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KÖCO 805i Operating Manual

Compact stud welding equipment, stud welding guns
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Operating Manual
KÖCO Compact Stud Welding Equipment
805i
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. 399-0581-000. It is a translation of the original document.
Issue 02/2023 ver. 1.2
Page 1 of 62
Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38
• E-Mail:
Internet:
http://www.koeco.net
koeco@koeco.net

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Summary of Contents for KÖCO 805i

  • Page 1 Operating Manual KÖCO Compact Stud Welding Equipment 805i 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. 399-0581-000. 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: 805i Serial Number: 83010118 - 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: 805i Seriennummer: 83010118 - 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 805i KÖCO Stud Welding Guns CLASSIC SK 14 from no. 10000 SK 14-ISO from no. 17200 SK 14short SK 15 K 22 UKCA-Declaration of Conformity Original-EG-Konformitätserklärung Table of Contents Introduction...
  • Page 5 Remedies for Malfunctions Other Malfunctions Pictures of the Power Source 805i Spare Parts for Welding Power Source 805i Pictures of Stud Welding Guns CLASSIC Spare Parts for Stud Welding Guns CLASSIC Spare parts list gun series SK 14 and SK 15...

  • Page 6: Introduction

    Safety Instructions The KÖCO stud welding equipment 805i and the KÖCO stud welding gun CLASSIC is designed for use in drawn- arc stud welding only. It must not be used for any other purpose, with the exception of manual electrode welding, and then only if the appliance is equipped for this purpose.

  • Page 7: Operational Safety Of The Equipment

    ▪ No metallic jewellery (rings, chains, etc.) or watches may be worn during welding. ▪ 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. ▪...

  • Page 8: Safety When Working

    1.2.3 Safety When Working ▪ Do not operate the equipment in areas of fire or explosion danger. Remove all inflammable objects from the surroundings! ▪ Keep in mind that welding splashes are likely to ignite inflammable objects, for example cleaning rags soaked with oil, grease or solvent, or packing materials, even at several metres’...

  • 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 Power Source 805I

    Technical Data on Power Source 805i Technical data 805i-8 805i-10 2 – 8 2 – 10 Stud welding with ceramic ferrule weldable stud range Ø (mm) 2 – 8 2 – 8 Short-cycle stud welding weldable stud range Ø (mm) 2 –...

  • Page 11: The Power Source

    805i - 10 805i - 8 Welding time (ms) Figure 2: Power ranges 805i-8 and 805i-10 The Power Source The power source consists of a primary chopped inverter with constant current control, a choke connected in series, and an electronic control. The machine is laid out for a mains voltage of 230 V (1-phase). Operation with other voltages is also possible by interposing a transformer.

  • Page 12: The Welding Gun

    The Welding Gun In drawn-arc stud welding the welding gun is used to generate the arc between stud and workpiece, and to unite the two welding pools at the end of welding time. There is a choice of two different concepts. The guns K 22 to K 26 have an automatic length adjustment facility, i.e.

  • Page 13: Technical Data On Stud Welding Guns Classic

    Please note: connecting the K 22-D to K 26 guns to a 805i power source is not recommended, since all types of studs that can be processed with a 805i power source can also be welded with SK 14 or K 22 guns.

  • Page 14: Setting Guidelines For Welding With Ceramic Ferrule Or Shielding Gas

    Setting Guidelines for welding with ceramic ferrule or shielding gas The settings given in figure 2 have been tested for welds on clean metallic surfaces and standard type studs in downhand position. The decisive parameter is the actual diameter at the welding end of the stud, not the nominal diameter.

  • Page 15: Setting Guidelines For Short Cycle Stud Welding Without Weld Pool Protection Or With Shielding Gas

    Setting guidelines for short cycle stud welding without weld pool protection or with shielding gas Short cycle stud welding is used where it is desirable to keep the penetration on thin work pieces as shallow as possible, normally with studs ranging from M 3 to M 12 (PS type flanged studs according to EN ISO 13918). If the outward appearance of welding collars is not important, protection of the welding pool can be omitted.

  • Page 16: 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 wheels (casters) are in perfect condition! 4.
  • Page 17 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 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 sockets of the welding power source and the workpiece. The con- nection points on the workpiece must be bright metal.

  • Page 19: Counter Functions

    3.4.3 Counter functions Immediately following a weld (also following a „shot in the air”, which is not added to the counter reading), the current counter reading will be shown on the display panel for about 1 second. As long as the pushbutton of the gun is kept pressed, the display will remain visible. This also applies if the ma- chine is not unlocked (closed welding circuit), i.e.
  • Page 20 impediment the plunging of the stud may not be stopped, but delayed. In this case a „cold weld“ with an incom- plete connection may result, without any faults showing on the outside. (chart 2 figure 5). Therefore the final as- sessment of a weld should never be made on the basis of visual tests alone, without mechanical tests being carried out as well.

  • Page 21: Maintenance Of The Welding Power Source

    Maintenance of the Welding Power Source Prior to any maintenance operation, the mains plug must be disconnected. In case of a fixed connection the voltage must be cut off, and the cut-off switch secured against unintentional switching on. The housing must not be opened unless the voltage is cut off.

