
  • Page 32 Figure 14: Exploded view of gun K 22 with option K 22-D Issue 02/2023 ver. 1.3 Page 32 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net •...

  • Page 33: Spare Parts For Stud Welding Guns Classic

    Spare Parts for Stud Welding Guns CLASSIC Spare parts list gun SK 14, SK 14-ISO, SK 14 short and SK 15 Part-no. Item Description SK 14 SK 14-ISO SK 14 short SK 15 welding gun body 322-0601-000 322-0601-000 322-0604-000 322-0605-000 322-0597-000 lower gun handle 322-0597-000 322-0597-000...
  • Page 34 8.2 Spare parts list gun K 22 Pos. Designation Part Number Gun body 322-6051-000 Handle cover 322-0075-000 Mounting plate with guide bushes 322-6045-000 Piston cylinder 322-6085-000 Piston 322-0109-000 Adapter screw 329-0026-000 Bellows 322-0098-000 Threaded bolt 322-0108-000 Spring guide 322-0125-000 Main tension spring 322-0083-000 Lifting ring pin 322-0200-000...

  • Page 35: Pictures Of Cables

    Pictures of Cables Figure 14: Welding cable extension and ground cable Issue 02/2023 ver. 1.3 Page 35 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net •...

  • Page 36: Cable Spare Part List

    Cable Spare Part List Pos. Designation Part No. Welding and control cable extensions 10 m, 50 mm² (complete set) 317-5015-000 Welding and control cable extensions 10 m, 70 mm² (complete set) 317-5010-000 Pair of earth cable 10 m, 70 mm² with pole clamp (complete set) 317-5031-000 Pole clamp, jaws width 200 mm 325-0174-000...

  • Page 37: Schematic Circuit Diagram

    Schematic Circuit Diagram Figure 16: Schematic circuit diagram ELOTOP 510 (version 400 V) Issue 02/2023 ver. 1.3 Page 37 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38...
  • Page 38 Figure 17: Schematic circuit diagram ELOTOP 510 (version 230 V) Issue 02/2023 ver. 1.3 Page 38 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net...
  • Page 39 Figure 18: Schematic circuit diagram ELOTOP 510 (version 460 V) Issue 02/2023 ver. 1.3 Page 39 of 51 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 Internet: http://www.koeco.net • E-Mail: koeco@koeco.net...

  • Page 40: Accessories

    Accessories 12.1 Gun accessories for gun K 22 Figure 19: Gun accessories for threaded studs, tapped studs and plain pins Chuck Ferrule grip Foot plate Type P Type D Type R Pos. 1 Pos. 3 Pos. 2 M 4 x > 20 M 4 x >...
  • Page 41 Stud length up to (mm) Required length of Part No. legs (mm) Pos. 4 K 22 and K 22-D K 24 K 26 370-0240-000 370-0300-000 370-0400-000 370-0500-000 370-0322-000 370-0323-000 Washer Pos. 5 370-0055-000 Screw with hexagon socket Pos. 6 322-0372-000 For studs below 10 mm diameter and lengths L >...
  • Page 42 Figure 20: Gun accessories for Insulation pins Chuck Stud dimension Foot plate Pos. 2 Supporting tube Pos. 3 Pos. 1 350-0086-000 (Steel) from 3 x 35 350-0087-000 (Copper) 370-0103-000 370-0167-000 from 4 x 35 350-0088-000 (Steel) from 5 x 35 350-0089-000 (Steel) Stud length up to Required length...
  • Page 43 Figure 21: Gun accessories for short cycle stud welding without shielding gas Supporting Stud diameter d Chuck Pos. 1 Foot plate Pos. 2 Leg Pos. 4 tube Pos. 3 350-0001-000 350-0002-000 350-0003-000 360-0103-000 370-0240-000 370-0167-000 350-0005-000 350-0007-000 350-0009-000 Washer Pos. 5 370-0055-000 Screw with hexagon socket Pos.
  • Page 44 Figure 22: Gun accessories for Stud welding with shielding gas (Gun K 22) Foot plate with 3 Supporting tube Chuck socket head cap with 3 socket head Stud diameter d Pos. 1 screws M 4 x 10 Pos. 4 cap screws M 4 x Pos.
  • Page 45 Figure 23: Gun accessories for grid fastening Dimension Chuck Pos. 1 Ferrule grip Pos. 3 Supporting Insulating Foot plate tube Pos. 4 tube Pos. 5 Pos. 2 M 6 x > 20 350-0033-000 355-0002-000 M 6 x > 60 350-0005-000 M 8 x >...
  • Page 46 Figure 24: Gun accessories for welding of Fibrefix-pins Ø 5, Length L Chuck Pos. 1 Foot plate Pos. 2 Ferule grip Pos. 3 Leg Pos. 4 370-0240-000 Up to L = 160 mm 370-0300-000 Up to L = 220 mm 350-0100-000 360-0101-000 355-0002-000...

  • Page 47: Gun Accessories For Gun Sk 14, Sk 14-Iso And Sk 14 Short

    12.2 Gun accessories for gun SK 14, SK 14-ISO and SK 14 short Figure 25: Gun accessories for short-cycle stud welding without shielding gas (gun SK 14) Stud dimen- Chuck Foot plate Supporting Leg Pos. 4 sion (D x L) Pos.
  • Page 48 Figure 26: Gun accessories for threaded studs and plain pins (SK 14 with ceramic ferrule) Type P Type D Type R Chuck Ferrule grip Foot plate Pos. 1 Pos. 3 Pos. 2 M 4 x > 16 M 4 x > 16 350-0002-000 355-0001-000 M 5 x >...
  • Page 49 Figure 27: Gun accessories for insulation pins (gun SK 14 and SK 14-ISO) Chuck Foot plate Supporting Stud dimension Pos. 1 Pos. 2 tube Pos. 3 350-0086-000 (Steel) from 3 x 35 350-0087-000 (Copper) 360-0012-000 360-0335-000 from 4 x 35 350-0088-000 (Steel) from 5 x 35 350-0089-000 (Steel)
  • Page 50 Figure 28: Gun accessories for stud welding with shielding gas (gun SK 14) Foot plate with 2 Supporting tube Chuck socket head cap with 2 socket Stud diameter d Leg Pos. 4 Pos. 1 screws M 4 x 10 head cap screws Pos.

  • Page 51: Literature

    Literature EN ISO 14555 “Drawn arc stud welding of metallic materials“ EN ISO 13918 “Studs and Ceramic Ferrules for Drawn Arc Stud Welding“ DVS-Technical bulletin 0901 “Stud Welding Procedures 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:

Classic sk 14Classic sk 14-isoClassic sk 14 shortClassic sk 15Classic k 22

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