  • Page 22: Calibration

    3.10 Calibration Stud welding equipment, which is used in the legally regulated area, e.g. in construction, or for work in which quality requirements according to ISO 3834-2 are agreed, must be calibrated at fixed intervals. In general, the calibration interval is 1 year. More details can be found in DVS code of practice 3009 and in DVS Guideline 0714.

  • Page 23: Remedies For Malfunctions

    Remedies for Malfunctions Error signals are shown in plain text; with the word “error” in the first line. The error descriptions will then be listed in the following lines. If more than three types of error occur simultaneously, the display screen will be temporarily extended to show a complete list of errors diagnosed.
  • Page 24 Malfunction Cause Remedy Mains or welding circuit volt- Make sure that permissible cable length and correct di- age too low ameter are chosen. Welding results un- Function of gun irregular After operating the gun for a longer period, scattering reliable (sometimes in the lift will increase.

  • Page 25: Pictures Of The Power Source 805I

    Pictures of the Power Source 805i Figure 10: Front view 805i Issue 02/2023 ver. 1.2 Page 25 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...
  • Page 26 Figure 11: Side view 805i (left side) Issue 02/2023 ver. 1.2 Page 26 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net...
  • Page 27 Figure 12: Side view 805i (right side) Issue 02/2023 ver. 1.2 Page 27 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net...
  • Page 28 Figure 13: View from above left side 805i Issue 02/2023 ver. 1.2 Page 28 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net...

  • Page 29: Spare Parts For Welding Power Source 805I

    Spare Parts for Welding Power Source 805i Part number No. of Pos. units Designation hood, laminated 325-0827-000 chassis, laminated and printed 325-0826-000 front foil 325-0828-000 machine foot 320-0263-000 handle 320-0049-000 power switch 325-0297-000 power connection cable 3 × 2.5 mm² HO7RN, 3 m, with plug...
  • Page 30 Switching power supply 325-0864-000 Control board T42 330-0303-000 control board TB1-805i (only together with IGBT-module) 330-0370-000 control board HZG12A for 805i-8 330-0361-000 control board HZG12A for 805i-10 330-0362-000 control board SS1V4 330-5189-000 control board PFC 325-0772-000 control board HVI 325-0773-000...

  • Page 31: Pictures Of Stud Welding Guns Classic

    7 Pictures of Stud Welding Guns CLASSIC Figure 14: Exploded view of gun SK 14 Issue 02/2023 ver. 1.2 Page 31 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...
  • Page 32 Figure 15: Exploded view of gun SK 14-ISO Issue 02/2023 ver. 1.2 Page 32 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net koeco@koeco.net...
  • Page 33 Figure 16: Exploded view of gun SK 14 short Issue 02/2023 ver. 1.2 Page 33 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net koeco@koeco.net...
  • Page 34 Figure 17: Exploded view of gun SK 15 Issue 02/2023 ver. 1.2 Page 34 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net koeco@koeco.net...
  • Page 35 Figure 18: Exploded view of gun K 22 with option K 22-D Issue 02/2023 ver. 1.2 Page 35 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...
  • Page 36 Figure 19: Exploded view of gun K 24 Issue 02/2023 ver. 1.2 Page 36 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net koeco@koeco.net...
  • Page 37 Figure 20: Exploded view of gun K 26 (from no. 400130) Issue 02/2023 ver. 1.2 Page 37 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...

  • Page 38: Spare Parts For Stud Welding Guns Classic

    Spare Parts for Stud Welding Guns CLASSIC Spare parts list gun series SK 14 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 lower gun handle 322-0597-000 322-0597-000 322-0597-000 322-0597-000...

  • Page 39: Spare Parts List Guns K 22, K 22-D

    Part-no. Item Description SK 14 SK 14-ISO SK 14 short SK 15 wing screw 322-0631-000 Spare parts list guns K 22, K 22-D, K 24, K 26 Part Number Pos. Designation K 22 K 22-D K 24 K 26 gun body 322-6051-000 322-6051-000 322-6050-000 322-6096-000 handle cover...
  • Page 40 Part Number Pos. Designation K 22 K 22-D K 24 K 26 welding cable, 2 m, 50 mm² with pro- tective conduit 329-5216-000 329-5216-000 welding cable 2 m, 95 mm² without plug, with protective conduit 329-5223-000 welding cable 2 m, 120 mm² without plug, with protective conduit 329-5225-000 29a welding cable 2 m, 50 mm²...

  • Page 41: Pictures Of Cables

    Pictures of Cables Figure 21: Welding cable extension and ground cable Issue 02/2023 ver. 1.2 Page 41 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...

  • Page 42: 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 welding and control cable extensions 10 m, 95 mm² (complete set) 317-5014-000 welding and control cable extensions 10 m, 120 mm²...

  • Page 43: Schematic Circuit Diagram

    Schematic Circuit Diagram Figure 22: Schematic Circuit Diagram 805i Issue 02/2023 ver. 1.2 Page 43 of 62 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 • E-Mail: Internet: http://www.koeco.net...

  • Page 44: Accessories

    Accessories 12.1 Gun accessories for stud welding guns K 22 to K 26 Figure 23: Gun accessories for shear connectors from 50 mm length Chuck Foot plate Ferrule grip Stud diameter pos. 1 pos. 2 pos. 3 350-0056-000 360-0116-000 355-0031-000 350-0164-000 360-0117-000 355-0033-000...
  • Page 45 Figure 24: Gun accessories for shear connectors up to 50 mm length Screw with Foot plate/ Stud diame- Chuck Washer hexagon ferrule holder Leg pos. 3 pos. 1 pos. 4 socket pos. 2 pos. 5 350-0058-000 360-0164-000 350-0059-000 360-0085-000 350-0059-000 360-0086-000 370-0240-000 370-0055-000...
  • Page 46 Figure 25: Gun accessories for shear connectors in an interior angle Chuck Foot plate Ferrule grip Stud diameter pos. 1 pos. 2 pos. 3 350-0056-000 360-0116-000 355-0263-000* 350-0164-000 360-0117-000 355-0043-000 350-0059-000 360-0118-000 355-0044-000 350-0060-000 360-0119-000 355-0268-000* For pos. 4, 5 and 6 see figure 23. * Discontinued types, not for new projects.
  • Page 47 Figure 26: Gun accessories for threaded studs, tapped studs and plain pins Chuck Ferrule grip Foot plate Type PD Type DD Type RD pos. 1 pos. 3 pos. 2 M 4 x > 20 M 4 x > 20 350-0002-000 355-0001-000 M 5 x >...
  • Page 48 Stud length up to (mm) Required length of Part No. legs (mm) pos. 4 K 22 and K 22-D K 24 K 26 370-0240-000 370-0300-000 370-0400-000 370-0500-000 370-0322-000 370-0323-000 370-0055-000 Washer pos. 5 322-0372-000 Screw with hexagon socket pos. 6 For studs below 12 mm diameter and lengths L >...
  • Page 49 Figure 27: Gun accessories for Insulation pins Stud dimension Chuck pos. 1 Foot plate pos. 2 Supporting tube pos. 3 350-0086-000 (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 50 Figure 28: 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 51 Figure 29: Gun accessories for stud welding with shielding gas Supporting tube Foot plate with 3 Chuck with 3 socket head Stud diameter d socket head cap pos. 1 pos. 4 cap screws M 4 x 10 screws M 4 x 10 pos. 2 pos.
  • Page 52 Figure 30: Gun accessories for flat anchors W x T x L (Width x thickness x length) Foot plate Chuck pos. 3 Stopping piece pos. 4 pos. 2 15 x 3 x > 25 360-0096-000 350-6045-000 350-0324-000 15 x 3 x > 35 360-0096-000 350-6045-000 20 x 3 x >...
  • Page 53 Figure 31: Gun accessories for Y-anchors Dimension Chuck pos. 1 Foot plate pos. Chuck extension Counter nut Compensation pos. 3 pos. 4 (M 10 flat) piece pos. 7 6 x 80° 360-0122-000 350-6121-000 350-0075-000 322-0378-000 8 x 80° 360-0123-000 350-0327-000 Leg pos.
  • Page 54 Figure 32: Gun accessories for reduced Y-anchors Chuck pos. 1 Ferrule holder pos. 2 Foot plate pos. 3 Knurled nut pos. 4 350-0365-000 355-0272-000 360-0108-000 355-0250-000 Leg pos. 5 Screw with hexagon Washer socket pos. 6 pos. 7 370-0240-000 322-0372-000 370-0055-000 Issue 02/2023 ver.
  • Page 55 Figure 33: Gun accessories for boiler pins Stud dimension Chuck pos. 1 Ferrule holder Knurled nut Supporting Assembling pos. 2 pos. 3 tube pos. 4 plate pos. 5 6 x 14 - 20 350-0071-000 355-0151-000 8 x 14 - 20 350-0072-000 355-0151-000 355-0250-000...
  • Page 56 Figure 34: 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 57 Figure 35: 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 58: Gun Accessories For Gun Series Sk 14 And Sk

    12.2 Gun accessories for Gun series SK 14 and SK 15 Figure 36: Gun accessories for short-cycle stud welding without shielding gas Stud dimen- Chuck Foot plate Supporting Leg pos. 4 sion (D x L) pos. 1 pos. 2 tube pos. 3 Ø...
  • Page 59 Figure 37: Gun accessories for threaded studs and plain pins Type PD Type DD Type RD 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 > 16 M 5 x >...
  • Page 60 Figure 38: Gun accessories for insulation pins 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) Stud length up to Required length of...
  • Page 61 Figure 39: Gun accessories for stud welding with shielding gas Foot plate with 2 Supporting tube with 2 Chuck Stud diameter d socket head cap Leg pos. 4 socket head cap pos. 1 screws M 4 x 10 pos. 2 screws M 4 x 10 pos.

  • Page 62: 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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